Hyster F003 Operating instructions

Hyster F003 (H2.00J H2.50J H3.00JS Europe) Forklift

GENERAL
This section has the instructions that are necessary
forcorrectperiodicmaintenance.Thissectionhastwo
parts:Maintenance Scheduleand MaintenancePro-
cedures. The Maintenance Schedule has the maxi-
mumtimeintervalsbetweenmaintenancechecks.The
MaintenanceProcedureshastheinstructionsfordo-
ingthemaintenancechecks.
MAINTENANCE SCHEDULE
TheMaintenance Scheduleisaprogramthat
INTRODUCTION
includes periodic inspection and lubrication. The
scheduleuses theoperatinghoursonthehourmeter.
The table for the Maintenance Schedule has two
schedules;thehour schedule and theperiodsched-
ule.Ifthelifttruckisoperated morethan eighthours
eachday,the hour schedule mustbeused. If the lift
truckisoperated less thaneighthours each day,the
periodschedulemust beused. The itemnumbers in
thecolumn ontheleft oftheMaintenance Schedule
areused withFigure1.
CAUTION
The maintenance schedules are made
according to the maximum service
intervals.Servicethelifttruckmoreoften
whenoperating inbadconditions.
FIGUREl.MAINTENANCE POINTS

MAINTENANCE SCHEDULE

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Putthelifttruckonalevelsurface.Completelylower
the carriage and forks. Stop the engine. Open the
hood.
CHECKS WITH THE ENGINE
STOPPED
General WARNING
Inspect the lift truck every eight hours
ordailypriorto use.
Report damage or faulty operation im-
mediately.
Donot operatethelifttruckuntilrepairs
aremade.
If repair is necessary, put a tag in the
operator’sarea, DONOTOPERATE.
Remove the key.
Beforestarting theengine,makesurethelifttruckis
clean.Cleanany oilorfuel spills.Checkthe engine
compartment and clean any dust, paper, lint, oil or
othermaterials.
WARNING
Do not use combustible agents or sol-
vents for cleaning. Observe the
manufacturer’scautionsregardingven-
tilation,firesafetyandtoxicity.
Hydraulic System
Checkthehydraulicsystemforleaksand damageor
loosecomponents,linesandfittings.
CAUTION
Never operate the engine without oil in
thehydraulicsystem.Afewrevolutions
without oil can damage the hydraulic
pump.
Checkthehydraulic oillevelwith thecarriagelow-
eredandthe engineOFF. Make suretheoil is atop-
eratingtemperature.Thedipstickhasthreemarks(see
Figure2).Addoilonlyasrequiredoroilwillflowout
ofthe breather.
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY
WARNING
Theoperatingtemperatureforthehydraulic
oil is 130° to 200° F (54° to 93° C).
Air Cleaner (Item 2)
Clean orreplace the airfilter asnecessary. To clean
theairfilter,tapthefilterelementuntildirtisremoved
fromtheelement.Donotusecompressedairtoclean
the filter element. Clean the inside of the cannister
whenchangingfilters.
Engine Oil (Item 3)
The oil in the crankcase must be kept between the
AddandFull mark on thedipstick.Stopthe engine
beforecheckingthe oil level. Removethedipstick;
wipeitclean, then insertitall the wayandagain re-
moveitto takethereading. Add oilasrequired, but
donotoverfill.
Fuel Filter (Diesel) (Item 4)
Drainthewater from the primaryfilterdaily.Open
thevalveon the bottom ofthefilter and drainsome
fueland anywaterinto acup.Close thevalve.
FIGURE2.CHECKING THEHYDRAULIC
SYSTEM

Battery (Item 5) WARNING
Disconnect the ground cable at the bat-
terybeforeperforminganyworkonthe
electrical system.
Checktheelectricalsystemforbrokenorloosewires
and terminals. Check the battery case for cracks.
Keep the battery and cable terminals clean. Check
themelectrolytelevel.Keeptheelectrolytelevelabove
theplates. Usedistilledwater.Donotfill thebattery
pastthebottomoftheinternalfiller neck.
Cooling System (Item 6)
Checkthehoses for cracksorleaks. Make surethat
allthe clampsare tight.Keep thecoolant levelin the
radiatortothefullmarkonthecoolantrecoverytank.
Filltheradiatorwitha solutionofanti-freeze(Ethyl-
ene-Glycoltype)andwater.Periodic addingofcool-
antmustbe doneatthecoolantrecoverytankONLY.
Whenevertheradiator is to bedrainedand refilled,
fillthroughradiatoruntilfull,replacecap,thenfillcool-
antrecovery tanktoFull mark.
WARNING
Donotremovethecapfromtheradiator
orcoolantrecoverytankwhentheengine
is hot. Steam and boiling coolant can be
released when the cap is removed caus-
ingsevereburns.
CAUTION
Never add cold water to an overheated
engine.Cooltheenginebyallowingitto
idle as coolant is added to the radiator.
Continuethisprocedureuntilthe gauge
indicatesanormaloperatingtemperature.
Drive Belts (Item 7)
Checkthetensiononthedrivebeltforthewaterpump
andthealternator.Push withapproximatelya l l kg
(25lb)forceinthemiddleofthe longestdistancebe-
tween pulleys. When the tension is correct, the fan
beltwillmove tol3-l7mm(1/2to5/8inch).Adjust
thealternatorsupport bracket to adjustthebelt ten-
sion.Movethealternatortogivethe correctbelt ten-
sionandtightenthecapscrew(diesel).Adjusttheidler
pulleyto givethecorrect tensionof thefanbelt (gas
engine).
FIGURE 4. MAINTENANCE POINTS
(GASENGINE)
FIGURE 3. MANTENANCE POINTS

Tires and Wheels (Item 8)
WARNING
Air pressure in tires can cause tire and
wheel parts to explode. This can cause
seriousinjuryor death.
Tiresmustberemovedandinflatedina
safetycageif the airpressureislessthan
80%ofthecorrectpressure. Followpro-
ceduresunderCHANGINGTIRES.
Deflatetiresbeforeremovingthemfrom
thelifttruck.
Checkthetires fordamage.Check the treadandre-
moveany objectsthat willcause damage.Check for
bent or damaged rims. Check for loose or missing
hardware.Remove anywire,strappingorother ma-
terial that may be wrapped on the axle. Keep the
tiresat thecorrect airpressure. Usea gaugeto check
theairpressure whenthetires arecold.
FIGURE7.CHECK THE TIRES
FIGURE 6. MAINTENANCE POINTS
(DIESELENGINE)
FIGURE 5. MAINTENANCE POINTS
(DIESELENGINE)

Whenaddingairtotires,useequipmentwithagauge
or preset pressure regulator and a clip-on chuck.
Makesure thehoseislongenough toavoid beingin
thepathof thewheel parts incase of anexplosion.
WARNING
Stay clear of the path of wheel parts in
case of an explosion.
If it is necessary to add air to a tire that is warm,
checkoneofthe other tires. Add air tothetirewith
lowpressureso thattheair pressuresareequal. The
tirepressureofwarmtiresmustalwaysbeequaltoor
greaterthan tirepressure specifiedforcoldtires.
Checkthatall of the wheelnutsare tight. Whenthe
wheels are removed and installed again, check the
nuts for the correct torque as shown in MAINTE-
NANCEevery eighthours. Whenthe nutsstay tight
after an eight hour check, the interval for checking
withatorque wrenchcan be extendedto 350 hours.
Lift Mechanism
WARNING
Lower lift mechanism completely. Never
stand under a raised carriage.
Do not put any part of the body in the lift
mechanism unless all parts of the upright
are completely lowered and the engine is
OFF.
Always block or chain the upright weld-
ments and carriage before inspecting the
upright or attempting any repairs.
Forks (Item 9)
A.Check thatthetipsarealignedwithin13mm(0.5
inch)of eachother(I).
WARNING
Do not try to correct the alignment by
bending the forks or adding shims. Re-
place bent or damaged forks.
B.Checkforcracks(2)inthe heelof theforksandat
theattachmentpoints.
WARNING
Neverrepairdamaged forks by heating
or welding. Forks are made of special
steel using special procedures. Replace
damagedforks.
C. Check for cracks (2) or damage (4) in the fork
hooksorpins. Replace asnecessary.
Lift Chain (Item 10)
A.Check theliftchainfortheproperlubrication.
B. Inspect the lift chain for cracks or broken links
and pins. Check for corrosion or worn holes in the
links.Whenthepinsorholesbecomeworn,thechain
becomes longer. If a section of chain is 3~q longer
thanthesection ofnew chain, thechain is wornand
mustbereplaced.
If a chain scale is available, check the lift chain as
shown.Ifa chain scaleisnot available, measure20
linksofchain. Comparethelength with thechartin
Figure9.Replacethechainifthelengthof201inksof
thewornsectionismorethanthemaximumwearlimit.
WARNING
If one chain has a defect, replace both
chains.Donottrytorepairawornchain.
D.Checkeach latchfor proper operation.The latch
shouldsecurely locktheforktothe carriage.
FIGURE 8. CHECK THE FORKS

C.Inspectthechainanchorsforcracksorwornholes.
Replacechainanchorpinsthataredamagedorworn.
Replacebroken ormissing cotterpins.
D. Inspect chains for proper adjustment. Chains
shouldbeequallytight.
Upright (Item 11)
A.Checktheweldson theuprightsforcracks.Make
surethat allthenutsandbolts aretight.
B.Check thechannels forwear orgouging inthe ar-
easofroller contact. Checktherollers for flatspots
ordamage.
C. Check the sliding surfaces on the crosshead for
lubricationandwear.
D. Inspect upright latches (if equipped). Lubricate
latches. Replace broken springs or other damaged
parts.
Carriage
A.Checktheweldsonthecarriage forcracks. Make
surethat allnuts andboltsaretight.
B.Check thatthe rollersand carriagemove freelyin
theuprightchannels.
C.Checkhydraulicattachmentsforleaksordamage.
FIGURE 9. CHECKING THE CHAINS
Load Backrest Extension
A.Checkthewelds for cracks
B.Makesure thatall nuts andbolts are tight.
Powershift Transmission
Checkthetransmissionlines and fittings for leaks.
Makesurethatfittingsandclampsare tight.
CHECKS WITH THE ENGINE
RUNNING
WARNING
Makesurethe area aroundthelifttruck
is clear before starting the engine or
makinganychecks.Proceed carefully.
Checktheinterlockswitches. The engine will start
duringthefollowingconditions:
•OilClutchTransmission
The“FORWARDandREVERSE” lever must
beinthe“NEUTRAL”position.
•PowershiftTransmission
Theparking brakemust beappliedorthebrake
pedalmustbe pusheddown.