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
tor’s area. Remove the key from the key switch. forks is used to tow the disabled lift truck, that lift truck

1

How To Raise Drive Tire (See FIGURE 1. See forks. even and level. the lift truck that is used for towing. 1. Use a special low clearance hydraulic jack. CAUTION For correct operation of the wire guidance system. If the lift truck used the jack. 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.) both load wheels must always be replaced at the 1. er lift points are not designed to support the weight of the lift truck. Additional weight on the forks will DECREASE the nameplate. crane or other lift truck has the correct mini- for towing has a master drive unit or drive unit similar mum capacity rating. of the lift truck including the battery. age or possible injury. Put blocks under the base arm at the rear of the load fall on someone causing serious injury. one–piece high can make the lift truck tip over and cause dam- units. crane or another lift truck to lift Do not raise the lift truck by attaching an overhead the base arms. maintenance and repair. The removal of the follow- ing assemblies will cause large changes in the center WARNING of gravity: mast. The lift truck can be damaged or it can 3. Put blocks on both sides (front and back) of the drive tire to prevent movement of the lift truck. Install a load of ap. Put blocks on each side (front and back) of the load same time. Carefully fasten the tow chain to the drive unit How To Raise Load Wheels (See FIGURE 1. 2 . Attach the wheel to support the lift truck. Raising the base arms too used to support the lift truck are solid. 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. the traction of the drive wheel(s).039 in).) end of the lift truck. 2. This load will in. tire. Make sure the chain is fastened so that the chain will not cause damage to either lift truck.must have weight added to the forks. Some of these components and oth. Install additional blocks under the frame near the drive tire. 2. Make sure that forks lowered as much as possible. The total weight CAUTION of the lift truck and load must be equal or greater than the weight of the disabled lift truck. Put a block in front and back of the tires touch. 5. Make sure the tow chain has the capacity to tow the weight. ing the ground to prevent movement of the lift truck. ameter within 1 mm (0. 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. Make sure the sensors are not damaged on trucks proximately half the maximum capacity on the forks of that have wire guidance. Make sure that the lift truck has a total weight equal to or greater than the 3. Always raise both base not solid. The load wheels must have the same di- wheels to prevent movement of the lift truck. Raise the lift truck only enough to suspend the drive weight of the disabled lift truck. The capacity must equal at least to the R40E/EA/EF/ES. chain or sling to a support structure of the lift truck frame. crane or crease the traction of the lift truck. Use a hydraulic jack. Make sure that the jack. Make sure that any blocks arms at the same time. do NOT add weight to the 2/3 the weight of the lift truck including the battery. Keep the load on the another lift truck to raise the drive tire.

R30E/EA/EF R30ES 12292 DRIVE/STEER WHEEL LOAD WHEEL FIGURE 1. MAINTENANCE POINTS 3 . PUT THE LIFT TRUCK ON BLOCKS MAINTENANCE SCHEDULE 1 22 4 6 11 13 9 23 3 2 20 7 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.

L Check Operation Multi–Purpose Grease3 10 DIRECTION/SPEED CONTROL X L Check Operation MIL–G–7711A or equivalent 11 HYDRAULIC TANK BREATHER X Clean Or Replace See Parts Manual 13 HYDRAULIC PUMP COUPLING L Clean And Soak Hyster Part No. AGL–5 (R30E/EA/EF) X C 3. 3 Multi–Purpose Grease with 2–4% Molybdenum Disulfide. 2 Equalization Charge approximately each month but not more than each week.9 gal) –18°C to 38°C R30EF X C1 36 litre (9. CABLE SHEAVES L As Required Multi–Purpose Grease3 22 BASE ARM BEARINGS L As Required Multi–Purpose Grease3 23 PALLET CLAMP L As Required Multi–Purpose Grease3 24 EMERGENCY STOP KNOB X Check Operation LIMIT SWITCH ROLLERS L As Required Multi–Purpose Grease3 MISC. 347031 20 HYDRAULIC FILTER C 1 ea.6 qt) MIL–L–2105 B. 4 .5 litre (2. Change oil every 1000 hours or six months with corrosion/freezer option. NOTE: Never use steam to clean electrical parts.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.8 litre (1 gal) SAE 80W–90 or 85W–140 19 STEERING CHAIN L As Required Multi–Purpose Grease3 STEERING GEAR HOUSING C 325 ml (11 oz. FUSES X Check Operation 9 STEERING X. See Parts Manual 21 ELECTRIC.m (100 lbf ft) 18 MASTER DRIVE UNIT (R30ES) X C 2. TABLE 1.) Hyster Part No. L As Required Hyster Part No.6 litre (3. MAINTENANCE SCHEDULE (Item No. Reference Figure 2) 8 350 2000 ITEM Hr/ Hr/ Hr/ PROCEDURE OR ITEM SPECIFICATION NO. HORN.L As Required SAE 20 Oil or P/N 171550 16 SLIDING SURFACES L As Required Multi–Purpose Grease3 17 WHEEL NUT TORQUE X Tighten if Required 136 N. 347031 X = Check C = Change L = Lubricate 1 Change oil after first 250 hours.5 gal) (0°F to 100°F) R30ES X C1 14. 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 Multi–Purpose Grease3 4 FORK PIN AND GUIDES L As Required Multi–Purpose Grease3 5 LIFT CHAINS AND SHEAVES X. 1 day 2 mo 1 yr QUANTITY 1 HYDRAULIC OIL (Full Mark) R30E/EA X C1 30 litre (7.

PLATE ASSEMBLY hydraulic compartment to check for the correct level 3. R30ES tank is smaller. Use a con. HOW TO MAKE CHECKS WITH KEY NOTE: If the filter element slips off the tube during re- SWITCH OFF moval or installation. tube and filter element Do NOT operate a lift truck that needs repairs. open the door of the 1. use the end of the tube to move the element into the correct position to insert the tube in Hydraulic System (See FIGURE 3. install the plate assembly and connect the hose to switch. HYDRAULIC TANK operation. Turn the key switch to the OFF position and disconnect the battery. Never operate the hydraulic pump without oil in the 4 hydraulic system. The filter element is port the need for repairs immediately. HOSE CONNECTOR and to fill the tank if necessary. To replace the element. The operation of the hydraulic 5 pump without oil will damage the pump. put a “DO NOT OPERATE” tag in the in FIGURE 7. Tools on the battery each oil change. remove and can cause a short circuit and possible damage or in- plug the hose at the fitting near the breather. The platform must be lowered and the key switch must be OFF. TUBE 8 7. When the hydraulic oil is at oper- ating temperature. R30E/EA standard hydraulic tank shown. Remove the key from the key tube. the oil level is above or below the sight gauge. the fitting. GROMMET 12293 To drain the oil. The R30EF and R30ES units need a container with a capacity of 36 Battery litre (9. WARNING Carefully lift the plate assembly. 8. FILTER ELEMENT with solvent. 3 Check the hydraulic oil level at the sight gauge when 6 the oil is at operating temperature. put the lift truck on a level surface. Re. tainer with a 36 litre (9. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY the three nuts that fasten the plate to the top of the tank. WARNING Replace the element every 2000 hours or yearly with Do not put tools on the battery. Install and tighten the fill cap.5 gal) capacity near the supply FIGURE 3. 1 1 3 5 2 CAUTION Do not permit dirt to enter the hydraulic system 4 when the filter is changed. Install the replacement element on the operator’s area. the oil will leak from the breather during 5. while keeping the tube vertical. Clean the breather and fill cap by flushing 6. If too much hydraulic 4.5 gal). Do not permit the hot hydraulic oil to touch the skin and cause a burn.) the element. R30EF tank is larger. Completely lower the mast and the forks. SIGHT GAUGE 7 oil is added. Inspect the hydraulic system for leaks and damaged or WARNING loose components. FILL/BREATHER 2. HYDRAULIC CHECKS hose of the hydraulic tank to hold the oil. 5 . If the oil level is not visible at the sight gauge. Remove jury. If repair is held on the bottom of the tube by a grommet as shown necessary. it is HOT.

Check that each battery compartment panel fits ate (soda) . Make BATTERY SPECIFICATIONS at the end of this sec- the acid neutral with a solution of sodium bicarbon. INSPECT THE LIFT CHAINS AND installed for that battery. of one cell. tion. TIP ALIGNMENT 2. If the battery can 4. Batteries are very heavy Lower the platform or use chains on the mast weld- and can cause an injury. Keep the top of the bat. The spacer must 6705 allow the battery to move not more than 13 mm (0. When chains are used. To check and add water to the cells. RUST move more than the maximum amount. See the battery dealer in your area to repair any damage. The correct level is half–way be. If the Dealer for the correct spacers. and FIGURE 5. position when the notch is engaged. dry and free of corrosion.5 in) toward the front or rear of the compartment. surface to remove the battery. HOLE WEAR 7. use water to flush the area. the battery Mast. EDGE WEAR 6. tween the top of the plates and the bottom of the fill hole. CRACKS 5. LOOSE LEAVES the battery cannot move more than 13 mm (0. as necessary. ments and platform so that they can not move. check flushed with water. con. battery and a solid object. CRACKS 3.The acid in the electrolyte can cause injury. Check the battery case. 3 Check that the correct spacer is installed across the mast side of the battery compartment. DAMAGED PIN across the width of the lift truck. WORN PIN 2. Remove the battery as described in CHANGING THE BATTERY in this section. to all Each latch must be free to operate and remain in the Up cells if the cell is low. Platform. 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. Add only distilled water. FIGURE 4. cracks or breaks. FORK PIN DAMAGE 4. See your Hyster Lift Truck CABLES 3 5 2 2 2 4 1 6706 1. On R30E/EA/EF units. arms. 4 6 tery clean. Acid in the eyes must be immediately correctly and is not bent. make sure the battery is the correct weight and the correct spacers are FIGURE 4. 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. 1 7 nector and cables for damage. NEWER STYLE 5. Check that 1. Keep the battery case. feet or legs between the NEVER work under a raised platform or forks. The correct battery is in electrolyte leaks. HOW TO INSPECT THE FORKS 6 . OLDER STYLE FIGURE 5. Forks And Lift Chains (See must be out of the battery compartment.5 in) 3.) WARNING WARNING Do NOT put hands. and the battery compartment clean and painted. 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.

the inter- 7 . Do not substitute other types of rope. Add or remove shims for alignment. or other material wound bricate the lift chains using the oil specified in the around the axles or caster. Schedule table. MAINTENANCE SCHEDULE in this section. strapping. drive tire and load 2. In. objects that will cause damage. it must be done by authorized personnel. Tire. If the chains need repair or adjustment. Inspect the channels for wear in the areas where the wheels for damage. When the nuts stay tight after eight hours.5 in) of each other. Inspect the tread and remove any rollers travel. Never repair damaged forks by heating or welding. shown in the MAINTENANCE SCHEDULE table. INSPECTING THE TIRE AND keep the forks locked in position. Lu- move any wire. See FIGURE 6. Some movement may occur. the pallet is supported by the forks. 4. 11402 8. Tighten the nuts in a cross pattern to the 1. Check all lift chains for the correct lubrication. MAKE SMOOTH EDGES 2. Inspect the belt for cracks. Always replace forks in pairs. ter of the back. Use shims to align the fork tips. REMOVE NAILS. Inspect the chain anchors and pins for cracks or dam- age. Inspect forks for cracks and 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. cuts or damage. 2 5. cuts or wear. Inspect the wheels and caster for loose or missing parts. 2 7. Inspect the tether line for wear. Inspect the rollers for wear or damage. empty pallet on the forks. See item 1 of FIGURE 5. Make sure that the nuts and bolts are tightened. Inspect the welds on the mast and platform for (See FIGURE 6. Pallet Clamp WARNING Do not try to correct alignment of the fork tips by Check for correct operation of the pallet clamp. Re- 3. WHEELS Tether Line And Belt Make sure the wheel nuts are tightened to the correct torque value. Check tension by pulling horizon- tally on both chains and checking that they move the same amount. Inspect the lift chains for cracks or broken links and 1 pins. but the board under the Forks are made of special steel using special proce- opposite fork must not raise enough to contact the fork. Make sure the lift chains are adjusted so that they have equal tension. check during a fall. dures. all wheel nuts after 2 to 5 hours of operation. Replace any damaged or broken parts that are used to FIGURE 6. Inspect the caster (R30EF only). 6. With the forks raised so that Replace damaged forks. Tighten 2. stand on the corners of the pallet farthest from the operator’s platform. correct torque value shown in the Maintenance spect the clips for cracks and proper operation. Check that the fork tips are aligned within 13 mm (0. Replace damaged forks. 1. GLASS AND ALL METAL 9.) cracks. Wheels and Caster 1. WARNING CAUTION The tether line is specially made to lessen the shock If the wheels have been removed and installed. Put an bending the forks. See FIGURE 4.

SLOW LIFT SWITCH BUTTON 7. Horn And Fuses panel. EMERGENCY STOP KNOB 17. FAST LIFT SWITCH BUTTON 4. after connecting a fore moving the lift truck or checking for correct op. 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. Lights. If the battery meter needle is in the red area SWITCH ON or the light (lift interrupt) is ON. 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. Check the op. HOUR METER 16. The battery meter operates whenever hours. LIFT SWITCH 9. Some types of fuses must be checked with an in the ON position to operate the horn. FAN SWITCH BUTTON 13. The key switch must be burned. Be careful when making the checks. DIRECTION/SPEED CONTROL 11 3. charged battery. The battery meter correctly indicates the condition of HOW TO MAKE CHECKS WITH THE KEY the battery. Normal operation. GUIDANCE BUTTON 11. will reset the indicator. There are two NOTE: None of the electrical controls will operate until power fuses in the electrical compartment. SLOW LOWER SWITCH BUTTON 8. disconnect the must be ON and the foot switch depressed for the hour battery before replacing the fuse. The power the power disconnect circuit is energized by the key fuses have the following ratings: switch. STEERING CONTROL 2. and Table 1) and fan. SPOT LIGHT SWITCH BUTTON 14. INSTRUMENTS AND CONTROLS 8 . cate correctly. There can also be a 15 amp fuse for the spot light (See FIGURE 7. STEER TIRE R30ES ONLY 1 POSITION INDICATORS 10. eration. BATTERY INDICATOR 15. Check that the fuses are the correct size and are not eration of the gauges and horn. SLOW LIFT/LOWER ROCKER SWITCH 5. There is also a 35 amp fuse near the steer mo- tor contactor in the motor compartment. a charged battery is connected. Traction Motor – 300 amp Hydraulic Pump Motor – 500 amp Check that all the instruments and controls operate as described in OPERATING MANUAL.val for checking the torque can be extended to 350 meter to operate. There is a 15 amp control fuse under the instrument Gauges. If any of the fuses are bad. FAST LOWER SWITCH BUTTON 6. NOTE: Location of Guidance Button and Light can be different than shown. LOWER SWITCH FIGURE 7. charge the battery. The key switch ohmmeter. KEY SWITCH 18. HORN SWITCH BUTTON AND LIGHT 12.

The maximum travel speed must be slower when pressed. 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. have the lift truck checked and adjusted Lower the lift mechanism completely. Check for leaks in the hydraulic system. must raise and lower smoothly. Remove the key. Never allow by authorized service personnel. Push the 6. 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. anyone under a raised platform or forks. The location of the knob is shown in FIGURE 7. (150 in) unless the lift truck has the Override function and the Override button is depressed. 1. Check the operation of the limit switches on the knob with the key switch ON and the foot switch de.25 to 6. R30EF and R30ES ERATING MANUAL. Make sure the load on a 5% grade [a slope of 0. with a ca. The R30EA.75 ble 1 of the OPERATING MANUAL. in) above the floor for the R30EA.5 ft in 10 ft)]. foot switch and Direction/Speed control operates as de. the lift truck. mast. 9 . All electrical circuits must NOT operate. Check that the to 3. Check that the forks are 159 to 171 mm (6. START and ON positions to must not move when the platform is above 3810 mm reset the power disconnect circuit. The R30E units Move the key to the OFF. Refer to the procedures on hydraulic components under pressure. Check that the top of the forks are 70 to 83 mm (2. the platform is above 910 mm (24 in). the brake needs to be checked by Do not try to find hydraulic leaks by putting hands authorized service personnel. Slowly raise and lower the forks and the platform WARNING several times without a load. The brake is applied position. the chain anchors must be adjusted. YEARLY of this section. Check that the steering system operates smoothly and pacity load. WARNING 7. All moving components There is NO steering if there is no electrical power. Raise the platform one metre (three feet). 4. lift truck on the grade.75 scribed in the Operating Procedures section of the OP. Check that the Direction/Speed control and the switches for Lift and Lower operate as described in Ta. will hold the lift truck with a capacity platform so that they can not move.25 inches) above the floor for the R30E units. The brake.Switches And Direction/Speed Control raise smoothly. Hydraulic for the BRAKE in EVERY 2000 HOURS OR oil can be injected into the body by pressure. Check the condition of the hydraulic hoses and tubes. If the brake does not hold the move. Steering System 2.5 metre in 10 metres (a moving parts are fastened to the parts that can not slope of 0. All mov- ing components must lower smoothly. The inner weldment and platform must gives good steering control. as the operator’s foot is removed from the foot switch. 5. units. The platform and the forks must lower completely. completely lower the an incline. make sure the electric power steering is operating correctly before moving 3. Check the operation of the Emergency Stop knob. when in good condition and cor- platform or use chains on the mast weldments and rectly adjusted. Lower the platform and forks. If the clearance is not correct. If necessary. To prevent injury or damage. The brake must not let the lift truck move if parked on Before making any repairs.

This will discharge the operate the lift truck using a battery that has a spe- capacitors to prevent electrical shocks. CAUTION pacitors can cause electrical shock and personal in. for the correct replacement procedures of contactors on the a. Use an insulated screwdriver or jumper wire to for a longer time to do the same work. Replace the contacts when the surface is worn motors. See the section EV–100 MOTOR following procedure: CONTROLLER – REPAIR. The Power Disconnect circuit will not reset and lift truck operation cannot be con- WARNING trolled if the contacts are welded. or deenergized with the power disconnect circuit. Always replace welded contacts. and tool damage can occur if the battery is not dis- connected. The charge on the ca. Personal injury or equipment and tool surfaces become a dark color and rough. Remove gravity of 1. not necessary. Do not use a file or emery cloth on the Open the front compartment doors for access to the contacts. See the section CURTIS TRAN. 2200 SRM 288. Disconnect the battery connector before making any Open the electrical compartment for access to the con- inspections or repairs. Visually inspect the commutator and brushes R30E/EA/EF units. disassemble the contactor to get access to the motor. Do not to discharge each capacitor. HYDRAULIC TANK BREATHER can damage motors and weld contactor contacts. to the base material. Motor Brushes (See FIGURE 8. Cleaning is damage can occur if the battery is not disconnected.) Do not touch the terminals of capacitor C1 of the traction or lift control circuits. Pull the brush from the holder. in- spect for welded contacts BEFORE connecting a ELECTRICAL INSPECTION charged battery. 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.130 or less. 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.) Never try to repair contactor contacts that are welded. 2200 SRM 411. cific gravity of 1. 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. every 350 hours on all electric motors. the contact the motors. EVERY 350 HOURS OR TWO MONTHS Do these procedures in addition to the 8 hour checks. These currents surface of the commutator. These currents make a short–circuit across the capacitor terminals can damage motors and contactor contacts. Remove SISTOR MOTOR CONTROLLER. (See FIGURE 3.130 or less. Always replace the contacts in sets To check the motor brushes. Replace brushes 10 . holder. If necessary. Low battery voltage makes motors use high currents jury. the fill cap assembly from the hydraulic tank and clean the filter material of the breather in solvent. Personal injury or equipment tactors. 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. Contactors WARNING The contact surfaces of the contactor are a silver alloy Disconnect the battery before making any checks on over a copper base. Make sure the surface of the commutator is good and the CAUTION operation of the motor is correct. In normal operation. Check motor brushes using the inspect the contacts. disconnect the battery and (two pairs).

TRACTION MOTORS 2. NOTE: It can be necessary to remove the contactor WARNING from the steering pump motor for access to the brushes. read. If labels that have warnings or instructions are dam- aged. rollers travel. make sure the moving parts are fastened to a part that can not move. A scraper and solvent can be used to mation about possible hazards. not have wire breaks. ACCESS COVER FIGURE 8. damaged brush spring. c. repair of the commutator and brushes. SAFETY LABELS 1. 4 4 4 1 2 3 1. When chains are used. they must be replaced immediately. Replace a dures. INSPECT THE MOTOR BRUSHES 11 . before they are worn to the values shown in safety labels are installed on the lift truck and can be TABLE 2. Inspect the surfaces in the channels where the load Safety labels are installed on the lift truck to give infor. It is important that all clean dirt from the mast channels. LIFT PUMP MOTOR 3. 620 SRM 294. Use dry compressed air under low pressure to remove any brush dust. b. Lower NOTE: See the section DC MOTOR MAINTE- the platform and the forks or use chains on the mast NANCE. Inspect the brush holders for burns or damage. If necessary. Make sure all labels are freely and smoothly in the brush holders and do not damaged and that they can be read. WARNING Never work under a raised platform or forks. Make sure the brush holder is fastened tightly to Check that all safety labels are installed in the cor- the mounts. MAST d. Check the brush springs for damage from heat See the FRAME section for the installation proce- (color changes) and corrosion. Make sure the brushes will move rect location on the lift truck. for additional information for weldments and carriage so that they can not move. see the FRAME section or the PARTS MANUAL for your lift truck for the correct location of the labels. STEERING GEARMOTOR 4.

NOTE: The mast and platform load rollers have sealed Check for leaks. bearings that do not need additional lubrication. Make sure the moving parts are fastened to the parts 4.) 2 During test procedures for the hydraulic system. Neutral position. 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 free–lift cylin- carriage are completely lowered and the key is in the der. Do not put any part of your body in or through lower the forks.) A (SPRING) STEERING GEARMOTOR 7 mm 2. Raise the load. forks 50 cm (1–1/2 ft). 2. Check both the slow–lift and fast– lift systems. Put a capacity load on load rollers travel. der. or lift chains. the base of each main lift cylinder. when there are internal leaks is 50 mm (2 in) per 10 minutes.) SION SHORTEST SIDE LIFT PUMP MOTOR 14 mm 1. Raise the OFF position. Use multi–purpose grease to lubricate all sliding sur. Completely lower the forks. Raise the carriage and load one metre (3 ft). carriage slowly lowers when the control valve is in the faces and the chain sheaves at the top of the masts. the load slowly lowers. surfaces and the thrust surfaces in the mast. If draulic oil can be injected into the body by the pres. or water to be used on the load rollers. TABLE 2. one lowering speed. Close the gate valve. If there are leaks in the hydraulic system. If the 3. Push a Lower rocker switch to lower the mast. Lubricate the lift chains using the oil specified in the The maximum speed that the forks can slowly lower MAINTENANCE SCHEDULE. WEAR END (0. there are leaks inside the hydraulic system. MOTOR BRUSH MINIMUM DIMENSIONS MOTOR DIMENSION “A” 1 TRACTION MOTOR 16 mm A* = MINIMUM DIMEN- (0. Operate both the slow–lift and fast–lift functions. Keep all personnel away from the lift to clean the mast channels. If the forks Before making any repairs. leaks. The cylinder that has the leak is the cylinder with 12 . The steam or water will damage the bearings Check The Lift Cylinders For Leaks in the load rollers and sheaves. the seals in the free–lift cylinder have weldments and carriage so that they can not move. If the temperature of the Check the hydraulic system for internal leaks after hydraulic oil is 70°C (160°F). 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. the specification in- every 350 hours of operation. creases to 150 mm (6 in) per 10 minutes. and cause corrosion NOTE: R30ES units have only one lifting speed and in the lift chains. They do not have a free–lift cylin- 2. This maximum leak rate is specified for an oil CHECK FOR LEAKS IN THE LIFT SYSTEM temperature of 30°C (90°F). use chains on the mast slowly lower. Hy.25 in. Do NOT permit the steam truck during the tests.63 in. Operate the hydraulic system. Install a gate valve at that can not move. Never allow anyone under a raised platform or R30E/EA/EF units only. check the WARNING lift cylinders for internal leaks. the seals in one main cylinder sure. Remove the load and fully forks. 4. Apply a thin layer of multi–purpose grease to the der. Apply the grease to both the roller the forks and raise and lower the load several times. sheaves. 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. surfaces in the channels of the free–lift mast where the 1. TAPERED END (0. leak. Put a capacity load on the forks again. 3.55 in.

If the load lowers when the gate valve is open. MAINTENANCE SCHEDULE in this section. Replace damaged forks. If the load does not lower with either gate valve If a section of chain is 3% longer than a similar section closed. Never repair damaged forks. 5. or placed if one lift chain needs replacing. 13 . If a chain scale is available. 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. the lowering valve can have a mal- measure 20 links of chain. Do not heat. CHAIN WEAR SCALE 5122 FIGURE 9. If no shown in FIGURE 9. mum wear limit. Both chains must be re.the closed valve. bend forks. open the gate valve and check the movement of new chain. Check the attachment points of the forks with a penetrant or magnetic particle inspection. Replace a worn lift WARNING chain with a new lift chain. replace the worn chain. again. weld. Remove the load from the forks. the chart in FIGURE 9. check the lift chains as check for leaks in the hydraulic lines and fittings. 1 9488 NOTE: The instructions for measuring chain wear are shown on the Chain Wear Scale. Remove all gate valves of 20 links of the worn section is more than the maxi- and connect the hydraulic lines to the cylinders. and FIGURE 9. Completely lower the forks.) main cylinder. Repeat the check for the other main lift Lubricate the lift chains using the oil specified in the cylinder. 1. Compare the lengths with function. INSPECT THE LIFT CHAINS FORKS (See FIGURE 5. Replace the chain if the length 6. leaks are found.) WARNING Do not repair a worn lift chain. If a chain scale is not available.

MASTER DRIVE UNIT TO PUT A LIFT TRUCK ON BLOCKS in this sec- tion. install the plate assembly and connect the hose to 1. replace under the end of the hose. EVERY 2000 HOURS OR YEARLY Do these procedures in addition to the 8 hour and the 350 hour checks. To replace the element. The Remove each load wheel and the bearings as described hydraulic tank is drained at the supply hose. clean and fill the outer grease shown in the MAINTENANCE SCHEDULE. Check hydraulic compartment door for access to the tube end each bearing for smooth operation. Use a tion. Open the in GENERAL PROCEDURES in this section. The load wheels must be removed for lubricating as de- scribed in GENERAL PROCEDURES if there are no STEERING CHAIN grease fittings. The filter element is held on the bottom of the tube by a grommet as shown 11390 in FIGURE 11. axle bearing with Shell Alvania R3 grease. 2 Replace the element every 2000 hours or yearly with each oil change.) Check that the drive wheel nuts are tightened to the value shown in the MAINTENANCE SCHEDULE in WARNING this section. clean and fill each bearing with multi–purpose approximately 30 litre (7. Do not permit the hot hydraulic oil to touch the skin and cause a burn. The hydraulic oil is HOT at operating temperature.) the bearing. Drain the described in GENERAL PROCEDURES in this sec- oil when it is warm by removing the drain plug. remove and plug the hose at the fitting near the breather. There is no drain plug in this hydraulic tank. Completely lower the mast and the forks. If the operation is of the supply hose. 2.9 gal) for the oil. FILL PLUG 3. Put a container with a capacity large enough to hold the quantity of oil shown in the PERIODIC MAINTENANCE table for your unit. NOTE: On units that have the freezer and corrosion op- Lubricate the steering chain with the grease shown in tion. Put the pan grease. Remove the three nuts that fasten the plate to the top of the tank. Install the bearings with the seal toward the outside of the load wheel. container to keep oil off the floor. On older units Lubricate the bearings of the load wheels with the (MDU Part Number 338600). Install the load wheels as Change the oil every 2000 hours or each year. Install the replacement element on the tube. MASTER DRIVE UNIT (See FIGURE 10. Disconnect the hose from the 14 . tube and filter element while keeping the tube vertical. Put the lift truck on a level surface. the MAINTENANCE SCHEDULE in this section. Put 1 the container near the supply hose of the hydraulic tank. If the bearing operation is not smooth. Flush the breather us- ing solvent each time the oil is replaced. Use a shallow pan with a capacity of smooth. DRAIN PLUG Raise the front of the lift truck as described in HOW FIGURE 10. Turn the key switch to the OFF position and dis- connect the battery. HOW TO CHANGE THE HYDRAULIC OIL WHEELS AND BEARINGS AND FILTER (See FIGURE 11. 3 Carefully lift the plate assembly. add grease through each of the grease fittings. MASTER DRIVE UNIT the fitting.

33 5 to 0. RETURN SPRING (3) 7. use the end of the tube to move the filter into position and insert the tube in the filter element. linkages.tube and drain the oil. cables BRAKE and levers as necessary. HUB door. MAGNET ASSEMBLY 5 1 2 1 3 5. CHANGE THE OIL FILTER LUBRICATION Lubricate limit switch rollers. to check or repair the HOW TO MAKE CHECKS WITH THE KEY brake or to replace the friction disc. 0. tube and filter while keeping the tube 1 vertical. See the section THE ELEC- MAINTENANCE SCHEDULE in this section. Carefully lift the plate assembly. have the adjustment checked by authorized SCHEDULE in this section. ELECTRIC BRAKE 4 If the brake needs adjustment. when in good condition and cor- tighten the hose clamp. 2.33 to 0. See FIGURE 12. CAPSCREW (3) 8. HOSE CONNECTOR 4. 8 12293 LIMIT SWITCH ROLLERS AND OTHER FIGURE 11. Install the replace- ment filter on the tube. Remove the three nuts that fas. BACK PLATE 10.013 to 0. FRICTION DISC 3. See TRIC BRAKE. 1800 SRM 305. 15 . The brake. The filter is held on the bottom of the tube by a grommet as shown in FIGURE 11. Close the hydraulic compartment 1. FILL/BREATHER Lubricate the cable sheaves at the top of the mast and 2. 3 6 ELECTRICAL CABLE SHEAVES 1. HYDRAULIC TANK PALLET CLAMP 6. 3. 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.5 meter in 10 meters (a gauge. SPRING WASHER (3) 9. NOTE: If the filter slips off the tube during removal or 12350 installation. install the plate assembly and connect the hose on the fitting. CAPSCREW FIGURE 12.5 ft in 10 ft)].38 mm 8 (0. TUBE 7 Use multi–purpose grease to lubricate the pawls of the 7. SIGHT GAUGE 5. SWITCH OFF for the correct filling procedure.015 in) 10 9 Check the hydraulic system for leaks and damage or loose components. have authorized person- nel evenly tighten the capscrews until the clearance be- 4 tween the electric magnet and the armature plate is 0. BORE. 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. PLATE ASSEMBLY cylinder head using multi–purpose grease. FILTER ELEMENT 8. Fill the hydraulic tank with the oil shown in the slope of 0. GROMMET pallet clamp. To replace the filter. all pins.38 mm (0.015 in). remove and plug the hose at the 3 5 6 7 fitting near the breather. ARMATURE PLATE 6. 4 2 7 ten the plate to the top of the tank. Connect the hose to the tube and personnel.013 to 0. SPRING (12) 4. Remove the fill cap and fill the rectly adjusted.

is more than 0.) and equalizing charge is normally given approximately proper operation of the battery charger is important. Dis- connect the battery when doing cleaning and main- tenance. Many customers charge the battery at regular in- Contacts in this manual. Prevent sparks from the battery connectors. Do tions of the charger manufacturer. sparks and burning material away from the battery charger area. 1. You can damage the traction control more charge can decrease the life of the battery. When charging the batteries. tervals that depend on use. circuit. Never permit equalizing charge. GENERAL PROCEDURES HOW TO CHARGE THE BATTERY WARNING The acid in the electrolyte can cause injury. Never let the battery not give an equalizing charge more than once a week. Consult your battery dealer. If the lift truck has been operated using a low battery FIGURE 13. use water to flush the area. If elec- trolyte is spilled. once a month. EQUALIZING CHARGE: This charge is at a low rate and balances the charge in all of the cells. equalizing charge.265 to 1. function. The battery charger area must have ventilation so that explosive fumes are removed.020 between cells of a battery after and trolyte temperature above 49°C (120°F). inspect for welded contacts BEFORE connecting a charged battery. Always make sure the charger voltage is the correct voltage for the battery. A fully charged battery will have a specific gravity for a charged battery will be after an specific gravity of 1. The most accurate specific gravity measurement of tery manufacturer. keep the vent caps clean. HOW TO CHECK or deenergized using the Emergency Stop Knob (see SPECIFIC GRAVITY “Emergency Stop Knob” in the OPERATING MANUAL). Keep fire. Acid in the eyes must be imme- diately flushed with water.310 at 25°C (77°F). Charge batteries only in the special area for charg- ing batteries. see tion. discharge below the minimum value given by the bat. Batteries generate explosive fumes when they are be- ing charged. six hours in addition to the regular charging cycle. 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. there can be a cell that has a mal- a battery to stay discharged for long periods. To check the contacts. Frequent charging of a battery that has a 2/3 or the lift truck. This procedure will keep the battery correctly charged if the battery is not dis- charged below the limit. If the difference in specific gravity Never charge a battery at a rate that will raise the elec. Make the acid neutral with a solution of sodium bicarbon- ate (soda) and water. 2. 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. The Correct use of the hydrometer (FIGURE 13. The circuit will not re. It is a charge at a slow rate for three to Operate the battery charger according to the instruc. 16 .

Do NOT put hands. The maximum battery weight is shown on Lift and tilt the panel to remove it. Use the recommendations of the battery manufac- follow a program to automatically charge a battery ac. BATTERY PULLER 2. BATTERY STAND 7. BATTERY 4. cording to recommendations of the battery manufac- 2 6 7 6 5 4 3 4 4 3 5 7 12057 1 1. arms. The panel will tip to. If the battery is lifted. Align the battery stand with the battery so that the end of the stand is against the roller frame for the bat- General tery. Move to a position in front of the battery compart- ment panel on the side for the battery stand.) 1. the ratchet and operate the crank to pull the battery onto the battery stand. turer for charging the battery. 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. 2. Use the Battery 4. Make sure is moving. the lift truck nameplate. lift the battery from the battery stand.NOTE: Many customers have battery chargers that can turer. On R30ES units. the battery must be level when it hook to make contact with cell connectors. LATCH FOR COMPARTMENT PANEL 6. tery case. use a spreader bar and crane to Disconnect to disconnect the battery. release the following procedure. bar is greater than the weight of the battery. 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. On R30E/ WARNING EA/EF units. HOW TO CHANGE THE BATTERY HOW TO CHANGE THE BATTERY 3. Adjust all four capscrew legs of to avoid injury. The spreader bar must 17 . Stand on the base of the battery puller. Move the key to the OFF position. puller on the end of the stand at the center. See FIGURE 15. ROLLERS FIGURE 14. 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 ward you. Remove the Battery (See FIGURE 15. RATCHET LOCK LEVER 3. Release the ratchet lock and attach the To prevent personal injury and battery movement hook to the lifting hole of the battery. See FIGURE 15. Use care bottom of the battery. BATTERY COMPARTMENT PANEL 5. Do not permit the that is not expected. Install the battery legs between the battery and a solid object. feet and or the stand so that the rollers are level. there is a weight of the battery is normally shown on the bat- small panel at the bottom of the battery compartment.

Remove the wheel nuts that fasten the drive/steer that the battery compartment has the correct spacers for wheel to the hub. Tighten tor has the block for the Battery Disconnect Lever in- the nuts in a cross pattern to the correct torque value stalled.m (100 lbf ft) torque rection. the battery move more than 13 mm (0. deenergized using the Emergency Stop Knob (see Emergency Stop Knob in the OPERATING MANU- AL). 1 Make sure that the battery voltage and weight of the replacement battery is correct as shown on the 1. On R30E/EA/EF units. A press that has a ca- and attach the hook to the battery lifting hole. 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. See CAUTION your Hyster Lift Truck Dealer for the correct spacers. check On R30E/EA/EF units. Make sure the foot switch is re- Batteries are heavy. The spacers must not let truck. tery compartment. Make sure tion. The correct tools. The spacers must keep the battery as far from after installation. equipment and press ring lock. leased and the key is in the OFF position before con- necting the battery. inspect for welded contacts BEFORE connect- ing a charged battery. the wheel must be pressed out the battery stand. make sure the 2. 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. This is not a tors. Do not pacity of approximately 36 000 kg (80 000 lb) is also permit the hook to make contact with the cell connec. the mast as possible. 12582 CAUTION FIGURE 16. Make sure the battery is the correct size and weight for the lift truck. When the cables during installation. See FIGURE 15. The circuit will not reset and 2 lift truck operation cannot be controlled if the con- tacts are welded. BATTERY CABLES 2 nameplate. Release the ratchet of the rim.NOT be made of metal or it must have insulated the crank to pull the battery off the stand into the bat- straps.5 in) in any di. If the wheels have been removed and installed. Install the Battery (See FIGURE 15. Tighten the wheel nuts to 136 N. center of the battery compartment on the side opposite To change the drive tire. Stand on the base of the battery puller and operate job that an operator should attempt. nuts stay tight after an eight hour check. make sure the battery connec- all wheel nuts after 2 to 5 hours of operation. Do not damage the battery shown in the Maintenance Schedule table. Slide the wheel out from under the lift the battery you are installing. BATTERY CONNECTOR 1 battery half of the connector block has the block for the Battery Disconnect Lever. required to press the wheel out of the rim. pass the hook through the battery compartment must be used for each size wheel. Install the battery puller on the lift truck frame at the for checking can be extended to 350 hours. the interval 2. HOW TO CHANGE WHEELS AND TIRES 1. Use the reverse procedure to install the wheel. TO PUT A LIFT TRUCK ON BLOCKS in this sec- nector can be connected after installation. BATTERY CONNECTOR The replacement battery must fit the battery com- partment. See FIGURE 16. Have authorized personnel re- place or adjust the battery spacers for that battery. see Contacts in this manual. Use care to avoid injury.) WARNING WARNING Before connecting the battery. To check the contacts. Have the tires 18 .

50 x 38.00/14.0 in). N/A 35. Install the load wheel. AXLE SLEEVE units. equipment and experience. N/A = Minimum battery size is Not Available for the R30ES. To replace the load wheels on R30EA and R30EF 2 5. BEARING 8 lation on R30E/ES units.25 in. remove and install one load 7. 8 1. The load 8.25 in).38 in. GREASE FITTING wheel brackets are held in the base arms by the load 7 (FREEZER 4 CORROSION ONLY) wheels. 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. 19 . 3 4 5 all load wheels must always be replaced at the same 7 time. N/A 13. battery width in- stalled front–to–back. Maximum height for R30ES batteries is 591 mm (23. Fill FIGURE 17. Remove the axle sleeve from the load wheel.50 x 36 in. 13. LOAD WHEEL 6 4.changed by authorized personnel that have the proper the area between the bearings with the same grease and tools. 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. remove the axle and load wheel. axle and axle nut. AXLE tion. Battery length installed across lift truck. made from softer or harder material. can be installed as optional equipment. install the axle sleeve.88 in. 3 Completely fill new bearings with the grease shown in the MAINTENANCE SCHEDULE in this section. Make sure the seal of each bearing is toward the outside. * Maximum height for all R30E/EA/EF batteries is 787 mm (31. 1 12058 stall the bearings in the replacement load wheel.00/38. 2 6.25 in. 6 3. 1025 lb 1210 lb Y Compartment width is across width of lift truck. (See FIGURE 17. add additional grease through each of the grease How To Replace Load Wheels fittings.) 1 CAUTION For correct operation of the wire guidance system. In. NOTE: On units that have the freezer and corrosion op- tion. BASE ARM 2. For easier instal. 35.25 in. AXLE NUT wheel before removing the next load wheel. Similar tires. LOAD WHEEL Put the base arms up on blocks as described in HOW BRACKET TO PUT THE LIFT TRUCK ON BLOCKS in this sec.