Hyster A244 Operating instructions

Hyster A244 (BE80ZHD, BE100ZHD) Forklift

PERIODIC
MAINTENANCE
BE80ZHD, BE100ZHD [A244]
PART NO. 4110886 8000 SRM 1705

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Operator's Compartment Covers/Console ......................................................................................................... 1
Operator's Compartment Covers ................................................................................................................... 1
Remove ........................................................................................................................................................1
Install ..........................................................................................................................................................2
Operator's Compartment Console ..................................................................................................................3
Remove ........................................................................................................................................................3
Install ..........................................................................................................................................................4
Console Tray ................................................................................................................................................... 4
Remove ........................................................................................................................................................4
Install ..........................................................................................................................................................4
Drive Unit Compartment Door .......................................................................................................................... 5
Caster Wheel Cover ............................................................................................................................................ 5
How to Move a Disabled Truck .......................................................................................................................... 5
How to Tow the Lift Truck ............................................................................................................................. 6
How to Put a Lift Truck on Blocks .....................................................................................................................6
How to Raise Drive/Steer Tire ....................................................................................................................... 6
How to Raise Load Wheels .............................................................................................................................7
Special Precautions ................................................................................................................................................. 7
Discharging the Capacitors ................................................................................................................................ 7
Welding Repairs ...................................................................................................................................................... 8
Maintenance Schedule ............................................................................................................................................ 9
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 14
Checks With Key Switch Turned OFF .............................................................................................................14
Battery ...........................................................................................................................................................14
Hydraulic Leaks ............................................................................................................................................15
Drive Tire, Load Wheels, Casters, and Frame ............................................................................................15
Checks With Key Switch Turned ON .............................................................................................................. 16
Operation ...................................................................................................................................................... 16
Maintenance Procedures Every 250 Hours or Every 6 Weeks ........................................................................... 18
Caster Lubrication ............................................................................................................................................ 18
Casters ...............................................................................................................................................................18
Caster Adjustment Check ............................................................................................................................ 18
Caster Adjust Procedure .............................................................................................................................. 19
Maintenance Procedures Every 500 Hours or Every 3 Months ..........................................................................22
Hydraulic System ..............................................................................................................................................22
Hydraulic Oil .................................................................................................................................................22
Hydraulic Reservoir Breather ......................................................................................................................22
Steering System ................................................................................................................................................ 22
Power Steering ..............................................................................................................................................22
Lift Linkage and Load Wheels ......................................................................................................................... 22
Master Drive Unit .............................................................................................................................................23
Change Gear Oil ........................................................................................................................................... 23
Check Oil Level .............................................................................................................................................23
Drive Tire Check ............................................................................................................................................... 24
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................... 24
Lubrication ........................................................................................................................................................ 24
Repack Load Wheel Bearings ...................................................................................................................... 24
Hydraulic System ..............................................................................................................................................24
Oil Change .................................................................................................................................................... 24
Table of Contents
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TABLE OF CONTENTS (Continued)
Brake ................................................................................................................................................................. 25
Electrical ............................................................................................................................................................25
Battery Maintenance ............................................................................................................................................ 26
How to Charge the Battery ...............................................................................................................................26
Equalizing Charge ........................................................................................................................................ 26
Normal Charge ............................................................................................................................................. 26
How to Change the Battery ..............................................................................................................................27
Transporting ..........................................................................................................................................................28
Loading .............................................................................................................................................................. 28
Unloading .......................................................................................................................................................... 28
Preparation for Storage .........................................................................................................................................29
Short-Term Storage (1 to 6 months) ................................................................................................................ 29
Long-Term Storage (6 months or longer) .........................................................................................................29
Preparation for Use ...............................................................................................................................................29
Preparation After Shipment .............................................................................................................................29
Preparation After Storage ................................................................................................................................ 29
This section is for the following models:
(BE80ZHD, BE100ZHD) [A244]
Table of Contents
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General
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Repairs and adjustments that are incorrect
can create dangerous operating conditions.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, attach a DO
NOT OPERATE tag on the control handle. Remove
the key from the key switch.
This section contains the instructions for periodic
maintenance and inspection, and a Maintenance
Schedule.
The Maintenance Schedule has time intervals for
inspection, lubrication, and periodic maintenance.
The time intervals are based on a normal
operation. A normal operation is considered to be
one 8-hour shift per day in a relatively clean
environment on an improved surface. Multiple
shifts, dirty operating conditions, etc., will require
a reduction in the recommended time periods in the
Maintenance Schedule.
NOTE: The front end of the lift truck is the control
handle end. Forward travel is movement with the
forks trailing. Rear travel is movement in the
direction of the forks. The right-hand side of the lift
truck is to the operator's right hand, facing the
truck from the control handle end in the position
for operating the controls.
Your Hyster lift truck dealer has the trained
personnel and equipment to provide a complete
program of inspection, lubrication, and
maintenance. This complete program will help your
lift truck operate properly over a longer period of
time.
Some users have service personnel and facilities to
do the items listed in the Maintenance Schedule.
Service Manuals are available from your Hyster lift
truck dealer to help users who do their own repairs.
OPERATOR'S COMPARTMENT COVERS/
CONSOLE
Operator's Compartment Covers
Remove
NOTE: There is an overlap from one pad to the
next. They should be removed in sequence to
prevent damage.
NOTE: Please note the order of removal to aid in
installation.
1. Remove four capscrews and backrest pad from
frame. See Figure 1.
2. The hip pad is held in place by four capscrews
that attach to the back of the pad and then
align with four slots in the frame. Remove hip
pad from frame by pushing upward and pulling
outward. See Figure 2.
1. CAPSCREW
2. BACKREST PAD
3. FRAME
Figure 1. Backrest Pad
8000 SRM 1705 General
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3. Remove four capscrews and front pad from
frame. See Figure 3.
Install
NOTE: Install pads in reverse order that they were
removed.
1. Using four capscrews, install front pad onto
frame. See Figure 3.
NOTE: Prior to installing hip pad, make sure
capscrews are finger tight to prevent them from
coming out during install and operation of lift
truck.
2. Install hip pad onto frame by aligning
capscrews on back of pad with slots in frame.
Push inward and downward. See Figure 2 .
3. Using four capscrews, install backrest onto
frame. See Figure 1.
1. HIP PAD 2. FRAME
Figure 2. Hip Pad
1. CAPSCREW 2. FRONT PAD
Figure 3. Front Pad
General 8000 SRM 1705
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Operator's Compartment Console
Remove
1. Turn key to the OFF position.
2. Disconnect battery from lift truck at battery
connector .
3. Open drive unit compartment door.
4. Remove seven capscews that secure console
cover to lift truck. See Figure 4.
5. Disconnect all electrical wiring from under
console cover. Tag wiring to assist when
reinstalling steering handle assembly.
6. Remove console cover from lift truck. See
Figure 4.
7. Disconnect wiring for steering handle assembly
at the harness connector. See Figure 5.
1. CONSOLE COVER 2. CAPSCREW
Figure 4. Upper Console Cover
8000 SRM 1705 General
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1. HARNESS CONNECTOR
2. STEERING HANDLE
3. CAPSCREW
Figure 5. Steering Handle
8. Remove three capscrews that hold steering
handle assembly to lift truck. See Figure 5.
9. Remove steering handle assembly from lift
truck and place assembly on a clean work
surface.
Install
1. Connect harness for steering handle assembly
to connector on main truck harness. See
Figure 5.
2. Using three capscrews, install steering handle
assembly onto lift truck. See Figure 5.
3. Position console cover onto lift truck. See
Figure 4.
4. Connect wiring to console cover as noted and
tagged during removal.
5. Install seven capscrews that secure console
cover to lift truck. See Figure 4.
6. Close drive unit compartment door.
7. Connect battery to lift truck.
8. Turn key switch to the ON position and test for
proper operation.
Console Tray
Remove
1. Remove four capscrews and four washers from
console tray. See Figure 6.
2. Remove console tray from heat shield and
frame assembly. See Figure 6.
3. Remove heat shield from frame assembly. See
Figure 6.
Install
NOTE: Align tabs on heat shield with slots in
frame.
1. Install heat shield onto frame. See Figure 6.
2. Install console tray into heat shield and frame
assembly. See Figure 6.
NOTE: Align holes in console tray with clips on
frame to aid in installation.
3. Install four washers and four capscrews into
console tray and frame. See Figure 6.
1. CAPSCREW
2. WASHER
3. CONSOLE TRAY
4. HEAT SHIELD
5. FRAME ASSEMBLY
Figure 6. Console Tray
General 8000 SRM 1705
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