100888, OPR, HYSTER, Hyster2, SRM
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//-->INTRODUCTIONGENERALThis section contains a description and service proce-dures for the parts of the frame for the E30FR-24,E30FR, E35FR, E40FR, E45FR and E50FR series ofelectric lift trucks. These parts include the overheadguard, access panels, battery compartment tray and la-bel positions.There are three standard frame sizes used for these lifttrucks. Frame size is determined by the size of the bat-tery compartment. The E30FR-24 has the smallest bat-tery compartment. The battery compartment on thestandard E30FR and E35FR frames is 5 mm (0.2 inch)shorter but 16 mm (0.63 inch) wider than the E30FR-24.The battery compartment on the standard E40FR,E45FR and E50FR frames is slightly wider than theE30-35FR but slightly narrower than the E30FR-24 and133.4 mm (5.25 inches) higher than the E30FR-24 and117.4 mm (4.62 inches) higher than the E30-35FR se-ries frames.For extra stability, all lift trucks with a three stage fullfree lift mast capable of lifting a load above 6248 mm(246 inches) and all lift trucks with a four stage full freelift (FFL) mast, have a wide track frame that is 116.8 mm(4.6 inches) wider than standard.All models use solid tires. The E30FR-24, E30FR andE35FR lift trucks come equipped with rubber tires asstandard equipment. The E40FR, E45FR and E50FR lifttrucks come equipped with poly tires as standardequipment.DESCRIPTIONThe frame is a single weldment. The frame providesmounting for the overhead guard, mast, steer fork as-sembly, traction motor drive assembly and the hydraulictank. The battery compartment is equipped with a slid-ing roller tray for battery removal. An access door is lo-cated on the rear of the lift truck to allow for inspectionand maintenance of the hydraulic lift pump and the pow-er steering mechanism. An access panel in front of theoperator’s compartment allows for maintenance inspec-tion of the motor controller, electrical components andthe hydraulic control valve. The hydraulic tank is lo-cated on the front of the electric lift truck.1921.2.3.4.5.6.7.8.576OVERHEAD GUARDMASTLOAD BACKREST EXTENSIONCARRIAGEFORKSDRIVE WHEELBATTERYSTEER WHEEL(NOT SHOWN IN THIS VIEW)9. OPERATOR’S COMPARTMENT348FIGURE 1 – COMPONENTS MOUNTED ON THE FRAME1DISASSEMBLY AND ASSEMBLYOVERHEAD GUARDRemoval(See FIGURE 2)1. Lower the forks completely.2. Move the mast to the full forward position.3. Turn the key switch to the off “O” position.10. Remove the four bolts securing the rear post of theoverhead guard to the rear frame of the truck.CAUTIONWhen removing the overhead guard, do not allowthe posts to swing and damage any components onthe lift truck.11. Using the lifting device, carefully lift the overheadguard straight up and away from the truck. It may benecessary to tap the front crossbar of the overhead guardwith a rubber mallet to free the overhead guard from theframe.InstallationNOTE:If the truck is equipped with work lights or aflashing light attached to the overhead guard, specialcare should be used when installing the overhead guardto avoid damaging the wiring.1. Lower the overhead guard assembly into positionon the truck.NOTE:The front crossbar of the overhead guard restson supports on the inner surface of the frame, and isclamped between the front of the frame and angleswelded within the frame. See FIGURE 2.2. Attach the front of the overhead guard to the frontframe of the truck. Do not completely tighten the frontattachment bolts at this time.3. Lower the overhead guard until the bolt holes of therear post align with the holes in the rear frame. Attachthe rear post to the truck frame.4. Tighten the front and rear bolts to 108 NSm (80 lbfft) torque.5. Connect any light harness disconnected during theremoval portion of this procedure.NOTE:Ensure the top cover front clip is in place onthe front crossbar of the overhead guard.6. Replace the top cover and front cover (refer to TOPCOVER–INSTALLATION and FRONT COVER–INSTALLATION procedures in this section).2WARNINGTo prevent electrical shock and injury, disconnectthe battery, separate the connector and dischargethe capacitor bank before inspecting or repairingany component.4. Disconnect the battery and separate the battery con-nector.5. Turn the key switch to the “I” position. The operatordisplay will light and go off. After the display is com-pletely dark, the capacitor bank is fully discharged.6. Turn the key switch to the off “O” position.7. Remove the front cover and the top cover (refer toFRONT COVER–REMOVAL and TOP COVER–RE-MOVAL procedures in this section).8. Attach a lifting device to the top of the overheadguard and take up any slack.NOTE:If the truck is equipped with a flashing lightor work lights attached to the overhead guard, discon-nect the two-pin connector (at the rear post for a flashinglight; at the front for work lights) and remove any wireties attaching the wires to the truck.WARNINGThe overhead guard assembly is heavy. Be sure thatall lifting devices (hoists, cables, chains, slings, etc.)are suitable and of adequate capacity to lift the over-head guard assembly.9. Remove the two bolts securing the overhead guardto the front of the truck.7. Connect the battery.BATTERY RETAINERSRemovalNOTE:The battery retainers for the lift truck are notinterchangeable from side to side.1. Lower the forks completely.2. Move the mast to the full forward position.3. Turn the key switch to the off “O” position.OVERHEAD GUARD REAR POSTRemoval1. Remove the overhead guard from the truck (seeOverhead Guard Removal procedure in this section).2. Remove the rear post for the overhead guard.Installation1. Install the rear post between the two tabs of theoverhead guard. See FIGURE 2. Tighten the lock nut toremove any excess movement.2. Install the overhead guard (see OVERHEADGUARD–INSTALLATION procedure in this section).WARNINGTo prevent electrical shock and injury, disconnectthe battery, separate the connector and dischargethe capacitor bank before inspecting or repairingany component.4. Disconnect the battery by separating the batteryconnector.5. Turn the key switch to the “I” position. The operatordisplay will light and go off. After the display is com-pletely dark, the capacitor bank is fully discharged.6. Turn the key switch to the off “O” position.7. Lift the battery retainer straight up until the tabs onthe front of the battery retainer align with the cutouts inthe truck frame.8. Rotate the front edge of the battery retainer out untilthe tabs of the retainer clear the frame of the truck.9. Move the battery retainer toward the front of thetruck until the rear flange of the battery retainer is freefrom the frame of the truck.Installation1. Insert the rear tabs of the battery retainer into theslot at the rear of the battery compartment opening.2. Rotate the front of the battery retainer toward thetruck until the tabs on the front of the battery retainer en-ter the slots.3. Lower the battery retainer to its normal position.NOTE:There should be no more than a 12.5 mm (0.5inch) gap around the battery in any horizontal direction.If necessary, install shims to meet this specification.4. Connect the battery.121. OVERHEAD GUARD2. REAR POSTBATTERY ROLLERSRemovalFIGURE 2 – OVERHEAD GUARD ASSEMBLY31. Lower the forks completely.2. Move the mast to the full forward position.3. Turn the key switch to the off “O” position.5. Turn the key switch to the “I” position. The operatordisplay will light and go off. After the display is com-pletely dark, the capacitor bank is fully discharged.6. Turn the key switch to the off “O” position.7. Locate the two cover latch handles on the frontcover. See FIGURE 3.8. Gently lift up on the latch handles and pull forward,away from the front of the truck.9. Once the top of the cover is released, lift upward onthe cover and remove from the truck.Installation1. Place the lower edge of the front cover into the sup-port channels.2. Gently press the upper portion of the front coverinto place until the latches click into position.3. Connect the battery connector.WARNINGTo prevent electrical shock and injury, disconnectthe battery, separate the connector and dischargethe capacitor bank before inspecting or repairingany component.4. Disconnect the battery by separating the batteryconnector.5. Turn the key switch to the “I” position. The operatordisplay will light and go off. After the display is com-pletely dark, the capacitor bank is fully discharged.6. Turn the key switch to the off “O” position.7. Remove the battery retainer and the battery..8. Lift upward on the battery roller to remove the bat-tery roller assembly from the holder.9. Slide the washers and plastic roller off the batteryroller shaft.Installation1. Slide the plastic battery roller onto the battery rollershaft and install one flat washer at each end.2. Align the flats on the end of the shaft verticallyabove the slots in the floor of the battery compartmentand lower the assembly into the slots.3. Install the battery. Install the battery retainer. Con-nect the battery connector.TOP COVERRemovalNOTE:The top cover is held in place with six frame-mounted spring-type retaining clips and one front clipon the overhead guard crossbar. See FIGURE 3. Nor-mally this cover does not require any tools to remove.Care must be used when removing this cover to avoidpossible breakage.1. Lower the forks completely.2. Move the mast to the full forward position.3. Turn the key switch to the off “O” position.FRONT COVERRemoval(See FIGURE 3)1. Lower the forks completely.2. Move the mast to the full forward position.3. Turn the key switch to the off “O” position.WARNINGTo prevent electrical shock and injury, disconnectthe battery, separate the connector and dischargethe capacitor bank before inspecting or repairingany component.4. Disconnect the battery by separating the batteryconnector.WARNINGTo prevent electrical shock and injury, disconnectthe battery, separate the connector and dischargethe capacitor bank before inspecting or repairingany component.4. Disconnect the battery by separating the batteryconnector.41.2.3.4.5.6.7.1TOP COVERRIGHT PADFRONT PADCONTROL COVERFLOOR MATFRONT COVERFRONT COVER LATCH3245767FIGURE 3 – PADS, COVERS AND FLOOR MAT5
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