Hyster B218 User manual

Hyster B218 (W40Z) Forklift

PERIODIC
MAINTENANCE
W40Z [B218];W45Z[C215]
PART NO. 1499808 8000 SRM 1009

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.
•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 Mainte-
nance 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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
How to Move a Disabled Truck ..................................................................................................................... 1
How to Tow the Lift Truck ........................................................................................................................ 2
How to Put a Lift Truck on Blocks................................................................................................................ 2
How to Raise Drive/Steer Tire.................................................................................................................. 2
How to Raise Load Wheels ....................................................................................................................... 3
Welding Repairs............................................................................................................................................. 3
Battery Maintenance ......................................................................................................................................... 4
How to Charge the Battery ........................................................................................................................... 4
Equalizing Charge..................................................................................................................................... 4
Normal Charge .......................................................................................................................................... 4
Maintenance Free Battery Charger ......................................................................................................... 5
Battery Charger (W40Z only) ................................................................................................................... 5
How to Change the Battery........................................................................................................................... 5
Maintenance Schedule....................................................................................................................................... 6
Checks and Inspection Procedures ............................................................................................................... 6
Hydraulic System...................................................................................................................................... 7
Lifting Mechanism .................................................................................................................................... 8
Controls...................................................................................................................................................... 8
Electrical and Battery............................................................................................................................... 9
Wheels and Tires....................................................................................................................................... 9
Recommended Schedule of Maintenance.......................................................................................................... 9
Lubrication Instructions.................................................................................................................................... 15
Every 8 Hours or Daily.................................................................................................................................. 15
Every 350 Hours or 2 Months ....................................................................................................................... 15
Check Hydraulic Oil Level........................................................................................................................ 15
Every 2000 Hours or 1 Year .......................................................................................................................... 15
To Fill Hydraulic Tank .............................................................................................................................. 15
This section is for the following models:
W40Z [B218];
W45Z [C215]
©2003 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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8000 SRM 1009 General
General
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can make
a dangerous operating condition.
WARNING
Do not operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, put a DO
NOT OPERATE tag on the control handle. Re-
move 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 in-
spection, lubrication, and periodic maintenance. The
time intervals are based on a normal operation. A
normal operation is considered to be one eight 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 recom-
mended 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 direc-
tion 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 person-
nel and equipment to do a complete program of in-
spection, lubrication, and maintenance. This com-
plete program will help your lift truck operate better
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.
HOW TO MOVE A DISABLED TRUCK
This lift truck is not normally towed. If the traction
system will not operate, make repairs at the location
if possible. If the lift truck must be towed, refer to
the Maintenance Manual.
WARNING
Never carry a disabled lift truck unless the lift
truckMUSTbemoved. Thelifttruckusedto
lift the disabled lift truck MUST have a rated
capacity 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 capacity plate on
the disabled lift truck for the approximate total
weight. The forks must extend the full width
of the disabled lift truck. Put the weight of
the disabled lift truck at the center of the forks
and be careful not to damage the under side of
the disabled lift truck. Tilt the mast back and
travel slowly.
WARNING
Make sure no one except the driver is near the
lift trucks during towing. Both the tow truck
and the disabled truck can cause personal in-
jury during towing.
WARNING
To avoid personal injury, use extra care when
moving a lift truck during the following condi-
tions:
• Brake does not operate correctly
• Steering does not operate correctly
• Tire is damaged
• Traction conditions are bad
WARNING
Until repairs are complete, keep a DO NOT OP-
ERATE tag on the control handle. Remove the
key.
CAUTION
Never carry the lift truck faster than the speed
of a person walking. Steering can be difficult
and motor damage can occur at higher speeds.
Always travel smoothly without sudden starts.
The electric brake must be released before the lift
truck can be moved. If there is not sufficient battery
power, placing the control handle in the operating
position will not release the electric brake. Refer to
Towing The Lift Truck of the Maintenance Manual.
Usethecontrolhandletosteerthelifttruckwhileit
is being towed. Use one hand and walk to one side
1

General 8000 SRM 1009
of the lift truck. Do not walk or stand between the
towing vehicle and the lift truck.
How to Tow the Lift Truck
WARNING
Stay clear of the tow chain, towing vehicle, and
the lift truck during the towing operation to
prevent personal injury.
WARNING
Make sure no one except the driver is near the
lift trucks during towing. Both the tow truck
and the disabled truck can cause personal in-
jury during towing.
CAUTION
Travel slowly and do not tow on grades.
NEVER tow the lift truck faster than a normal
walking speed. Always tow smoothly without
sudden starts or stops.
CAUTION
Until repairs are complete, keep a DO NOT OP-
ERATE tag on the control handle. Remove the
key.
1. Disconnect the battery, remove the hood, and fas-
ten the chain to the lift truck. Make sure the tow
chainhasthecapacitytotowtheweight. Care-
fully fasten the tow chain completely around the
motor and battery compartments on top of the
forks. The chain must not cause damage to ei-
ther lift truck.
2. The electric brake must be released before the lift
truck can be towed. Disconnect connector 6 and
plug in brake override connector. See Schemat-
ics.
NOTE: The brake override connector must be re-
moved after repairs are completed before returning
the truck to service. Otherwise the truck will not op-
erate.
3. If there is not sufficient battery power, placing
the control handle in the operating position will
not release the electric brake.
4. Steer the lift truck with the control handle while
it is being towed. Use one hand and walk to one
side of the lift truck. Do not walk or stand be-
tween the towing vehicle and the lift truck.
5. Tow the lift truck slowly.
6. If another lift truck that has the drive wheels
near the forks is used to tow the disabled lift
truck, that lift truck must have weight added to
the forks. The total weight of the lift truck and
load must be equal to or greater than the weight
of the disabled lift truck. Install a load of approx-
imately half the maximum capacity on the forks
of the lift truck that is used for towing. This load
will increase the traction of the lift truck. Keep
the load on the forks lowered as much as possi-
ble.
If the lift truck used for towing has a master
drive unit (MDU) or drive unit similar to this lift
truck, do NOT add weight to the forks. Addi-
tional weight on the forks may decrease the trac-
tion of the drive wheel(s). Make sure that the lift
truck has a total weight equal to or greater than
theweightofthedisabledlifttruck.
HOW TO PUT A LIFT TRUCK ON BLOCKS
WARNING
Do NOT put the lift truck on blocks if the sur-
face is not solid, even, and level. Make sure that
any blocks used to support the lift truck are
solid, one-piece units. Put a block in front and
back of the tires touching the ground to pre-
vent movement of the lift truck.
Do not raise the lift truck by attaching an
overhead crane to areas that will be damaged.
Some of these points are not designed to sup-
port the weight of the lift truck. The lift truck
can be damaged or it can fall causing serious
personal injury. Attach the chain or sling to a
support structure of the lift truck frame.
SeeFigure1.
How to Raise Drive/Steer Tire
1. Putblocksoneachside(frontandback)ofthe
load wheels to prevent movement of the lift truck.
2. Use a special low clearance hydraulic jack, crane,
or another lift truck to raise the drive tire. Make
sure that the jack, crane, or other lift truck has
the correct capacity rating. The capacity must
equal to 2/3 the weight of the lift truck including
the battery. See the capacity plate.
2

8000 SRM 1009 General
3. Raise the lift truck only enough to suspend the
drive tire. Install additional blocks under the
frame near the drive tire.
How to Raise Load Wheels
WARNING
Never raise the forks any higher than neces-
sary to change the load wheels. Always raise
both forks at the same time. Raising the forks
too high can make the lift truck tip over and
cause property damage or possible, personal
injury.
1. Putblocksonbothsides(frontandback)ofthe
drivetiretopreventmovementofthelifttruck.
2. Use an overhead crane and web sling under the
forks to raise the load wheels. Another lift truck
can also be used to raise the forks. Make sure
that the crane and sling or other lift truck has a
capacity of at least 2/3 the total weight of the lift
truck as shown on the capacity plate.
3. Raise the forks only enough to suspend the
wheels. Install blocks under the forks at the rear
of the wheels to support the lift truck.
Figure 1. Putting Lift Truck on Blocks
WELDING REPAIRS
WARNING
Forklift truck frames and components may
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position of the paint may release isocyanates.
These chemicals are allergic sensitizers to skin
and respiratory tract and overexposure may
occur without odor warning. Should work
be performed, utilize good industrial hygiene
practices including removal of all paint (prime
and finish coats) to the metal around the area
to be welded, local ventilation, and/or sup-
plied-air respiratory protection.
WARNING
Remove the battery before welding. Welding
can cause a fire and or an explosion. Make sure
there is no fuel, oil, or grease near the weld
area. Make sure the area is well ventilated.
CAUTION
When using an arc welder, always disconnect
the battery connector to prevent damage to cir-
cuit components. Connect the welding ground
clampasclosetotheweldareaaspossibleto
prevent welding current from damaging bear-
ings.
Observe previous WARNINGS and CAUTIONS be-
fore doing any welding.
3

Battery Maintenance 8000 SRM 1009
Battery Maintenance
HOW TO CHARGE THE BATTERY
WARNING
The acid in the electrolyte can cause personal
injury. If electrolyte is spilled, flush the area
with water. Use a solution of sodium bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
WARNING
Batteries generate explosive hydrogen when
they are being charged. Keep fire, sparks,
and burning material away from the battery
charger area. Prevent sparks from the battery
connectors. Open the battery cover to disperse
explosive gas.
WARNING
Charge batteries only in the special area for
charging batteries. When charging the bat-
teries, keep the vent caps clean. The battery
charger area must have ventilation so that
explosive fumes are removed. Move the key to
the OFF position and disconnect the battery
when doing cleaning and maintenance.
WARNING
If the lift truck has been operated using a
battery that is almost discharged, inspect
for welded contacts BEFORE connecting a
charged battery. A contactor with welded
contacts can cause operations that are not
expected and possible personal injury when
a charged battery is connected. Check the
battery connector for damage.
CAUTION
Never connect the battery charger plug to the
plug of the lift truck. You can damage the
traction control circuit. Always make sure the
charger voltage is the correct voltage for the
battery.
Correct use of the hydrometer and proper operation
of the battery charger is important. Operate the
battery charger according to the instructions of
the charger manufacturer. Never let the battery
discharge below the minimum value given by the
battery manufacturer. A fully charged battery will
have a specific gravity of 1.265 to 1.310 at 25 C
(77 F). See Table 1. Never charge a battery at a rate
that will raise the electrolyte temperature above
49 C(120F). Never permit a battery to stay dis-
charged for long periods.
Table 1. Specific Gravity Corrections
Specific
Gravity
Reading
Electrolyte
Temperature
Cor-
rection
Points
Cor-
rect
Value
1.210 31 C(87F) +0.003 1.213
1.210 27 C(80F) +0.001 1.211
1.210 25 C(77F) +0.000 1.210
1.210 18 C(64F) 0.004 1.206
+0.001 for each 1.7 C(3F) from the 25 C(77F).
Base Value Degrees C + 17.8 × 1.8 = Degrees F.
Equalizing Charge
This charge is at a low rate and balances the charge
in all of the cells. The equalizing charge is normally
given approximately once a month. It is a charge at
a slow rate for three to six hours in addition to the
regular charging cycle. Do NOT give an equalizing
charge more than once a week. The most accurate
specific gravity measurement for a charged battery
will be after an equalizing charge. If the difference
in specific gravity is more than 0.020 between cells
of a battery after an equalizing charge, there can be
a cell that has a malfunction. Consult your battery
dealer.
NOTE: Many customers have battery chargers that
can follow a program to automatically charge a
battery according to recommendations of the bat-
tery manufacturer. Use the recommendations of
the battery manufacturer for charging the battery.
Use only battery chargers approved by the battery
manufacturerordealer.
Normal Charge
This charge is normally given to a battery that is
discharged from normal operation. Many customers
charge the battery at regular intervals that depend
on use. This procedure will keep the battery correctly
charged if the battery is not discharged below the
limit. Always use a hydrometer to check the battery
4

8000 SRM 1009 Battery Maintenance
if the battery is charged at regular intervals. Fre-
quent charging of a battery that has a 2/3 or more
charge can decrease the life of the battery.
Maintenance Free Battery Charger
WARNING
To reduce the risk of fire, use only on circuits
provided with 5 amps branch circuit protec-
tion in accordance with the National Electrical
Code, ANSI/NFPA 70.
For lift trucks equipped with maintenance free bat-
teries or industrial batteries, the battery connector
must be disconnected from the truck and connected
to a suitable battery charger. Refer to OPERATOR
MANUAL.
Battery Charger (W40Z only)
For lift trucks equipped with the standard battery
pack and on-board charger, it is not required to
disconnect the battery connector before charging the
battery. Connect AC cord to a 120 volt AC outlet.
This will automatically charge the batteries. Refer
to OPERATOR MANUAL.
NOTE: The utility tray must remain open during
charging to allow batteries proper ventilation.
HOW TO CHANGE THE BATTERY
WARNING
Batteries are heavy and can cause personal
injury or property damage. Do NOT put hands,
arms, feet, or legs between the battery and
a solid object. Makesurethecapacityofthe
crane and spreader bar is greater than the
weight of the battery. The weight of the bat-
tery is normally shown on the battery case.
The maximum battery weight is shown on the
lift truck capacity plate. The spreader bar
must NOT be made of metal or it must have
insulated straps.
WARNING
Put blocks under both sides of the frame in the
area of the battery compartment. The blocks
must prevent the lift truck from falling and
causing personal injury or property damage.
CAUTION
If the lift truck was operated using a low bat-
tery, inspect for welded contacts BEFORE con-
necting a charged battery. The circuit will not
reset and lift truck operation cannot be con-
trolled if the contacts are welded. Prevent side-
to-side movement of the battery by adjusting
thebracketsoneachsideofthebatteryand
tighten the capscrews, lockwashers, and nuts
to retain the batteries.
CAUTION
The replacementbatterymustfitthebattery
compartment. Make sure the battery cables
have clearance to move during lifting and
lowering of theforks. Makesurethatthere-
placement battery is the correct voltage and
weight as shown on the capacity plate. See
Figure 2.
1. Move the keytotheOFF position. Disconnect
the battery. Use a spreader bar and lifting device
to remove the battery.
1. CRANE
2. SPREADER BAR
3. INSULATOR STRAPS
4. BATTERY
Figure 2. Changing the Battery
5

Maintenance Schedule 8000 SRM 1009
2. Position blocks under both sides of the truck in
the area of the battery compartment.
3. Loosen and remove buckle and strap from around
battery.
4. Lift the battery out of the truck. Do not let the
battery move from side to side. Make sure the
battery cables have clearance.
5. Before installing a new battery, make sure the
battery is the correct size and weight for the lift
truck. Make sure the battery has clearance for
installation. Check that the battery connector
can be attached to the lift truck connector with-
out pulling during lifting and lowering opera-
tions. Do not damage the battery cables during
installation. Install the battery.
6. Replace buckle and strap and tighten to prevent
the battery from moving.
7. Remove the blocks from under the truck.
8. Connect the battery. Test the operation of the
motorized hand truck before returning the truck
to service.
Maintenance Schedule
CHECKS AND INSPECTION PROCEDURES
WARNING
Hyster Industrial Trucks are equipped with
certain safety devices as standard equipment,
for example: horns, reversing button, etc. If for
any reason these safety devices are removed
when the truck is being serviced, adjusted,
repaired, or overhauled, these safety devices
must be properly reinstalled before any testing
or operation of the truck is to be done. Failure
to comply with this warning could result in
serious personal injury to the mechanic and/or
the operator.
WARNING
Disconnect the battery before removing the
hood.
WARNING
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If re-
pair is necessary, put a DO NOT OPERATE tag
on the control handle. Remove the key from
the key switch.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
The Recommended Schedule of Maintenance is lo-
cated in this section. The Maintenance Schedule has
the time intervals for inspection, lubrication, and
maintenance. The Maintenance Schedule is based
on normal operations. Severe or unusual operating
conditions will require a reduction in the recom-
mended time periods in the Maintenance Schedule.
Your HYSTER dealer has the facilities and trained
personnel to do complete lift truck maintenance.
A complete program of inspection, lubrication, and
maintenance will help your lift truck perform ef-
ficiently and operate over a longer period of time.
Service manuals are available from your HYSTER
dealer to help users who do their own maintenance.
Put the lift truck on a level surface. Lower the forks,
disconnect the battery, and remove the hood. Check
for any leaks and conditions that are not normal.
Clean any oil spills.
6

8000 SRM 1009 Maintenance Schedule
1. BREATHER CAP
2. HYDRAULIC OIL TANK
Figure 3. Hydraulic Tank 12 Volt
Hydraulic System
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic lines. Hy-
draulic oil can be injected into the body by
pressure. Clean oil spills from the floor.
WARNING
The operating temperature of the hydraulic oil
is 32 to 72 C (90 to 162 F).
CAUTION
Never operate the pump without oil in the
hydraulic system. Operation of the hydraulic
pump without oil will damage it.
CAUTION
Donotpermitdirttoenterthehydraulicsys-
tem when oil is added.
Make sure the temperature of the oil is at least 32 C
(90 F).Makesuretheforksarefullylowered. The
fluid level full mark is labeled on the hydraulic tank.
The hydraulic tank fluid level can be seen through
the tank. Do not overfill. Oil will leak from the
breather if too full. After filling, make sure to tighten
the breather cap to prevent oil leaks. Check the hy-
draulic system for leaks and damaged or loose com-
ponents. See Figure 3 and Figure 4.
NOTE: There is no filter on this hydraulic system.
There is a screen on the pump inlet. This screen
and the magnet in the bottom of the tank, must be
cleaned each time the tank is removed for repairs.
1. BREATHER CAP
2. HYDRAULIC OIL TANK
Figure 4. Hydraulic Tank 24 Volt
7

Maintenance Schedule 8000 SRM 1009
Lifting Mechanism
WARNING
Pressurized hydraulic oil can be injected into
the body by pressure. Do not try to locate hy-
draulic leaks by putting hands on pressurized
hydraulic components. Check for the location
of high-pressure leaks by holding a piece of
cardboard in front of the suspected area.
WARNING
To avoid personal injury, never allow any part
of your body under the forks. Do not put any
part of your body in or through the lift mecha-
nism.
1. Raise the forks slowly without a load. Check for
smooth operation and mechanical interference.
Mechanical interference is caused by damaged or
worn linkage or shafts or by incorrect adjustment
of the tension rods.
2. Check for damaged or worn linkage bushings or
shafts.
3. Check for missing or loose shaft pins.
4. Check load wheels and support bearings, shafts,
and shaft pins for wear, damage, or missing
parts.
Controls
WARNING
If any function does not operate or operates in-
correctly, report the faulty operation immedi-
ately. Do not operate the lift truck until the
problem is corrected. Put a tag on the control
handle stating DO NOT OPERATE. Remove the
key and disconnect the battery.
WARNING
Do the following checks in an area that is clear
of other personnel or equipment.
1. Check the operation of the key switch. Functions
should not operate with the key in the OFF posi-
tion except the steering. Turn the key to the ON
position. Lower control handle to the operating
position. The horn, hydraulic system, traction
system, and brake should now be operational.
2. Check the operation of the brake switch. Release
the control handle to allow it to return to the ver-
tical position. Move the speed/direction control
without lowering the control handle. The trac-
tion system must not operate.
3. Check the operation of the speed/direction con-
trol. Lower the control handle to release the
brake. Slowly rotate the speed/direction control.
The lift truck must accelerate smoothly. Rotate
the control in the opposite direction. The lift
truck must stop smoothly and then change direc-
tion. The control must return to the OFF position
when released.
4. Check the operation of the lift and lower func-
tions. Push the lift button and then the lower
button. Check that the forks raise and lower.
5. Check the operation of the traction reverse func-
tion. Slowly rotate the speed/direction control for
slow travel in the control handle direction. Push
the traction reverse button without changing the
position of the speed/direction control. The lift
truck must stop and then accelerate in the op-
posite direction. The horn will sound. Once the
lift truck changes direction and moves with the
control handle trailing, release the traction re-
verse button without releasing the speed/direc-
tion control. The lift truck should not accelerate
in the control handle direction. (Once the trac-
tion reverse button has been pressed, the trac-
tion motor should not accelerate the lift truck to-
ward the control handle). Full direction control
may be re-established by rotating the speed/di-
rection control to the OFF position or moving the
control handle to a brake ON position.
6. Check the steering function. Move the control
handle to the right and left. Check for smooth
movement of the steer (drive) wheel in the same
direction. Steering will be more difficult if the lift
truck is stopped.
7. Check the operation of the optional creep speed
button. The optional slow speed or "turtle" mode
button enables the truck to be operated at a slow
speed with the control handle in the fully upright
position. To operate, press and hold the slow
speed button, and rotate the speed/direction con-
trol button in the direction of desired travel. Re-
leasing the button will re-apply the brake. If the
control handle is lowered to the normal drive po-
sition while the slow speed button is depressed,
the truck will continue to operate in the slow
8

8000 SRM 1009 Recommended Schedule of Maintenance
speed mode until the button is released. The
truck should operate at only 1.6 km/h (1 mph).
Electrical and Battery
WARNING
Do not put tools on the battery.
WARNING
The acid in the electrolyte can cause injury. If
the electrolyte is spilled, use water to flush the
area and make the acid neutral with a solution
of soda and water (one pound of baking or com-
mercial soda to one gallon of water). Acid in
the eyes must be flushed with water. Have a
doctor check the eyes.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. Do not make
sparks with the battery connectors. Discon-
nect the battery when doing maintenance.
Check for loose or broken electrical connections and
damaged wires or cables. Examine the battery case
for damage and leakage. See the battery dealer in the
area to repair any damage to the battery or cables.
WARNING
Broken electrical connections, damaged wires
or cables, and leakage or corrosion from the
battery can cause the electrical controls of the
lift truck to operate incorrectly.
Keep the battery case, top cover, and battery areas
clean and painted. Use a water and soda solution to
clean the battery and the battery area (one pound of
baking or commercial soda ash to one gallon of wa-
ter). Keepthetopofthebatteryclean,dryandfree
of corrosion.
NOTE: The following electrolyte level and specific
gravity checks are not necessary for low mainte-
nance batteries.
Check that the vent caps are clear. Check the elec-
trolyte level daily on a minimum of one cell and on
all cells every week. Fill to the correct level accord-
ing to the battery manufacturer’s recommendations.
Add only distilled water. Use a hydrometer to check
that the battery is not discharged below the mini-
mum specific gravity given by the manufacturer and
hasenoughchargetocompleteaworkperiod.
Wheels and Tires
Check the drive tire, caster, and load wheels for for-
eign material, cuts, and tears. Remove all foreign
material and smooth any cuts or tears to prevent fur-
ther damage. See Figure 5.
1. SMOOTH EDGES
2. REMOVE NAILS, GLASS, AND ALL METAL
Figure 5. Tires
NOTE: The load wheel bearings have lube fittings.
Under normal conditions it is recommended that
they be lubricated every 50 hours minimum or once
per month. The load wheel bearings are cleaned and
repacked every 1000 hours or once per year.
Recommended Schedule of Maintenance
Although this Recommended Schedule of Mainte-
nance is intended for use with all motorized hand
lift truck models, not all models are equipped with
all the items listed in this schedule. Be certain this
schedule is read thoroughly and all operations are
followed. If in doubt of any procedure or component
to be inspected, adjusted and lubricated, or if the
truck is specially equipped and used for special ap-
plications, consult your nearest authorized Hyster
Industrial Truck Dealer for assistance.
9

Recommended Schedule of Maintenance 8000 SRM 1009
NOTE: Some items on the following charts may not
be applicable to your truck.
Legend
A - Every 8 Hours
B - Every 350 Hours
C-Every2000Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
SAFETY AND OPERATIONAL CHECK
(Prior to each shift)
Onlythe8hourCHECKSaretobeperformedbytheoperator.Haveaqualified
mechanic correct all problems in accordance with appropriate HYSTER
maintenance instructions.
ABC
Leaks - Hydraulic Fluid X
Tires-Condition(SeeNote1) X
Forks - Condition X
Load Backrest - Cracks and Mounting X
Hydraulic Hoses - Check Visually X
Safety Warnings - Attached (Refer to Parts Manual for Location) X
Internal Checks:
Battery - Water/Electrolyte Level and Charge X
Hydraulic Tank Fluid Level - Check Level X
Operating Manual in Container X
Nameplate Attached - Information Matches Model, Serial Number & Attachments X
Battery Restraints in Place X
Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately:
Brake System - Functioning Smoothly X
Directional/Speed Control- Functioning Smoothly X
Lift and Lower Control - Functioning Smoothly X
Gauges, Horn, and Fuses - Functioning X
Steering Operation - Functioning Smoothly X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
10

8000 SRM 1009 Recommended Schedule of Maintenance
NOTE: The following inspections and necessary cor-
rections are the responsibility of the user.
Legend
A - Every 8 Hours
B - Every 350 Hours
C - Every 2000 Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
LUBRICATION CHECK
Blow off, clean when necessary and inspect for damage. ABC
Lubricate - Chassis (All Fittings) X
AllLinkageandLoadWheels(SeeNote2) X
Clean and Repack Load Wheel Bearings X
Hydraulic Tank Oil Level XO
Hydraulic Tank Breather X
Caster Wheel Clearance X
Drive Unit Oil Level XO
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
Legend
A - Every 8 Hours
B - Every 350 Hours
C - Every 2000 Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
HYDRAULIC SYSTEM CHECK ABC
Hydraulic Pump for Noise and Operation X
Hydraulic Control Valve for Leaks and Operation X
Relief Valve Settings X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
11

Recommended Schedule of Maintenance 8000 SRM 1009
Legend
A - Every 8 Hours
B - Every 350 Hours
C-Every2000Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
All Hoses, Tubing and Fittings for Wear and Leaks X
For General Leaks X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
Legend
A - Every 8 Hours
B - Every 350 Hours
C-Every2000Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
DRIVE UNIT CHECK ABC
Brake Wear and Adjustment X
Electric Motor and Drive Unit Mounting Bolts X
Wheel Bolts - Torque to Specifications X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
12

8000 SRM 1009 Recommended Schedule of Maintenance
Legend
A - Every 8 Hours
B - Every 350 Hours
C - Every 2000 Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
ELECTRICAL SYSTEM CHECK
NOTE: DO NOT use Steam to Clean Electrical Parts ABC
Clean all Controls X
Interlock Switches - Functioning X
All Motors - Clean with Compressed Air - Functioning X
All Motors - Clean Power Wire Terminals - Functioning X
Battery Box and Connectors - Neutralize and Clean X
Battery Condition - Physical and Electrical X X
All Wire Connections - Tightness and Corrosion X
Contactors - Tips and Wire Connections - Tightness and Corrosion X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
13

Recommended Schedule of Maintenance 8000 SRM 1009
Legend
A - Every 8 Hours
B - Every 350 Hours
C-Every2000Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
GENERAL CHECK ABC
All Bolts, Nuts, Cotter Pins, Etc. X
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
Legend
A - Every 8 Hours
B - Every 350 Hours
C-Every2000Hours
X - Indicates Visual Inspection, Repair, or
Replace as Required
O - Indicates Drain and Fill
ROAD AND LOAD TEST TRUCK
The following items must be tested at initial installation of the truck and after every
maintenance inspection or repair.
Test the rated load in a clear area. Report any questionable functions or unusual noises.
Steering
Brake System
Emergency Disconnect
NOTES:
1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.
2. Under normal conditions it is recommended that the Load Wheel Bearings be lubricated every 200 hours
minimum. The load wheel bearings are cleaned and repacked every 2000 hours.
3. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.
4. Recycle all waste oils.
14