100582, OPR, HYSTER, Hyster2, SRM
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//-->INTRODUCTIONGENERALThis section has a description and the service proce-dures for the parts of the frame. These parts include theframe, counterweight assembly, overhead guard, hoodand seat assembly, access panels, and label positions.The procedure for removing the traction motor is alsodescribed in this section.Other Frame Weldments (See FIGURE 1.)These frame parts are the right–hand and left–hand sidestep and fender weldments, and the cowl weldment.Each part is a weldment fastened to the main frame tomake the frame assembly. The cowl weldment is amount for the front of the overhead guard (seeFIGURE 3.), the steering column assembly (seeFIGURE 4.), the release linkage of the parking brakeand the instrument panel with light switches. The dis-play panel (see FIGURE 4.) is not part of the instrumentpanel. The steering column housing is the mount for thedisplay panel assembly.Overhead Guard (See FIGURE 3.)DESCRIPTIONMain Frame (See FIGURE 1.)The main frame is a single weldment. The main framehas mounts for the following: 1) counterweight, 2) over-head guard, 3) battery restraint and hood, 4) tilt cylin-ders, 5) steering axle, 6) drive axle assembly, 7) cowl as-sembly, 8) floor pedals and floor plates, 9) side step andfender weldments, 10) hydraulic tank, pump and motorassemblies, 11) control valves and 12) the levers. Thehood is part of the operator and battery restraint system.The seat is part of the operator restraint system. Thefloor plates can be removed for access to components.The panels on the sides of the battery compartment canalso be easily removed. The hydraulic tank, lift pumpmotor assembly and the steering pump motor assemblyare in a compartment between the battery and thecounterweight. The SCR (silicon controlled rectifier) ortransistor electronic controllers and contactors are in thetop of the counterweight. The top cover of the counter-weight can be removed for access to the controllers andcontactors. See FIGURE 3.There are two main frames for lift trucks made for use inNorth America and two main frames for lift trucks madefor use in Europe. The frames are different because ofthe different battery compartment sizes. There are twobattery compartment lengths. The battery compartmentwidths are also different for Europe and North America.See BATTERY SPECIFICATIONS, at the back of thismanual.The weight of the battery is a large part of the counter-weight system on an electric lift truck. Make sure thatthe battery is within the weight limits indicated on thenameplate. Each model of lift truck has a cast–ironcounterweight that provides the additional weight nec-essary for the indicated capacity.WARNINGDo not operate the lift truck without the overheadguard and cowl correctly fastened to the lift truck.The overhead guard is a weldment that fastens to themain frame and cowl to help protect the operator fromfalling objects. A slot in the overhead guard permits re-moval of the battery without removing the overheadguard.Battery Restraint, Hood And Seat Assembly(See FIGURE 2., FIGURE 6. and FIGURE 7.)The hood and battery restraint as well as the latchfor the hand lever assembly must operate correctlybefore a lift truck is operated. These parts are part ofthe battery restraint system. The battery restraintsystem must operate correctly to help providereasonable protection to the operator if the lift trucktips over.A battery restraint system is installed as a safety device.See FIGURE 7. The function on the battery restraintsystem is to hold the battery in the battery compartmentin case of a tip over. Part of the battery restraint system isa battery restraint at the rear of the battery compartment.See FIGURE 6. This restraint rod extends over the rearedge of the battery case to help hold the battery withinthe battery compartment during a tip over. A handle isused to move the restraint rod. The handle of the battery1WARNING2173BATTERYCOMPARTMENT4556COWLBATTERY SPACER PLATEBATTERY RETAINER RODFRAMESIDE STEP AND FENDERWELDMENT6. ACCESS PANEL7. FLOORPLATES1.2.3.4.5.NOTE:SIDE PANELS FOR BATTERYCOMPARTMENT SHOWN IN FIGURE 2.COUNTERWEIGHT AND OVERHEADGUARD SHOWN IN FIGURE 3.FIGURE 1. LIFT TRUCK MAIN FRAME21324567BATTERYCOMPARTMENT98581.2.3.4.5.HOOD ASSEMBLYINSTRUMENT PANEL COVERCOWL COVERHAND LEVER ASSEMBLY COVERBATTERY COMPARTMENT SIDE DOOR6. MAIN FRAME7. SHIELD8. SIDE STEP AND FENDERWELDMENT9. COWL WELDMENTFIGURE 2. HOOD, COVERS AND PANELS312341. OVERHEAD GUARD2. COVER OF ELECTRONICSCOMPARTMENT3. COUNTERWEIGHT4. TOW PIN AND HANDLEFIGURE 3. OVERHEAD GUARD AND COUNTERWEIGHT481762934541.2.3.4.5.STEERING WHEELSTEERING CONTROL UNITLATCH MECHANISMCOLUMN COVERCOLUMN FRAME6. HORN SWITCH CONNECTOR7. ON–DEMAND STEERINGCOMPONENTS (NOT ALL UNITS)8. ENHANCED DISPLAY PANEL9. STANDARD DISPLAY PANELFIGURE 4. STEERING COLUMN AND INSTRUMENT PANELrestraint must be in the DOWN position to close thehood. The handle can be moved to the DOWN positiononly after the restraint rod is extended over the battery.The restraint rod can only be retracted when the hood isin the UP position.other parts of the operator restraint system fasten to thehood assembly.The operator restraint system has the seat, hip restraintsand the seat belt. The system helps the operator staywithin the lift truck in case of a tipover. See FIGURE 8.The batteries for these lift trucks must fit the batterycompartment width with a maximum of 13 mm (0.5 in)clearance. The BATTERY SPECIFICATIONS, at theback of this manual, shows the minimum sizes of thebattery compartments.WARNINGThe gas springs for the hood can raise the hood at arapid rate and cause an injury. Do NOT get overhood when raising hood.Another important part of the battery restraint system isthe steel weldment that is also the hood frame. This hoodframe is connected to the lift truck frame with hinges atthe rear of the hood. The front of the hood and frame islocked in the closed position by the assembly for the hy-draulic hand levers. A latch releases the assembly to tiltforward and allow the hood to raise. See FIGURE 7.Gas springs help lift the hood assembly. The seat andWARNINGThe battery must fit the battery compartment so thatthe battery restraint will operate correctly. A loosebattery can cause serious injury and propertydamage if the lift truck overturns. The battery mustnot be able to move more than 13 mm (0.5 in)forward, backward or side–to–side.5
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