Hyster D435-R1.4 Manual

1 (12/2014)Revision:Part no.:
Technical information for Hyster service
centres
This manual is intended solely for the specialized technicians of
the Hyster service network.
4065749
D435.....
R1.4 R1.6N
R1.6 R1.6HD
R2.0 R2.0HD
R2.5

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2
INTRODUCTION
IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modica-
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.
Product support group

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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.
Signals danger due to high temperatures.
Signals important notes or information to take into particular consideration.
Signals disposal/recycling of harmful substances under the protection of current legislation.
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.
GUIDE TO USING THE MANUAL

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4
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.
Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut-•
toned jackets or tops with open zippers that can get caught up in moving parts.
Never do any cleaning, lubrication or maintenance work with the battery connected.•
Using compressed air to clean the parts, protect yourself with goggles that have side protection. The•
maximum air pressure must not exceed 1 bar.
SAFETY AT THE WORKPLACE
Make sure that all the work tools are perfectly efcient and ready for use. Keep the work surfaces clean •
and clear of debris that can come into contact with parts of the machine and cause damage.
Make sure you keep sparks, naked lights and cigarettes away from fuels or ammable materials such •
as the gas of the batteries and fuels.
Make sure that the work area is ventilated, well illuminated, dry and clean. Remove any puddles of•
water or oil stains.
Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable•
manner.
Never use gasoline, diesel fuel or other ammable liquids such as detergents: instead use non-ammable •
and non-toxic trade solvents.
When working outside the garage, move the machine preferably onto the level and block it. If working•
on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as pos-
sible with a certain margin of safety.
Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine•
and every attachment that has to be raised.
Never perform any servicing on the machine with persons at the controls, unless they are accredited•
operators and help with the operation to be performed.
When towing use solely the prescribed coupling points and check that the pins and/or bolts are rmly •
secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity.
Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.
Avoid twisting chains or metal ropes.•
Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the•
safety gloves to handle them.
Do not accumulate rags soaked in grease or oil: they are a great re hazard. Always put them away •
into a closed metal container.
Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.•
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls,•
gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they
remain nearby during the welding.

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5
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 ammable. 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 orice can be virtually invisible and have sufcient 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 specic instruments.•
BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE
Keep a record of all the suspension elements used, stating the characteristics of the suspension ele-•
ments and the data given on the identication plate .
Never leave belts, cords or suspension elements in use whose identication plate has been lost.•
Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension•
elements, take into consideration the lifting angle and any unbalancing of the load.
The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling•
crane and anyhow must be free to move easily.
Always rest the load in the race of the hook.•
Never load the tip of the hook.•
When lifting, avoid sudden operations that can jerk on the ropes and belts.•
Never do any lifting with the ropes and belts twisted.•
Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp •
edges.
When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and•
close the safety ones.
Using suspension elements under conditions of unbalanced load
If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting ele-
ments:
Slings with 2 booms, consider them as corresponding to 1 boom.•
Slings with 3 and 4 booms, consider them as corresponding to 2 booms.•
Tips for maintenance
Periodically examine the belts, ropes and suspension elements according to current legislation to dene
their state of service.
Change them in the following cases:
When the components show: deformation, cracks, hollows, cuts or abrasions.•
When the wear of the components exceeds 10% of the original dimensions.•
When the sling shows signs of overloading.•

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SERVICE
6
INTRODUCTION
Belt capacity table
Rope capacity table
Colour Track
(mm)
Working load
capacity (kg)
black 35 500 1000 700 400
purple 50 1000 2000 1400 800
black 50 1500 3000 2100 1200
green 60 2000 4000 2800 1600
yellow 75 3000 6000 4200 2400
grey 120 4000 8000 5600 3200
red 150 5000 10000 7000 4000
brown 180 6000 12000 8400 4800
blue 240 8000 16000 11200 6400
orange 300 10000 20000 14000 8000
Coefcient 1 2 1.4 0.8
Colour
Working load
capacity (kg)
purple 1000 2000 1400 800
green 2000 4000 2800 1600
yellow 3000 6000 4200 2400
grey 4000 8000 5600 3200
red 5000 10000 7000 4000
brown 6000 12000 8400 4800
blue 8000 16000 11200 6400
orange 10000 20000 14000 8000
orange 12000 24000 16800 9600
orange 15000 30000 21000 12000
orange 20000 40000 28000 16000
orange 25000 50000 35000 20000
orange 30000 60000 42000 24000
Coefcient 1 2 1.4 0.8

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INTRODUCTION
Suspension element capacity table
Colour
Working load
capacity (kg)
purple 1000 1400 2100 2100
green 2000 2800 4200 4200
yellow 3000 3800 6300 6300
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefcient 1 1.4 2.1 2.1
Working load capacity: the working load capacity is calculated with an angle at the
centre of 90°

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8
INTRODUCTION
TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS
Before disassembling the various parts
and nuts and bolts, read the following
carefully.
To make the threaded matings secure, LOCTITE 270 is
used for tightening the screws.
If it is not possible to unscrew the bolts because this
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (at most 50°C)
so as to eliminate the LOCTITE 270 effect.
In the cases described, reapply LOCTITE 270 during
installation in a moderate quantity (30% of the mating
surface).
The torque setting used for tightening the threaded
couplings is extremely important to make the coupling
secure and the machine safe.
The tables on this page give the classes of bolts normally
used with the relevant torque settings.
Nominal
diameter
TORQUE SETTING Nm
Class 8 Class 10
M3 4 5.2
M4 7 9.15
M5 12.14 14.8
M6 17.2 20.9
M8 31.8 38.1
M10 50.5 60.3
M12 74.2 88.5
M14 101.2 120.8
M16 138.2 164.9
M18 176.6 203.5
M20 225.4 259.7
M22 278.8 321.2
M24 324.8 374.2
M27 422.3 486.5
M30 516.1 594.7
Pre-load N
TORQUE SETTING Nm
Class 5.8 Class 8.8 Class 10.9
M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13
M5 0.8 8 4 3880 3.88 2.91 6.2 4.65 8.43 6.33
M6 1 10 5 5490 6.58 4.94 10.5 7.9 14.3 10.8
M8 1.25 13 6 9990 16 12 25.6 19.2 34.8 26.1
M8 1 13 6 10700 17.1 12.8 27.4 20.5 37.3 27.9
M10 1.5 16 8 15825 31.7 23.8 51 38 69 52
M10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55
M12 1.75 18 10 23025 55 41.4 88 66 120 90
M12 1.25 18 10 25150 60 45.3 96 72 130 98
M14 2 21 12 31400 88 66 140 105 190 145
M14 1.5 21 12 34125 96 72 155 115 210 155
M16 2 24 14 42850 135 105 220 165 300 225
M16 1.5 24 14 45600 145 110 235 175 320 240
M20 2.5 30 17 66875 270 200 430 320 580 435
M20 1.5 30 17 74250 295 225 475 355 650 485
= with lubricant

SERVICE
9
INTRODUCTION
CORRECT METHOD FOR APPLYING FEMALE FITTINGS
To assure a reliable seal between female ttings and the adapters in this manual, it is necessary to observe
the following procedure, which differs from the one for assembling rigid pipes.
Female ttings 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.
Female ttings with O-ring
Screw on the nut by hand and then, with the aid of a wrench, tighten by another half turn.
In every case make sure that the pipe is properly aligned before tightening the nut on the adapter.
TORQUE SETTINGS
REVOLVING FEMALE jic 37°
UNF
thread Size
Torque setting Nm
Nominal torque min / max
7/16-20 -4 15 9 - 21
1/2-20 -5 20 13 - 27
9/16-18 -6 30 18 - 42
3/4-16 -8 50 30 - 70
7/8-14 -10 69 44 - 94
1.1/16-12 -12 98 63 - 133
1.3/16-12 -14 118 73 - 163
1.5/16-12 -16 140 90 - 190
1.5/8-12 -20 210 135 - 285
1.7/8-12 -24 290 200 - 380
2.1/2-12 -32 450 300 - 600
REMOVING FEMALE BSP
UNF
thread
Torque setting Nm
Nominal torque max
G1/4 20 15 - 25
G3/8 34 27 - 41
G1/2 60 42 - 76
G5/8 69 44 - 94
G3/4 115 95 - 135
G1 140 115 - 165
G1.1/4 210 140 - 280
G1.1/2 290 215 - 365
G2 400 300 - 500
METRIC REVOLVING FEMALE
UNF
thread
Outside
diameter
of the pipe
Torque setting Nm
Nominal torque min / max
M 12x1.5 6 20 15 -25
M 14x1.5 8 38 30 - 45
M 16x1.5 845 38 - 52
10
M 18x1.5 10 51 43 - 85
12
M 20x1.5 12 58 50 - 65
M 22x1.5 14 74 60 - 88
15
M 24x1.5 16 74 60 - 88
M 26x1.5 18 105 85 - 125
M 30x2 20 135 115 - 155
22
M 36x2 25 166 140 - 192
28
M 42x2 30 240 210 - 270
M 45x2 35 290 255 - 325
M 52x2 38 330 280 - 380
42
REVOLVING FEMALE ORFS
UNF
thread Size
Torque setting Nm
Nominal torque max.
9/16-18 -4 14 16
11/16-16 -6 24 27
13/16-16 -8 43 47
1-14 -10 60 68
1.3/16-12 -12 90 95
1.3/16-12 -14 90 95
1.7/16-12 -16 125 135
1.11/16-12 -20 170 190
2-12 -24 200 225
2-1/2-20 -32 460 490
The values given in the tables refer to galvanized steel ttings. Fittings of other materials
have other values.

SERVICE
10
Special wrench for hydraulic couplings
INTRODUCTION
INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS
Inspection of pipes and ttings
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;
• the presence of damage, cuts or abrasions on the surface layer;
• hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• the presence of cracks, damage or bad corrosion on the connector;
• the presence of leaks along the pipe or at the connector;
• the presence of permanent creases, compression, attening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
Pre-installation inspection
Before installing a exible 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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1
2
3
4
6
6
6
8
7
7
5
1
2
3
4
6
7
8
10
9
11
5
INTRODUCTION
SECTION CONTENTS
Installation and settings
Diagnostics and measurements
Electrical system
Truck base mechanics
Mast assembly mechanics
Small fork mast mechanics
Braking system
Reduction gear
Standard maintenance
Hydraulic system
Presentation

SERVICE
12
INTRODUCTION

1
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
SERVICE

2
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 benet from the use of three phase AC alternate current technology: traction motor, steering
motor and pump motor�
The high battery efciency 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 efciency,
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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3
PRESENTATION
VIEWS OF THE TRUCK
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4
PRESENTATION
TRUCK AND LOAD IDENTIFICATION DATA
TRUCK IDENTIFICATION DATA PLATE
The truck identication data plate is located inside the
driver's cab
• Manufacturer's name
• Model
• Serial number
• Weight without battery
• Year of manufacture
• Max. battery weight
• Min. battery weight
• Battery voltage
• Nominal load capacity
• Persons on board
RESIDUAL LOAD PLATE
The load plate is located on the roof assembly
The load plate bears the following data:
• Model
• Liftable load values up to varying heights up to the maximum load with different distances from the
load centre of gravity of the forks.
Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
SERVICE

5
PRESENTATION
MAST SERIAL NUMBER PUNCHING AND LOCATION OF DOCUMENTATION
The mast serial number is stamped on the
mast itself�
The truck documentation is stored in the docu-
ment holder behind the backrest of the seat�
xxxxxxxx
SERVICE

6
PRESENTATION
GENERAL SPECIFICATIONS
SERVICE

7
PRESENTATION
GENERAL SPECIFICATIONS
CHARACTERISTICS
1�2 manufacturer’s type designation
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
WEIGHTS
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
WHEELS &
TYRES
3�1 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan
3�2 front wheel size ø (mm x mm) 343 x 140 343 x 140 343 x 140
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
DIMENSIONS
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
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�1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2825 2834 2898
4�34�2 working 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
4�43 wheelbase height (between the steps between the footboard and the
ground) mm 371 371 371
PERFORMANCE
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)
5�2 lift speed with/without load (7) m/s 0,37 / 0,63
(0,47 / 0,73)
0,32 / 0,63
(0,42 / 0,73)
0,32 / 0,63
(0,42 / 0,73)
5�3 lowering speed with/without load m/s 0�55 0�55 0�55
5�4 Retractable carriage speed m/s 0,15 / 0,15 0,15 / 0,15 0.15 / 0.15
5�7 grade ability with/without load %12 / 15 11 / 15 11 / 15
5�8 maximum gradeability with/without load %12 / 15 12 / 15 12 / 15
5�9 acceleration time, laden/unladen s- / - - / - - / -
5�10 service brake Electrical
MOTOR UNITS
6�1 traction motor, power S2 60 minutes kW 6,4 6,4 6,4
6�2 lifting motor, power S3 15% kW 14 14 14
6�3 battery in compliance with DIN 43531/35/36 A,B,C, no C C B
6�4 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/700 (6) 48/700 (6)
6�5 battery weight (4) kg 1119 1119 1119
6�6 consumption per VDI cycle kWh/h - / - - / - - / -
OTHER
DATA
8�1 type of drive control AC
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
SERVICE
R1.4 R1.6 R1.6N