Hyster R30XMF3 to R30XM3 Wire Driver Manual Maintenance And Repair

Description

• Model List:
  • R30XMF3, R30XMA3, C1.0, C1.3, C1.5B, C1.8X, C1.5, R30ES, R30XMS, R30XMS2, N30XMH2, V30ZMD, R30F, R30FA, R30FF, R30XMS3, R30XM, R30XMA, R30XMF, R30XM2, R30XMA2, R30XMF2, R30XM3

• 1. RM1229-(01-2012)-US-EN
• 1.1. Wire Driver Manual
• 1.2. Safety Precautions Maintenance and Repair
• 1.3. General
• 1.4. Description
• 1.5. Installation Procedure
• 1.6. Checks and Adjustments
• 1.7. Adjustments (Early Model)
• 1.8. Adjustments (Late Model)
• 1.9. Troubleshooting
• 1.10. Wire Driver Troubleshooting
• 1.11. Guide Wire Troubleshooting
• 1.12. Guide Wire Repair
• 1.13. Short Circuit Repair
• 1.14. Open Circuit Repair
• 1.15. System II Wire Guidance Specifications
• 1.16. Table 1. Wire Driver Troubleshooting
• 2. RM1230-(01-2012)-US-EN
• 2.1. Guide Wire Installation
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Description
• 2.5. Guide Wire Physical Installation
• 2.6. Equipment
• 2.7. Specifications
• 2.8. Wire Slot and Expansion Loop Specifications
• 2.9. Material and General Specifications
• 2.10. System II Wire Guidance Specifications
• 2.11. Pre-Installation Information Form
• 2.12. Table 1. Equipment
• 2.13. Table 2. Material Specifications
• 2.14. Table 3. General Specifications
• 3. RM0285-(06-2010)-US-EN
• 3.1. Drive Axle, Speed Reducer, and Differential
• 3.2. Safety Precautions Maintenance and Repair
• 3.3. General
• 3.4. Description
• 3.5. Drive Axle, Speed Reducer, and Differential Repair
• 3.6. Drive Axle, Remove
• 3.7. Drive Axle, Disassemble
• 3.8. Speed Reducer and Differential, Disassemble
• 3.9. Inspect
• 3.10. Assemble
• 3.11. Speed Reducer and Differential, Assemble
• 3.12. Drive Axle, Assemble
• 3.13. Drive Axle Assembly, Install
• 3.14. Torque Specifications
• 3.15. Wheel Nuts
• 3.16. Axle Shaft Capscrews
• 3.17. Axle Hangers to Frame
• 3.18. Back Plate to Axle Mount Capscrews
• 3.19. Wheel Cylinder Capscrews
• 3.20. Ring Gear to Differential Case
• 3.21. Differential Case Halves
• 3.22. Bearing Cap Capscrews
• 3.23. Retainer Capscrews
• 3.24. Axle Housing to Differential Housing
• 3.25. Pinion Nut
• 3.26. Speed Reducer Housing to Differential Housing
• 3.27. Traction Motor to Transmission
• 3.28. Troubleshooting
• 3.29. Table 1. Adjustment of Shims for Pinion Assembly
• 3.30. Table 2. Ring and Pinion Tooth Contact Adjustment
• 4. RM0480-(04-2008)-US-EN
• 4.1. Safety Precautions Maintenance and Repair
• 4.2. General
• 4.3. Mast Weldments
• 4.4. Carriages
• 4.5. Two-Stage Mast
• 4.6. Description
• 4.7. Operation
• 4.8. Three-Stage Mast
• 4.9. Description
• 4.10. Operation
• 5. RM0481-(07-2013)-US-EN
• 5.1. Lift Cylinders
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Description
• 5.5. Lowering Control Valve
• 5.6. Main Cylinder Repair
• 5.7. Disassemble
• 5.8. Assemble
• 5.9. Free-Lift Cylinder Repair
• 5.10. Disassemble
• 5.11. Assemble
• 5.12. Troubleshooting
• 6. RM0482-(04-2008)-US-EN
• 6.1. Safety Precautions Maintenance and Repair
• 6.2. General
• 6.3. Safety Procedures When Working Near Mast
• 6.4. Load Backrest Extension, Carriage, Load Rollers, Side Rollers, a
• 6.5. Load Backrest Extension, Remove and Install
• 6.6. Carriage Assembly, Remove and Install
• 6.7. Carriage Load Rollers, Remove and Install
• 6.8. Side Rollers, Disassemble and Assemble
• 6.9. Fork, Replace
• 6.10. Hook-Type Forks
• 6.11. Two-Stage Mast Assembly
• 6.12. Clean and Inspect
• 6.13. Lift Cylinders, Remove and Install Dual-Lift Cylinders
• 6.14. Lift Cylinder, Remove and Install Single Main-Lift Cylinders
• 6.15. Install
• 6.16. Inner Mast Assembly, Remove and Install
• 6.17. Hoses, Replace
• 6.18. Hose and Cable Sheaves, Replace
• 6.19. Two-Stage Lift Chains
• 6.20. Remove and Install
• 6.21. Clean and Inspect
• 6.22. Two-Stage Chain Sheave, Remove and Install
• 6.23. Load Rollers and Wear Plugs, Remove and Install
• 6.24. Two-Stage Mast Assembly, Install
• 6.25. Three-Stage Mast Assembly
• 6.26. Three-Stage Mast Assembly, Remove
• 6.27. N30XHM, N30XMH 2 (C210), and V30ZMD (D210/E210) Only
• 6.28. Clean and Inspect
• 6.29. Free-Lift Cylinder, Remove and Install
• 6.30. Main Cylinders (Standard), Remove and Install
• 6.31. Main Cylinders N30XMH, N30XMH 2 (C210) and V30ZMD (D210/E210), R
• 6.32. Inner and Intermediate Mast Assemblies, Remove and Install
• 6.33. Hoses, Replace
• 6.34. Hose and Cable Sheaves, Replace
• 6.35. Free-Lift Hose Sheave
• 6.36. Carriage Sheaves
• 6.37. Three-Stage Lift Chains, Remove and Install
• 6.38. General
• 6.39. Free-Lift Chains
• 6.40. Main-Lift Chains
• 6.41. Three-Stage Chain Sheaves, Disassemble and Assemble
• 6.42. Free-Lift Chain Sheaves
• 6.43. Main-Lift Chain Sheaves
• 6.44. Load Rollers and Wear Plugs, Remove and Install
• 6.45. Three-Stage Mast Assemble, Install
• 6.46. Mast Operation Check
• 6.47. Hydraulic System Leaks Check
• 6.48. Lift Chains Check
• 6.49. General
• 6.50. Clean and Inspect
• 6.51. Lubrication
• 6.52. Mast Adjustments
• 6.53. General
• 6.54. Adjust Wear Plugs – Mast
• 6.55. Adjust Free-Lift Chain (Three-Stage Only)
• 6.56. Adjust Main-Lift Chains
• 6.57. Two-Stage
• 6.58. Three-Stage
• 6.59. Adjust Wear Strips
• 6.60. Carriage Adjustments
• 6.61. Adjust Wear Plug – Carriage
• 6.62. Adjust Side Rollers – Carriage
• 6.63. Adjust Thrust Rollers – Carriage
• 6.64. Troubleshooting
• 7. RM0485-(08-2003)-US-EN
• 7.1. Steering System for Electric Lift Trucks
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description
• 7.5. Steering Wheel and Column Assembly Repair
• 7.6. Assembly Components, Remove
• 7.7. Assembly Components, Install
• 7.8. Power Steering Motor and Pump
• 7.9. Description
• 7.10. Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.
• 7.11. Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X
• 7.12. Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
• 7.13. Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
• 7.14. Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
• 7.15. Assemble and Install – All models with a vertical mount except J
• 7.16. Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2
• 7.17. Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
• 7.18. Power Steering Pump, Repair
• 7.19. Seal, Replace
• 7.20. Hydraulic Steering Motor
• 7.21. Description
• 7.22. Hydraulic Steering Motor Repairs
• 7.23. Disassemble
• 7.24. Clean and Inspect
• 7.25. Assemble
• 7.26. Install
• 7.27. Steering System Air Removal
• 7.28. Steering Pressure Check
• 7.29. Steering Chain Tension Check (Unit With MDU Only)
• 7.30. Optical Encoder and Activator Circuits Check
• 7.31. Troubleshooting
• 8. RM0512-(08-2003)-US-EN
• 8.1. Steering Housing and Control Unit
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. General
• 8.4. Description
• 8.5. Operation
• 8.6. Steering Wheel and Column Assembly Repair
• 8.7. Steering Column Assembly, Remove
• 8.8. Steering Control Unit
• 8.9. Steering Column Assembly, Install
• 8.10. System Air Removal
• 8.11. Troubleshooting
• 9. RM0514-(01-2004)-US-EN
• 9.1. Instrument Cluster
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. General
• 9.4. Description
• 9.5. Display Panels on Steering Column, Internal Combustion
• 9.6. Display Panels on Steering Column, Electric Lift Trucks
• 9.7. Standard Display Panel
• 9.8. Enhanced Display Panel
• 9.9. Curtis 1215 Display Panel
• 9.10. Description and Features
• 9.11. Operation
• 9.12. Cluster-Type Display Panel (Internal Combustion) Replacement
• 9.13. Remove and Disassemble
• 9.14. Assemble and Install
• 9.15. Cluster Display Panel (Electric Lift Truck) Replacement
• 9.16. Display Panel Assembly, Replace
• 9.17. LED Indicators
• 9.18. Battery Indicators
• 9.19. Digital Display (Enhanced Display Panel Only)
• 9.20. Status Code or Performance Level Switches and LED indicators (En
• 9.21. Standard Display Panel Parts, Replace
• 9.22. Enhanced Display Panel Parts, Replace
• 9.23. Curtis 1215 Display Panel Replacement
• 9.24. Install
• 9.25. Table 1. Instrument Cluster, Internal Combustion
• 10. RM0551-(08-2003)-US-EN
• 10.1. Electrical Diagrams
• 10.2. Safety Precautions Maintenance and Repair
• 11. RM0555-(10-1999)-US-EN
• 12. RM0557-(08-2003)-US-EN
• 12.1. EV-100ZX SCR Motor Controller
• 12.2. Safety Precautions Maintenance and Repair
• 12.3. General
• 12.4. Model Number Data For EV-100ZX Controller
• 12.5. Register Parameters
• 12.6. General
• 12.7. Function Numbers
• 12.8. Control Card, Checks and Adjustments
• 12.9. Handset
• 12.10. How to Check and Adjust Registers
• 12.11. How to Scroll through Fault Codes and Clear Them
• 12.12. Checks and Adjustments on Workbench
• 12.13. When Handset Is Connected to Control Card Installed In Lift Truc
• 12.14. Function Numbers 1 through 15
• 12.15. Function Numbers 16 through 30
• 12.16. Function Numbers 48 through 62
• 12.17. Control Cards
• 12.18. Function Number Descriptions
• 12.19. Traction Control Cards (Label Letters – ZH and ZY)
• 12.20. Function Number 1 STORED STATUS CODE
• 12.21. Function Number 2 CREEP SPEED
• 12.22. Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
• 12.23. Function Number 4 CURRENT LIMIT
• 12.24. Function Number 5 PLUGGING DISTANCE (CURRENT)
• 12.25. Function Number 6 1A DROP OUT CURRENT
• 12.26. Function Number 7 FIELD WEAKENING PICK UP
• 12.27. Function Number 8 FIELD WEAKENING DROP OUT
• 12.28. Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
• 12.29. Function Number 10 REGENERATIVE BRAKING START
• 12.30. Function Number 13 SPEED LIMIT 3 (SL3)
• 12.31. Function Number 14 INTERNAL RESISTANCE COMPENSATION
• 12.32. Function Number 15 BATTERY VOLTS
• 12.33. Function Numbers GREATER THAN 15
• 12.34. Function Number 16 PEDAL POSITION PLUG
• 12.35. Function Number 17 CARD TYPE SELECTION
• 12.36. Function Number 18 STEERING PUMP TIME DELAY
• 12.37. Function Number 19 MAINTENANCE ALERT (Tens/Units)
• 12.38. Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
• 12.39. Function Number 21 MAINTENANCE SPEED LIMIT
• 12.40. Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
• 12.41. Function Number 29 HOURMETER (Tens/Units)
• 12.42. Function Number 30 HOURMETER (Thousands/Hundreds)
• 12.43. Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
• 12.44. Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
• 12.45. Function Number 49 FIELD WEAKENING PICK UP
• 12.46. Function Number 50 SPEED LIMIT 1
• 12.47. Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
• 12.48. Function Number 53 FIELD WEAKENING PICK UP
• 12.49. Function Number 54 SPEED LIMIT 1
• 12.50. Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
• 12.51. Function Number 57 FIELD WEAKENING PICK UP
• 12.52. Function Number 58 SPEED LIMIT 1
• 12.53. Function Number 60 CONTROLLED ACCELERATION AND 1A TIME
• 12.54. Function Number 61 FIELD WEAKENING PICK UP
• 12.55. Pump Control Card (Label Letter ZP)
• 12.56. Function Number 1 STORED STATUS CODE
• 12.57. Function Number 2 INTERNAL RESISTANCE COMPENSATION START
• 12.58. Function Number 3 CONTROLLED ACCELERATION
• 12.59. Function Number 4 CURRENT LIMIT
• 12.60. Function Number 7 CONTROLLED ACCELERATION COMPENSATION
• 12.61. Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) – Tilt and S
• 12.62. Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) – Slow Lif
• 12.63. Function Number 13 SPEED LIMIT 3 (SL3)
• 12.64. Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
• 12.65. Function Numbers Greater Than 15
• 12.66. Function Number 16 INTERNAL RESISTANCE COMPENSATION
• 12.67. Function Number 17 CARD TYPE SELECTION
• 12.68. Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
• 12.69. Function Number 29 HOURMETER (Tens/Units)
• 12.70. Function Number 30 HOURMETER (Thousands/Hundreds)
• 12.71. Function Number 48 CONTROLLED ACCELERATION
• 12.72. Function Number 49 SPEED LIMIT 2
• 12.73. Function Number 50 SPEED LIMIT 3
• 12.74. Function Number 52 CONTROLLED ACCELERATION
• 12.75. Function Number 53 SPEED LIMIT 2
• 12.76. Function Number 54 SPEED LIMIT 3
• 12.77. Function Number 56 CONTROLLED ACCELERATION
• 12.78. Function Number 57 SPEED LIMIT 2
• 12.79. Function Number 58 SPEED LIMIT 3
• 12.80. Function Number 60 CONTROLLED ACCELERATION
• 12.81. Function Number 61 SPEED LIMIT 2
• 12.82. Function Number 62 SPEED LIMIT 3
• 12.83. Register Parameters
• 12.84. Troubleshooting
• 12.85. General
• 12.86. Status Codes
• 12.87. Register Maps
• 12.88. Status Code Charts
• 12.89. EV-100ZX SCR Motor Controller Repair
• 12.90. SCR, Check
• 12.91. SCR Assembly
• 12.92. Thermal Protector
• 12.93. SCR 1 Assembly, Replace
• 12.94. OFF Circuit for SCR 1
• 12.95. Reactor Assembly, Check
• 12.96. Suppressors for SCR 2 and SCR 5, Check
• 12.97. SCR 2 and SCR 5, Check
• 12.98. SCR 2 and SCR 5, Replace
• 12.99. Capacitor C1, Check
• 12.100. Diodes D3 and D4
• 12.101. Diodes D3 and D4, Check
• 12.102. Diodes D3 and D4, Replace
• 12.103. Motor Current Sensor
• 12.104. Contactors