Hyster A265 User manual

Hyster A265 (N35ZRS N40ZRS N30ZDRS) Forklift

PERIODIC
MAINTENANCE
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
PART NO. 1590959 8000 SRM 1197

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•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.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•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 exceed 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
flammable. 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.

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Removing Covers ........................................................................................................................................... 1
Front Frame Panel (Left and Right) ........................................................................................................ 1
Operator Compartment Cover.................................................................................................................. 2
Drive Unit Compartment Door................................................................................................................. 3
Caster Wheel Cover................................................................................................................................... 3
Discharging the Capacitors........................................................................................................................... 3
How to Move Disabled Truck ........................................................................................................................ 4
How to Tow Lift Truck............................................................................................................................... 4
How to Put Lift Truck on Blocks................................................................................................................... 5
How to Raise Load Wheels ....................................................................................................................... 5
How to Raise the Drive Tire End.............................................................................................................. 6
How to Raise the Entire Lift Truck.......................................................................................................... 6
Manual Lowering Valve ................................................................................................................................ 7
N30-35ZDR and N35-40-45ZR ................................................................................................................. 7
N30ZDRS and N35-40ZRS ....................................................................................................................... 7
Transporting....................................................................................................................................................... 8
Loading........................................................................................................................................................... 8
Unloading....................................................................................................................................................... 9
Preparation for Use............................................................................................................................................ 9
Preparation After Shipment ......................................................................................................................... 9
Preparation After Storage............................................................................................................................. 9
Safety Procedures When Working Near Mast.................................................................................................. 10
Maintenance Schedule....................................................................................................................................... 11
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 16
Checks With Key Switch Turned OFF.......................................................................................................... 16
Battery ....................................................................................................................................................... 16
Tires and Wheels....................................................................................................................................... 17
Frame and Load Wheels ........................................................................................................................... 17
Safety Labels ............................................................................................................................................. 17
Overhead Guard........................................................................................................................................ 18
Forks Check............................................................................................................................................... 18
Lift Chain Check ....................................................................................................................................... 19
Mast Check ................................................................................................................................................ 20
Reach, Tilt, and Sideshift.......................................................................................................................... 20
Checks With Key Switch Turned ON ........................................................................................................... 20
Operation ................................................................................................................................................... 20
Hydraulic System...................................................................................................................................... 21
Dash Display ............................................................................................................................................. 21
Lift System Operation............................................................................................................................... 22
Multifunction Control Handle .................................................................................................................. 23
Brake.......................................................................................................................................................... 23
Steering System ........................................................................................................................................ 24
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 24
Master Drive Unit ......................................................................................................................................... 24
Hydraulic System .......................................................................................................................................... 24
Hydraulic Filter Element Change ................................................................................................................ 26
Caster Adjustment......................................................................................................................................... 26
Elastomer Spring Type Adjustment......................................................................................................... 26
Belleville Spring Type Adjustment .......................................................................................................... 28
Spring Pack Replacement......................................................................................................................... 29
©2009 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
Remove Spring Assembly ..................................................................................................................... 29
Replace Spring Pack ............................................................................................................................. 30
Install Spring Assembly ....................................................................................................................... 30
Drive Tire Check............................................................................................................................................ 31
Lift System Operation ................................................................................................................................... 31
Forks .......................................................................................................................................................... 31
Mast ........................................................................................................................................................... 31
Lift Chains................................................................................................................................................. 32
Other Lubrication.......................................................................................................................................... 32
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 32
Brakes ............................................................................................................................................................ 32
Check.......................................................................................................................................................... 32
Electric System .............................................................................................................................................. 33
Main Contactor.......................................................................................................................................... 33
Inspect ................................................................................................................................................... 33
Master Drive Unit ......................................................................................................................................... 33
Hydraulic System .......................................................................................................................................... 34
Drain .......................................................................................................................................................... 34
Cylinder Identification.......................................................................................................................... 35
Fill .............................................................................................................................................................. 37
Main Lift Cylinders............................................................................................................................... 37
Free-Lift Cylinders................................................................................................................................ 38
Hydraulic Filter Change ........................................................................................................................... 39
Check Hydraulic Strainer......................................................................................................................... 39
Lift and Tilt System Leaks Check..................................................................................................................... 40
Lift System..................................................................................................................................................... 40
Tilt System..................................................................................................................................................... 40
Battery Maintenance ......................................................................................................................................... 41
How to Charge Battery.................................................................................................................................. 41
How to Change Battery................................................................................................................................. 42
Tires and Wheels................................................................................................................................................ 45
Drive Tire ....................................................................................................................................................... 45
How to Change Drive Tire............................................................................................................................. 45
Tandem Load Wheels .................................................................................................................................... 46
Caster Wheels ................................................................................................................................................ 46
Remove....................................................................................................................................................... 46
Install......................................................................................................................................................... 47
Preparation for Storage ..................................................................................................................................... 48
Short-Term Storage (1 to 6 months) ............................................................................................................. 48
Long-Term Storage (6 months or longer) ..................................................................................................... 48
This section is for the following models:
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
ii

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8000 SRM 1197 General
General
WARNING
DO NOT make repairs or adjustments un-
less you have been properly trained and
specifically authorized to do so. Repairs and
adjustments that are not correct 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, disconnect
the battery and attach a DO NOT OPERATE tag
to the control handle.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
before removal or installation. If the proper
location for connection is unclear, consult the
wiring diagram for the truck. Make sure test-
ing meters have adequate voltage and current
capacities to handle the output of the electri-
cal components they are used to check. Never
wire aftermarket components to this truck
without factory approval.
Certain welding repairs require factory ap-
proval. Structural members such as base
arms, axle weldments, and mast components
require written Hyster®engineering approval
before repairing or replacing. Contact your
local dealer for assistance.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule is divided into three time
intervals which call for particular maintenance pro-
cedures to be performed. The intervals are 1 Day
or 8 hours, 3 Months or 500 Hours, and 1 Year or
2000 Hours for normal operations (whichever comes
first).Normal operation is considered one 8-hour
shift per day, in a relatively clean environment, on
an improved surface. Operating a lift truck for more
than eight hours per day is considered Heavy opera-
tion and requires the 3-month checks to be performed
at 350 hours. Lift trucks operating in freezer envi-
ronments or dirty conditions are considered Severe
operation and require the 3-month checks to be per-
formed at 200hours.
Your lift truck dealer has the facilities and trained
personnel to perform required maintenances. A com-
plete program of inspection, lubrication, and mainte-
nance will help your lift truck perform efficiently and
operate over a longer period of time.
Some users have service personnel and facilities to
perform the tasks listed in the Maintenance Sched-
ule. Service Manuals are available from your lift
truck dealer to help users who do their own mainte-
nance.
DO NOT make repairs or adjustments unless you
have been properly trained and specifically autho-
rized to doso.
Put the lift truck on a level surface. Lower the car-
riage and forks, apply the parking brake, and turn
the key switch to the OFF position. Open the access
panels and inspect for leaks and conditions that are
not normal. Clean any oil spills. Make sure that lint,
dust, paper, and other materials are removed from
the compartments.
REMOVINGCOVERS
Front Frame Panel (Left and Right)
Remove the screws from the upper and lower ends of
the front frame panel. Pull the lower end of the panel
away from the frame of the lift truck and gently work
up the side of the panel to pull it from the retainer
clips securing the panel to the frame. Pull the top end
tabs out of the operator compartment cover. Repeat
for opposite side as necessary. See Figure 1.
1

General 8000 SRM 1197
1. OPERATOR COMPARTMENT COVER
2. FRAME
3. LOWER BRACKET
4. LOWER SCREW
5. FRONT FRAME PANEL (LEFT)
6. TABS
7. UPPER BRACKET
8. UPPER SCREW
Figure 1. Front Frame Panel (Left Side)
NOTE: On right side front frame panels, ensure the
diagnostic connector cap is positioned to allow the
cover to seat properly.
To install the panel, position the upper end of the
panel partially into the retaining clip on the frame.
Insert the tabs on the upper end of the panel into
the slots in the operator compartment cover. Work
the sides of the panel into the retaining clips until all
areas of the panel are aligned with the frame. Align
the holes in the panel with the mounting brackets
on the frame and loosely install the screws into the
upper end and lower end of the panel. Make certain
the panel is seated correctly against the frame and
tighten the screws to secure in place. See Figure 1.
Operator Compartment Cover
Remove the front frame panels from the lift truck.
RefertoFrontFramePanel(LeftandRight). Re-
move the two screws securing the operator cover to
the frame brackets. One is located on the lower right
side of the operator compartment above the opera-
torpresenceswitch. Theotherislocatedbesidethe
overhead guard post mount, at the bottom of the cup
holder. Pull the operator compartment cover up from
the front right corner. Continue pulling the cover up
along the edge of the frame in both directions until
the cover is free from the retaining clips. See Fig-
ure 2.
1. OPERATOR COMPARTMENT COVER
2. OVERHEAD GUARD POST MOUNT
3. FRAME
4. FRONT FRAME PANEL (LEFT)
Figure 2. Operator Compartment Cover
To install, position the cover over the electrical com-
partment. See Figure 2. Align the lip of the cover to
the retaining clips. Press the lip of the cover into the
retaining clips starting at the overhead guard post
and continue around until completely seated. Align
the holes in cover with the mounting brackets and in-
stall retaining screws as removed. Install the front
frame panels to complete assembly. Refer to Front
Frame Panel (Left and Right) in this section.
2

8000 SRM 1197 General
Drive Unit Compartment Door
Completely loosen the two socket head capscrews se-
curing the drive unit compartment door closed. The
screws are spring loaded and retained to the door
by clips. Pull the door open on its hinges. To close,
push the door closed and start both socket head cap-
screws loosely into the mounting holes. When both
screws are started, verify that the door seats prop-
erly against the frame and tighten the screws.
Caster Wheel Cover
Remove the socket head capscrews on top of the
caster wheel cover and lift cover from the clips se-
curing it to the frame.
To replace, fit the bottom of the cover into the clips
inside the opening and slide the cover into place. In-
stall two socket head capscrews to secure the top of
the cover in place.
DISCHARGING THE CAPACITORS
WARNING
Capacitors inside the controllers can hold
an electrical charge after the battery is dis-
connected. Discharge the capacitors before
servicing the electrical system to prevent in-
jury or electronic damage.
1. Move the lift truck to a safe, level area and com-
pletely lower the mast. Turn the key switch to
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the drive
wheel to prevent unexpected movement.
2. Disconnect the battery power cable connector
from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.
3. Remove the operator compartment cover.
4. Discharge the capacitor in the controllers by
connecting a 200-ohm, 2-watt resistor across the
controller B+ and B terminals of the motor
controller for 10 seconds. Remove the resistor
after discharging the capacitors. See Figure 3.
1. POSITIVE CONNECTION (B+)
2. NEGATIVE CONNECTIONS (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. PUMP MOTOR CONTROLLER
6. TRACTION MOTOR CONTROLLER
Figure 3. Discharging the Capacitors
3

General 8000 SRM 1197
HOW TO MOVE DISABLED TRUCK
How to Tow Lift Truck
WARNING
Use extra care when moving a lift truck during
the following conditions:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
•Thelifttruckmustbemovedonasteep
grade.
Poor traction can cause the disabled lift truck
or towing vehicle to slide. Steep grades will
require additional brake force to stop the lift
truck.
Never carry a disabled lift truck unless the lift
truck MUST be moved and cannot be towed.
The mast MUST be removed before the lift
truck can be lifted. The lift truck used to carry
the disabled lift truck MUST have a rated ca-
pacity equal to or greater than the weight of
the disabled lift truck. The capacity must be
for a load center equal to half the width of the
disabled lift truck. See the nameplate of the
disabled lift truck for the approximate total
weight. The forks must extend the full width
of the disabled lift truck. Center the weight
of the disabled lift truck on the forks and be
careful not to damage the under side of the lift
truck.
If towing a lift truck equipped with a steered
caster, the caster may resist tracking with the
drive wheel.
If there is no electrical power to the lift truck,
the electric parking brake will not automati-
cally release and the steering will not operate.
NOTE: The parking brake can be manually released
by installing two service capscrews into the brake as-
sembly. Ensure the two capscrews are removed prior
to returning to the lift truck to service.
1. Manually release the parking brake if problems
preventitfromreleasingnormally.
a. Insert two 1/4-20 × 1 (UNC) capscrews into
the two holes on the outer edge of the top of
theparkingbrakeassembly.SeeFigure4.
b. Tighten the capscrews alternately until the
brake is released.
1. CAPSCREWS (1/4-20 × 1)
2. MANUAL RELEASE HOLE
3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES
Figure 4. Manual Release
2. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Use safety
chains to secure in place if the mast is not func-
tional.
3. Attach a towing strap of adequate capacity to
the LOWER truck frame beneath the operator’s
compartment.
4. If a counterbalanced lift truck is used to tow the
disabled lift truck, that lift truck must have an
equal or larger capacity than the disabled lift
truck. If an increased load will increase the load
on the drive tire(s), install an approximate half-
capacity load on the forks of the lift truck that
is being used to tow the disabled lift truck. This
half-capacity load will increase the traction of the
lift truck. Keep the load as low as possible.
4

8000 SRM 1197 General
WARNING
If towing a lift truck equipped with a steered
caster, the caster may resist tracking with the
drive wheel.
The towed lift truck must have an operator.
5. Tow the lift truck slowly.
6. Remove the capscrews from the brake, lower the
mast, and disconnect the towing strap when com-
plete.
HOW TO PUT LIFT TRUCK ON BLOCKS
WARNING
Thelifttruckmustbeputonblocksoranap-
proved stand for some types of maintenance
and repair. The removal of the following as-
semblies will cause large changes in the center
of gravity: mast and load axle, battery, and the
counterweight. When the lift truck is put on
blocks, put additional blocks under the rear of
the frame before removing the mast so the lift
truck cannot fall backward or to the side.
DO NOT raise any point of the truck more than
50 mm (2 in.) without raising the opposite side
to level the truck. If raising the frame above
150 mm (6 in.) remove the mast first and raise
both ends of the frame in 50 mm (2 in.) incre-
ments.
DO NOT raise the lift truck by attaching an
overhead crane to the overhead guard or ar-
eas of the mast that will be damaged. Some
of these components and other lift points are
not designed to support the weight of the lift
truck. The truck can be damaged or it can fall
on someone causing serious injury. Attach a
chain or sling to a support structure of the lift
truck frame.
Put the lift truck on blocks only if the surface is solid,
even, and level. Make sure that any blocks used to
support the lift truck are solid, one-piece units. Put
blocks in front and back of the tires to prevent move-
ment of the lift truck.
How to Raise Load Wheels
Refer to the precautions at the beginning of the How
to Put Lift Truck on Blocks instructions in this sec-
tion before attempting to raise the lift truck.
1. Putblocksonbothsides(frontandback)ofthe
drive/steer tire and the caster wheels to prevent
movement of the lift truck. See Figure 5.
2. Use an overhead crane and web sling under the
base arms at the mast to raise the load wheels.
Another lift truck can also be used to raise the
base arms. Make sure that the crane and sling
or other lifting device has a capacity of at least
2/3 of the total weight of the lift truck as shown
on the nameplate.
3. Raise the base arms only enough to suspend the
wheels. Install blocks under the base arms at
therearofthewheelsnearthetruckframeto
support the lift truck.
5

General 8000 SRM 1197
1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS
Figure 5. How to Put Lift Truck on Blocks
How to Raise the Drive Tire End
Refer to the precautions at the beginning of the How
to Put Lift Truck on Blocks instructions in this sec-
tion before attempting to raise the lift truck.
1. Put blocks on each side (front and back) of the
load wheels to prevent movement of the lift truck.
SeeFigure5.
2. Use a low-clearance, hydraulic jack under the
rear of the frame to raise the drive/steer tire and
caster wheels. Another lift truck can also be used
to raise the lift truck. Make sure that the jack or
other lifting device has a capacity of at least 2/3
of the total weight of the lift truck as shown on
the nameplate.
3. Raise the lift truck only enough to suspend the
drive/steer tire and the caster wheels. Install
blocks under the rear of the frame to support the
lift truck.
How to Raise the Entire Lift Truck
Refer to the precautions at the beginning of the How
to Put Lift Truck on Blocks instructions in this sec-
tion before attempting to raise the lift truck.
WARNING
The mast MUST BE REMOVED to raise the
frame above 150 mm (6 in.).
1. Remove the mast from the lift truck. Refer to
Mast,Repair 4000 SRM 1195.
2. Turn the key switch to the OFF position and dis-
connect the battery from the lift truck at the bat-
tery connector.
6

8000 SRM 1197 General
WARNING
The battery is heavy. Use appropriate lifting
equipment to avoid personal injury.
3. Remove the battery from the lift truck.
WARNING
The truck must be kept level while raising.
4. Raise the lift truck and position solid, one-piece
hardwood blocks or an approved lift truck frame
stand under the frame. The truck must be kept
level while raising. Frequently reposition jack
stands or blocks under the frame while raising as
a safety precaution in case of equipment failure.
DO NOT raise any point of the frame 50 mm
(2 in.) more than any other point of the frame.
MANUAL LOWERING VALVE
N30-35ZDR and N35-40-45ZR
WARNING
Allow no on under or near the lift mechanism
or load during the manual lowering procedure.
Always verify that there are no obstructions
beneath the lift mechanism or load before at-
tempting to lower the mast manually.
The manual lowering valve is located on the main
lift pump manifold beside the hydraulic tank. The
manual lowering valve can be opened by turning the
valve knob counterclockwise to relieve pressure from
the hydraulic system. This can be used to manu-
ally lower the mast in case of malfunction or to re-
lieve pressure from the system before servicing the
hydraulics. If the mast leaks down during operation,
lower the mast and check that the knob is completely
closed (turn clockwise). Always close the manual
lowering valve after use. See Figure 6.
1. LOWERING CONTROL VALVE
2. UPPER MOUNTING HOLE
3. M2 TEST PORT
4. MANUAL LOWERING VALVE KNOB
5. M1 TEST PORT
6. RETURN FITTING
7. RELIEF VALVE
8. SUPPLY FITTING
9. LOWER MOUNTING HOLE
10. OVERRUN CHECK VALVE
11. PRESSURE FLANGE
Figure 6. Pump (Valve Manifold)
N30ZDRS and N35-40ZRS
WARNING
Allow no on under or near the lift mechanism
or load during the manual lowering procedure.
Always verify that there are no obstructions
beneath the lift mechanism or load before at-
tempting to lower the mast manually.
Manual lowering is accomplished by pushing in the
manual lowering valve knob and turning it counter-
clockwise 180 until the knob pops back out. See Fig-
ure 7. This will open the valve and the mast will be-
gin lowering at a controlled rate. Push the load hold-
ing check valve knob in and turn it clockwise 180
until it pops back out to close. See Figure 7.
7

Transporting 8000 SRM 1197
Figure 7. Main Control Valve
Legend for Figure 7
A. MANUAL LOWERING VALVE KNOB
B. MAIN CONTROL VALVE BODY
Transporting
WARNING
Maintain a safe distance from the edge of
docks, ramps, platforms, and other similar
working surfaces. Watch the "tailswing." Re-
member, when traveling in the forward direc-
tion, and the steering wheel is turned to move
the lift truck away from the edge of the dock,
the rear will swing toward the edge. This can
cause the lift truck to fall off the dock.
Ifthelifttruckfallsoffthedock,DONOTjump
off! Hold firmly to the steering wheel, brace
your feet, and lean forward and away from the
point of impact.
Before the lift truck is transported, check the se-
lected route to make sure there is adequate clearance
for the lift truck as loaded on the transport vehicle
(bridges, overpasses, power lines, and natural bar-
riers). In some cases, removal of the mast can be
required.
If a trailer is the method of transportation, use blocks
in front and back of the trailer tires to prevent move-
ment of the trailer when the lift truck is loaded and
unloaded. If a loading ramp is used, make sure that
the ramp is the proper design and capacity.
Use approved lifting eyes to lift the truck. If the lift
truck is not equipped with approved lifting eyes, DO
NOT lift the truck by attaching a lifting device to any
other part of the lift truck for the purposes of loading
or unloading.
LOADING
If components attached to the lift truck must be re-
moved for transport, refer to the section(s) for those
components for proper handling procedures.
The operator must never leave a lift truck in a condi-
tion so it can cause damage or injury. When parking
the lift truck, do the following operations:
1. After the lift truck has been loaded, apply the
parking brake.
2. If the mast is mounted on the lift truck, fully
lower the forks or carriage. If the lift truck is fur-
nished with a tilt mechanism, tilt the forks for-
ward until the tips of the forks touch the ground.
3. Turn the key switch to the OFF position to stop
the engine.
8

8000 SRM 1197 Preparation for Use
4. Check that all switches and accessories are
turned off.
5. Put blocks in front and back of the lift truck tires
to prevent any movement of the lift truck. Make
sure the blocks are attached to the transport sur-
face.
WARNING
The straps or chains used to attach the lift
truck to the transporter must be directly at-
tached to the lift truck frame or to a component
(drive axle, tow pin) that is solidly attached to
the frame. DO NOT attach the straps or chains
to the mast or any attachment.
CAUTION
Make sure that any straps or chains used to at-
tach the lift truck to the transporter do not con-
tact any tubes, hoses, hydraulic cylinders, or
other parts of the lift truck that are easily dam-
aged.
6. If the lift truck is transported in severe weather
or any other condition that can damage the lift
truck, cover the lift truck. Make sure the tarp
or protective material is designed for the appli-
cation and is securely attached.
UNLOADING
If components attached to the lift truck must be re-
moved for transport, refer to the section(s) for those
components for proper handling procedures.
1. If used, remove any covering.
2. Make sure the park brake is applied.
3. Disconnect the straps or chains.
4. Remove the wheel blocks.
5. Check that all switches and accessories are
turned off.
6. Unload the lift truck.
Preparation for Use
CAUTION
Transporting trucks in the horizontal position
may cause some looseness in the mast chains,
hoses, and other components. Always check for
loose or shifted components before raising the
mast. Raise the mast very slowly after standing
the truck up, to ensure all hoses and chains are
properly seated in their respective sheaves and
anchor points. Raise the mast up and down a
few times to ensure the hoses and chains are
working and adjusted properly. If the truck is
equipped with displacement main or free-lift
cylinders, the cylinders should be bled. See Lift
Cylinders 4000 SRM 481.
After being transported or stored, the lift truck must
be prepared for proper operation. All problems must
be corrected before use of the lift truck. See the
proper section for component repair procedures.
PREPARATION AFTER SHIPMENT
1. Complete the unloading procedures.
2. Inspect the lift truck for damage and missing
components.
3. Follow the steps in the section Maintenance Pro-
cedures Every 8 Hours or Daily.
PREPARATION AFTER STORAGE
1. Remove all tape, covers, and preservation mate-
rials.
2. Check the lift truck for damaged or missing com-
ponents. Repair damage and/or replace missing
components.
NOTE: If the lift truck has been stored longer than
1 year, all lubricants and fluids must be drained and
replaced. Refer to Maintenance Schedule.
3. Clean battery cables. Check the battery volt-
age. If the voltage is less than nominal, charge
the battery. Connect the cables to battery and
tighten.
4. Follow the steps in the section Maintenance Pro-
cedures Every 8 Hours or Daily.
9

Safety Procedures When Working Near Mast 8000 SRM 1197
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery on electric lift trucks and put a
tag or lock on the battery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal
of the mast or carriage. Follow the repair
procedures in the correct Service Manual
section for the mast.
WHEN WORKING NEAR THE MAST, ALWAYS:
1. Lower the mast and carriage completely. Press
the lower button on the control handle. If the
lowering controls do not operate correctly, slowly
open the lowering control valve to relieve pres-
sure from the hydraulic system. and make sure
there is no movement in the mast. Make sure
that all parts of the mast that move are fully low-
ered.
OR
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving parts
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Raise the mast to align the bottom cross-
member of the weldment that moves in the
outer weldment with a crossmember on the
outer weldment (1). See Figure 8.
b. Use a 3/8-in. minimum safety chain with
a hook (4) to fasten the crossmembers to-
gether so that the movable member cannot
lower. Put the hook on the back side of the
mast. Makesurethehookiscompletelyen-
gaged with a link in the chain. Make sure
the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings, or other
parts on the mast.
c. Lower the mast until there is tension in the
safety chain, and the free-lift cylinder (5) is
completely retracted. Install a DO NOT RE-
MOVE tag on the safety chain(s).
d. Install another safety chain (3/8 in. min-
imum) around the safety chain already
installed as a secondary safety precaution.
Hook the chain as tight as possible by hand.
1. OUTER MAST
2. INNER MAST
3. INTERMEDIATE MAST
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 8. Safety Chains
10

8000 SRM 1197 Maintenance Schedule
3. After lowering or restraining the mast, shut off
the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment.
Disconnect the battery and put a tag or lock on
the battery connector.
Maintenance Schedule
NOTE: Certain components on the truck require an
initial inspection earlier than the prescribed main-
tenance schedule to preserve the original manufac-
turer’s warranties. Perform the 3 month 500 hour
inspection at 150 to 250 hours after the initial instal-
lation of the truck and then follow the scheduled in-
spections as listed in the maintenance schedule (see
the notes after Table 1).
The Maintenance Schedule is divided into three time
intervals which call for particular maintenance pro-
cedures to be performed. The intervals are 1 Day
or 8 Hours, 3 Months or 500 Hours, and 1 Year or
2000 Hours for normal operations (whichever comes
first). Normal operation is considered one 8-hour
shift per day, in a relatively clean environment, on
an improved surface. Operating a lift truck for more
than eight hours per day is considered Heavy opera-
tion and requires the 3-month checks to be performed
at 350 hours. Lift trucks operating in freezer envi-
ronments or dirty conditions are considered Severe
operation and require the 3-month checks to be per-
formed at 200 hours. For an approximate location of
the items listed in Table 1, see Figure 9.
Figure 9. Maintenance Points
11

Maintenance Schedule 8000 SRM 1197
Table 1. Maintenance Schedule
Item
No. Item 1 day/
8hr 3mo/ 500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
Battery X, C1Check for Full
Charge Charge or Change Out
Fluid Level XCheck Distilled Water
Restraint Panels XCheck Condition Repair as Necessary
1
Power Disconnect XCheck Operation Repair as Necessary
XCheck Operation Repair as Necessary
2Brake
XHold on Grade
Test Capacity Load on
10% Slope
3Control Handle XCheck Operation Repair as Necessary
Electrical Circuits XCheck Operation Repair as Necessary
4
Contactors XCheck Condition Repair as Necessary
Forks XCheck for Damage
Guides and Locks X L As Required Multipurpose Grease2
5
Sideshift Wear Bearings XCheck Wear Replace as Necessary
6Dash Display, Horn, Lights,
Fuses XCheck Operation Repair as Necessary
X=Check C=Change L=Lubricate
12

8000 SRM 1197 Maintenance Schedule
Table 1. Maintenance Schedule (Continued)
Item
No. Item 1 day/
8hr 3mo/ 500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
XVisually Inspect
for Leaks Repair as NecessaryHydraulic System
XCheck for Proper
Operation Repair as Necessary
XCheck Level See Table 3
CChange Oil
(Standard
Operation)
ISO VG 46 Antiwear
Hydraulic Oil
CChange Oil
(Freezer
Applications)
Exxon Univis®HVI 26
Breather Cap XInspect Replace as Necessary
Hydraulic Oil Filter C5CReplace See Parts Manual
Hydraulic OilStrainer XInspect Replace as Necessary
XInspect for Visible
Damage and
Defects
Adjust, Repair, or
Replace as Necessary
7
Hydraulic Hoses, Fittings, and
Clamps XInspect for
Kinked,
Flattened, Stiff,
or Charred Hoses
Replace as Necessary
XInspect for Visible
Damage Check Operation
XCheck Stretch Replace as Necessary
8Lift Chains
LLubricate as
Required SAE20or30Engine Oil
X=Check C=Change L=Lubricate
13

Maintenance Schedule 8000 SRM 1197
Table 1. Maintenance Schedule (Continued)
Item
No. Item 1 day/
8hr 3mo/ 500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
Mast XInspect for Visible
Damage Check Operation
Bleed Cylinders (Displacement
Type Only) XRemove all air from cylinders
using bleeder
screws
See Cylinder
Identification.
XInspect for Visible
Damage and
Defects
Adjust, Repair, or
Replace as Necessary
Header Hoses, Fittings, and
Clamps
XInspect for
Kinked,
Flattened, Stiff,
or Charred Hoses
Replace as Necessary
9
Sliding Surfaces L2As Required Multipurpose Grease2
Reach Carriage Assembly XInspect for Visible
Damage Check Operation
Single Reach Scissor Arms L4 Lube Fittings Multipurpose Grease2
Double Reach Scissor Arms L8 Lube Fittings Multipurpose Grease2
Reach Cylinder Pivot Pins L4LubeFitti
ngs Multipurpose Grease2
Tilting Frame L2 Lube Fittings Multipurpose Grease2
10
Side Shift Carriage L4 Lube Fittings Multipurpose Grease2
Frame XVisually Inspect Repair as Necessary
Overhead Guard XVisually Inspect Replace as Necessary
11
Door Hinges LLightly Oil SAE20or30Engine
Oil
12 Safety Labels and Operating
Manual XReplace if
Necessary See Parts Manual
13 Steering Operation XCheck Operation
X=Check C=Change L=Lubricate
14