Hyster N30XMXDR, N45XMXR (A264 A861) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 2348

File Size: 70.49 MB (Speed Download Link)

Brand: Hyster

Model: N30XMH (Pre-SEM) (C210) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster N30XMXDR, N45XMXR (A264 A861) Forklift Service Manual

Hyster N30XMXDR3, N45XMXR3 (B264 B861) Forklift Service Manual

📘 Show Index

Hyster N30XMXDR3, N45XMXR3 (B264 B861) Forklift Index:

toc
- Electrical System
- Safety Precautions Maintenance and Repair
- General
- Component Repair and Testing – General
- Contactor Panel Assembly
  - Description/Features
  - Remove
  - Install
- Contactors
  - Description/Features
  - Auxiliary Switch
  - Testing
  - Remove
  - Install
  - EE Contactors
- Fuses
- Relays
  - Description/Features
  - Enable Relay
  - Hourmeter Relay
  - Lift/Lower Relay (Trucks Built After 1 August 2002)
  - Coil Testing
  - Contact Testing
  - Remove and Install
- Height Proximity Switch
  - Remove
  - Test
  - Install
  - Adjust
- Key Switch
  - Description
  - Remove
  - Install
- Battery Disconnect Switch
  - Description
  - Remove
  - Install
- Proportional Electro-Hydraulic Control Valves
  - Manual Lowering
  - Operation
  - Repair
- Carriage Valve Assembly and Selector Valves
  - Test/Remove/Install
- Multifunction Control Handle
  - Description/Features
  - Remove
  - Disassemble
  - Assemble
  - Install
- Shelf Height Selector
  - Description/Features
  - Programming
  - System Errors
  - Main Interface Board (MIB) Adjustments
- Main Interface Board (MIB)
  - Description/Features
  - Operation
  - LED Display
  - MIB, Remove
  - MIB J-Connector, Repair
  - MIB, Install
- Main Interface Board (MIB) Setup Procedures
  - General
  - Default Values
  - Checking Model Code, Software Version, and Setup Status
  - MIB Generation II Setup Procedure
  - Max Speed and Low End Adjustments
  - Customizing MIB Functions
- MIB Status, Warning, and Fault Codes
  - General
  - Troubleshooting Charts
- Blank or Undefined Code Conditions
- Status Codes
- Warning Codes
- Fault Codes
- SEM Traction Motor Controller
  - Description/Features
  - Remove
  - Test
  - Install
- 1307 Programmer Handset
  - Description/Features
  - SCROLL DISPLAY Keys
  - CHANGE VALUE Keys
  - MORE INFO Key
  - Operation
  - Operating Modes
- Programming the Traction Motor Controller – 1307 Handset
- 1311 Programmer Handset
  - Description/Features
  - Operation
  - Main Menu Selections
- Programming the Traction Motor Controller – 1311 Handset
- Troubleshooting
  - Status LED Diagnostics
  - Programmer Diagnostics
  - Diagnostics Menu
  - Test Menu
- Dash Display Assembly
  - Description and Features
  - Operation
  - Remove
  - Install
  - Voltage Selection
  - Dash Display, Adjust
  - Battery Indicator Profile Settings
  - Troubleshooting
tables
- Table 1. Contactor Coil Voltages
- Table 2. Fuses
- Table 3. Hydraulic Control Valve/Relay Coil Resistance Values
- Table 4. OPTS Bits
- Table 5. Truck Unit and Model Codes
- Table 6. MIB Function Code Values for N30XMR3 Software 06/01/01
- Table 7. MIB Function Code Values for N40XMR3 06/01/01 to 01/14/
- Table 8. MIB Function Code Values for N25XMDR3
- Table 9. MIB Function Code Values for N50XMA3
- Table 10. MIB Function Code Values for N45XMR3
- Table 11. MIB Function Code Values for N30XMDR3
- Table 12. MIB Function Code Values for N45XMXR3 Mast Full Height
- Table 13. MIB Function Code Values for N45XMXR3 Mast Full Height
- Table 14. MIB Function Code Values for N30XMXDR Mast Full Height
- Table 15. MIB Function Code Values for N30XMXDR Mast Full Height
- Table 16. MIB Software 01/14/02 to 03/27/02
- Table 17. MIB Software 01/14/02 to 03/27/02 NXMR3 and NXMXR3 (G1
- Table 18. MIB Software Post 03/27/02 NXMR3, NXMDR3 C470
- Table 19. MIB Software Post 03/27/02 NXMR3, NXMDR3 (G138) and N3
- Table 20. NXMXDR3, NXMXR3 (B264)
- Table 21. Program Menu
- Table 22. Test Menu
- Table 23. Dash Display Drive Mode Inputs
- Table 24. Diagnostic and Diagnostic History Display
- Table 25. Special Program Menu
- Table 26. Program Menu Range and Default Values
- Table 27. Status LED Fault Codes
- Table 28. Dash Display Drive Mode Inputs
- Table 29. Dash Display Drive Mode Test Voltages
- Table 30. Dash Display Status/Warning/Fault Test Voltages

toc
- Electrical System
- Safety Precautions Maintenance and Repair
- General
- Component Repair and Testing – General
- Contactor Panel Assembly
  - Description/Features
  - Remove
  - Install
- Contactors
  - Description/Features
  - Auxiliary Switch
  - Testing
  - Remove
  - Install
  - EE Contactors
- Fuses
- Relays
  - Description/Features
  - Enable Relay
  - Hourmeter Relay
  - Lift/Lower Relay (Trucks Built After 1 August 2002)
  - Coil Testing
  - Contact Testing
  - Remove and Install
- Height Proximity Switch
  - Remove
  - Test
  - Install
  - Adjust
- Key Switch
  - Description
  - Remove
  - Install
- Battery Disconnect Switch
  - Description
  - Remove
  - Install
- Proportional Electro-Hydraulic Control Valves
  - Manual Lowering
  - Operation
  - Repair
- Carriage Valve Assembly and Selector Valves
  - Test/Remove/Install
- Multifunction Control Handle
  - Description/Features
  - Remove
  - Disassemble
  - Assemble
  - Install
- Shelf Height Selector
  - Description/Features
  - Programming
  - System Errors
  - Main Interface Board (MIB) Adjustments
- Main Interface Board (MIB)
  - Description/Features
  - Operation
  - LED Display
  - MIB, Remove
  - MIB J-Connector, Repair
  - MIB, Install
- Main Interface Board (MIB) Setup Procedures
  - General
  - Default Values
  - Checking Model Code, Software Version, and Setup Status
  - MIB Generation II Setup Procedure
  - Max Speed and Low End Adjustments
  - Customizing MIB Functions
- MIB Status, Warning, and Fault Codes
  - General
  - Troubleshooting Charts
- Blank or Undefined Code Conditions
- Status Codes
- Warning Codes
- Fault Codes
- SEM Traction Motor Controller
  - Description/Features
  - Remove
  - Test
  - Install
- 1307 Programmer Handset
  - Description/Features
  - SCROLL DISPLAY Keys
  - CHANGE VALUE Keys
  - MORE INFO Key
  - Operation
  - Operating Modes
- Programming the Traction Motor Controller – 1307 Handset
- 1311 Programmer Handset
  - Description/Features
  - Operation
  - Main Menu Selections
- Programming the Traction Motor Controller – 1311 Handset
- Troubleshooting
  - Status LED Diagnostics
  - Programmer Diagnostics
  - Diagnostics Menu
  - Test Menu
- Dash Display Assembly
  - Description and Features
  - Operation
  - Remove
  - Install
  - Voltage Selection
  - Dash Display, Adjust
  - Battery Indicator Profile Settings
  - Troubleshooting
tables
- Table 1. Contactor Coil Voltages
- Table 2. Fuses
- Table 3. Hydraulic Control Valve/Relay Coil Resistance Values
- Table 4. OPTS Bits
- Table 5. Truck Unit and Model Codes
- Table 6. MIB Function Code Values for N30XMR3 Software 06/01/01
- Table 7. MIB Function Code Values for N40XMR3 06/01/01 to 01/14/
- Table 8. MIB Function Code Values for N25XMDR3
- Table 9. MIB Function Code Values for N50XMA3
- Table 10. MIB Function Code Values for N45XMR3
- Table 11. MIB Function Code Values for N30XMDR3
- Table 12. MIB Function Code Values for N45XMXR3 Mast Full Height
- Table 13. MIB Function Code Values for N45XMXR3 Mast Full Height
- Table 14. MIB Function Code Values for N30XMXDR Mast Full Height
- Table 15. MIB Function Code Values for N30XMXDR Mast Full Height
- Table 16. MIB Software 01/14/02 to 03/27/02
- Table 17. MIB Software 01/14/02 to 03/27/02 NXMR3 and NXMXR3 (G1
- Table 18. MIB Software Post 03/27/02 NXMR3, NXMDR3 C470
- Table 19. MIB Software Post 03/27/02 NXMR3, NXMDR3 (G138) and N3
- Table 20. NXMXDR3, NXMXR3 (B264)
- Table 21. Program Menu
- Table 22. Test Menu
- Table 23. Dash Display Drive Mode Inputs
- Table 24. Diagnostic and Diagnostic History Display
- Table 25. Special Program Menu
- Table 26. Program Menu Range and Default Values
- Table 27. Status LED Fault Codes
- Table 28. Dash Display Drive Mode Inputs
- Table 29. Dash Display Drive Mode Test Voltages
- Table 30. Dash Display Status/Warning/Fault Test Voltages

toc
- Steering System
- Safety Precautions Maintenance and Repair
- General
- Description
- Steering Control Unit Assembly
  - Description
  - Remove
- Steering Control Unit
  - Description
  - Operation
  - Remove
  - Repair
  - Install
- Steering Pump and Motor Assembly
  - Description
  - Pump and Motor
  - Pump
- Axle Assembly Repair
  - General
  - Traction Motor
  - Master Drive Unit
  - Hydraulic Steering Motor
  - Caster Wheels
  - Axle Weldment
  - Check and Adjust
- Troubleshooting
tables
- Table 1. Articulation Adjustment Chart

toc
- Steering System
- Safety Precautions Maintenance and Repair
- General
- Description
- Steering Control Unit Assembly
  - Description
  - Remove
- Steering Control Unit
  - Description
  - Operation
  - Remove
  - Repair
  - Install
- Steering Pump and Motor Assembly
  - Description
  - Pump and Motor
  - Pump
- Axle Assembly Repair
  - General
  - Traction Motor
  - Master Drive Unit
  - Hydraulic Steering Motor
  - Caster Wheels
  - Axle Weldment
  - Check and Adjust
- Troubleshooting
tables
- Table 1. Articulation Adjustment Chart

General
Safety Procedures When Working Near Mast
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks
- Load Backrest Extension, Remove and Install
- Carriage Assembly, Remove and Install
- Carriage Load Rollers, Remove and Install
- Side Rollers, Disassemble and Assemble
- Fork, Replace
  - Hook-Type Forks
Two-Stage Mast Assembly
- Remove
- Clean and Inspect
- Lift Cylinders, Remove and Install Dual-Lift Cylinders
- Lift Cylinder, Remove and Install Single Main-Lift Cylinders
  - Remove
  - Install
- Inner Mast Assembly, Remove and Install
- Hoses, Replace
- Hose and Cable Sheaves, Replace
- Two-Stage Lift Chains
  - Remove and Install
  - Clean and Inspect
- Two-Stage Chain Sheave, Remove and Install
- Load Rollers and Wear Plugs, Remove and Install
- Two-Stage Mast Assembly, Install
Three-Stage Mast Assembly
- Three-Stage Mast Assembly, Remove
  - N30XHM, N30XMH (C210), and V30ZMD (D210/E210) Only2
- Clean and Inspect
- Free-Lift Cylinder, Remove and Install
- Main Cylinders (Standard), Remove and Install
- Main Cylinders N30XMH, N30XMH (C210) and V30ZMD (D210/E210), Remove and Install2
- Inner and Intermediate Mast Assemblies, Remove and Install
- Hoses, Replace
- Hose and Cable Sheaves, Replace
  - Free-Lift Hose Sheave
  - Carriage Sheaves
- Three-Stage Lift Chains, Remove and Install
  - General
  - Free-Lift Chains
  - Main-Lift Chains
- Three-Stage Chain Sheaves, Disassemble and Assemble
  - Free-Lift Chain Sheaves
  - Main-Lift Chain Sheaves
- Load Rollers and Wear Plugs, Remove and Install
- Three-Stage Mast Assemble, Install
Mast Operation Check
Hydraulic System Leaks Check
Lift Chains Check
- General
- Clean and Inspect
- Lubrication
Mast Adjustments
- General
- Adjust Wear Plugs – Mast
- Adjust Free-Lift Chain (Three-Stage Only)
- Adjust Main-Lift Chains
  - Two-Stage
  - Three-Stage
- Adjust Wear Strips
Carriage Adjustments
- Adjust Wear Plug – Carriage
- Adjust Side Rollers – Carriage
- Adjust Thrust Rollers – Carriage
Troubleshooting