Hyster R30XM, R30XMA, R30XMF, R30XMS Forklift OEM Service & Repair Manual

%$77(5< ,1',&$7256 ALL ELECTRIC LIFT TRUCKS PART NO. 910114 2260 SRM 138

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. • Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte- nance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage!

Battery Indicators Table of Contents TABLE OF CONTENTS General ............................................................................................................................................................... 1 Indicators With Meter Movements ............................................................................................................... 1 Battery Indicators With LCD or LED Displays ........................................................................................... 4 Liquid Crystal Displays ............................................................................................................................ 4 Display Panels Description (ZX or Earlier Motor Controllers) .......................................................... 4 SEM Display Panels Description.............................................................................................................. 6 Light Emitting Diode Displays ................................................................................................................. 7 Description LX Series ............................................................................................................................... 7 ZX Series Display Panels Description ...................................................................................................... 9 SEVCON POWERGAUGE™ Battery Display Panel Description.......................................................... 10 Battery Indicators Without Lift Interrupt Adjustment (Early Models) ......................................................... 10 Battery Indicators With Lift Interrupt Adjustment (Early Models) ............................................................... 11 Reset Potentiometer ...................................................................................................................................... 11 Specific Gravity Alarm .................................................................................................................................. 11 Battery Indicators Without Lift Interrupt Check (Later Models) ................................................................... 12 Battery Indicators With Lift Interrupt Adjustment (Later Models) ............................................................... 12 Reset Potentiometer ...................................................................................................................................... 12 Discharge Potentiometer ............................................................................................................................... 12 LED Display With Lift Interrupt ...................................................................................................................... 13 Curtis 933-1 Meter Check and Adjustment...................................................................................................... 13 Check .............................................................................................................................................................. 13 Reset Check ............................................................................................................................................... 14 Discharge Check ........................................................................................................................................ 14 Lockout Check ........................................................................................................................................... 15 LEDs Do Not Illuminate ........................................................................................................................... 15 Hourmeter Check ...................................................................................................................................... 15 Hourglass Icon ........................................................................................................................................... 15 Adjust ............................................................................................................................................................. 15 SEVCON POWERGAUGE™ Adjustment ........................................................................................................ 16 Curtis Dash Display Assembly.......................................................................................................................... 16 Description/Features ..................................................................................................................................... 16 Operation ....................................................................................................................................................... 17 Testing ............................................................................................................................................................ 17 Inoperative Dash Display Assembly ........................................................................................................ 17 Inoperative Drive Mode Selection ............................................................................................................ 18 Troubleshooting With a Programmer Handset ........................................................................................ 18 Troubleshooting Without a Programmer Handset .................................................................................. 19 No Warnings or Faults Displayed ............................................................................................................ 19 MIB/Dash Display Communication.......................................................................................................... 20 Lift Interrupt ............................................................................................................................................. 20 Lost MIB Signal Displayed ....................................................................................................................... 21 Lift Pump Hourmeter Input ..................................................................................................................... 21 Forward/Reverse Hourmeter Inputs ........................................................................................................ 21 Remove ........................................................................................................................................................... 22 Install ............................................................................................................................................................. 22 Adjust (Setup, Early Models) ........................................................................................................................ 22 Adjust (Setup, Later Model) .......................................................................................................................... 23 Battery Indicators Replacement ....................................................................................................................... 24 Battery Indicator Controller Replacement ....................................................................................................... 24 Display Panel Components Replacement ......................................................................................................... 25 SEM Display Panel Replacement ..................................................................................................................... 25 ©2002 HYSTER COMPANY i

Table of Contents Battery Indicators TABLE OF CONTENTS (Continued) Remove and Replace ...................................................................................................................................... 25 This section is for the following models: All Electric Lift Trucks ii

2260 SRM 138 General General WARNING If the lift truck has been operated using a low battery, check all contactors for welded con- tacts before connecting a charged battery. Lift truck operation cannot be controlled if the con- tacts are welded. CAUTION Do not operate an electric lift truck with a discharged battery. Continued operation can damage contactors, motors, and the battery. This section has a description and the repair and adjustment procedures for the different battery indicators used on electric lift trucks. INDICATORS WITH METER MOVEMENTS The lift truck can have one of two types of battery indicators. One type of indicator does not have Lift Interrupt and is not adjustable. See Figure 1. The other type of battery indicator has Lift Interrupt and is adjustable for different batteries or operating con- ditions. See Figure 2. The indicator that does not have Lift Interrupt is a voltmeter. The face of the meter has a green and red band. Some meters also have a yellow band between the red and green bands. During operation, the indicator needle moves from the green to the red band to indicate a discharged battery. When the battery is fully charged, the needle is in the green band. The early (D of Figure 1) battery indicator with Lift Interrupt automatically measures the charge of the battery. A separate controller for the meter has an electronic circuit. This circuit controls the meter movement, a warning light (early units only), and an electronic switch for the main hydraulic pump. The circuit can remember the charge on the battery when the battery is disconnected and connected. The meter face has a band that is red at the left end and green at the right. Some indicators have a split area with green on top and yellow on the bottom. Some other meters have a yellow band between the red and green bands. The needle location indicates the battery charge level. When the needle is at the edge of the red area of the band, the warning light illuminates if the indicator has one. At this point, the battery has approximately 5% (reserve) capacity remaining. If the reserve is used, the needle enters the red band and power to the hydraulic pump motor is interrupted until the battery is charged or replaced. Normally there is enough battery power to move the lift truck to a battery charger or to a place where a charged battery can be installed. When the needle of the indicator is in the red band, the battery must be charged or changed. Continued operation will damage the battery, contactors, or motors. Another of the battery indicators with Lift Interrupt is also a gauge type instrument (E of Figure 1). A separate controller for this indicator has an electronic circuit that controls the indicator needle, a red warning light, and an electronic switch for the main hydraulic pump. The circuit can remember the charge on the battery when the battery is disconnected and connected. This gauge indicator has a band that is a split area with green on the top and red on the bottom. The needle location indicates the battery charge level. When the battery has been discharged so the warning light illuminates, there is still some capacity in the battery. If operation is continued, power to the main hydraulic pump circuit is interrupted (specific gravity is approximately 1.140). This action prevents the operation of the main hydraulic pump. Normally there is enough battery power to move the lift truck to a battery charger or to a place where a charged battery can be installed. When the warning light illuminates, the battery must be charged or changed. Continued operation will damage the battery, contactors, or motors. 1

Hyster R30XM, R30XMA, R30XMF, R30XMS Forklift OEM Service & Repair Manual

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Hyster R30XM, R30XMA, R30XMF, R30XMS Forklift OEM Service & Repair Manual

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