Professional Documents
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R1.4 R1.6N
R1.6 R1.6HD
D435.....
R2.0 R2.0HD
R2.5
INTRODUCTION SERVICE
IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifica-
tions. The updated technical information is in any case available from your nearest authorised Hyster®
dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by
appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained
in this manual could cause damage to property or injury and even death to people.
We therefore recommend that you read this manual carefully and keep it in a good condition so it is always
decipherable and complete.
This manual does not replace the use and maintenance manual, it is a supplement to it.
2
SERVICE INTRODUCTION
SECTIONS
This handbook is composed of the following sections:
Section 1: Presentation
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Section 5: Hydraulic system
Section 6: Truck base mechanics
Section 7: Mast assembly mechanics
Section 8: Small fork mast mechanics
Section 9: Reduction gear
Section 10: Braking system
Section 11: Standard maintenance
Use the sections index with the numbered black bands to go quickly to the desired section.
SYMBOLS
Signals a danger that can cause accidents to people or damage to the machine.
INSTALLATION PROCEDURES
For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and
information given for the truck to function properly.
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INTRODUCTION SERVICE
4
SERVICE INTRODUCTION
• Before using the batteries, make sure that both ends of the cables are connected to the terminals as
prescribed: (+) with (+) and (-) with (-).
• Do not short-circuit the terminals.
• The gas released when charging is highly flammable. When charging, leave the battery compartment
uncovered for more effective ventilation and take off the plugs.
• Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.
• Before taking any action, check that no elements are shorted.
• Always disconnect the battery before working on the electrical system.
• For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground
connection to avoid any electric shocks.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Having to check the system pressure, use the specific instruments.
5
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Colour
Track
Colour
(mm)
6
SERVICE INTRODUCTION
Colour
Working load capacity: the working load capacity is calculated with an angle at the
centre of 90°
7
INTRODUCTION SERVICE
TORQUE SETTING Nm
Pre-load N Class 5.8 Class 8.8 Class 10.9
= with lubricant
8
SERVICE INTRODUCTION
TORQUE SETTINGS
G1/4 20 15 - 25 9/16-18 -4 14 16
G3/8 34 27 - 41 11/16-16 -6 24 27
G1/2 60 42 - 76 13/16-16 -8 43 47
G5/8 69 44 - 94 1-14 -10 60 68
G3/4 115 95 - 135 1.3/16-12 -12 90 95
G1 140 115 - 165 1.3/16-12 -14 90 95
G1.1/4 210 140 - 280 1.7/16-12 -16 125 135
G1.1/2 290 215 - 365 1.11/16-12 -20 170 190
G2 400 300 - 500 2-12 -24 200 225
2-1/2-20 -32 460 490
The values given in the tables refer to galvanized steel fittings. Fittings of other materials
have other values.
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INTRODUCTION SERVICE
Pre-installation inspection
Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size,
reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the
outer layer or any other visible defects.
Installation
Avoid twisting the pipe, which could cause it to burst under pressure.
There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assem-
bled pipe decreases considerably when below the minimum radius of curvature.
The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly
greater length than the requirement in order to compensate for these changes.
Code:
4075291 (C8 - C10)
4075292 (C12)
4075293 (C16)
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SERVICE INTRODUCTION
SECTION CONTENTS
Presentation 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Truck base mechanics 6
Mast assembly mechanics 6
7
Small fork mast mechanics 6
8
Reduction gear 7
9
Braking system 10
8
Standard maintenance 11
7
11
INTRODUCTION SERVICE
12
SERVICE PRESENTATION
Presentation
TRUCK PRESENTATION������������������������������������������������������������������������������������������������������������������������������������������� 2
VIEWS OF THE TRUCK��������������������������������������������������������������������������������������������������������������������������������������������� 3
TRUCK AND LOAD IDENTIFICATION DATA����������������������������������������������������������������������������������������������������������� 4
TRUCK IDENTIFICATION DATA PLATE��������������������������������������������������������������������������������������������������������������������� 4
RESIDUAL LOAD PLATE ������������������������������������������������������������������������������������������������������������������������������������������� 4
MAST SERIAL NUMBER PUNCHING and location of documentation������������������������������������������������������ 5
GENERAL SPECIFICATIONS������������������������������������������������������������������������������������������������������������������������������������ 6
BATTERIES TABLE��������������������������������������������������������������������������������������������������������������������������������������������������� 10
1
PRESENTATION SERVICE
TRUCK PRESENTATION
The new range of retractable trucks consists of 7 models with nominal load capacities from 1400 kg to
2500 kg.
Electrical system
All the motors benefit from the use of three phase AC alternate current technology: traction motor, steering
motor and pump motor.
The high battery efficiency is ensured by the regenerative inversion and release braking.
The electronic controls VCM, ACE2 Traction, ACE2 Pump and EPS ACW communicate via a CAN-Bus
system (Controller Area Network Bus). There are two separate CAN-Bus lines to improve the efficiency,
reliability and independence of the modules.
Hydraulic system
The 14 kW pump motor provides excellent performance thanks to the technology with proportional sole-
noid valves for the carriage out/return, lifting/lowering, fork tilting and side shifting operations with smooth
movements of the actuators.
Mast
The masts comprise three stages: external, middle and internal.
The rigidity and stability characteristics of the masts allow the forks to reach maximum heights of between
5 and 12 metres depending on the model.
The lifting cylinders are single-acting plungers.
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SERVICE PRESENTATION
3
PRESENTATION SERVICE
Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
4
SERVICE PRESENTATION
xxxxxxxx
The mast serial number is stamped on the The truck documentation is stored in the docu-
mast itself. ment holder behind the backrest of the seat.
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PRESENTATION SERVICE
GENERAL SPECIFICATIONS
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SERVICE PRESENTATION
GENERAL SPECIFICATIONS
1.2 manufacturer’s type designation R1.4 R1.6 R1.6N
WEIGHTS CHARACTERISTICS
1.3 motor unit: battery, diesel, LPG, petrol, electric electric (battery)
1.4 driving: manual, on ground, standing, seated seated
1.5 load capacity/rated load Q (t) 1.4 1.6 1.6
1.6 load centre of gravity c (mm) 600 600 600
1.8 load distance from load wheel axle - forks x (mm) 258 308 202
1.9 wheelbase (WB) y (mm) 1400 1450 1450
2.1 weight with no load (including battery) kg 3495 3546 3498
2.3 load on axle with no load (front/rear) (5) kg 2055/1440 2103/1443 1955/1543
2.4 load on axle with forks out with load (front/rear) kg 885/4010 810/4336 757/4341
2.5 load on axle with forks retracted with load (front/rear) kg 1711/3184 1779/3367 1514/3584
3.1 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 100 285 x 100
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1155 1025
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4 2/4
4.2 height of closed mast h1 (mm) 2195 2195 2195
4.3 free lift h2 (mm) 1648 1648 1648
4.4 lifting height h3 (mm) 5000 5000 5000
4.5 height, mast extended (1) h4 (mm) 5563 5563 5563
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175 2175
4.8 seat height h7 (mm) 1082 1082 1082
4.10 armrest height h8 (mm) 308 308 308
4.19 total length l1 (mm) 2523 2523 2629
4.20 length to face of forks l2 (mm) 1373 1373 1479
4.21 overall width (3) b1/b2 (mm) 1265 1265 1125
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150 40/120/1150 40/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A 2A
4.24 fork carriage width b3 (mm) 700 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 220/640 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900 795
4.28 retractable travel I4 (mm) 441 491 385
4.31 ground clearance under mast with load m1 (mm) 75 75 75
4.32 ground clearance at wheelbase centre m2 (mm) 75 75 75
4.34.1working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2825 2834 2898
4.34.2working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2895 2896 2976
4.35 turning radius Wa (mm) 1671 1718 1700
4.37 length between the wheel arms I7 (mm) 1795 1845 1845
4.42 wheelbase height (from ground to footboard) mm 550 550 550
wheelbase height (between the steps between the footboard and the
4.43 mm 371 371 371
ground)
5.1 traction speed with/without load (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
5.1.1 traction speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
0,37 / 0,63 0,32 / 0,63 0,32 / 0,63
PERFORMANCE
10.1 working pressure for additional attachments bar 180 180 180
10.2 volume of oil for additional attachments l/min 20 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7 <69.7
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PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.2 manufacturer’s type designation R2.0 R2.5
WEIGHTS CHARACTERISTICS
1.3 motor unit: battery, diesel, LPG, petrol, electric electric (battery)
1.4 driving: manual, on ground, standing, seated seated
1.5 load capacity/rated load Q (t) 2.0 2.5
1.6 load centre of gravity c (mm) 600 600
1.8 load distance from load wheel axle - forks x (mm) 358 431
1.9 wheelbase (WB) y (mm) 1500 1650
2.1 weight with no load (including battery) kg 3801 4230
2.3 load on axle with no load (front/rear) (5) kg 2296/1504 2565/1665
2.4 load on axle with forks out with load (front/rear) kg 770/5030 876/5855
2.5 load on axle with forks retracted with load (front/rear) kg 1971/3829 2306/4424
3.1 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 140
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height of closed mast h1 (mm) 2195 2195
4.3 free lift h2 (mm) 1582 1582
4.4 lifting height h3 (mm) 4650 4650
4.5 height, mast extended (1) h4 (mm) 5263 5263
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175
4.8 seat height h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2523 2600
4.20 length to face of forks l2 (mm) 1373 1450
4.21 overall width (3) b1/b2 (mm) 1265 1345
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900
4.28 retractable travel I4 (mm) 541 614
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance at wheelbase centre m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2846 2938
4.34.2 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2900 2978
4.35 turning radius Wa (mm) 1767 1911
4.37 length between the wheel arms I7 (mm) 1895 2045
4.42 wheelbase height (from ground to footboard) mm 550 550
wheelbase height (between the steps between the footboard and the
4.43 mm 371 371
ground)
5.1 traction speed with/without load (7) km/h 14 / 14 14 / 14
5.1.1 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 14
PERFORMANCE
5.2 lift speed with/without load (7) m/s 0.37 / 0.64 0.30 / 0.64
5.3 lowering speed with/without load m/s 0.55 / 0.50 0.55 / 0.50
5.4 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.15
5.7 grade ability with/without load % 10 / 15 8 / 14
5.8 maximum gradeability with/without load % 12 / 15 12 / 15
5.9 acceleration time, laden/unladen s -/- -/-
5.10 service brake Electrical
6.1 traction motor, power S2 60 minutes kW 6,4 6,4
MOTOR UNITS
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SERVICE PRESENTATION
GENERAL SPECIFICATIONS
1.2 manufacturer’s type designation R1.6HD R2.0HD
WEIGHTS CHARACTERISTICS
1.3 motor unit: battery, diesel, LPG, petrol, electric electric (battery)
1.4 driving: manual, on ground, standing, seated seated
1.5 load capacity/rated load Q (t) 1.6 2.0
1.6 load centre of gravity c (mm) 600 600
1.8 load distance from load wheel axle - forks x (mm) 308 281
1.9 wheelbase (WB) y (mm) 1450 1500
2.1 weight with no load (including battery) kg 4224 4617
2.3 load on axle with no load (front/rear) (5) kg 2428/1796 2577/2040
2.4 load on axle with forks out with load (front/rear) kg 979/4845 985/5632
2.5 load on axle with forks retracted with load (front/rear) kg 2104/3720 2149/4468
3.1 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 140
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height of closed mast h1 (mm) 3227 3227
4.3 free lift h2 (mm) 2680 2614
4.4 lifting height h3 (mm) 7900 7750
4.5 height, mast extended (1) h4 (mm) 8463 8363
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175
4.8 seat height h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2523 2600
4.20 length to face of forks l2 (mm) 1373 1450
4.21 overall width (3) b1/b2 (mm) 1265 1345
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900
4.28 retractable travel I4 (mm) 491 464
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance at wheelbase centre m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2834 2903
4.34.2 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2896 2970
4.35 turning radius Wa (mm) 1718 1767
4.37 length between the wheel arms I7 (mm) 1845 1895
4.42 wheelbase height (from ground to footboard) mm 550 550
wheelbase height (between the steps between the footboard and the
4.43 mm 371 371
ground)
5.1 traction speed with/without load (7) km/h 14 / 14 14 / 14
5.1.1 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 14
PERFORMANCE
5.2 lift speed with/without load (7) m/s 0,42 / 0,73 0,37 / 0,68
5.3 lowering speed with/without load m/s 0.55 0.55
5.4 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.15
5.7 grade ability with/without load % 10 / 14 8 / 13
5.8 maximum gradeability with/without load % 12 / 15 12 / 15
5.9 acceleration time, laden/unladen s -/- -/-
5.10 service brake Electrical
6.1 traction motor, power S2 60 minutes kW 6,4 6,4
MOTOR UNITS
9
PRESENTATION SERVICE
NOTES
(1)
with load grille h4 + 508 mm (all models except for 2 ton and 2.5 ton), h4 + 443 mm (2 ton and 2.5 ton models only)
(2)
with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm
(3) with load wheel side cover: 1289 mm (all models except for Narrow, 2.5 ton, HD 2.0 ton versions), 1153 mm (Narrow model only), 1373
mm (2.5 ton, HD 2.0 ton models only)
(4)
This value can vary by ± 5%
(5)
Forks retracted
(6)
see “batteries table”
(7)
the values in
parentheses are optional
(8)
the side shift travel is ± 75 mm on all models. It is reduced to ± 25 mm for the Narrow model
BATTERIES TABLE
1.2 manufacturer’s type designation R1.4
1.8 load distance from load wheel axle - forks x (mm) 402 330 402 330 258
1.9 wheelbase (WB) y (mm) 1400 1400 1400 1400 1400
2.1 weight with no load (including battery) kg 3112 3309 3112 3320 3541
2.3 load on axle with no load (front/rear) (5) kg 1977/1135 2025/1285 1977/1135 2032/1289 2084/1457
2.4 load on axle with forks out with load (front/rear) kg 682/3830 792/3917 682/3830 800/3921 914/4027
load on axle with forks retracted with load (front/
2.5 kg 1778/2735 1753/2956 1778/2735 1760/2960 1741/3201
rear)
4.19 total length l1 (mm) 2379 2451 2379 2451 2523
4.20 length to face of forks l2 (mm) 1229 1301 1229 1301 1373
4.28 retractable travel I4 (mm) 585 513 585 513 441
working aisle for pallet length 1000 x 1200 cross-
4.34.1 Ast (mm) 2718 2771 2718 2771 2826
wise
working aisle for pallet length 800 x 1200 length-
4.34.2 Ast (mm) 2764 2829 2764 2829 2895
wise
4.35 turning radius Wa (mm) 1671 1671 1671 1671 1671
battery in compliance with DIN 43531/35/36 A,B,C,
6.3 C C C "Super" C "Super" C "Super"
no
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/420 48/560 48/465 48/620 48/775
6.5 battery weight (4) kg 750 939 750 950 1165
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