Hyster C174 (R30XMS) Service Manual

Description

• Model List:
  • C174 (R30XMS)

• 1. INTRODUCTION
• 2. GENERAL
• 3. LEAD-ACID BATTERIES
• 4. SPECIFIC GRAVITY
• 5. THE CHEMICAL REACTION IN A CELL
• 6. ELECTRICAL TERMS
• 7. HOW TO SELECT THE BATTERY
• 8. VOLTAGE OF A BATTERY
• 9. THE BATTERY AS A COUNTERWEIGHT
• 10. BATTERY RATINGS
• 11. Kilowatt-Hours
• 12. BATTERY MAINTENANCE
• 13. SAFETY PROCEDURES
• 14. MAINTENACE RECORDS
• 15. THE NEW BATTERY
• 16. HOW TO CLEAN THE BATTERY
• 17. HOW TO ADD WATER
• 18. THE HYDROMETER
• 19. BATTERY TEMPERATURE
• 20. CHARGING THE BATTERY
• 21. Types Of Battery Charges
• 22. Methods Of Charging
• 23. Troubleshooting The Charger
• 24. How To Know When The Battery Is Fully Charged
• 25. WHERE TO CHARGE THE BATTERIES
• 26. Equipment Needed
• 27. BATTERY CONNECTORS
• 28. BATTERY CARE
• 29. INTRODUCTION
• 30. General
• 31. Description
• 32. Removal And Disassembly
• 33. Covers, Panels And Plates
• 34. R30EA-FS Caster And Caser Wheel
• 35. Description
• 36. Replacing Caster
• 37. Replacing Caster Wheels
• 38. Painting Instructions
• 39. Label Replacement
• 40. INTRODUCTION
• 41. GENERAL
• 42. DESCRIPTION
• 43. REMOVAL AND DISASSEMBLY
• 44. COVERS, PANELS AND PLATES
• 45. CASTER AND CASTER WHEEL
• 46. Description
• 47. Replace The Caster
• 48. Replace the Caster Wheels
• 49. PAINTING INSTRUCTIONS
• 50. LABEL REPLACEMENT
• 51. INTRODUCTION
• 52. DESCRIPTION
• 53. OPERATION
• 54. Flow Control Valve
• 55. Relief Valve
• 56. REPAIRS
• 57. REMOVAL
• 58. DISASSEMBLY
• 59. CLEANING
• 60. INSPECTION
• 61. ASSEMBLY
• 62. INSTALLATION
• 63. CHECKS AND ADUSTMENTS
• 64. CHECK THE OUTPUT OF THE PUMP
• 65. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 66. TROUBLESHOOTING
• 67. DC Motor Maintenance
• 68. Safety Precautions Maintenance and Repair
• 69. General
• 70. Brush and Commutator Inspection
• 71. Hydraulic Pump Motor and Traction Motor
• 72. Steering Pump Motor
• 73. Normal Commutator Surface
• 74. Commutator Problems
• 75. Brush Replacement
• 76. Stoning the Commutator
• 77. Motors Repair
• 78. Disassemble
• 79. Traction Motor and Hydraulic Pump Motor
• 80. Steering Pump Motor
• 81. Assemble
• 82. Traction Motor and Hydraulic Pump Motor
• 83. Steering Pump Motor
• 84. Brush Alignment, Traction and Hydraulic Motors
• 85. Tests for Damaged Field and Armature
• 86. Test for an Open Circuit in Armature
• 87. Test for Short Circuit in One Armature Winding
• 88. Test for Short Circuit to Armature Shaft
• 89. Test for Open Circuit in Field Coil
• 90. Test for Short Circuit in Field Coil
• 91. Test for Short Circuit between Field and Motor Case
• 92. Brush Holder Test
• 93. Troubleshooting
• 94. Table 1. Normal Commutator Surfaces
• 95. Table 2. Commutator Problems
• 96. Table 3. Brush Wear Replacement Guide
• 97. INTRODUCTION
• 98. GENERAL
• 99. DESCRIPTION
• 100. REMOVAL
• 101. Mount Type A
• 102. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
• 103. Mount Type B (R30DH Only)
• 104. DISASSEMBLY
• 105. ASSEMBLY
• 106. General
• 107. Installing The Spiral Bevel Pinion
• 108. Installing Thr Spiral Bevel Gear
• 109. INSTALLATION
• 110. Mount Type A
• 111. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
• 112. Mount Type B (R30DH Only)
• 113. CHECKS AND ADJUSTMENTS
• 114. ADJUST THE BACKLASH AND TOOTH CONTACT
• 115. ADJUST BEARING CONTACT
• 116. TROUBLESHOOTING
• 117.
• 118.
• 118.1. Power Steering
• 118.2. Safety Precautions Maintenance and Repair
• 118.3. General
• 118.4. EPS III
• 118.5. Description
• 118.6. EPS III
• 118.7. APS System
• 118.8. Checks and Adjustments
• 118.9. General
• 118.10. Checks, EPS III
• 118.11. Dipswitches, EPS III
• 118.12. LED Indicators, EPS III
• 118.13. Check Steering System for Correct Operation, EPS III
• 118.14. Check Slow Travel Speed, EPS III
• 118.15. Check High Lift Traction Shutoff, EPS III
• 118.16. Checks, APS
• 118.17. Dipswitches, APS
• 118.18. LED Indicators, APS
• 118.19. Adjustments
• 118.20. General
• 118.21. Steer Motor With Steering Chain Replacement, EPS III
• 118.22. Steer Motor With Steering Gear Replacement, APS
• 118.23. Return-to-Center Steering System
• 118.24. Tach Generator Steering System, EPS III
• 118.25. Slow Travel Adjustment, EPS III
• 118.26. Return-to-Center and Multiturn System, APS
• 118.27. Steering Chain Adjustment, EPS III
• 118.28. Repairs
• 118.29. RTC Steering System, EPS III
• 118.30. Command Potentiometer Replacement, EPS III
• 118.31. TGS System, EPS III
• 118.32. Tach Generator Replacement, EPS III
• 118.33. Feedback Potentiometer Replacement, EPS III
• 118.34. ECM Replacement, EPS III
• 118.35. Steer Motor Assembly and Steering Chain Replacement, EPS III
• 118.36. Typical Operating Voltages, EPS III
• 118.37. Steering Proximity Switch and Centering Proximity Switch, APS
• 118.38. Troubleshooting
• 118.39. EPS III
• 118.40. Table 1. LED Indicators
• 118.41. Table 2. Sensitivity Adjustment
• 118.42. Table 3. Typical Operating Voltages
• 119.
• 119.1. INTRODUCTION
• 119.1.1. GENERAL
• 119.1.2. DESCRIPTION AND OPERATION
• 119.2. REPAIRS
• 119.2.1. ELECTRIC BRAKE
• 119.2.2. BRAKE SWITCH
• 119.3. TROUBLESHOOTING
• 120.
• 120.1. INTRODUCTION
• 120.1.1. GENERAL
• 120.2. DESCRIPTION AND OPERATION
• 120.2.1. Electric Brake
• 120.3. REPAIRS
• 120.3.1. Electric Brake
• 120.4. TROUBLESHOOTING
• 121.
• 121.1. INTRODUCTION
• 121.1.1. Description
• 121.2. REPAIRS
• 121.2.1. Hydraulic Pump
• 121.2.2. Control Valve
• 121.3. CHECKS AND ADJUSTMENTS
• 121.3.1. Relief Valve Adjustments
• 121.4. TROUBLESHOOTING
• 121.4.1. Hydraulic Pump
• 121.4.2. Control Valve
• 121.5. SPECIFICATIONS
• 122.
• 123.
• 123.1. INTRODUCTION
• 123.1.1. GENERAL
• 123.2. DESCRIPTION
• 123.2.1. GENERAL
• 123.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 123.2.3. LED DISPLAY PANEL
• 123.2.4. LX SERIES DISPLAY PANEL
• 123.2.5. ZX SERIES DISPLAY PANELS
• 123.3. CHECKS AND ADJUSTMENTS
• 123.3.1. GENERAL
• 123.4. REPLACEMENT
• 123.4.1. GENERAL
• 123.4.2. METER REPLACEMENT
• 123.4.3. SENDER REPLACEMENT
• 123.4.4. DISPLAY PANEL
• 123.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 123.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 123.5. SPECIFICATIONS
• 123.6. TROUBLESHOOTING
• 124.
• 125.
• 125.1. INTRODUCTION
• 125.1.1. General
• 125.1.2. Operation
• 125.2. CHECKS AND ADJUSTMENTS
• 125.2.1. General
• 125.2.2. Adjustments
• 126.
• 126.1. INTRODUCTION
• 126.1.1. GENERAL
• 126.1.2. STEERING MECHANISM
• 126.1.3. REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM
• 126.1.4. REPLACE MDU POTENTIOMETER
• 126.1.5. REPLACE THE ECM
• 126.1.6. REPLACE THE STEERING CONTACTOR
• 126.1.7. REPLACE THE GEARMOTOR ASSEMBLY AND STEERING CHAIN
• 126.1.8. REPLACE THE SENSORS
• 127.
• 128.
• 128.1. INTRODUCTION
• 128.1.1. GENERAL
• 128.1.2. INDICATORS WITH METER MOVEMENT
• 128.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 128.2. CHECKS AND ADJUSTMENTS
• 128.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
• 128.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 128.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 128.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 128.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 128.2.6. CHECKING CURTIS 933-1 METER
• 128.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 128.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
• 128.3. CURTIS DASH DISPLAY ASSEMBLY
• 128.3.1. Description/Features
• 128.3.2. Operation
• 128.3.3. Testing
• 128.4. REPAIRS
• 128.4.1. BATTERY INDICATORS
• 128.4.2. CONTROLLER FOR THE BATTERY INDICATOR
• 128.4.3. DISPLAY PANEL COMPONENTS
• 128.4.4. REPLACING SEM DISPLAY PANEL
• 128.4.5. SEM DISPLAY PANEL REMOVAL
• 129.
• 130.
• 130.1. INTRODUCTION
• 130.1.1. GENERAL
• 130.1.2. MAST WELDMENTS
• 130.1.3. CARRIAGES
• 130.2. VISTA TWO-STAGE MAST
• 130.2.1. DESCRIPTION
• 130.2.2. OPERATION
• 130.3. VISTA THREE-STAGE MAST
• 130.3.1. DESCRIPTION
• 130.3.2. OPERATION
• 131.
• 131.1. INTRODUCTION
• 131.1.1. GENERAL
• 131.1.2. DESCRIPTION
• 131.2. REPAIRS
• 131.2.1. MAIN CYLINDER – DISASSEMBLY
• 131.2.2. MAIN CYLINDER – ASSEMBLY
• 131.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
• 131.2.4. FREE-LIFT CYLINDER – ASSEMBLY
• 131.3. TROUBLESHOOTING
• 132.
• 132.1. INTRODUCTION
• 132.1.1. General
• 132.2. SAFETY PROCEDURES
• 132.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
• 132.3.1. Load Backrest Extension – Removal And Installation
• 132.3.2. Carriage Assembly – Removal And Installation
• 132.3.3. Carriage Load Rollers – Removal And Installation
• 132.3.4. Side Rollers – Disassembly And Assembly
• 132.3.5. Fork Replacement
• 132.4. TWO-STAGE MAST ASSEMBLY
• 132.4.1. Two-Stage Mast Assembly – Removal
• 132.4.2. Cleaning And Inspection
• 132.4.3. Lift Cylinders – Removal And Installation
• 132.4.4. Inner Mast Assembly – Removal And Installation
• 132.4.5. Hoses – Replace
• 132.4.6. Hoses And Cable Sheaves – Replace
• 132.4.7. Two-Stage Lift Chains
• 132.4.8. Two-Stage Chain Sheave – Removal And Installation
• 132.4.9. Load Rollers And Wear Plugs – Removal And Installation
• 132.4.10. Two-Stage Mast Assembly – Installation
• 132.5. THREE-STAGE MAST ASSEMBLY
• 132.5.1. Three-Stage Mast Assembly – Removal
• 132.5.2. Cleaning And Inspection
• 132.5.3. Free-Lift Cylinder – Removal And Installation
• 132.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
• 132.5.5. Hoses – Replace
• 132.5.6. Hose And Cable Sheaves – Replace
• 132.5.7. Three-Stage Lift Chains – Removal And Installation
• 132.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
• 132.5.9. Load Rollers And Wear Plugs – Removal And Installation
• 132.5.10. Three-Stage Mast Assembly – Installation
• 132.6. CHECKS AND ADJUSTMENTS
• 132.6.1. Check The Operation Of The Mast
• 132.6.2. Check For Leaks In The Hydraulic System
• 132.6.3. Check Lift Chains
• 132.6.4. Mast Adjustments
• 132.6.5. Carriage Adjustments
• 133.
• 134.
• 134.1. INTRODUCTION
• 134.1.1. GENERAL
• 134.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 134.1.3. How To Tow The Lift Truck
• 134.1.4. HOW TO PUT A LIFT TRUCK ON BLOCKS
• 134.1.5. How To Raise Drive Tire
• 134.1.6. How To Raise Load Wheels
• 134.2. MAINTENANCE SCHEDULE
• 134.3. MAINTENANCE PROCEDURES- EVERY 8 HOURS OR DAILY
• 134.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
• 134.3.2. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
• 134.4. EVERY 350 HOURS OR TWO MONTHS
• 134.4.1. HYDRAULIC TANK BREATHER
• 134.4.2. ELECTRICAL INSPECTION
• 134.4.3. SAFETY LABELS
• 134.4.4. CHECK FOR LEAKS IN THE LIFT SYSTEM
• 134.4.5. LIFT CHAINS
• 134.5. EVERY 2000 HOURS OR YEARLY
• 134.5.1. MASTER DRIVE UNIT
• 134.5.2. STEERING CHAIN
• 134.5.3. WHEELS AND BEARINGS
• 134.5.4. HOW TO CHANGE THE HYDRAULIC OIL AND FILTER
• 134.5.5. ELECTRICAL CABLE SHEAVES
• 134.5.6. PALLET CLAMP
• 134.5.7. LIMIT SWITCH ROLLERS AND OTHER LUBRICATION
• 134.6. GENERAL PROCEDURES
• 134.6.1. HOW TO CHARGE THE BATTERY
• 134.6.2. HOW TO CHANGE THE BATTERY
• 134.6.3. HOW TO CHANGE WHEELS AND TIRES
• 134.7. BATTERY SPECIFICATIONS
• 135.
• 135.1. BATTERY SPECIFICATIONS
• 135.2. TRANSISTOR CONTROLLER ADJUSTMENT POINTS
• 135.3. EV100 TRACTION CARD SETTINGS
• 135.4. MASTER DRIVE UNIT
• 135.5. SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING)
• 135.6. TERMINAL AND PIN ARRANGEMENTS FOR THE EV100 CONTROL CARD
• 135.7. TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X 4406
• 135.8. SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE)
• 135.9. TRANSISTOR RESISTANCE
• 135.10. SYSTEM II WIRE GUIDANCE SPECIFICATIONS
• 135.11. HYDRAULIC SYSTEM
• 135.12. TORQUE SPECIFICATIONS
• 136.
• 136.1. FIGURE 1. HYDRAULIC SCHEMATIC
• 136.2. FIGURE 2. SCHEMATIC DIAGRAM WITHOUT WIRE GUIDANCE
• 136.3. FIGURE 3. WIRING DIAGRAM WITHOUT WIRE GUIDANCE
• 136.4. FIGURE 4. INSTRUMENT PANEL WIRING WITHOUT WIRE GUIDANCE
• 136.5. FIGURE 5. SCHEMATIC DIAGRAM WITH WIRE GUIDANCE
• 136.6. FIGURE 6. WIRING DIAGRAM WITH WIRE GUIDANCE
• 136.7. FIGURE 7. INSTRUMENT PANEL WIRING WITH WIRE GUIDANCE
• 136.8. FIGURE 8. DETAIL DIAGRAM
• 136.9. FIGURE 9. ACCESSORY WIRING DETAIL DIAGRAM
• 136.10. FIGURE 10. WIRING GUIDANCE CABLING AND DETAIL DIAGRAM
• 137.
• 137.1. WIRING SCHEMATIC-EPS III
• 137.2. OPTIONS SCHEMATIC-EPS III
• 137.3. WIRING DIAGRAM-EPS III
• 137.4. OPTIONAL DIAGRAM-EPS III
• 137.5. HYDRAULIC SCHEMATIC
• 138.