Hyster G118 (R30XM2, R30XMA2, R30XMF2) Forklift Parts Manual

PARTS MANUAL R30XM2, R30XMA2, R30XMF2 (G118)

CUSTOMER EDITION

1485650 01/2002

©2002 Hyster Company

UNIT CODE G118 NORTH AMERICA

01/2002

SECTIONS

1

FRAME

2

ELECTRICAL SYSTEM

3

DRIVE UNIT

4

STEERING SYSTEM

5

HYDRAULIC SYSTEM

6

MAST-THREE STAGE FULL FREE-LIFT

7

OPTIONS

8

NUMERICAL INDEX

This Parts Manual is divided into 8 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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01/2002

UNIT CODE G118 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

B BATTERY CONNECTOR ASSEMBLY.................................................................................................................. 2-8 BATTERY DISCONNECT................................................................................................................................... 2-10 BATTERY TRAY AND PULLER............................................................................................................................ 7-6 C CASTER ............................................................................................................................................................. 1-24 CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-16 COLD STORAGE HEATER PLATE .................................................................................................................... 7-24 CONNECTING AND TAKE-UP HOSES THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-2 CONSOLE ELECTRICAL ARRANGEMENT........................................................................................................ 2-4 CONTACTOR PANEL ASSEMBLY 24/36 VOLT ’E’ ................................................................................................................................................ 2-12 24/36 VOLT ’EE’.............................................................................................................................................. 2-14 CONTROL COMPARTMENT ............................................................................................................................... 1-6 D DECAL AND PLATE LOCATION .......................................................................................................................... 1-8 DRIVE MOTOR ⇒ S/N PENDING PER ECN 83579-08............................................................................................................. 3-8 S/N PENDING PER ECN 83579-08⇒............................................................................................................ 3-12 DRIVE UNIT ......................................................................................................................................................... 3-4 DRIVE UNIT INSTALLATION ............................................................................................................................... 3-2 E ELECTRIC BRAKE............................................................................................................................................. 3-14 ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-2 F FIXED CONSOLE .............................................................................................................................................. 7-10 FORKS ............................................................................................................................................................... 1-26 FULL BODY FAN INSTALLATION ........................................................................................................................ 7-8 FURNITURE OVERHEAD GUARD WELDMENT .............................................................................................. 7-22 G GUIDE ROLLER ASSEMBLY ............................................................................................................................... 7-4 H HEIGHT ENCODER ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-8 HOIST CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................ 2-18 24/36 VOLT ’EE’.............................................................................................................................................. 2-20 HOODS AND COVERS........................................................................................................................................ 1-2 HYDRAULIC ARRANGEMENT ............................................................................................................................ 5-2 HYDRAULIC PUMP ASSEMBLY........................................................................................................................ 5-10 HYDRAULIC TANK ASSEMBLY........................................................................................................................... 5-6

©2002 HYSTER COMPANY

See Service Manual for service procedures.

i

UNIT CODE G118 NORTH AMERICA

01/2002

TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE

L LIFT MOTOR ........................................................................................................................................................ 5-8 LIGHT AND FAN ASSEMBLY............................................................................................................................... 7-2 LOAD WHEEL SINGLE........................................................................................................................................................... 1-20 TANDEM ......................................................................................................................................................... 1-22 LOWER COILED CABLE ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-4 M MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..................................................................................................................

MAIN LIFT CYLINDER ARRANGEMENT THREE STAGE FULL FREE-LIFT ..................................................................................................................

MAIN/TRACTION CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................

24/36 VOLT ’EE’..............................................................................................................................................

MULTI-FUNCTION CONTROL HANDLE ...........................................................................................................

MULTI-FUNCTION CONTROL HANDLE ASSEMBLY .......................................................................................

6-20 6-10 2-16 2-17 4-10 4-12

O OPERATOR PLATFORM CONTROLS ....................................................................................................................................................

INTERFACE ....................................................................................................................................................

STRUCTURE ..................................................................................................................................................

OUTER, INTERMEDIATE, AND INNER MAST THREE STAGE FULL FREE-LIFT ..................................................................................................................

1-16 1-14 1-10 6-12

P PALLET CLAMP ASSEMBLY ............................................................................................................................. 1-28 PIVOTING HANDRAIL ....................................................................................................................................... 1-18 S STEER ASSEMBLY MULTI-TURN (MTS) .........................................................................................................................................

RETURN-TO-CENTER (RTC) ..........................................................................................................................

STEERING CHAIN AND SENSOR ......................................................................................................................

STEERING GEAR AND MOTOR .........................................................................................................................

4-8 4-6 4-4 4-2

U UPPER COILED CABLE ASSEMBLY .................................................................................................................. 6-6 W WIRE DRIVER ASSEMBLY................................................................................................................................

WIRE GUARD ASSEMBLY ................................................................................................................................

WIRE GUIDANCE SENSORS............................................................................................................................

WIRE TAKE-UP ’EE’ AND COLD STORAGE............................................................................................................................

ii

See Service Manual for service procedures.

7-14 7-16 7-12 7-18

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

CRE

Corrosive Environment

millimeters

D/B

Date Break

MSTS

Microprocessor Spark Timing System

dbA

Decibel "A" Scale

NPT

National Pipe Threads

DE

Drive End

ECH

Empty Container Handler

ECH-3

Empty Container Handler - 3 High Stacking

ECH-4

Empty Container Handler - 4 High Stacking

ECH-5

Freezer Environment

O/S

Oversize

PTO

Power Take Off

RPM

Revolutions per Minute

S/N

Serial Number

TMM

Truck Management Module

UL Type D

Diesel-Powered Safety Rating

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type GS

Gasoline-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LP

Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

UL Type LPS

LP Gas-Powered Safety Rating

U/S

Undersize

EPROM

Electrically Programmable Read Only Memory

UL

Underwriters Laboratory

V

Volts

ECH-6

©2002 HYSTER COMPANY

See Service Manual for service procedures.

iii

UNIT CODE G118 NORTH AMERICA

01/2002

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

iv

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

10. Serial number breaks identify the most current parts information and are shown as follows: ⇒ S/N D001H-2628 Indicates last serial number affected.

S/N D001H-2629 ⇒ Indicates the first serial number affected.

S/N D001H-1553 ⇔ S/N D001H-3291 Indicates a range of serial numbers affected.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: 3. Determine the assembly the required part is used on. Turn to the Table of Contents on Page i.

4. Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: 5. Use the Numerical Index on Page 8-1 to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL: The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (☞Figure 10) 7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and subparts of assemblies. In the example on the ©2002 HYSTER COMPANY

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: ⇒ S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 ⇒ Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: ⇒ D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇒ Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

v

UNIT CODE G118 NORTH AMERICA

01/2002

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957 and 1980.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

vi

See Service Manual for service procedures.

©2002 HYSTER COMPANY

01/2002

UNIT CODE G118 NORTH AMERICA

PUBLICATIONS Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS MANUALS with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

PUBLICATION

HYSTER PART NUMBER

Operating Manual .................................................................................................................. 1485632 Service Manual (Complete) .................................................................................................. 1485926 Parts Manual .......................................................................................................................... 1485650

©2002 HYSTER COMPANY

See Service Manual for service procedures.

vii

NOTES

viii

UNIT CODE G118 NORTH AMERICA

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1

FRAME

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 1 FRAME DESCRIPTION

PAGE

CASTER ............................................................................................................................................................. 1-24 CONTROL COMPARTMENT ............................................................................................................................... 1-6 DECAL AND PLATE LOCATION .......................................................................................................................... 1-8 FORKS ............................................................................................................................................................... 1-26 HOODS AND COVERS........................................................................................................................................ 1-2 LOAD WHEEL SINGLE........................................................................................................................................................... 1-20 TANDEM ......................................................................................................................................................... 1-22 OPERATOR PLATFORM CONTROLS .................................................................................................................................................... 1-16 INTERFACE .................................................................................................................................................... 1-14 STRUCTURE .................................................................................................................................................. 1-10 PALLET CLAMP ASSEMBLY ............................................................................................................................. 1-28 PIVOTING HANDRAIL ....................................................................................................................................... 1-18

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-1

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS (Figure 1-1)

1-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 6 7 8 8 8 9 10 10 11 12 13 13 13 13 14 14 15 15 15 15 16 16 17 17 18 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31

2303427 2305960 2307518 2308460 188307 1460341 1460625 1310137 18497 18508 18513 2306205 2306243 2306243 15155 15055 16836 16836 18498 18498 2045084 2305315 2302703 2302703 2307479 2307479 2309538 2309538 15155 15155 15055 15055 368022 383274 383273 2034636 2038957 2308118 16723 197067 15152 15052 2035661 16729 2038678 269200

Stud .............................................................................................................................

Spring ..........................................................................................................................

Washer ........................................................................................................................

Retainer .......................................................................................................................

Nut ...............................................................................................................................

Cover ...........................................................................................................................

Cover ...........................................................................................................................

Pin ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Spacer .........................................................................................................................

Tube .............................................................................................................................

Tube .............................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Plate ........................................................................................................................

Plate ........................................................................................................................

Spacer .........................................................................................................................

Spacer .........................................................................................................................

Cover ...........................................................................................................................

Cover ...........................................................................................................................

Tube .............................................................................................................................

Tube .............................................................................................................................

Lockwasher..................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Nut ...............................................................................................................................

Roller ...........................................................................................................................

Door (RH) ....................................................................................................................

Door (LH) .....................................................................................................................

Strobe Lamp ................................................................................................................

Strobe Light Bulb.....................................................................................................

Connector ....................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Guard...........................................................................................................................

Screw...........................................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

a j m d g o ajm ajm b i n p

e f e f k l c h c h

4 4 4 4 4 1 1 2 2 2 2 1 1 2 1 2 2 4 2 4 1 2 1 2 1 2 2 1 2 4 2 4 6 1 1 1 1 1 2 6 4 4 1 2 2 2

FOOTNOTES: a 0.5 in. and 1.00 in. Battery Spacer Front to Back b 0.5 in. and 2.50 in. Battery Spacer Side to Side c 0.5 in. Battery Spacer Side to Side ©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-3

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS d e f g h i j k l m n o p

1-4

0.5 in., 1.50 in., 2.50 in. Battery Spacer Front to Back 0.5 in., 1.50 in., 2.50 in. Battery Spacer Side to Side 1.00 in. and 3.00 in. Battery Spacer Side to Side 1.00 in., 1.50 in., 2.00 in., 2.50 in. Battery Spacer Front to Back 1.00 in., 1.50 in., 2.00 in., 2.50 in., 3.00 in. Battery Spacer Side to Side 1.00 in., 1.50 in., 2.00 in., Battery Spacer Side to Side 1.50 in. and 2.00 in. Battery Spacer Front to Back 1.50 in. Battery Spacer Side to Side 2.00 in., 2.50 in., 3.00 in. Battery Spacer Side to Side 2.50 in. and 3.00 in. Battery Spacer Front to Back 2.50 in. Battery Spacer Side to Side 3.00 in. Battery Spacer Front to Back 3.00 in. Battery Spacer Side to Side

See Service Manual for service procedures.

©2002 HYSTER COMPANY