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INTRODUCTION

GENERAL HOW TO MOVE A DISABLED LIFT TRUCK

This section contains a MAINTENANCE SCHED- WARNING


ULE and the instructions for maintenance and inspec- Use extra care when moving a lift truck during the
tion. following conditions:
a. Brakes do not operate correctly
The MAINTENANCE SCHEDULE has time intervals b. Steering does not operate correctly
for inspection, lubrication and maintenance. The time c. Tires are damaged
intervals are based on a normal operation. A normal d. Traction conditions are bad
operation is considered to be one eight hour shift per e. The lift truck must be towed on a steep grade.
day in a relatively clean environment on an improved If there is no electrical power, there is no steering and
surface. Multiple shifts, dirty operating conditions, the brake will be applied. Do NOT tow the lift truck if
etc., will require a reduction in the recommended time there is no power. Poor traction can cause the disabled
periods in the Maintenance Schedule. lift truck or towing vehicle to slide. Steep grades will
require additional brake force to stop the lift truck.
Some users have service personnel and facilities to do
the items listed in the MAINTENANCE SCHEDULE. Never carry a disabled lift truck unless the lift truck
Service Manuals are available from your Hyster lift MUST be moved and can not be towed. The lift truck
truck dealer to help users who do their own mainte- used to lift the disabled lift truck MUST have a rated
nance. capacity equal to or greater than the weight of the dis-
abled lift truck. The capacity must be for a load center
Your Hyster lift truck lift truck dealer has the personnel equal to half the width of the disabled lift truck. See the
and equipment to do a complete program of inspection, nameplate on the disabled lift truck for the approximate
lubrication and maintenance. Periodic maintenance total weight. The forks must extend the full width of the
will help your lift truck operate better over a longer pe- disabled lift truck. Center the weight of the disabled lift
riod. truck on the forks and be careful not to damage the un-
der side of the disabled lift truck. Tilt the mast back and
Put the lift truck on a level surface. Lower the platform travel slowly.
and forks, apply the parking brake and turn the key
switch to OFF. Open the access panels and check for CAUTION
leaks and conditions that are not normal. Clean any oil Do NOT tow the lift truck by fastening a towing de-
or other spills. Make sure that lint, dust, paper and other vice to the attachment or base arms. Make sure the
materials are removed from the compartments. guidance sensors are not damaged when connecting
a chain to the lift truck.

WARNING How To Tow The Lift Truck


Do not make repairs or adjustments unless you have 1. If the lift truck must be towed, the operator must be
both authorization and training. Repairs and ad- on the lift truck to release the brake and steer the lift
justments that are not correct can be made on a lift truck.
truck by people without authorization and training.
Repairs and adjustments that are not correct can 2. Tow the lift truck slowly.
make a dangerous operating condition. 3. Raise the platform approximately 30 cm (12 inches)
from the surface. Install a chain to prevent the platform
Do not operate a lift truck that needs repairs. Report
and mast channels from moving.
the need for repairs immediately. If repair is neces-
sary, put a DO NOT OPERATE tag in the opera- 4. If another lift truck that has the drive wheels near the
tors area. Remove the key from the key switch. forks is used to tow the disabled lift truck, that lift truck

1
must have weight added to the forks. The total weight
CAUTION
of the lift truck and load must be equal or greater than
the weight of the disabled lift truck. Install a load of ap- Make sure the sensors are not damaged on trucks
proximately half the maximum capacity on the forks of that have wire guidance.
the lift truck that is used for towing. This load will in- 2. Use a special low clearance hydraulic jack, crane or
crease the traction of the lift truck. Keep the load on the another lift truck to raise the drive tire. Make sure that
forks lowered as much as possible. If the lift truck used the jack, crane or other lift truck has the correct mini-
for towing has a master drive unit or drive unit similar mum capacity rating. The capacity must equal at least
to the R40E/EA/EF/ES, do NOT add weight to the 2/3 the weight of the lift truck including the battery. See
forks. Additional weight on the forks will DECREASE the nameplate.
the traction of the drive wheel(s). Make sure that the lift
truck has a total weight equal to or greater than the 3. Raise the lift truck only enough to suspend the drive
weight of the disabled lift truck. tire. Install additional blocks under the frame near the
drive tire.
5. Make sure the tow chain has the capacity to tow the
weight. Carefully fasten the tow chain to the drive unit
How To Raise Load Wheels (See FIGURE 1.)
end of the lift truck. Make sure the chain is fastened so
that the chain will not cause damage to either lift truck. 1. Put blocks on both sides (front and back) of the drive
tire to prevent movement of the lift truck.
HOW TO PUT A LIFT TRUCK ON BLOCKS
CAUTION
WARNING
Make sure the sensors are not damaged on trucks
The lift truck must be put on blocks for some types of that have wire guidance.
maintenance and repair. The removal of the follow-
ing assemblies will cause large changes in the center WARNING
of gravity: mast, battery and master drive unit.
Never raise the base arms any higher than necessary
Do NOT put the lift truck on blocks if the surface is to change the load wheels. Always raise both base
not solid, even and level. Make sure that any blocks arms at the same time. Raising the base arms too
used to support the lift truck are solid, onepiece high can make the lift truck tip over and cause dam-
units. Put a block in front and back of the tires touch- age or possible injury.
ing the ground to prevent movement of the lift truck.
2. Use a hydraulic jack, crane or another lift truck to lift
Do not raise the lift truck by attaching an overhead the base arms. Make sure that the jack, crane or other
crane to the overhead guard or areas of the mast that lift truck has a capacity equal to at least half the weight
can be damaged. Some of these components and oth- of the lift truck including the battery.
er lift points are not designed to support the weight of
the lift truck. The lift truck can be damaged or it can 3. Put blocks under the base arm at the rear of the load
fall on someone causing serious injury. Attach the wheel to support the lift truck.
chain or sling to a support structure of the lift truck
frame. CAUTION
For correct operation of the wire guidance system,
How To Raise Drive Tire (See FIGURE 1.)
both load wheels must always be replaced at the
1. Put blocks on each side (front and back) of the load same time. The load wheels must have the same di-
wheels to prevent movement of the lift truck. ameter within 1 mm (0.039 in).

2
R30E/EA/EF R30ES

12292

DRIVE/STEER WHEEL LOAD WHEEL


FIGURE 1. PUT THE LIFT TRUCK ON BLOCKS

MAINTENANCE SCHEDULE
1
22 4 6 11 13
9 23 3 2 20

3
17
4 8 19
24

12296

5 15 12
10 3 16 18
22 21 13
R30E/EA/EF SHOWN
R30ES SIMILAR

FIGURE 2. MAINTENANCE POINTS

3
TABLE 1. MAINTENANCE SCHEDULE (Item No. Reference Figure 2)
8 350 2000
ITEM Hr/ Hr/ Hr/ PROCEDURE OR
ITEM SPECIFICATION
NO. 1 day 2 mo 1 yr QUANTITY
1 HYDRAULIC OIL (Full Mark)
R30E/EA X C1 30 litre (7.9 gal) 18C to 38C
R30EF X C1 36 litre (9.5 gal) (0F to 100F)
R30ES X C1 14.6 litre (3.9 gal) SAE 10W API SC/CC
OIL LEAKS Check For Leaks
2 BATTERY X 2 Check Level See BATTERY
PANELS LATCHES X Check Operation SPECIFICATIONS
3 DRIVE TIRE AND WHEELS X Check Condition See Parts Manual
4 FORKS X Check Condition See Parts Manual
5 LIFT CHAINS X Check Condition See Parts Manual
6 MAST AND PLATFORM X Check Condition
7 BRAKE X Check Operation Hold On 5% Grade
8 GAUGES, HORN, FUSES X Check Operation
9 STEERING X,L Check Operation MultiPurpose Grease3
10 DIRECTION/SPEED CONTROL X L Check Operation MILG7711A or equivalent
11 HYDRAULIC TANK BREATHER X Clean Or Replace See Parts Manual
13 HYDRAULIC PUMP COUPLING L Clean And Soak Hyster Part No. 351333
12 CONTACTOR TIPS X Check Condition See Parts Manual
13 MOTOR BRUSHES X Check Condition See Parts Manual
SAFETY LABELS X Replace if Necessary See Parts Manual
6 MAST AND PLATFORM
15 ROLLERS L As Required MultiPurpose Grease3
4 FORK PIN AND GUIDES L As Required MultiPurpose Grease3
5 LIFT CHAINS AND SHEAVES X,L As Required SAE 20 Oil or P/N 171550
16 SLIDING SURFACES L As Required MultiPurpose Grease3
17 WHEEL NUT TORQUE X Tighten if Required 136 N.m (100 lbf ft)
18 MASTER DRIVE UNIT (R30ES) X C 2.5 litre (2.6 qt) MILL2105 B, AGL5
(R30E/EA/EF) X C 3.8 litre (1 gal) SAE 80W90 or 85W140
19 STEERING CHAIN L As Required MultiPurpose Grease3
STEERING GEAR HOUSING C 325 ml (11 oz.) Hyster Part No. 347031
20 HYDRAULIC FILTER C 1 ea. See Parts Manual
21 ELECTRIC. CABLE SHEAVES L As Required MultiPurpose Grease3
22 BASE ARM BEARINGS L As Required MultiPurpose Grease3
23 PALLET CLAMP L As Required MultiPurpose Grease3
24 EMERGENCY STOP KNOB X Check Operation
LIMIT SWITCH ROLLERS L As Required MultiPurpose Grease3
MISC. L As Required Hyster Part No. 347031
X = Check C = Change L = Lubricate
1 Change oil after first 250 hours. Change oil every 1000 hours or six months with corrosion/freezer option.
2 Equalization Charge approximately each month but not more than each week.
3 MultiPurpose Grease with 24% Molybdenum Disulfide.

NOTE: Never use steam to clean electrical parts.

4
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY
the three nuts that fasten the plate to the top of the tank.
WARNING
Carefully lift the plate assembly, tube and filter element
Do NOT operate a lift truck that needs repairs. Re- while keeping the tube vertical. The filter element is
port the need for repairs immediately. If repair is held on the bottom of the tube by a grommet as shown
necessary, put a DO NOT OPERATE tag in the in FIGURE 7. Install the replacement element on the
operators area. Remove the key from the key tube, install the plate assembly and connect the hose to
switch. the fitting.
HOW TO MAKE CHECKS WITH KEY NOTE: If the filter element slips off the tube during re-
SWITCH OFF moval or installation, use the end of the tube to move
the element into the correct position to insert the tube in
Hydraulic System (See FIGURE 3.) the element.
Inspect the hydraulic system for leaks and damaged or
WARNING loose components.
Do not permit the hot hydraulic oil to touch the skin
and cause a burn. When the hydraulic oil is at oper-
ating temperature, it is HOT. 1 1 3
5 2

CAUTION
Do not permit dirt to enter the hydraulic system 4
when the filter is changed.
Never operate the hydraulic pump without oil in the 4
hydraulic system. The operation of the hydraulic 5
pump without oil will damage the pump. 3
Check the hydraulic oil level at the sight gauge when 6
the oil is at operating temperature. The platform must
be lowered and the key switch must be OFF. If the oil
level is not visible at the sight gauge, the oil level is
above or below the sight gauge. open the door of the 1. FILL/BREATHER
2. PLATE ASSEMBLY
hydraulic compartment to check for the correct level
3. HOSE CONNECTOR
and to fill the tank if necessary. If too much hydraulic 4. SIGHT GAUGE 7
oil is added, the oil will leak from the breather during 5. HYDRAULIC TANK
operation. Clean the breather and fill cap by flushing 6. TUBE 8
7. FILTER ELEMENT
with solvent. Install and tighten the fill cap. 8. GROMMET
12293
To drain the oil, put the lift truck on a level surface. R30E/EA standard hydraulic tank shown.
Completely lower the mast and the forks. Use a con- R30EF tank is larger. R30ES tank is smaller.
tainer with a 36 litre (9.5 gal) capacity near the supply FIGURE 3. HYDRAULIC CHECKS
hose of the hydraulic tank to hold the oil. The R30EF
and R30ES units need a container with a capacity of 36
Battery
litre (9.5 gal). Turn the key switch to the OFF position
and disconnect the battery.
WARNING
Replace the element every 2000 hours or yearly with Do not put tools on the battery. Tools on the battery
each oil change. To replace the element, remove and can cause a short circuit and possible damage or in-
plug the hose at the fitting near the breather. Remove jury.

5
The acid in the electrolyte can cause injury. If the Dealer for the correct spacers. The correct battery is in
electrolyte leaks, use water to flush the area. Make BATTERY SPECIFICATIONS at the end of this sec-
the acid neutral with a solution of sodium bicarbon- tion. Check that each battery compartment panel fits
ate (soda) . Acid in the eyes must be immediately correctly and is not bent. On R30E/EA/EF units, check
flushed with water. that each panel latch engages the panel bracket cor-
Check the level of the electrolyte daily on a minimum rectly and that the welds on the bracket are not broken.
of one cell. Add only distilled water, as necessary, to all Each latch must be free to operate and remain in the Up
cells if the cell is low. The correct level is halfway be- position when the notch is engaged.
tween the top of the plates and the bottom of the fill
hole. To check and add water to the cells, the battery Mast, Platform, Forks And Lift Chains (See
must be out of the battery compartment. FIGURE 4. and FIGURE 5.)

WARNING WARNING
Do NOT put hands, arms, feet or legs between the NEVER work under a raised platform or forks.
battery and a solid object. Batteries are very heavy Lower the platform or use chains on the mast weld-
and can cause an injury. ments and platform so that they can not move. When
chains are used, make sure the moving parts are fas-
The lift truck and battery stand must be on a level
tened to a part that can not move.
surface to remove the battery.
Remove the battery as described in CHANGING THE
BATTERY in this section. Check the battery case, con- 1
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nector and cables for damage, cracks or breaks. See the
battery dealer in your area to repair any damage. Keep
the battery case, and the battery compartment clean and
painted. Leaks and corrosion from the battery can
cause a malfunction in the electric controls of the lift
truck. Use a water and soda solution to clean the battery 5
2
and the battery compartment. Keep the top of the bat- 4 6
tery clean, dry and free of corrosion. 3
Check that the correct spacer is installed across the
mast side of the battery compartment. The spacer must
6705
allow the battery to move not more than 13 mm (0.5 in)
toward the front or rear of the compartment. Check that 1. WORN PIN
2. CRACKS 5. LOOSE LEAVES
the battery cannot move more than 13 mm (0.5 in)
3. EDGE WEAR 6. DAMAGED PIN
across the width of the lift truck. If the battery can 4. HOLE WEAR 7. RUST
move more than the maximum amount, make sure the
battery is the correct weight and the correct spacers are FIGURE 4. INSPECT THE LIFT CHAINS AND
installed for that battery. See your Hyster Lift Truck CABLES

3
5
2 2
2
4
1
6706

1. TIP ALIGNMENT 2. CRACKS 3. FORK PIN DAMAGE 4. NEWER STYLE 5. OLDER STYLE
FIGURE 5. HOW TO INSPECT THE FORKS

6
Pallet Clamp
WARNING
Do not try to correct alignment of the fork tips by Check for correct operation of the pallet clamp. Put an
bending the forks. Use shims to align the fork tips. empty pallet on the forks. With the forks raised so that
Replace damaged forks. the pallet is supported by the forks, stand on the corners
of the pallet farthest from the operators platform.
Never repair damaged forks by heating or welding.
Some movement may occur, but the board under the
Forks are made of special steel using special proce-
opposite fork must not raise enough to contact the fork.
dures. Replace damaged forks. Always replace forks
in pairs.
Tire, Wheels and Caster
1. Inspect the welds on the mast and platform for (See FIGURE 6.)
cracks. Make sure that the nuts and bolts are tightened.
Inspect the caster (R30EF only), drive tire and load
2. Inspect the channels for wear in the areas where the wheels for damage. Inspect the tread and remove any
rollers travel. Inspect the rollers for wear or damage. objects that will cause damage. See FIGURE 6. Inspect
the wheels and caster for loose or missing parts. Re-
3. Check all lift chains for the correct lubrication. Lu-
move any wire, strapping, or other material wound
bricate the lift chains using the oil specified in the
around the axles or caster.
MAINTENANCE SCHEDULE in this section.

4. Inspect the lift chains for cracks or broken links and


1
pins. See FIGURE 4.
2
5. Inspect the chain anchors and pins for cracks or dam-
age.

6. Make sure the lift chains are adjusted so that they


have equal tension. Check tension by pulling horizon-
tally on both chains and checking that they move the
same amount. If the chains need repair or adjustment, it
must be done by authorized personnel. 2
7. Check that the fork tips are aligned within 13 mm
(0.5 in) of each other. See item 1 of FIGURE 5. Add or
remove shims for alignment. 11402

8. Inspect forks for cracks and wear. 1. MAKE SMOOTH EDGES


2. REMOVE NAILS, GLASS AND ALL METAL
9. Replace any damaged or broken parts that are used to
FIGURE 6. INSPECTING THE TIRE AND
keep the forks locked in position.
WHEELS

Tether Line And Belt Make sure the wheel nuts are tightened to the correct
torque value. Tighten the nuts in a cross pattern to the
1. Inspect the tether line for wear, cuts or damage. In- correct torque value shown in the Maintenance
spect the clips for cracks and proper operation.
Schedule table.
WARNING CAUTION
The tether line is specially made to lessen the shock If the wheels have been removed and installed, check
during a fall. Do not substitute other types of rope. all wheel nuts after 2 to 5 hours of operation. Tighten
2. Inspect the belt for cracks, cuts or wear. The operator the nuts in a cross pattern to the correct torque value
must fasten the belt snugly with the D ring in the cen- shown in the MAINTENANCE SCHEDULE table.
ter of the back. When the nuts stay tight after eight hours, the inter-

7
val for checking the torque can be extended to 350 meter to operate. The battery meter operates whenever
hours. a charged battery is connected.
The battery meter correctly indicates the condition of
HOW TO MAKE CHECKS WITH THE KEY
the battery. If the battery meter needle is in the red area
SWITCH ON
or the light (lift interrupt) is ON, charge the battery.
There must be a current flow from the battery before
WARNING the indicator for the lift interrupt will be reset and indi-
Make sure the area around the lift truck is clear be- cate correctly. Normal operation, after connecting a
fore moving the lift truck or checking for correct op- charged battery, will reset the indicator.
eration. Be careful when making the checks.
There is a 15 amp control fuse under the instrument
Gauges, Lights, Horn And Fuses panel. There can also be a 15 amp fuse for the spot light
(See FIGURE 7. and Table 1) and fan. There is also a 35 amp fuse near the steer mo-
tor contactor in the motor compartment. There are two
NOTE: None of the electrical controls will operate until power fuses in the electrical compartment. The power
the power disconnect circuit is energized by the key fuses have the following ratings:
switch. Traction Motor 300 amp
Hydraulic Pump Motor 500 amp
Check that all the instruments and controls operate as
described in OPERATING MANUAL. Check the op- Check that the fuses are the correct size and are not
eration of the gauges and horn. The key switch must be burned. Some types of fuses must be checked with an
in the ON position to operate the horn. The key switch ohmmeter. If any of the fuses are bad, disconnect the
must be ON and the foot switch depressed for the hour battery before replacing the fuse.

NOTE: Location of Guidance Button and Light can be different than


shown. 4 7 9 15
5 6 8 10

12

11
12 14
16
OLDER UNIT NEWER UNITS
(EXCEPT R30ES) (EXCEPT R30ES)
1 3 13
18
17
11 14
2
12294
1. STEERING CONTROL
2. STEER TIRE R30ES ONLY
1
POSITION INDICATORS 10. DIRECTION/SPEED CONTROL 11
3. GUIDANCE BUTTON 11. HORN SWITCH BUTTON
AND LIGHT 12. FAST LIFT SWITCH BUTTON
4. FAN SWITCH BUTTON 13. SLOW LIFT/LOWER ROCKER SWITCH
5. SPOT LIGHT SWITCH BUTTON 14. FAST LOWER SWITCH BUTTON
6. BATTERY INDICATOR 15. SLOW LIFT SWITCH BUTTON
7. HOUR METER 16. SLOW LOWER SWITCH BUTTON
8. EMERGENCY STOP KNOB 17. LIFT SWITCH
9. KEY SWITCH 18. LOWER SWITCH
FIGURE 7. INSTRUMENTS AND CONTROLS

8
Switches And Direction/Speed Control raise smoothly. Lower the platform and forks. All mov-
ing components must lower smoothly.
Check that the Direction/Speed control and the
switches for Lift and Lower operate as described in Ta- 5. Check that the top of the forks are 70 to 83 mm (2.75
ble 1 of the OPERATING MANUAL. Check that the to 3.25 inches) above the floor for the R30E units.
foot switch and Direction/Speed control operates as de- Check that the forks are 159 to 171 mm (6.25 to 6.75
scribed in the Operating Procedures section of the OP- in) above the floor for the R30EA, R30EF and R30ES
ERATING MANUAL. units. If the clearance is not correct, the chain anchors
must be adjusted.
Check the operation of the Emergency Stop knob. The
location of the knob is shown in FIGURE 7. Push the 6. Check the operation of the limit switches on the
knob with the key switch ON and the foot switch de- mast. The maximum travel speed must be slower when
pressed. All electrical circuits must NOT operate. the platform is above 910 mm (24 in). The R30E units
Move the key to the OFF, START and ON positions to must not move when the platform is above 3810 mm
reset the power disconnect circuit. (150 in) unless the lift truck has the Override function
and the Override button is depressed. The R30EA,
R30EF and R30ES units will move when the platform
Lift System Operation is above 3810 mm (150 in) if the steering system is
within 7 of straight travel.
WARNING
7. If necessary, have the lift truck checked and adjusted
Lower the lift mechanism completely. Never allow by authorized service personnel.
anyone under a raised platform or forks. Do not put
any part of your body in or through the lift mecha-
Brake
nism unless all parts of the mast and platform are
completely lowered and the key switch is in the OFF Check the operation of the brake. The brake is applied
position. Remove the key. as the operators foot is removed from the foot switch.
The brake must not let the lift truck move if parked on
Before making any repairs, completely lower the
an incline. The brake, when in good condition and cor-
platform or use chains on the mast weldments and
rectly adjusted, will hold the lift truck with a capacity
platform so that they can not move. Make sure the
load on a 5% grade [a slope of 0.5 metre in 10 metres (a
moving parts are fastened to the parts that can not
slope of 0.5 ft in 10 ft)]. If the brake does not hold the
move.
lift truck on the grade, the brake needs to be checked by
Do not try to find hydraulic leaks by putting hands authorized service personnel. Refer to the procedures
on hydraulic components under pressure. Hydraulic for the BRAKE in EVERY 2000 HOURS OR
oil can be injected into the body by pressure. YEARLY of this section.
1. Check for leaks in the hydraulic system. Check the
condition of the hydraulic hoses and tubes. Steering System

2. Slowly raise and lower the forks and the platform WARNING
several times without a load. All moving components There is NO steering if there is no electrical power.
must raise and lower smoothly. To prevent injury or damage, make sure the electric
power steering is operating correctly before moving
3. The platform and the forks must lower completely.
the lift truck.
4. Raise the platform one metre (three feet), with a ca- Check that the steering system operates smoothly and
pacity load. The inner weldment and platform must gives good steering control.

9
EVERY 350 HOURS OR TWO MONTHS
Do these procedures in addition to the 8 hour checks.

HYDRAULIC TANK BREATHER can damage motors and weld contactor contacts.
(See FIGURE 3.) Never try to repair contactor contacts that are
welded. Always replace welded contacts. Do not op-
The fill cap and breather assembly are in the hydraulic erate the lift truck using a battery that has a specific
compartment at the top of the hydraulic tank. Remove gravity of 1.130 or less.
the fill cap assembly from the hydraulic tank and clean
the filter material of the breather in solvent. Replace WARNING
the fill cap and breather assembly if air will not flow If the lift truck has been operated using a low battery
through it easily. or deenergized with the power disconnect circuit, in-
spect for welded contacts BEFORE connecting a
ELECTRICAL INSPECTION charged battery. The Power Disconnect circuit will
not reset and lift truck operation cannot be con-
WARNING trolled if the contacts are welded.
Disconnect the battery connector before making any Open the electrical compartment for access to the con-
inspections or repairs. Personal injury or equipment tactors.
and tool damage can occur if the battery is not dis-
connected. Motor Brushes (See FIGURE 8.)
Do not touch the terminals of capacitor C1 of the
traction or lift control circuits. The charge on the ca- CAUTION
pacitors can cause electrical shock and personal in- Low battery voltage makes motors use high currents
jury. Use an insulated screwdriver or jumper wire to for a longer time to do the same work. These currents
make a shortcircuit across the capacitor terminals can damage motors and contactor contacts. Do not
to discharge each capacitor. This will discharge the operate the lift truck using a battery that has a spe-
capacitors to prevent electrical shocks. cific gravity of 1.130 or less.

Contactors WARNING
The contact surfaces of the contactor are a silver alloy Disconnect the battery before making any checks on
over a copper base. In normal operation, the contact the motors. Personal injury or equipment and tool
surfaces become a dark color and rough. Cleaning is damage can occur if the battery is not disconnected.
not necessary. Do not use a file or emery cloth on the Open the front compartment doors for access to the
contacts. Replace the contacts when the surface is worn motors.
to the base material. Always replace the contacts in sets
To check the motor brushes, disconnect the battery and
(two pairs). If necessary, disassemble the contactor to
get access to the motor. Check motor brushes using the
inspect the contacts. See the section EV100 MOTOR
following procedure:
CONTROLLER REPAIR, 2200 SRM 288, for the
correct replacement procedures of contactors on the a. Visually inspect the commutator and brushes
R30E/EA/EF units. See the section CURTIS TRAN- every 350 hours on all electric motors. Remove
SISTOR MOTOR CONTROLLER, 2200 SRM 411, the brush cover near one end of the motor. Move
for the correct replacement procedures of contactors on the brush spring to remove a brush from the
the R30ES units. holder. Pull the brush from the holder. Make sure
the surface of the commutator is good and the
CAUTION operation of the motor is correct. All motor
Low battery voltage makes motors use high currents brushes must be replaced before they damage the
for a longer time to do the same work. These currents surface of the commutator. Replace brushes

10
before they are worn to the values shown in safety labels are installed on the lift truck and can be
TABLE 2. read.
NOTE: It can be necessary to remove the contactor WARNING
from the steering pump motor for access to the brushes. If labels that have warnings or instructions are dam-
aged, they must be replaced immediately.
b. Inspect the brush holders for burns or damage.
Make sure the brush holder is fastened tightly to Check that all safety labels are installed in the cor-
the mounts. Make sure the brushes will move rect location on the lift truck. Make sure all labels are
freely and smoothly in the brush holders and do not damaged and that they can be read. If necessary,
not have wire breaks. see the FRAME section or the PARTS MANUAL for
your lift truck for the correct location of the labels.
c. Check the brush springs for damage from heat See the FRAME section for the installation proce-
(color changes) and corrosion. Replace a dures.
damaged brush spring.
MAST
d. Use dry compressed air under low pressure to
remove any brush dust. WARNING
Never work under a raised platform or forks. Lower
NOTE: See the section DC MOTOR MAINTE-
the platform and the forks or use chains on the mast
NANCE, 620 SRM 294, for additional information for
weldments and carriage so that they can not move.
repair of the commutator and brushes.
When chains are used, make sure the moving parts
are fastened to a part that can not move.
SAFETY LABELS
1. Inspect the surfaces in the channels where the load
Safety labels are installed on the lift truck to give infor- rollers travel. A scraper and solvent can be used to
mation about possible hazards. It is important that all clean dirt from the mast channels.

4 4

4
1
2

1. TRACTION MOTORS
2. LIFT PUMP MOTOR
3. STEERING GEARMOTOR
4. ACCESS COVER
FIGURE 8. INSPECT THE MOTOR BRUSHES

11
TABLE 2. MOTOR BRUSH MINIMUM DIMENSIONS
MOTOR DIMENSION A
1
TRACTION MOTOR 16 mm A* = MINIMUM DIMEN-
(0.63 in.) SION SHORTEST SIDE

LIFT PUMP MOTOR 14 mm 1. TAPERED END


(0.55 in.) A
(SPRING)
STEERING GEARMOTOR 7 mm 2. WEAR END
(0.25 in.)
2

During test procedures for the hydraulic system, fas-


CAUTION
ten the load to the carriage with chains to prevent it
Be careful when steam or high pressure water is used from falling. Keep all personnel away from the lift
to clean the mast channels. Do NOT permit the steam truck during the tests.
or water to be used on the load rollers, sheaves, or lift
chains. The steam or water will damage the bearings Check The Lift Cylinders For Leaks
in the load rollers and sheaves, and cause corrosion NOTE: R30ES units have only one lifting speed and
in the lift chains. one lowering speed. They do not have a freelift cylin-
2. Apply a thin layer of multipurpose grease to the der.
surfaces in the channels of the freelift mast where the 1. Operate the hydraulic system. Put a capacity load on
load rollers travel. Apply the grease to both the roller the forks and raise and lower the load several times.
surfaces and the thrust surfaces in the mast. Operate both the slowlift and fastlift functions.
NOTE: The mast and platform load rollers have sealed Check for leaks.
bearings that do not need additional lubrication. 2. Raise the carriage and load one metre (3 ft). If the
3. Use multipurpose grease to lubricate all sliding sur- carriage slowly lowers when the control valve is in the
faces and the chain sheaves at the top of the masts. Neutral position, there are leaks inside the hydraulic
system. Check both the slowlift and fast lift systems.
4. Lubricate the lift chains using the oil specified in the The maximum speed that the forks can slowly lower
MAINTENANCE SCHEDULE. when there are internal leaks is 50 mm (2 in) per 10
minutes. This maximum leak rate is specified for an oil
CHECK FOR LEAKS IN THE LIFT SYSTEM temperature of 30C (90F). If the temperature of the
Check the hydraulic system for internal leaks after hydraulic oil is 70C (160F), the specification in-
every 350 hours of operation. creases to 150 mm (6 in) per 10 minutes.
3. If there are leaks in the hydraulic system, check the
WARNING
lift cylinders for internal leaks.
Never allow anyone under a raised platform or R30E/EA/EF units only. Remove the load and fully
forks. Do not put any part of your body in or through lower the forks. Install a gate valve in the supply line
either lift mechanism unless all parts of the mast and between the main control valve and the freelift cylin-
carriage are completely lowered and the key is in the der. Put a capacity load on the forks again. Raise the
OFF position. forks 50 cm (11/2 ft). Close the gate valve. If the forks
Before making any repairs, use chains on the mast slowly lower, the seals in the freelift cylinder have
weldments and carriage so that they can not move. leaks.
Make sure the moving parts are fastened to the parts 4. Completely lower the forks. Install a gate valve at
that can not move. the base of each main lift cylinder. Raise the load.
Do not try to find hydraulic leaks by putting your Close the gate valve at the base of one main lift cylin-
hand on hydraulic components under pressure. Hy- der. Push a Lower rocker switch to lower the mast. If
draulic oil can be injected into the body by the pres- the load slowly lowers, the seals in one main cylinder
sure. leak. The cylinder that has the leak is the cylinder with

12
the closed valve. Open the gate valve of the first main LIFT CHAINS
cylinder and close the gate valve at the base of the other (See FIGURE 4. and FIGURE 9.)
main cylinder. Repeat the check for the other main lift
Lubricate the lift chains using the oil specified in the
cylinder.
MAINTENANCE SCHEDULE in this section.
5. If the load does not lower with either gate valve If a section of chain is 3% longer than a similar section
closed, open the gate valve and check the movement of new chain, replace the worn chain.
again. If the load lowers when the gate valve is open,
If a chain scale is available, check the lift chains as
check for leaks in the hydraulic lines and fittings. If no
shown in FIGURE 9. If a chain scale is not available,
leaks are found, the lowering valve can have a mal-
measure 20 links of chain. Compare the lengths with
function. Remove the load from the forks.
the chart in FIGURE 9. Replace the chain if the length
6. Completely lower the forks. Remove all gate valves of 20 links of the worn section is more than the maxi-
and connect the hydraulic lines to the cylinders. mum wear limit.

9488

NOTE: The instructions for measuring chain wear


are shown on the Chain Wear Scale.
1. CHAIN WEAR SCALE

5122

FIGURE 9. INSPECT THE LIFT CHAINS

FORKS (See FIGURE 5.)


WARNING
Do not repair a worn lift chain. Replace a worn lift WARNING
chain with a new lift chain. Both chains must be re- Never repair damaged forks. Do not heat, weld, or
placed if one lift chain needs replacing. bend forks. Replace damaged forks.
Check the attachment points of the forks with a
penetrant or magnetic particle inspection.

13
EVERY 2000 HOURS OR YEARLY
Do these procedures in addition to the 8 hour and the 350 hour checks.
MASTER DRIVE UNIT (See FIGURE 10.) the bearing. Install the bearings with the seal toward
the outside of the load wheel. Install the load wheels as
Change the oil every 2000 hours or each year. Drain the
described in GENERAL PROCEDURES in this sec-
oil when it is warm by removing the drain plug. Use a
tion.
container to keep oil off the floor. Flush the breather us-
ing solvent each time the oil is replaced. On older units Lubricate the bearings of the load wheels with the
(MDU Part Number 338600), clean and fill the outer grease shown in the MAINTENANCE SCHEDULE.
axle bearing with Shell Alvania R3 grease. The load wheels must be removed for lubricating as de-
scribed in GENERAL PROCEDURES if there are no
STEERING CHAIN grease fittings.
NOTE: On units that have the freezer and corrosion op-
Lubricate the steering chain with the grease shown in
tion, add grease through each of the grease fittings.
the MAINTENANCE SCHEDULE in this section.
HOW TO CHANGE THE HYDRAULIC OIL
WHEELS AND BEARINGS AND FILTER (See FIGURE 11.)
Check that the drive wheel nuts are tightened to the
value shown in the MAINTENANCE SCHEDULE in WARNING
this section. The hydraulic oil is HOT at operating temperature.
Do not permit the hot hydraulic oil to touch the skin
and cause a burn.
Put the lift truck on a level surface. Completely lower
the mast and the forks. Put a container with a capacity
large enough to hold the quantity of oil shown in the
PERIODIC MAINTENANCE table for your unit. Put
1
the container near the supply hose of the hydraulic
tank. Turn the key switch to the OFF position and dis-
connect the battery.
2
Replace the element every 2000 hours or yearly with
each oil change. To replace the element, remove and
plug the hose at the fitting near the breather. Remove
the three nuts that fasten the plate to the top of the tank.
3 Carefully lift the plate assembly, tube and filter element
while keeping the tube vertical. The filter element is
held on the bottom of the tube by a grommet as shown
11390
in FIGURE 11. Install the replacement element on the
tube, install the plate assembly and connect the hose to
1. MASTER DRIVE UNIT the fitting.
2. FILL PLUG
3. DRAIN PLUG Raise the front of the lift truck as described in HOW
FIGURE 10. MASTER DRIVE UNIT TO PUT A LIFT TRUCK ON BLOCKS in this sec-
tion. There is no drain plug in this hydraulic tank. The
Remove each load wheel and the bearings as described hydraulic tank is drained at the supply hose. Open the
in GENERAL PROCEDURES in this section. Check hydraulic compartment door for access to the tube end
each bearing for smooth operation. If the operation is of the supply hose. Use a shallow pan with a capacity of
smooth, clean and fill each bearing with multipurpose approximately 30 litre (7.9 gal) for the oil. Put the pan
grease. If the bearing operation is not smooth, replace under the end of the hose. Disconnect the hose from the

14
tube and drain the oil. Connect the hose to the tube and personnel. The brake, when in good condition and cor-
tighten the hose clamp. Remove the fill cap and fill the rectly adjusted, will hold the lift truck with a capacity
tank so that the oil level is at the center of the sight load on a 5% grade [a slope of 0.5 meter in 10 meters (a
gauge. Fill the hydraulic tank with the oil shown in the slope of 0.5 ft in 10 ft)]. See the section THE ELEC-
MAINTENANCE SCHEDULE in this section. See TRIC BRAKE, 1800 SRM 305, to check or repair the
HOW TO MAKE CHECKS WITH THE KEY brake or to replace the friction disc.
SWITCH OFF for the correct filling procedure.
To replace the filter, remove and plug the hose at the 3 5 6 7
fitting near the breather. Remove the three nuts that fas- 4 2 7
ten the plate to the top of the tank. Carefully lift the
plate assembly, tube and filter while keeping the tube 1
vertical. The filter is held on the bottom of the tube by a
grommet as shown in FIGURE 11. Install the replace-
ment filter on the tube, install the plate assembly and
connect the hose on the fitting.
NOTE: If the filter slips off the tube during removal or
12350
installation, use the end of the tube to move the filter into
position and insert the tube in the filter element. 0.33 to 0.38 mm 8
(0.013 to 0.015 in) 10 9
Check the hydraulic system for leaks and damage or
loose components. Close the hydraulic compartment 1. ARMATURE PLATE 6. HUB
door. 2. RETURN SPRING (3) 7. FRICTION DISC
3. CAPSCREW (3) 8. SPRING (12)
4. SPRING WASHER (3) 9. MAGNET ASSEMBLY
5 1 2 1 3 5. BACK PLATE 10. BORE, CAPSCREW
FIGURE 12. ELECTRIC BRAKE
4
If the brake needs adjustment, have authorized person-
nel evenly tighten the capscrews until the clearance be-
4 tween the electric magnet and the armature plate is 0.33
5 to 0.38 mm (0.013 to 0.015 in). See FIGURE 12.
3
6 ELECTRICAL CABLE SHEAVES

1. FILL/BREATHER Lubricate the cable sheaves at the top of the mast and
2. PLATE ASSEMBLY cylinder head using multipurpose grease.
3. HOSE CONNECTOR
4. SIGHT GAUGE
5. HYDRAULIC TANK PALLET CLAMP
6. TUBE
7 Use multipurpose grease to lubricate the pawls of the
7. FILTER ELEMENT
8. GROMMET pallet clamp.
8

12293 LIMIT SWITCH ROLLERS AND OTHER


FIGURE 11. CHANGE THE OIL FILTER LUBRICATION
Lubricate limit switch rollers, all pins, linkages, cables
BRAKE and levers as necessary. Use SAE 20 oil or Hyster part
If the brake will not hold the lift truck on the grade as number 328388 as shown in the MAINTENANCE
described, have the adjustment checked by authorized SCHEDULE in this section.

15
GENERAL PROCEDURES

HOW TO CHARGE THE BATTERY


WARNING
The acid in the electrolyte can cause injury. If elec-
trolyte is spilled, use water to flush the area. Make
the acid neutral with a solution of sodium bicarbon-
ate (soda) and water. Acid in the eyes must be imme-
diately flushed with water.

Batteries generate explosive fumes when they are be-


ing charged. Keep fire, sparks and burning material
away from the battery charger area. Prevent sparks
from the battery connectors.

Charge batteries only in the special area for charg-


ing batteries. When charging the batteries, keep the
vent caps clean. The battery charger area must have
ventilation so that explosive fumes are removed. Dis-
connect the battery when doing cleaning and main-
tenance.

If the lift truck has been operated using a low battery


FIGURE 13. HOW TO CHECK
or deenergized using the Emergency Stop Knob (see
SPECIFIC GRAVITY
Emergency Stop Knob in the OPERATING
MANUAL), inspect for welded contacts BEFORE
connecting a charged battery. The circuit will not re- 1. NORMAL CHARGE: This charge is normally
set and lift truck operation cannot be controlled if given to a battery that is discharged from normal opera-
the contacts are welded. To check the contacts, see tion. Many customers charge the battery at regular in-
Contacts in this manual. tervals that depend on use. This procedure will keep the
battery correctly charged if the battery is not dis-
charged below the limit. Always use a hydrometer to
CAUTION
check the battery if the battery is charged at regular in-
Never connect the battery charger plug to the plug of tervals. Frequent charging of a battery that has a 2/3 or
the lift truck. You can damage the traction control more charge can decrease the life of the battery.
circuit. Always make sure the charger voltage is the
correct voltage for the battery. 2. EQUALIZING CHARGE: This charge is at a low
rate and balances the charge in all of the cells. The
Correct use of the hydrometer (FIGURE 13.) and equalizing charge is normally given approximately
proper operation of the battery charger is important. once a month. It is a charge at a slow rate for three to
Operate the battery charger according to the instruc- six hours in addition to the regular charging cycle. Do
tions of the charger manufacturer. Never let the battery not give an equalizing charge more than once a week.
discharge below the minimum value given by the bat- The most accurate specific gravity measurement of
tery manufacturer. A fully charged battery will have a specific gravity for a charged battery will be after an
specific gravity of 1.265 to 1.310 at 25C (77F). equalizing charge. If the difference in specific gravity
Never charge a battery at a rate that will raise the elec- is more than 0.020 between cells of a battery after and
trolyte temperature above 49C (120F). Never permit equalizing charge, there can be a cell that has a mal-
a battery to stay discharged for long periods. function. Consult your battery dealer.

16
NOTE: Many customers have battery chargers that can turer. Use the recommendations of the battery manufac-
follow a program to automatically charge a battery ac- turer for charging the battery.
cording to recommendations of the battery manufac-

6 7
6

5 4 3
4 4
3
5
7

12057

1
1. BATTERY COMPARTMENT PANEL 5. BATTERY PULLER
2. LATCH FOR COMPARTMENT PANEL 6. RATCHET LOCK LEVER
3. BATTERY STAND 7. BATTERY
4. ROLLERS

FIGURE 14. HOW TO CHANGE THE BATTERY

HOW TO CHANGE THE BATTERY 3. Align the battery stand with the battery so that the
end of the stand is against the roller frame for the bat-
General tery. Adjust the capscrew legs of the battery stand so
WARNING that the tops of the rollers are the same height as the
Batteries are heavy and can cause an injury. Use care bottom of the battery. Adjust all four capscrew legs of
to avoid injury. Do NOT put hands, arms, feet and or the stand so that the rollers are level. Install the battery
legs between the battery and a solid object. puller on the end of the stand at the center. See
FIGURE 15. Release the ratchet lock and attach the
To prevent personal injury and battery movement
hook to the lifting hole of the battery. Do not permit the
that is not expected, the battery must be level when it
hook to make contact with cell connectors. Make sure
is moving. Make sure the battery stand is on a level
the battery cables are not damaged during battery re-
surface and is aligned and adjusted as described in
moval. Stand on the base of the battery puller, release
the following procedure.
the ratchet and operate the crank to pull the battery onto
the battery stand.
Remove the Battery (See FIGURE 15.)
1. Move the key to the OFF position. Use the Battery 4. If the battery is lifted, use a spreader bar and crane to
Disconnect to disconnect the battery. lift the battery from the battery stand.

2. Move to a position in front of the battery compart-


ment panel on the side for the battery stand. On R30E/ WARNING
EA/EF units, raise the panel latch and move it to the Make sure the capacity of the crane and spreader
rear to keep it in the UP position. The panel will tip to- bar is greater than the weight of the battery. The
ward you. See FIGURE 15. On R30ES units, there is a weight of the battery is normally shown on the bat-
small panel at the bottom of the battery compartment. tery case. The maximum battery weight is shown on
Lift and tilt the panel to remove it. the lift truck nameplate. The spreader bar must

17
NOT be made of metal or it must have insulated the crank to pull the battery off the stand into the bat-
straps. tery compartment. Make sure the foot switch is re-
Batteries are heavy. Use care to avoid injury. leased and the key is in the OFF position before con-
necting the battery.
Install the Battery (See FIGURE 15.)
WARNING
WARNING Before connecting the battery, make sure the key
If the lift truck was operated using a low battery or switch is in the OFF position and the brake is on.
deenergized using the Emergency Stop Knob (see
Emergency Stop Knob in the OPERATING MANU-
AL), inspect for welded contacts BEFORE connect-
ing a charged battery. The circuit will not reset and
2
lift truck operation cannot be controlled if the con-
tacts are welded. To check the contacts, see Contacts
in this manual. 1
Make sure that the battery voltage and weight of the
replacement battery is correct as shown on the 1. BATTERY CABLES 2
nameplate. On R30E/EA/EF units, make sure the 2. BATTERY CONNECTOR 1
battery half of the connector block has the block for
the Battery Disconnect Lever.
12582

CAUTION FIGURE 16. BATTERY CONNECTOR


The replacement battery must fit the battery com-
partment.
HOW TO CHANGE WHEELS AND TIRES
1. Make sure the battery is the correct size and weight
for the lift truck. The correct battery is specified in the How To Change Drive And Steer Tire
table at the back of this manual. Make sure the battery Raise the front of the lift truck as described in HOW
has clearance for installation and that the battery con- TO PUT A LIFT TRUCK ON BLOCKS in this sec-
nector can be connected after installation. Make sure tion. Remove the wheel nuts that fasten the drive/steer
that the battery compartment has the correct spacers for wheel to the hub. Slide the wheel out from under the lift
the battery you are installing. The spacers must not let truck. Use the reverse procedure to install the wheel.
the battery move more than 13 mm (0.5 in) in any di- Tighten the wheel nuts to 136 N.m (100 lbf ft) torque
rection. The spacers must keep the battery as far from after installation.
the mast as possible. Have authorized personnel re-
place or adjust the battery spacers for that battery. See CAUTION
your Hyster Lift Truck Dealer for the correct spacers.
If the wheels have been removed and installed, check
On R30E/EA/EF units, make sure the battery connec-
all wheel nuts after 2 to 5 hours of operation. Tighten
tor has the block for the Battery Disconnect Lever in-
the nuts in a cross pattern to the correct torque value
stalled. See FIGURE 16. Do not damage the battery
shown in the Maintenance Schedule table. When the
cables during installation.
nuts stay tight after an eight hour check, the interval
2. Install the battery puller on the lift truck frame at the for checking can be extended to 350 hours.
center of the battery compartment on the side opposite To change the drive tire, the wheel must be pressed out
the battery stand. See FIGURE 15. Release the ratchet of the rim. The correct tools, equipment and press ring
lock, pass the hook through the battery compartment must be used for each size wheel. A press that has a ca-
and attach the hook to the battery lifting hole. Do not pacity of approximately 36 000 kg (80 000 lb) is also
permit the hook to make contact with the cell connec- required to press the wheel out of the rim. This is not a
tors. Stand on the base of the battery puller and operate job that an operator should attempt. Have the tires

18
changed by authorized personnel that have the proper the area between the bearings with the same grease and
tools, equipment and experience. install the axle sleeve. Install the load wheel, axle and
axle nut.
Similar tires, made from softer or harder material, can
be installed as optional equipment. NOTE: On units that have the freezer and corrosion op-
tion, add additional grease through each of the grease
How To Replace Load Wheels fittings.
(See FIGURE 17.)
1
CAUTION
For correct operation of the wire guidance system, 3
4 5
all load wheels must always be replaced at the same 7
time. 8 1. BASE ARM
2. LOAD WHEEL
Put the base arms up on blocks as described in HOW BRACKET
TO PUT THE LIFT TRUCK ON BLOCKS in this sec- 6 3. LOAD WHEEL
6 4. AXLE
tion. To replace the load wheels on R30EA and R30EF
2 5. AXLE SLEEVE
units, remove the axle and load wheel. For easier instal- 2 6. BEARING
8
lation on R30E/ES units, remove and install one load 7. AXLE NUT
wheel before removing the next load wheel. The load 8. GREASE FITTING
wheel brackets are held in the base arms by the load 7 (FREEZER
4 CORROSION ONLY)
wheels. Remove the axle sleeve from the load wheel. 3
Completely fill new bearings with the grease shown in
the MAINTENANCE SCHEDULE in this section. In- 1
12058
stall the bearings in the replacement load wheel. Make
sure the seal of each bearing is toward the outside. Fill FIGURE 17. REPLACE THE LOAD WHEELS

BATTERY SPECIFICATIONS
MINIMUM BATTERY SIZE* WEIGHT
MODEL VOLTS COMPARTMENT SIZE MIN/MAX
LENGTH X WIDTH LENGTH WIDTH MIN MAX

681 kg 817 kg
R30E/EA/EF 24V
1500 lb 1800 lb
368 x 975 mm 889/972 mm 330/362 mm
14.50 x 38.38 in. 35.00/38.25 in. 13.00/14.25 in.
817 kg 1089 kg
R30E/EA/EF 36V
1800 lb 2400 lb

24V 343 x 914 mm N/A 911 mm N/A 337 mm 466 kg 550 kg


R30ES
ONL 13.50 x 36 in. N/A 35.88 in. N/A 13.25 in. 1025 lb 1210 lb
Y

Compartment width is across width of lift truck. Battery length installed across lift truck, battery width in-
stalled fronttoback.
* Maximum height for all R30E/EA/EF batteries is 787 mm (31.0 in).
Maximum height for R30ES batteries is 591 mm (23.25 in).
N/A = Minimum battery size is Not Available for the R30ES.

19

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