Hyster N25XMDR3, N30.40XMR3 (C470) Order Picker Service Manual
600 pages · Publication 1496168
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- Models
- N25XMDR3, N30.40XMR3 (C470)
- Manual type
- Service Manual
- Pages
- 600
- Publication
- 1496168
- Condition
- Brand new
What's inside
From the manual's own table of contents: 202 sections, 554 entries. See sample pages (PDF, 267 KB)
DC Motor Maintenance
Safety Precautions Maintenance and Repair
General
Brush and Commutator Inspection4 topics
- Hydraulic Pump Motor and Traction Motor
- Steering Pump Motor
- Normal Commutator Surface
- Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair6 topics
- Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
- Assemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
- Test for an Open Circuit in Armature
- Test for Short Circuit in One Armature Winding
- Test for Short Circuit to Armature Shaft
- Test for Open Circuit in Field Coil
- Test for Short Circuit in Field Coil
- Test for Short Circuit between Field and Motor Case
- Brush Holder Test
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Vista® Mast
Mast Weldments
Carriages
Two-Stage Mast2 topics
- Description
- Operation
Three-Stage Mast
Lift Cylinders
Description1 topic
- Lowering Control Valve
Main Cylinder Repair
Free-Lift Cylinder Repair
Mast
Safety Procedures When Working Near Mast
Show all 202 sections
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, a6 topics
- Load Backrest Extension, Remove and Install
- Carriage Assembly, Remove and Install
- Carriage Load Rollers, Remove and Install
- Side Rollers, Disassemble and Assemble
- Fork, Replace
- Forks - Hook Type
Two-Stage Mast Assembly15 topics
- Remove
- Clean and Inspect
- Lift Cylinders, Remove and Install Dual-Lift Cylinders
- Lift Cylinder, Remove and Install Single-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 Assembly16 topics
- Three-Stage Mast Assembly, Remove
- N30XHM Only
- Free-Lift Cylinder, Remove and Install
- Main Cylinders (Standard), Remove and Install
- Main Cylinders (N30XMH), Remove and Install
- Inner and Intermediate Mast Assemblies, Remove and Install
- 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
- Three-Stage Mast Assemble, Install
Mast Operation Check
Hydraulic System Leaks Check
Lift Chains Check2 topics
- General
- Lubrication
Mast Adjustments6 topics
- Adjust Wear Plugs - Mast
- Adjust Free-Lift Chain (Three-Stage Only)
- Adjust Main-Lift Chains
- Two-Stage
- Three-Stage
- Adjust Wear Strips
Carriage Adjustments3 topics
- Adjust Wear Plug - Carriage
- Adjust Side Rollers - Carriage
- Adjust Thrust Rollers - Carriage
Instrument Cluster7 topics
- Display Panels on Steering Column, Internal Combustion
- Display Panels on Steering Column, Electric Lift Trucks
- Standard Display Panel
- Enhanced Display Panel
- Curtis 1215 Display Panel
- Description and Features
- Operation
Cluster-Type Display Panel (Internal Combustion) Replacement2 topics
- Remove and Disassemble
- Assemble and Install
Cluster Display Panel (Electric Lift Truck) Replacement7 topics
- Display Panel Assembly, Replace
- LED Indicators
- Battery Indicators
- Digital Display (Enhanced Display Panel Only)
- Status Code or Performance Level Switches and LED indicators (En
- Standard Display Panel Parts, Replace
- Enhanced Display Panel Parts, Replace
Curtis 1215 Display Panel Replacement1 topic
- Install
Table 1. Instrument Cluster, Internal Combustion
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings1 topic
- Kilowatt-Hours
Battery Maintenance16 topics
- Safety Procedures
- Maintenance Records
- New Battery
- Cleaning Battery
- Adding Water to Battery
- Hydrometer
- Battery Temperature
- Charging Battery
- Types of Battery Charges
- Methods of Charging
- Troubleshooting Charger
- Knowing When Battery Is Fully Charged
- Where to Charge Batteries
- Equipment Needed
- Battery Connectors
- Battery Care
Table 1. Battery Capacity Terms
Battery Indicators8 topics
- Indicators With Meter Movements
- Battery Indicators With LCD or LED Displays
- Liquid Crystal Displays
- SEM Display Panels Description
- Light Emitting Diode Displays
- Description LX Series
- ZX Series Display Panels Description
- SEVCON POWERGAUGE—42 Battery Display Panel Description
Battery Indicators Without Lift Interrupt Adjustment (Early Mode
Battery Indicators With Lift Interrupt Adjustment (Early Models)2 topics
- Reset Potentiometer
- Specific Gravity Alarm
Battery Indicators Without Lift Interrupt Check (Later Models)
Battery Indicators With Lift Interrupt Adjustment (Later Models)1 topic
- Discharge Potentiometer
LED Display With Lift Interrupt
Curtis 933-1 Meter Check and Adjustment8 topics
- Check
- Reset Check
- Discharge Check
- Lockout Check
- LEDs Do Not Illuminate
- Hourmeter Check
- Hourglass Icon
- Adjust
SEVCON POWERGAUGE—42 Adjustment
Curtis Dash Display Assembly14 topics
- Description/Features
- Testing
- Inoperative Dash Display Assembly
- Inoperative Drive Mode Selection
- Troubleshooting With a Programmer Handset
- Troubleshooting Without a Programmer Handset
- No Warnings or Faults Displayed
- MIB/Dash Display Communication
- Lift Interrupt
- Lost MIB Signal Displayed
- Lift Pump Hourmeter Input
- Forward/Reverse Hourmeter Inputs
- Adjust (Setup, Early Models)
- Adjust (Setup, Later Model)
Battery Indicators Replacement
Battery Indicator Controller Replacement
Display Panel Components Replacement
SEM Display Panel Replacement1 topic
- Remove and Replace
Table 1. Battery Indicator (Later Models)
Table 2. SEVCON Discharge Curve Selector Positions
Table 3. Dash Display Drive Mode Inputs
Table 4. Dash Display Drive Mode Test Voltages
Table 5. Dash Display Status/Warning/Fault Test Voltages
Table 6. Testing Dash Display Status/Warning/Fault Inputs
Table 7. Battery Indicator Reset Adjustment
Metric and Inch (SAE) Fasteners6 topics
- Threaded Fasteners
- Nomenclature, Threads
- Strength Identification
- Cotter (Split) Pins
- Fastener Torque Tables
- Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Diagrams
Periodic Maintenance5 topics
- How to Move Disabled Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Load Wheels
- How to Raise Steer Wheel
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily16 topics
- Checks With Key Switch Turned OFF
- Battery
- Hydraulic System
- Tires and Wheels
- Safety Labels
- Overhead Guard
- Mast, Forks, and Lift Chains
- Reach, Tilt, and Sideshift
- Forks
- Lift Chain Adjustments
- Check With Key Switch Turned ON
- Instruments and Controls
- Lift System Operation
- Multifunction Control Handle
- Brake
- Steering System
Maintenance Procedures Every 350 Hours or 2 Months14 topics
- Master Drive Unit
- Brake
- Hydraulic System
- Articulation Stop Adjustment
- Adjustment Procedure
- Lift System Operation
- Forks
- Mast
- Lift Chains
- Other Lubrication
- Electrical Inspection
- Fuses
- Contactors
- Motor Brushes
Maintenance Procedures Every 2000 Hours or Yearly4 topics
- Change Hydraulic Oil
- Change Hydraulic Oil Filter
- Check Hydraulic Oil Strainer
- Brakes
Maintenance Procedures Every 3000 Hours or Three Years1 topic
- Traction Motor
Lift and Tilt System Leaks Check2 topics
- Lift System
- Tilt System
Brakes Adjustment2 topics
- How to Charge Battery
- How to Change Battery
Tires and Wheels5 topics
- Drive Tire
- How to Change Drive Tire
- Tandem Load Wheels
- Single Load Wheel
- Caster Wheels
Preparation for Storage2 topics
- Short-Term Storage (1 to 6 months)
- Long-Term Storage (6 months or longer)
Transporting2 topics
- Loading
- Unloading
Preparation for Use2 topics
- Preparation After Shipment
- Preparation After Storage
Table 1. Maintenance Schedule
Table 2. Articulation Adjustment Chart
Table 3. Fuses
Table 4. Hydraulic Tank Capacities
Table 5. Battery Size Specifications
Table 6. Tires and Wheels
Reach Carriages1 topic
- Reach Assemblies
Repair - General
Load Backrest Removal and Installation
Fork Replacement1 topic
- Hook Forks
Reach Assembly Removal and Installation
Carriage Load Rollers Removal and Installation
Side Rollers Disassembly and Assembly
Reach Assembly Repair
Reach Assembly Outer Frame4 topics
- Remove Without Sideshifter
- Disassemble Without Sideshifter
- Assemble Without Sideshifter
- Install Without Sideshifter
Single-Reach Scissor Arms
Double-Reach Scissor Arms
Inner Frame Assembly
Reach Cylinders
Tilt Cylinder
Sideshift Cylinder
Reach/Tilt Selector Valve
Carriage or Reach Assembly Adjustments4 topics
- Adjust Wear Plug
- Adjust Side Rollers
- Adjust Thrust Rollers
- Adjust Reach Cylinders
Specifications
Table 1. General Specifications
Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMD
Table 3. Operating Times W20/30ZR
Capacities and Specifications
SEM Traction Motor Controllers Factory Values and Min/Max Ranges
Lift Capacities
Oil Capacities
Master Drive Unit Specifications
Hydraulic Tank Capacities
Articulation Adjustment
Hydraulic Systems Specifications
Reach Carriage Specifications
Battery Size Specifications
Tire Sizes
Fuses
Steering Pump Specifications
Hydraulic Control Valve/Relay Coil Resistance Values
Hydraulic System
Control Handle
Control Valve5 topics
- Trucks built before 15 July, 2002
- Trucks built after 15 July, 2002
- Control Valve-Manual Lowering
- Trucks built before 15 July, 2002
- Trucks built after 15 July, 2002
Lift Pump and Motor
Steering Pump
Hydraulic Tank
Schematics
Table 1. Hydraulic Tank Capacities
Steering System
Steering Control Unit Assembly
Steering Control Unit6 topics
- Repair
- Disassemble (Before May 2002)
- Disassemble (After May 2002)
- Clean
- Reassemble (Before May 2002)
- Reassemble (After May 2002)
Steering Pump and Motor Assembly8 topics
- Pump and Motor
- Remove and Disassemble
- Assemble and Install
- Pump
- Remove
- Install
- Disassemble
- Assemble
Axle Assembly Repair21 topics
- Description
- Remove
- Install
- Description
- Remove Chain-Steered MDU
- Install
- Hydraulic Steering Motor
- Description
- Remove
- Install
- Description
- Caster Replacement
- Wheel Replacement
- Axle Weldment
- Remove
- Install
- Check and Adjust
- Remove Air From Steering System
- Check Steering Chain
- Check Articulation Stop Adjustment
- Steering Pressure
Table 1. Articulation Adjustment Chart
SEM Traction Motor Controller1 topic
- Test
Programmer Handset12 topics
- SCROLL DISPLAY Keys
- CHANGE VALUE Keys
- MORE INFO Key
- Connecting Handset to Traction Motor Controller
- Disconnecting Handset From Traction Motor Controller
- Programmer Self Test
- Operating Modes
- Program Menu
- Test Menu
- Diagnostics Menu
- Diagnostic History
- Special Program Menu
Programming the Traction Motor Controller - 1307 Handset
Programmer Handset12 topics
- Menu Navigation Key
- Data Increase/Decrease Key
- Bookmark Keys
- Connecting Handset to Traction Motor Controller
- Disconnecting the Handset From the Traction Motor Controller
- Main Menu Selections
- Program Menu
- Monitor Menu
- Faults Menu
- Functions menu
- Information Menu
- Programmer Setup Menu
Programming the Traction Motor Controller - 1311 Handset3 topics
- Status LED Diagnostics
- Diagnostics Menu
- Test Menu
Table 1. Program Menu
Table 2. Test Menu
Table 4. Diagnostics and Diagnostic History Display
Table 5. Special Program Menu
Table 6. SEM Traction Motor Controller Factory Values and Minimu
Table 7. Status LED Fault Codes
Electrical System
Component Repair and Testing - General
Contactor Panel Assembly
Contactors2 topics
- Auxiliary Switch
- EE Contactors
Relays6 topics
- Enable Relay
- Hourmeter Relay
- Lift/Lower Relay (Trucks Built After 1 August 2002)
- Coil Testing
- Contact Testing
- Remove and Install
Height Proximity Switch
Key Switch
Battery Disconnect Switch
Proportional Electro-Hydraulic Control Valves3 topics
- Manual Lowering
- Trucks Built Before 1 August, 2002
- Trucks Built After 1 August, 2002
Carriage Valve Assembly and Selector Valves1 topic
- Test/Remove/Install
Multifunction Control Handle1 topic
- Tools Required
Main Interface Board (MIB)5 topics
- LED Display
- MIB, Remove
- MIB J-Connector, Repair
- Inspect
- MIB, Install
Main Interface Board (MIB) Setup Procedures15 topics
- Default Values
- Checking Model Code, Software Version, and Setup Status
- MIB Generation II Setup Procedure
- Entering the Setup Mode
- Editing Settings
- Changing the Setting Values
- Entering Text
- System Information and Fault Log
- Passwords
- Defaults
- Exit and Save
- Parameters
- Top Level Menu Items
- Max Speed and Low End Adjustments
- Customizing MIB Functions
MIB Status, Warning, and Fault Codes1 topic
- Troubleshooting Charts
Blank or Undefined Code Conditions
Status Codes
Warning Codes
Fault Codes20 topics
- Connecting Handset to Traction Motor Controller
- Disconnecting Handset from Traction Motor Controller
- Programmer Self Test
- Program Menu
- Test Menu
- Diagnostics Menu
- Diagnostic History
- Special Program Menu
- Menu Navigation Key
- Data Increase/Decrease Key
- Bookmark Keys
- Connecting Handset to Traction Motor Controller
- Disconnecting the Handset From the Traction Motor Controller
- Program Menu
- Monitor Menu
- Faults Menu
- Functions menu
- Information Menu
- Programmer Setup Menu
- Programmer Diagnostics
Dash Display Assembly14 topics
- Description and Features
- Battery Indicator
- Voltage Selection
- Dash Display, Adjust
- Battery Indicator Profile Settings
- Troubleshooting
- Inoperative Dash Display Assembly
- Inoperative Drive Mode Selection
- Troubleshooting the Dash Display With a Programmer Handset
- Troubleshooting Without a Programmer Handset
- No Warnings or Faults Displayed
- Lift Interrupt
- Lost MIB Signal Displayed
- Hourmeter Input
Table 1. Contactor Coil Voltages
Table 2. Fuses
Table 3. Hydraulic Control Valve/Relay Coil Resistance Values
Table 4. Truck Unit and Model Codes
Table 5. MIB Function Code Values for N30XMR3 Software 06/01/01
Table 7. MIB Function Code Values for N25XMDR3
Table 8. MIB Function Code Values for N50XMA3
Table 9. MIB Function Code Values for N45XMR3
Table 10. MIB Function Code Values for N30XMDR3
Table 11. MIB Function Code Values for N45XMXR3 Mast Full Height
Table 12. MIB Function Code Values for N45XMXR3 Mast Full Height
Table 13. MIB Function Code Values for N30XMXDR Mast Full Height
Table 14. MIB Function Code Values for N30XMXDR Mast Full Height
Table 20. Program Menu
Table 21. Test Menu
Table 22. Dash Display Drive Mode Inputs
Table 23. Diagnostic and Diagnostic History Display
Table 24. Special Program Menu
Table 25. Program Menu Range and Default Values
Table 26. Status LED Fault Codes
Table 27. Dash Display Drive Mode Inputs
Table 28. Dash Display Drive Mode Test Voltages
Table 29. Dash Display Status/Warning/Fault Test Voltages
Master Drive Unit
HFK400 Master Drive Unit5 topics
- Drive Unit Maintenance and Repair
- Remove
- Install
- Disassemble
- Assemble
GK Master Drive Unit4 topics
- Maintenance and Repair
- Mounting Electric Motor
- Pivoted Connection - Geared Steering
- Check the Backlash
Table 1. Tooth Contact Pattern
Inside this manual
Real pages from this service manual (600 pages). Open the sample pages (PDF, 266 KB)
- Specifications, page 216: General
- Diagram, page 360: Schematics
- Troubleshooting, page 513: MIB Status, Warning, and Fault Codes
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 600 pages
Quantity one is the manual described above.
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Other editions and similar models
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