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