Hyster B495 Operating instructions

Hyster B495 (W25ZA2 W30ZA2) Forklift Service
Repair Manual

PERIODIC
MAINTENANCE
W25-30ZA2 [B495]
PART NO. 1692609 8000 SRM 1379

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

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
How to Move a Disabled Lift Truck ................................................................................................................... 1
How to Tow a Lift Truck ................................................................................................................................ 2
How to Put The Lift Truck on Blocks ................................................................................................................ 3
How to Raise the Drive/Steer Tire .................................................................................................................3
How to Raise the Load Wheels ...................................................................................................................... 5
Special Precautions ................................................................................................................................................. 5
Discharging the Capacitor ..................................................................................................................................5
Safety Procedures When Working Near Mast .......................................................................................................7
Maintenance Schedule ............................................................................................................................................ 8
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 12
Checks Before Operation ..................................................................................................................................12
How to Make Checks With Key Switch OFF ...................................................................................................13
Safety Labels .................................................................................................................................................13
Battery ...........................................................................................................................................................13
Brake ............................................................................................................................................................. 14
Tires and Wheels .......................................................................................................................................... 14
Mast, Forks, and Lift Chains ....................................................................................................................... 14
Control Handle ..............................................................................................................................................16
Hydraulic System ......................................................................................................................................... 16
How to Make Checks With Key Switch ON .....................................................................................................17
Check for Leaks in Lift System ....................................................................................................................17
Control Buttons............................................................................................................................................. 17
Direction/Speed Control and Switches ........................................................................................................ 17
Gauges, Horn, Fuses .....................................................................................................................................18
Maintenance Procedures Every 350 Hours or Every 2 Months ..........................................................................19
Fittings Lubrication ..........................................................................................................................................19
Other Lubrication ............................................................................................................................................. 19
Base Arm Capscrews ........................................................................................................................................ 19
Battery ...............................................................................................................................................................19
Brake ................................................................................................................................................................. 20
Lift Chain Adjustments .................................................................................................................................... 20
Drive Wheel .......................................................................................................................................................22
Hydraulic System ..............................................................................................................................................22
Master Drive Unit .............................................................................................................................................22
Traction and Pump Motor Brushes ..................................................................................................................23
Contactor ........................................................................................................................................................... 25
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................... 26
Load Wheels ...................................................................................................................................................... 26
Hydraulic Oil Change ....................................................................................................................................... 26
How to Change Drive Unit Oil ......................................................................................................................... 27
Welding Repairs .................................................................................................................................................... 27
General Repairs .....................................................................................................................................................28
Load Wheels (W25-30ZA2)................................................................................................................................ 28
Remove .......................................................................................................................................................... 28
Install ............................................................................................................................................................ 28
Lift Cylinder Leak Test .................................................................................................................................... 29
Battery Maintenance ............................................................................................................................................ 29
How to Charge the Battery ...............................................................................................................................29
Normal Charge ............................................................................................................................................. 30
Table of Contents
i

TABLE OF CONTENTS (Continued)
Equalizing Charge ........................................................................................................................................ 30
Industrial Battery Charging ........................................................................................................................ 30
Battery Pack Charging .................................................................................................................................31
How to Change the Battery ..............................................................................................................................31
Standard Battery Spacer Adjustment ......................................................................................................... 31
Changing the Battery With an Overhead Crane ........................................................................................ 32
Remove ......................................................................................................................................................32
Install ........................................................................................................................................................33
This section is for the following models:
(W25-30ZA2) [B495]
Table of Contents
ii

Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete
manual
NOTE:
If there is no response to click on the link above,
please download the PDF document first, and then
click on it.
Have any questions please write to me:
[e-mail]

General
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for
inspection, lubrication, and periodic maintenance.
The time intervals are based on normal operation.
Normal operation is considered to be one 8-hour
shift per day in a relatively clean environment on
an improved surface. Multiple shifts, dirty
operating conditions, etc., will require a reduction
in the recommended time periods in the
Maintenance Schedule.
NOTE: The front end of the lift truck is the control
handle end. Forward travel is movement with the
forks trailing. Rear travel is movement in the
direction of the forks.
WARNING
DO NOT make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
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, place a DO
NOT OPERATE tag on the control handle and
remove the key from the key switch.
Some users have service personnel and facilities to
perform the tasks listed in the Maintenance
Schedule. Service Manuals are available from your
Hyster® lift truck dealer to help users who do their
own repairs.
Your Hyster lift truck dealer has the trained
personnel and equipment to do a complete program
of inspection, lubrication, and maintenance. This
complete program will help your lift truck operate
better over a longer period of time.
HOW TO MOVE A DISABLED LIFT TRUCK
WARNING
Use extra care when moving a lift truck during the
following conditions:
• Brake does not operate correctly
• Steering does not operate correctly
• Tire is damaged
• Traction conditions are bad
If there is no power, the drive wheel will not turn
freely. Poor traction can cause the disabled lift
truck or towing vehicle to slide. 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
lift truck used to 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 nameplate 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. Be careful not
to damage the underside of the disabled lift truck.
Tilt the mast back and travel slowly.
Lift trucks are not normally towed. If the traction
system will not operate, make repairs at the
location if possible. If the lift truck must be towed,
tow in the direction of the control handle, forks
trailing.
8000 SRM 1379 General
1

How to Tow a Lift Truck
WARNING
Prior to releasing the electric brake, make sure
the lift truck is blocked correctly to prevent
movement causing damage to personnel or
equipment.
Stay clear of the tow chain, towing vehicle, and
the lift truck during the towing operation to
prevent injury.
Make sure no one except the driver is near the lift
trucks during towing. Both the tow truck and the
disabled truck can cause an injury during towing.
Always unplug the Brake Override Circuit and
connect the Brake Harness prior to operating the
lift truck.
CAUTION
Never tow the lift truck faster than the speed of a
person walking. Steering can be difficult and
motor damage can occur at higher speeds.
Always tow smoothly without sudden starts.
Never tow the lift truck using the control handle.
Until repairs are complete, keep a tag on the
control handle stating DO NOT OPERATE.
Remove the key.
In order to move a disabled lift truck, the electric
brake must be released. A jumper is provided in the
wiring harness to supply battery voltage directly to
the electric brake to release it.
1. Block the lift truck to prevent it from moving.
2. Turn ignition key switch to the OFF position.
3. Disconnect and separate the battery
connectors.
4. Remove drive unit cover to allow access to
wiring harness.
5. Locate Brake Harness and Brake Override
Circuit Connector (three, 4-pin connectors in
the wiring harness near the brake). See
Figure 1.
6. Unplug the Brake Harness Connector from the
Normal Operation Connector. This will disable
the lift truck MDU.
1. BRAKE HARNESS
2. BRAKE OVERRIDE CIRCUIT CONNECTOR
3. NORMAL OPERATION CONNECTOR
Figure 1. Brake Override Connector
7. Plug the male side of the Brake Override
Circuit Connector into the female side of the
Brake Harness.
General 8000 SRM 1379
2

8. Fasten the chain to the lift truck. Make sure
the tow chain has the capacity to tow the
weight. Carefully fasten the tow chain
completely around the motor and battery
compartments on top of the forks. The chain
must not cause damage to either lift truck.
9. Steer the lift truck with the control handle
while it is being towed. Use one hand and walk
to one side of the truck. DO NOT get between
the towing vehicle and the lift truck.
10. Connect the battery connectors to disengage
the brake.
11. Tow the lift truck slowly.
12. 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 approximately 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 possible.
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. Additional
weight on the forks may DECREASE the traction of
the drive wheel(s). Make sure that the lift truck has
a total weight equal to or greater than the weight of
the disabled lift truck.
13. Make sure the Brake Override Circuit is
disconnected from the Brake Harness prior to
operating the lift truck.
HOW TO PUT THE LIFT TRUCK ON
BLOCKS
WARNING
DO NOT put the lift truck on blocks if the surface
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 prevent
movement of the lift truck.
DO NOT raise the lift truck by attaching an
overhead lifting device to areas that can be
damaged. Some of these points are not designed
to support the weight of the lift truck. The lift truck
can be damaged or it can fall, causing serious
injury. Attach the chain or sling to a support
structure of the lift truck frame.
DO NOT make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained service
technicians.
How to Raise the Drive/Steer Tire
1. Put blocks on both the front and back sides of
the load wheels to prevent movement of the lift
truck. Refer to Figure 3.
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 at least two-thirds (2/3) the weight of
the lift truck, including the battery. See the
nameplate for the lift truck weight.
8000 SRM 1379 General
3

WARNING
DO NOT lift both ends at once.
2. To raise drive end of the lift truck, hook a lift
strap under bumper on both sides or hook lift
strap under drive frame cowl. See Figure 2.
3. Install additional blocks under the frame near
the drive tire. See Figure 3.
A. TOP VIEW B. LEFT VIEW
1. DRIVE END
2. FORK END
3. STRAP
Figure 2. Lifting Points (W25-30ZA2)
Figure 3. Putting Lift Truck on Blocks
General 8000 SRM 1379
4

How to Raise the Load Wheels
WARNING
Never raise the base arms any higher than
necessary to change the load wheels. Always
raise both base arms at the same time. Raising
the base arms too high can make the lift truck tip
over and cause damage or possible injury.
1. Put blocks on both the front and back sides of
the drive tire to prevent movement of the lift
truck. Refer to Figure 3.
2. Use an overhead lifting device 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 the overhead
lifting device and web sling or other lift truck
has a capacity of at least two-thirds (2/3) the
total weight of the lift truck including the
battery. See the nameplate for the lift truck
weight.
WARNING
DO NOT lift both ends at once.
3. To raise the fork end of the lift truck, hook a lift
strap through each load wheel opening in the
top of each fork and lift together. See Figure 2.
Raise the outriggers only enough to suspend the
wheels. Install blocks under the outriggers at the
rear of the wheels to support the lift truck. See
Figure 3.
Special Precautions
DISCHARGING THE CAPACITOR
WARNING
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load
wheels. The blocks must prevent the lift truck
from falling and causing personal injury or prop-
erty damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
Discharge the capacitors in the controller by con-
necting a 200-ohm, 2-watt resistor across the con-
troller's B+ and B− terminals with insulated
jumper wires. DO NOT use a screwdriver to dis-
charge the traction motor controller. See Figure 4.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis-
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedure when servicing the controller.
1. Block the drive tire in front and back to prevent
unexpected movement. Refer to General in this
section.
2. Turn the key switch to the OFF position and
disconnect the battery.
3. Remove the drive unit compartment covers.
4. Discharge the capacitor in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B− terminals. See Fig-
ure 4. DO NOT short across the motor control-
ler terminals with a screwdriver or jumper
wire.
5. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
8000 SRM 1379 Special Precautions
5

Figure 4. Discharging the Capacitor
Legend for Figure 4
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Special Precautions 8000 SRM 1379
6

Safety Procedures When Working Near Mast
The following procedures must be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances be-
tween 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 completely
lowered or a safety chain is installed. Also, make
sure the power is off and the key is removed. Put
a DO NOT OPERATE tag in the operator's com-
partment. Disconnect the battery 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 removal of
parts and can require removal of the mast or car-
riage. Follow the repair procedures in the correct
Service Manual section.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower mast and carriage completely. Make
sure all parts of mast that move are fully low-
ered. Push lift/lower control button and make
sure there is no movement in mast.
OR
2. If parts of the mast must be in raised position,
install a safety chain to restrain moving parts
of mast. Connect moving parts to a part that
does not move. Follow these procedures:
8000 SRM 1379 Safety Procedures When Working Near Mast
7

a. Raise mast to align bottom or middle cross-
member of inner weldment with the top of
outer weldment. See Figure 5.
b. Install a safety chain (3/8-in. minimum) with
a hook. Put hook on back side of mast. Make
sure hook is completely engaged with a link
in the chain. Make sure safety chain does not
touch lift chains or chain sheaves, tubes, ho-
ses, fittings, or other parts on mast.
c. Lower mast until there is tension in safety
chain. Turn the key switch to the OFF posi-
tion and remove the key. Put a DO NOT
OPERATE tag in the operator's compart-
ment. Disconnect the battery and put a tag
or lock on the battery connector. Install a DO
NOT REMOVE tag on safety chain(s).
NOTE: MAST OPERATOR GUARD MUST BE RE-
MOVED TO INSTALL SAFETY CHAIN. REMOVE
SAFETY CHAIN AND INSTALL THE GUARD AF-
TER REPAIRS ARE COMPLETE.
1. MAST WELDMENT
2. MAST CROSSMEMBER
3. SAFETY CHAIN
4. CARRIAGE
Figure 5. Safety Chain the Mast (Operator Guard
Not Shown)
Maintenance Schedule
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance for your
lift truck. The service intervals are given in both
operating hours recorded on the lift truck hourme-
ter and in calendar time. Use the interval that
comes first.
CAUTION
Trucks operating in non-standard or severe appli-
cations may require special optional environmen-
tal packages, additional maintenance procedures,
more frequent service intervals, and/or special lu-
bricants.
Disposal of lubricants and fluids must meet local
environmental regulations.
The maintenance schedules are made according to
the maximum service intervals for average condi-
tions. Inspect and lubricate more frequently when
operating in dirty or difficult conditions.
Put the lift truck on a level surface. Lower the
forks, disconnect the battery, and remove the drive
unit cover. Check for any leaks and conditions that
are not normal. Clean any oil spills.
The approximate locations of the items indicated in
Table 1 are shown in Figure 6.
Maintenance Schedule 8000 SRM 1379
8

Figure 6. Maintenance Points
8000 SRM 1379 Maintenance Schedule
9

Table 1. Maintenance Schedule
Item 8 hr
or 1 day1
350 hr
or 2
month1
2000 hr
or 1 year1
Procedure or
Quantity Specification
No. Description
1 Safety Labels and
Operating Manual X Replace if Necessary See Parts Manual
2 Battery X Check Water Level
X
Review Battery
Records for
Equalization Charge
Equalization
Charge2
3Brake X Check Operation Releases and Applies
Smoothly
X
Park Truck Loaded
to Rated Capacity on
10% grade
Brake Holds Truck
on Grade
4 Drive Tire and
Wheel Rim X Check for Damage See Procedure, Tires and Wheels
Wheel Bolt
Torque X
Examine for Rust,
Damage, or
Corrosion
Check Torque
Tighten if Required
115 N•m (85 lbf ft)
5
Load Wheels X Check Condition
Load Wheels must
roll smoothly and not
be excessively loose
L 1 Fitting (Each) Multipurpose
Grease3
6 Mast X Check Condition
Lift/Lower
Control X Check Operation Smooth Operation, No Binding
Sideshift
Assembly X Check Operation Smooth Operation, No Binding
Channel Wear
Surfaces X and L Check Condition Clean and Lubricate
Multipurpose
Grease3
Header Hoses,
Fittings, and
Clamps
X Inspect for visible
Damage and Defects
Repair or Replace as
Necessary
X
Inspect for Kinked,
Flattened, Stiff, or
Charred Hoses
Replace as
Necessary
7 Lift Chains X Check Condition
X=Check C=Change L=Lubricate A=Adjust
Maintenance Schedule 8000 SRM 1379
10

Table 1. Maintenance Schedule (Continued)
Item 8 hr
or 1 day1
350 hr
or 2
month1
2000 hr
or 1 year1
Procedure or
Quantity Specification
No. Description
L Clean and Lubricate SAE 20 or 30 Motor
Oil
8Forks X Check Condition and
Operation
Check With Fork
Gauge
Fork Guides
and Locks
X L Lubricate Pins SAE 20 or 30 Motor
Oil
X L Sliding Surfaces SAE 20 or 30 Motor
Oil
9 Directional/Speed
Control X Check Operation Smooth Operation, No Binding
10 Electrical Circuits X Check Operation Repair as Necessary
Traction
Motor X Measure Brushes 19.00 mm (.75 in.) Minimum
Lift Pump
Motor X Measure Brushes 14.00 mm (.55 in.) Minimum
Springs X
Check for Heat
Damage
(Discoloration)
Replace as Required
Commutator X Clean Vacuum or Low
Pressure Air
Gauges, Horn,
and Fuses X Check Condition Replace as Required
11 Control Handle X Check Operation Smooth, No Binding
Pivot Pins L Clean and Lubricate SAE 20 or 30 Motor
Oil
12 Hydraulic System
Hydraulic Oil X C 8.0 liter (8.5 qt)
Hydraulic Oil4
Check level
Check for Leaks
Breather Cap X Clean or Replace Replace Damaged or
Unserviceable Parts
Hydraulic
Oil Strainer X Clean and Inspect Replace Damaged or Unserviceable Parts
Hydraulic
Hoses,
Fittings, and
Clamps
X Inspect for Visible
Damage and Defects
Repair or Replace as
Necessary
X
Inspect for Kinked,
Flattened, Stiff, or
Charred Hoses
Replace as
Necessary
X=Check C=Change L=Lubricate A=Adjust
8000 SRM 1379 Maintenance Schedule
11

Table 1. Maintenance Schedule (Continued)
Item 8 hr
or 1 day1
350 hr
or 2
month1
2000 hr
or 1 year1
Procedure or
Quantity Specification
No. Description
13 Base Arm Capscrews X Tighten if Required Torque to
300 N•m (221 lbf ft)
14 Steering Bearing L 1 Lube Fitting Multipurpose
Grease3
15 Drive Unit Gear Oil X C 0.18 liter (6 oz) SAE 80W-90 Gear
Oil
1Whichever comes first.
2Equalization Charge approximately each month but not more than each week.
3Use Mobilgrease® 28 synthetic extra-protection grease for standard, freezer, and cold storage
configurations.
4Use ISO VG 46 antiwear (HCE-140) for standard configurations. Use Exxon Univis® HVI 26 (synthetic) for
cold storage and freezer configurations.
X=Check C=Change L=Lubricate A=Adjust
Maintenance Procedures Every 8 Hours or Daily
WARNING
DO NOT operate a lift truck that needs repairs. If a
repair is necessary, put a DO NOT OPERATE tag
in the operator's area. Remove the key from the
key switch.
Disconnect the battery connector before remov-
ing the MDU cover. Personal injury or equipment
and tool damage can occur if the battery is not
disconnected.
The capacitor in the traction motor controller can
hold an electrical charge after the battery is dis-
connected. To prevent electrical shock and injury,
discharge the capacitor before inspecting or re-
pairing any component. See Special Precautions.
Inspect the lift truck every 8 hours or daily before
use. Put the lift truck on a level surface. Lower the
carriage and forks, and turn the key switch to the
OFF position.
CHECKS BEFORE OPERATION
Make the following checks:
• Safety labels in place and legible
• Battery electrolyte level
• Make sure the battery is clean and is the cor-
rect size and weight for the lift truck
• Condition of the wheels and tires
• Condition of the forks, carriage, and mast
• Oil level in the hydraulic reservoir
• Leaks in the hydraulic system
If repair is required, DO NOT operate a lift truck
until the problems are corrected.
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379
12

HOW TO MAKE CHECKS WITH KEY
SWITCH OFF
Safety Labels
WARNING
If labels that have warnings or instructions are
damaged, they must be replaced immediately.
Check that all safety labels are installed in the
correct locations on the lift truck. Make sure that
all labels are not damaged and that they can be
read. If necessary, see the PARTS MANUAL for
your lift truck for the correct location of the labels.
Safety labels are installed on the lift truck to give
information about possible hazards. It is important
that all safety labels are installed on the lift truck
and can be read. If labels are missing or damaged,
replace. See the Parts Manual for label replace-
ment for your lift truck.
Put the lift truck on a level surface. Lower the forks
and turn the key switch to the OFF position. Dis-
connect the battery. Open the drive unit compart-
ment cover. Check for leaks and conditions that are
not normal. Clean any oil leaks or spills. Make sure
that lint, dust, paper, and other materials are re-
moved from the compartment(s).
Battery
WARNING
DO NOT lay tools on top of the battery.
DO NOT put hands, arms, feet, or legs between
the battery and a solid object. Batteries are very
heavy and can cause an injury.
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area.
Make the acid neutral with a solution of sodium
bicarbonate (baking soda). Acid in the eyes must
be immediately flushed with water continuously
for fifteen minutes, then seek medical attention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT make
a spark from the battery connections. Disconnect
the battery when performing 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 ca-
bles.
Check that the vent caps are clear. Check the elec-
trolyte level daily on a minimum of one cell. If one
cell is low, check the rest of the cells. Check the
level when the electrolyte has stabilized. Check the
electrolyte level on all cells every week. Fill to the
correct level. The correct level is generally halfway
between the top of the plates and the bottom of the
fill hole. Refer to the battery manufacturer's recom-
mendations. Add only distilled water.
Check the battery case, connector, and cables for
damage, cracks, or breaks. See the battery dealer in
your area to repair any damage. Keep the battery
case and the battery compartment clean and pain-
ted. Leaks and corrosion from the battery can cause
a malfunction in the electric controls of the lift
truck. Use a water and soda solution to clean the
battery and the battery compartment. Keep the top
of the battery clean, dry, and free of corrosion.
8000 SRM 1379 Maintenance Procedures Every 8 Hours or Daily
13

Make sure the battery is the correct weight and
size. Prevent side-to-side movement of the battery
by adjusting the brackets on either side of the bat-
tery. See the section Capacities and Specifica-
tions 8000SRM1380. The proper battery specifica-
tions are provided in Battery Maintenance in this
section and in the Operating Manual. The Oper-
ating Manual is located in the container on the
drive unit cover. This is a permanent reference and
must be available for use at all times.
Brake
Fully raising or lowering the control handle will ap-
ply an electrical brake that is mounted on the drive
motor. See Figure 7. When the brake is applied, a
switch disconnects the power to the traction circuit.
When the control handle is released from the oper-
ating position, it will automatically return to the
vertical position and apply the brake.
Figure 7. Brake Operation
Tires and Wheels
CAUTION
If the drive wheel has been removed and installed,
check all wheel bolts after 2 to 5 hours of opera-
tion. Tighten the bolts in a cross pattern as shown
in Figure 13. Tighten the bolts to the value shown
in the . When the bolts stay tight after 8 hours, the
interval for checking the torque can be extended
to 350 hours.
Inspect the drive tire and load wheels for damage.
Inspect the tread and remove any objects that will
cause damage. See Figure 8. Inspect the wheels for
loose or missing parts. Remove any wire, strapping,
or other material wound around the axles.
1. REMOVE NAILS, GLASS, AND METAL
2. MAKE EDGES SMOOTH
Figure 8. Tire and Wheels Inspection
Mast, Forks, and Lift Chains
WARNING
When working on or near the mast or carriage,
see Safety Procedures When Working Near Mast.
DO NOT try to correct fork tip alignment by bend-
ing the forks or adding shims. Never repair dam-
aged forks by heating or welding. Forks are made
of special steel using special procedures. Replace
damaged forks.
Adjust the forks as far apart as possible for maxi-
mum support of the load. Hook forks are connected
to the carriage by hooks and lock pins. These lock
pins are installed through the top fork hooks and fit
into slots in the top carriage bar. Raise the lock pin
in each fork to slide the fork on the carriage bar.
See Figure 9.
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379
14