Hoist Fitness FR15/25 User manual

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
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PLANNEDMAINTENANCE
LUBRICATIONPOINTS
TIRE&WHEEL
POWERTRAIN
MAST,BOOM&ATTACHMENT
STEERAXLE
REFERENCEMATERIAL
HYDRAULIC
ELECTRICAL
OPERATORDISPLAY
SAFETYPRECAUTIONS
OPTIONALEQUIPMENT

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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INDEX
SafetySignsandSafetyMessages.....................................................1.1
GeneralSafetyRules.........................................................................1.2
MaintenanceSafetyPractices...........................................................1.4
Do’sandDon’ts...............................................................................1.10
Lockout/TagoutProcedure..............................................................1.11
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FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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SAFETY SIGNS AND SAFETY MESSAGES
Improper service operation can cause accidents. Don’t take chances with incorrect or damaged
equipment. Read and understand the procedures for safe driving and maintenance outlined
in the is manual. Don’t hesitate to ask for help. Stay alert! Follow safety rules, regulations, and
procedures. Avoid accidents by recognizing dangerous procedures or situations before they
occur. Drive and work safely and follow the safety signs and their messages on the truck and
in this manual.
Safety signs and messages are placed in this manual and on the truck to provide instructions
and identify specific areas where potential hazards exist and special precautions should be
taken. Know and understand the meaning of these instructions, signs, and messages. Damage
to the truck, death, or serious injury to you or other persons may result if these messages are
not followed. If warning decals are damaged, they must be replaced.
NOTICE
This message is used when special information, instructions, or identification
are required relating to procedures, equipment, tools, pressures, capacities,
and other special data.
IMPORTANT
This message is used when special precautions should be taken to ensure a
correct action or to avoid damage to or malfunction of the truck or a component
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in
death or serious injury.
DANGER
Indicates a potentially hazardous situation which, if not avoided, will result in
death or serious injury.
1.1

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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GENERAL SAFETY RULES
 Wear ALL Personnel Protective Equipment, or PPE, as dictated by the work being done
as well as any company policy. It is recommended that safety glasses, a hard hat and
protective footwear always be warn as well as hearing protection if noise is excessive.
 Do NOT wear loose clothing or jewelry that can catch on controls or other parts of the
forklift. Make sure long hair is tied back and out of the way of moving parts.
 Attach an “OUT OF SERVICE” or similar warning tag to the key switch before servicing
or repairing any forklift. Disconnect battery if leaving unattended.
 Keep ALL equipment guards and shield in place and installed correctly to prevent
vibration, rubbing and heat buildup.
 Keep a fire extinguisher and first aid kit available AT ALL TIMES.
 Use ONLY adequately rated lift equipment with capacity labeled or marked. Use
supports or straps on any component or structural member that may fall.
1.2

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GENERAL SAFETY RULES (CONT’D)
 Support equipment and attachments properly when working beneath them. Do NOT rely
on the vehicle hydraulics or hydraulic jacks to support the equipment.
 Keep the forklift free of dirt and oil. Secure ALL loose items such as tools that are not
part of the forklift.
 ALWAYS use the proper tool for the job and keep tools clean and in good working order.
 NEVER stand under suspended loads or raised forks or implements.
 Beware of pedestrians in the area. NEVER assume they see you. Do NOT proceed until
they are aware of your intended actions and have moved clear of the area.
 Read and thoroughly understand the Owner’s and Operator’s Manual PRIOR to
operating the forklift.
 Obey ALL traffic rules and warning signs.
 Do NOT let any unauthorized personnel operate the forklift at any time. NEVER carry
passengers on ANY part of the forklift.
 Do NOT stand on or between the counterweight when extended.
 Do NOT climb on any part of the mast or overhead guard/cab structure or permit others
to do so.
 Stay clear of ALL rotating and moving parts.
1.3

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SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES
Provisions for Maintenance
Powered industrial trucks may become hazardous if maintenance is neglected or repairs,
rebuilds or adjustments are performed contrary to manufacturer’s criteria. Therefore
maintenance and inspection shall be performed in accordance with the manufacturer’s
recommendations and the following practices:
 Planned maintenance, including but not limited to, lubrication and inspection shall be
performed in accordance with the Preventative Maintenance Schedule provided in this
manual.
 Only trained and authorized personnel shall be permitted to maintain, repair, adjust and
inspect industrial trucks in accordance with the provided specifications.
 Brakes, Steering Mechanisms, Control Mechanisms, Warning Devices, Lights, Lift
Overload Devices, Guards and Safety Devices, Steer Axle Articulation Stops, and Frame
Members shall be carefully and regularly inspected and maintained in a safe operation
condition.
Before Starting Any Maintenance
 Park the forklift in authorized areas ONLY
 Park the forklift on a level surface with the forks fully lowered and the mast tilted forward
such that the fork tips touch the ground. NEVER work on soft ground.
 Place the transmission in NEUTRAL
 Stop the engine AND set the Parking Brake
 Remove the key and tag the forklift OUT OF SERVICE
 Block the drive wheels. Block the load engaging means, mast, and chassis WHENEVER
working on them
1.4

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MAINTENANCE SAFETY PRACTICES (CONT’D)
Cleaning
 When using compressed (pressurized) air always use a general purpose nozzle to blow
dust and dirt from work area. ALWAYS wear eye protection, protective clothing and
protective shoes. Visually inspect the area prior to using an air hose. The maximum
pressure should NOT exceed 30 psi.
 Use ONLY approved, safe cleaning agents and solvents.
 Clean exterior of all parts when repairing. ALWAYS wear eye protection when steam
cleaning.
 Do NOT use steam, solvent, or high pressure to clean electrical components.
Engine and Cooling System
 Stop the engine whenever possible BEFORE performing service.
 Always start and run the engine in a well ventilated area. Avoid prolonged running of the
engine in closed areas. Vent exhaust to outside. NEVER operate the engine in a closed
building.
 Do NOT remove the radiator cap when the engine is running or hot. Engine coolant is
hot and under pressure and can cause severe burns. Allow the truck to cool down to
where the radiator cap is cool to the touch. When removing the radiator cap, turn slowly
to relieve pressure.
 When adding coolant MAKE SURE it is compatible and will mix with existing coolant.
 Cooling system additives contain alkali the can cause personnel injury. Avoid contact
with the skin and eyes. Do NOT ingest.
 Keep objects ALL away from moving fan blades.
1.5

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MAINTENANCE SAFETY PRACTICES (CONT’D)
 Do NOT use starting fluid. Use of starting fluid with an engine equipped with an intake
heater can result in severe engine damage.
 Do NOT tamper with or modify the exhaust in any way.
Fuel System
 All fuels are flammable and MUST be handled with care.
 NEVER refuel the machine while the engine is running.
 NEVER refuel or service the fuel system while smoking or near open flames or sparks.
 Fuel leaked or spilled on hot surfaces or components CAN CAUSE A FIRE.
 Before disconnecting any part of the fuel system on LP gas powered trucks, close LP
tank valves and run the engine UNTIL FUEL IS DEPLETED and engine stops. If the
engine will not run, close LP truck valve and vent fuel slowly in a non-hazardous area.
 Use extreme care to prevent contamination from dirt and moisture. Contaminated fuel
can result in SEVERE engine damage.
 ALWAYS clean up fuel spills.
Hydraulics
 Hydraulic systems present a HIGH PRESSURE FLUID HAZARD. System pressure
MUST be relieved PRIOR to repairing, adjusting, or disconnecting ANY part of the
hydraulic system, including loosening hoses and tubes. With the truck OFF, operate all
controls including steering and braking to relieve stored pressure. This will also prevent
unintended movement of the steering mechanism when servicing.
 NEVER use your hands to find a pressure leak. When check for leaks ALWAYS use a
board or piece of cardboard. ALWAYS wear proper hand and eye protection. Even a
pinhole size leak can penetrate skin. If ANY fluid is injected into the skin it must be
treated by a doctor IMMEDIATELY.
1.6

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MAINTENANCE SAFETY PRACTICES (CON’TD)
 At operating temperature the hydraulic tank will be hot. Remove the hydraulic tank filter
cap and cleanout cover ONLY AFTER engine has been stopped and the filter cap and
cleanout cover are cool to the touch. Remove slowly to allow any trapped pressure to
escape.
 Hot fluid and components can cause personal injury. Do NOT allow hot oil or
components to contact the skin.
 Ensure ALL hydraulic connections are tight and keep ALL components in good repair.
 Inspect hoses for damaged or leaking end fittings, chafed or cut outer covering, localize
ballooning or swelling, and evidence of kinking or crushing. REPLACE if any of these
conditions are present.
 All fluids should be handled with care. If you ingest any fluid or get fluid in the eyes seek
IMMEDIATE medical attention.
Electrical
 Batteries give off flammable fumes which can explode. Keep sparks, flames and
cigarettes AWAY. Use a flashlight to check electrolyte level if necessary.
 BEFORE servicing the electrical system disconnect the battery negative (-) cable to
prevent short circuits.
 Battery electrolyte can cause personal injury if it contacts skin or eyes. ALWAYS wear
PPE and in case of contact rinse area thoroughly with water and seek IMMEDIATE
medical attention.
1.7

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MAINTENANCE SAFETY PRACTICES (CON’TD)
 Charge batteries in well ventilated areas ONLY.
 ALWAYS wash hands after handling batteries.
 Clean and tighten ALL electrical connections. Check for loose or frayed wires and if
found repair or replace BEFORE operating the forklift.
 Do NOT operate in the vicinity of overhead power lines. Electrocution can occur without
direct contact.
Wheels and Tires
 Do NOT attempt to service a tire unless you have the proper equipment and training.
 ALWAYS wear PPE.
 Do NOT rely on the vehicle hydraulics or a hydraulic jack to support the forklift. The
forklift MUST be supported by suitable blocks or stands.
 Keep tires inflated to correct pressure. Do NOT over inflate tires.
 Servicing tires is potentially DANGEROUS. See Section 4, “TIRE & WHEEL SAFETY”
for detailed warnings and precautions.
1.8

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MAINTENANCE SAFETY PRACTICES (CON’TD)
Fire and Explosion Prevention
 Store all fuels and lubricants in approved, properly marked containers and AWAY FROM
unauthorized personnel.
 ALL oily rags and other flammable material should be placed in protective containers
and stored appropriately.
 NEVER weld, cut or grind on pipes, tubes, or reservoirs that contain flammable
materials.
 Do NOT operate in areas where explosive gases are present or suspected.
1.9

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SAFETYPRECAUTIONS
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DO’S AND DON’T’S
Don’t mix drugs or alcohol with your job.
Don’t block safety or emergency equipment
Don’t smoke in “NO SMOKING” areas or when refueling.
Do wear safety equipment when required.
Do watch for pedestrians
1.10

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SAFETYPRECAUTIONS
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LOCKOUT TAGOUT PROCEDURE
Purpose
This procedure establishes the minimum requirements
for lockout/tagout of energy sources that could cause
injury to personnel. All employees shall comply with the
procedure.
Responsibility
The responsibility for seeing that this procedure is
followed is binding upon all employees. All employees
shall be instructed in the safety significances of the
lockout/tagout procedure by (designated individual).
Each new or transferred affected employee shall be
instructed by (designated individuals) in the purpose and
use of the lockout/tagout procedure.
Preparation for Lockout/Tagout
Employees authorized to perform lockout/tagout shall be
certain as to which switch, valve, or other energy
isolating devices apply to the equipment being locked
out/tagged out. More than one energy source (electrical,
mechanical, or others) may be involved. Any
questionable identification of their supervisors. Before
lockout/tagout commences, job authorization should be
obtained.
Sequence of Lockout/Tagout Procedure
1. Notify all affected employees that a
lockout/tagout is required and the reason
therefor.
2. If the equipment is operating, shut it down by the
normal stopping procedure.
3. Operate the switch, valve, or other energy
isolating device so that the energy source(s)
(electrical, mechanical, hydraulic, etc.) is
disconnected or isolated from the equipment.
Stored energy, such as that in capacitors,
springs, elevated crane members, rotating
flysteam, or water pressure, etc. must also be
dissipated or restrained by methods such as
grounding, repositioning, blocking, bleeding
down, etc.
4. Lockout/tagout the energy isolating devices with
an assigned individual lock/tag.
5. After ensuring that no personnel are exposed
and as a check on having disconnected the
energy sources, operate the push button or
other normal operating controls to make certain
the equipment will not operate.
CAUTION: Return operating controls to
neutral after the test.
6. The equipment is now locked out/tagged out.
Restoring Equipment to Service
1. When the job is complete and equipment is
ready for testing or normal service, check the
equipment area to see that no one is exposed.
2. When equipment is all clear, remove all
locks/tags. The energy isolating devices may be
operated to restore energy to equipment.
Procedure Involving More Than One Person
In the preceding steps, if more than one individual is
required to lockout/tagout equipment, each shall place
their own personal lock/tag on the energy isolating
device(s). One designated individual of a work crew or a
supervisor, with the knowledge of the crew, may
lockout/tagout equipment for the whole crew. In such
cases, it shall be the responsibility of the individual to
carry out all steps of the lockout/tagout procedure and
inform he crew when it is safe to work on the equipment.
Additionally, the designated individual shall not remove
a crew lock/tag until it has been verified that all
individuals are clear.
Rules for Using Lockout/Tagout Procedure
All equipment shall be locked out/tagged out to protect
against accidental or inadvertent operation when such
operation could cause injury to personnel. Do not
attempt to operate any switch, valve, or other energy
isolating device bearing a locktag
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1.11

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PLANNEDMAINTENANCE
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INDEX
Introduction......................................................................................2.1
SafeMaintenancePractices..............................................................2.2
MajorComponentLocations.............................................................2.6
PlannedMaintenanceIntervals.........................................................2.7
PlannedMaintenanceReportForm...................................................2.8
HowtoPerformMaintenance.........................................................2.12
VisualInspection........................................................................2.12
FinalInspection..........................................................................2.12
Cab/OverheadGuard.................................................................2.12
LoadHandlingComponents.......................................................2.13
WheelsandTires........................................................................2.14
FunctionalTests.........................................................................2.15
SteeringSystem.........................................................................2.17
DirectionControl,Braking,andDeclutch....................................2.17
Fluids,Filters,andEngineAccessories........................................2.18
HydraulicFluidandFilterChange...............................................2.22
HydraulicTankBreatherMaintenanceandInspection...............2.22
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FR15/25,FR18/26,&FR25/35SERVICEMANUAL
PLANNEDMAINTENANCE
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INDEX
AirCleaning................................................................................2.23
CriticalFastenerTorqueChecks..................................................2.23
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NOTICE
THISSECTIONISFORTRAINEDSERVICEPERSONNELtouseasreferencefor
PlannedMaintenanceprocedures.
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MaintenanceinformationforOperatorscanbefoundinthe“Hoist Material
Handling Operator’sAndOwner’sManual”

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
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INTRODUCTION
Only Trained and Authorized Personnel should perform planned maintenance. Local
Hoist Material Handling dealers are prepared to establish a planned maintenance
program for checking and maintaining their lift trucks according to applicable safety
regulations.
CAUTION
Powered industrial trucks may become hazardous and dangerous to operate if
maintenance is neglected.
As outlined in the HMH Operators Manual, the operator should make a daily safety inspection of
the lift truck before operating it. The purpose of this daily examination is to check for any
obvious damage and maintenance problems and to have minor adjustments and repairs made
to correct any unsafe condition.
In addition to the operator's daily inspection, HMH recommends that the owner set up and
follow a periodic planned maintenance (PM) and inspection program . Performed on a regular
basis by trained personnel, the program provides thorough inspection and checks of the safe
operation condition of the lift truck. The "PM" identifies needed adjustments, potential repairs, or
part replacements so they can be addressed before failure occurs. The specific schedule
(frequency) for the PM inspections depends on the particular application and lift truck usage.
This section recommends TYPICAL Planned Maintenance and Lubrication Schedules for items
essential to the safety, longevity, and performance of the truck. It also outline safe maintenance
practices and gives brief procedures for inspections, operational checks, cleaning, lubrication,
and minor adjustments.
Specifications for selected components are found in later sections of this manual.
If you have need for more information on the care and/or repair of your truck, contact your HMH
dealer.
2.1

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SAFE MAINTENANCE PRACTICES
The following instructions have been prepared from current industry and government safety
standards applicable to industrial truck operation and maintenance. These recommended
procedures specify conditions, methods, and accepted practices that aid in the safe
maintenance of industrial trucks. They are listed here for the reference and safety of all workers
during maintenance operations. Carefully read and understand these instructions and the
specific maintenance procedures before attempting to do any repair work.
1. Powered industrial trucks can become hazardous if maintenance is neglected.
Therefore, suitable maintenance facilities as well as trained personnel and procedures
shall be provided.
2. Maintenance and inspection of all powered industrial trucks shall be performed in
conformance with the manufacturer's recommendations.
3. Follow a scheduled planned maintenance, lubrication, and inspection system.
4. Only trained and authorized personnel are permitted to maintain, repair, adjust, and
inspect industrial trucks - and must do so in accordance with the manufacturer's
specifications.
5. Always wear safety glasses. Wear a safety (hard) hat in industrial plants and in special
work areas where protection is necessary and required. Hearing protection and any
other personal protective equipment (PPE) must comply with OSHA and all company
policies specific to the task at hand.
6. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floors dry.
7. Avoid fire hazards and have fire protection equipment present in the work area. Do not
use an open flame to check for level or leakage fuel, electrolyte, or coolant. Do not use
open pans of fuel of flammable cleaning fluids for cleaning parts.
8. Operation of the truck to check performance must be conducted in an authorized, safe,
clear area.
9. Before starting to operate the truck:
A. Be seated in the normal operating position and fasten your seat belt.
B. Make sure the parking brake is applied.
C. Put the directional control lever in NEUTRAL.
D. Start the engine.
E. Check proper function of lift and tilt systems, direction and speed controls,
steering, brakes, warning devices, and load handling attachments.
2.2

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SAFE MAINTENANCE PRACTICES (CONT’D)
10. Before exiting the truck:
A. Stop the truck.
B. Fully lower the load-engaging means: mast, carriage, forks or attachments.
C. Put the direction control in NEUTRAL.
D. Apply the parking brake by PULLING the park brake switch out.
E. Stop the engine.
F. Turn the key switch to the OFF position.
G. Chock the wheels if the truck must be left on an incline.
11. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors,
lift overload devices, lift and tilt mechanisms, axle articulation stops, load back rest,
overhead guard and frame members must be carefully and regularly inspected and
maintained in a safe operating condition.
12. Special trucks or devices designed and approved for hazardous area operation must
receive special attention to insure that maintenance preserves the original approved safe
operating features.
13. Fuel systems must be checked for leaks and condition of parts. Special consideration
MUST be given in the case of a fuel system leak. Action must be taken to prevent the
use of the truck until the leak has been corrected.
14. All hydraulic systems must be regularly inspected and maintained in conformance with
accepted good practices. Tilt and lift cylinders, valves, and other parts must be checked
to assure that "drift" or leakage has not developed to the extent that it would create a
hazard.
15. When working on the hydraulic system, be sure the engine is turned off, masts are in the
fully-lowered position, and hydraulic pressure is relieved in hosing and tubing.
16. The truck manufacturer's capacity, operation, and maintenance instruction plates, tags,
or decals must be maintained in legible condition. Illegible or missing decals MUST be
replaced as mandated by OSHA.
17. Batteries, limit switches, protective devices, electrical conductors, and connections must
be maintained in conformance with accepted good practices. Special attention must be
paid to the condition of electrical insulation.
2.3

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SAFE MAINTENANCE PRACTICES (CONT’D)
18. To avoid injury to personnel or damage to the equipment, consult the manufacturer's
procedures in replacing contacts on any battery connection.
19. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in
the detection of loose or defective parts.
20. Modifications and additions that affect capacity and safe truck operation must not be
done without the manufacturer's prior written approval. Capacity, operation, and
maintenance instruction plates, tags, or decals must be changed accordingly.
21. Care must be taken to assure that all replacement parts, including tires, are
interchangeable with the original parts and of a quality at least equal to that provided in
the original equipment. Parts, including tires, are to be installed per the manufacturer's
procedures.
22. Use special care when removing heavy components such as counterweights, masts, etc.
Be sure that lifting and handling equipment is of the correct capacity and in good
condition.
23. Before starting any work on a truck:
A. Raise drive wheels off floor and use oak blocks or other positive truck positioning
devices.
B. Remove all jewelry.
C. Put oak blocks under the load-engaging means, inner masts, or chassis before
working on them.
D. Disconnect the battery ground cable (-) before working on the electrical system.
CAUTION
Refer to the “Lifting, Jacking, and Blocking" section in the reference section for complete
procedures.
2.4

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SAFE MAINTENANCE PRACTICES (CONT’D)
IMPORTANT
Your new lift truck has been built to meet all applicable mandatory requirements of ANSI
B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain
safety devices - such as a horn, operator protective structure, and backup alarms - as
standard equipment. No additions, omissions, or modifications should be made that
affect compliance to the above requirements or in any way minimize the effectiveness of
any safety device.
NOTICE
You should be familiar with additional operating and maintenance safety instructions
contained in the following publications:
ANSI/ASME B56.1 Safety Standard for Low Lift and High Lift Trucks (Safety Code for Powered
Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center,
345 E. 47th Street, New York, NY 100017. This standard is available for free at
WWW.ITSDF.ORG
NFPA 505-1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas
of Use, Maintenance and Operation. Available form National Fire Protection Association, Inc.,
Batterymarch Park, Quincy, MA 02269.
General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (929 CFR
19010), Subpart N-Materials Handling and Storage, Section 19010.178 Powered Industrial
Trucks. For sale by: Superintendent of Documents, US Government Printing Office,
Washington, DC 20402.
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