Page 1
Part no.: 4065749 Revision: 1 (12/2014) Technical information for Hyster service centres This manual is intended solely for the specialized technicians of the Hyster service network. R1.4 R1.6N R1.6 R1.6HD D435..R2.0 R2.0HD R2.5...
Page 2
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.
Page 3
SERVICE INTRODUCTION GUIDE TO USING THE MANUAL 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:...
SERVICE INTRODUCTION GENERAL SAFETY RULES PERSONAL SAFETY • Always wear the personal protective equipment in situations requiring it. • Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not properly secured when performing lifting operations or moving loads. •...
Page 5
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.
Page 6
Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
Page 7
SERVICE INTRODUCTION Belt capacity table Colour purple 1000 2000 1400 green 2000 4000 2800 1600 yellow 3000 6000 4200 2400 grey 4000 8000 5600 3200 5000 10000 7000 4000 brown 6000 12000 8400 4800 Working load blue 8000 16000 11200 6400 capacity (kg) orange...
Page 8
SERVICE INTRODUCTION Suspension element capacity table Colour purple 1000 1400 2100 2100 green 2000 2800 4200 4200 Working load yellow 3000 3800 6300 6300 capacity (kg) grey 4000 5600 8400 8400 5000 6600 9800 10500 Coefficient Working load capacity: the working load capacity is calculated with an angle at the centre of 90°...
Page 9
SERVICE INTRODUCTION TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS Before disassembling the various parts TORQUE SETTING Nm Nominal and nuts and bolts, read the following diameter carefully. Class 8 Class 10 To make the threaded matings secure, LOCTITE 270 is used for tightening the screws.
SERVICE INTRODUCTION CORRECT METHOD FOR APPLYING FEMALE FITTINGS To assure a reliable seal between female fittings and the adapters in this manual, it is necessary to observe the following procedure, which differs from the one for assembling rigid pipes. Female fittings without a gasket (metal/metal joint) Screw on the nut by hand and then, with the aid of a wrench, tighten by another quarter turn.
SERVICE INTRODUCTION INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS Inspection of pipes and fittings When even just one of the following conditions arises the pipe must immediately be disconnected and replaced: • a shift of the connector on the pipe; •...
SERVICE INTRODUCTION SECTION CONTENTS Presentation Installation and settings Diagnostics and measurements Electrical system Hydraulic system Truck base mechanics Mast assembly mechanics Small fork mast mechanics Reduction gear Braking system Standard maintenance...
Page 14
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 ������������������������������������������������������������������������������������������������������������������������������������...
SERVICE PRESENTATION 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�...
Page 16
SERVICE PRESENTATION VieWs oF tHe trUCK...
Page 17
SERVICE PRESENTATION trUCK anD LoaD iDentiFiCation Data trUCK iDentiFiCation Data PLate The truck identification data plate is located inside the driver's cab • • Manufacturer's name Max. battery weight • • Model Min. battery weight • • Serial number Battery voltage •...
Page 18
SERVICE PRESENTATION Mast seriaL nUMBer PUnCHinG anD LoCation oF DoCUMentation 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�...
Page 20
SERVICE PRESENTATION GeneraL sPeCiFiCations 1�2 manufacturer’s type designation r1�4 r1�6 r1�6n 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) 1�8 load distance from load wheel axle - forks...
Page 21
SERVICE PRESENTATION GeneraL sPeCiFiCations 1�2 manufacturer’s type designation r2�0 r2�5 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) 1�8 load distance from load wheel axle - forks...
Page 22
SERVICE PRESENTATION GeneraL sPeCiFiCations 1�2 manufacturer’s type designation r1�6HD r2�0HD 1�3 motor unit: battery, diesel, LPG, petrol, electric electric (battery) 1�4 driving: manual, on ground, standing, seated seated 1�6 2�0 1�5 load capacity/rated load Q (t) 1�6 load centre of gravity c (mm) 1�8 load distance from load wheel axle - forks...
Page 23
SERVICE PRESENTATION notes 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) with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm 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) This value can vary by ±...
Need help?
Do you have a question about the D435-R1.4 and is the answer not in the manual?
Questions and answers