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.

Gauges and Lights
(See Figure 10)
Start the engine. Check that the gauges and lights
operateasdescribedin Table 1. Checkthehorn.
Powershift Transmission
ShiftthetransmissionfromFORWARDtoREVERSE
severaltimes. TheMonotrolpedal ordirection con-
trollevershouldworksmoothly.
Brakes (Items 13 and 14)
A.Depressthe brake pedal completely.The brakes
should be applied before the pedal reaches the
floorplate. The brake pedal should stop firmly and
notcreep downwhen held.The brakesshould apply
equally.
FIGURE10.GAUGES ANDWARNING LIGHTS
WARNING
Loss of fluid from the master cylinder
indicates leakage. Repair before using.
Keep the brake fluid clean. Replace all
fluid in the system if there is dirt, water
or oil in the system.
B.Check theoperationof theparkingbrake. Afirm
pullshould benecessary toapplyandholdthelever.
Parkthelifttruck on a grade and applytheparking
brake. The parking brake should hold a loaded lift
truck on a 15% grade. To adjust the parking brake,
turnthe knobon theend ofthe lever.Whenthelever
isreleased, thebrakeshoes shouldnotdrag. Apply-
ingthe parkingbrake allowstheenginetobestarted
andputsthe powershifttransmissioninNEUTRAL.
Steering System
The steering system components should operate
smoothlywhenthesteeringwheelisturned.

Do NOT operate the lift truck until the prob-
lemsarecorrected.
TABLE 1. INSTRUMENT PANEL (See Figure 10)
CAUTION
Ifanyoftheinstrumentsdo not operate
as described in the following chart, re-
portthe problemsimmediately.

NOTE
Someparts oftheuprightmoveatdiffer-
ent speeds during raising and lowering.
All components should move smoothly
withoutjerking.
B.Allweldmentsandthecarriageshouldlowercom-
pletely. The lift cylindershouldreach the end ofits
stroke before the stop for the inner channel is con-
tacted.Theliftchain(s)mustbeadjustedifthestopis
contactedbeforetheliftcylindercompletelyretracts.
C.Raise andlowerthe uprightwitha capacityload.
Theuprightshould raise andlowersmoothly. If the
loaddriftsdownward whenthelift/lower leverisin
NEUTRAL,theremaybealeakinthehydraulicsys-
tem.
D.With theloadlowered, tilt theuprightbackward
andforward.Theuprightshouldtiltsmoothlyandboth
tiltcylindersshouldstopevenly.Excessivemovement
ofthetiltcylinderswhenthetiltleverisinNEUTRAL
mayindicatealeakinthesystem.
Attachments
Hydraulic attachments should operate smoothly.
Checkclampattachmentwithaloadraisedslightlyto
makesure theclampingaction ismaintained. There
shouldbe noleakage.
FIGURE11. CHECKINGTHE HYDRAULIC
SYSTEM
Hydraulic System (Item 1)
Checkthehydraulic oillevelwith thecarriagelow-
eredandthe engineOFF. Make suretheoil is atop-
eratingtemperature.Thedipstickhasthreemarks(see
Figure11). Addoilonly as requiredoroil will flow
outofthe breather.
WARNING
The operating temperature for the hy-
draulicoilis130°to200°F(54°to 93°C).
Uprights (Item 11)
A.Slowlyraise andlowerthe upright severaltimes
withoutaload.Theuprightshouldraiseandlowerin
thecorrect sequencewithoutjerking.

NOTE
Dothe8 hourprocedureplusthe follow-
ing:
ENGINE OIL AND FILTER
CAUTION
Neverruntheenginewithout oil.
Changetheoilfilteratthesametimetheengineoilis
changed.Use thecorrectoilaccordingthethespeci-
fication.Installanewfilter.Applycleanoiltothegas-
ket of the new filter. Turn the filter until the gasket
touches, then hand tighten 1/2 to 3/4 turn. Start the
engine.Check theareaaroundthefilter forleakage.
BRAKE FLUID (Item 13)
Removethe floorplates. Checkthefluidlevelinthe
reservoirofthe master cylinder. Add brake fluidas
necessary.Fillto8 mm(0.3 inch)of therim. Usethe
brakefluidshowninthe MaintenanceChart.
WARNING
Ifthemaster cylinder isempty,thereisa
leak in the brake system. The defect
mustberepairedbeforeoperatingthelift
truck. See THE BRAKE SYSTEM and
THE MASTER CYLINDER for repair
EVERY 350 HOURS OR TWO MONTHS
instructions. WARNING
Donotpermitwater,oil,ordirttoenter
the brake fluid. Replace all the fluid in
the brake system if there is oil, water or
dirtinthefluid.Ifthere is air in the sys-
tem,see THE BRAKE SYSTEM for in-
structionstoremovetheair.
HYDRAULIC TANK BREATHER
Cleanandcheckthehydraulictankbreather.Replace
thefilter whenit isdirtyandwillnotpermittheeasy
passageofair.
FORKS
WARNING
Neverrepairdamagedforks by heating,
welding or bending. Replace damaged
forks.
A.Checktheheelandattachmentpoints ofthe forks
withapenetrantormagneticparticleinspection.
B. Measure the thickness of the forks at a vertical
sectionwhere thereis nowear. Thisis dimensionX.
Nowmeasure thethickness attheheelofthefork.If
thethickness isnotmore than90%of dimensionX,
replacethefork.
C. Check for greater than the maximum angle per-
mittedatthe loadcenter of thefork.
FIGURE 12. CHECKING THE ANGLE OF THE FORKS

UPRIGHTS
WARNING
Do not work under a raised carriage.
Lowerthecarriageoruseasafety chain
to prevent the carriage from lowering
when servicing the uprights and lifting
chains.
A.Lubricate thesliding surfacesasshowninFigure
13. Apply lubricant only to the indicated surfaces.
Donot lubricatetherollingsurfacesof theload roll-
ers. Lubricant on the load rollers can hold dirt and
preventthe loadrollersfrom turning.Flat areaswill
wearontheloadrollerswhentheydo notturnfreely.
B.Lubricatethelatches(free-liftuprights).Checkfor
brokenspringsanddamagedparts.Replaceanyparts
thataredamagedormissing.
C. Lubricate the two grease fittings for the upright
pivots.
NOTE
Theloadrollers andsheaveshavesealed
bearingswhichdonotneedadditionallu-
brication.
FIGURE13. UPRIGHTLUBRICATION FIGURE 14.UPRIGHTLATCHES

OTHER LUBRICATION POINTS
Lubricatethehoodhinges,pins,linkages,cables,ped-
als,andleversasnecessary.UseSAE30oilandmulti-
purpose grease as needed.
EVERY 1000 HOURS OR SIX MONTHS
FINAL FUEL FILTER (DIESEL)
(Item 4)
Change the fuel filter as needed. The frequency of
changingthefuelfilterisaresultoffuelquality.
A.Cleantheareaaround thefinalfuelfilter.
B.Removethe bolt in thecenterof the topcoverof
thefilter.
C.Lower thebottom ofthefilterandremovethefil-
terelement.Discardthefilterelement.
D.Clean thetopandbottomcovers.Installnewgas-
kets.Installanewfilter elementandtightenthebolt.
E.Remove theair fromthefuelsystemasdescribed
inREMOVINGAIRFROMTHEFUELSYSTEM.
REMOVINGAIRFROMTHE
DIESEL FUEL SYSTEM (See
Figure 16)
Airmustberemovedfromthedieselfuelsystemifthe
enginehasrunoutoffuelorwhenafuellinehasbeen
disconnected. Remove air from the fuel system as
follows(SeeFigure16):
CAUTION
Do not start the engine until air is re-
movedfromthefuelsystem.
FIGURE15.FINAL FILTER

F.Loosenthenuts forthelines attwo injectors.
G. Start the engine. Tighten the nuts to 20 N.m (15
footpounds) whenfuel,without airbubbles,comes
fromthethreads.
IGNITION SYSTEM (GAS ENGINE)
Replacethespark plugsandcheck theignitiontim-
ing.Adjust asnecessary.
PCV VALVE (GAS ENGINE) (Item 24)
Checktheoperation ofthePCV system.
Makesureairwillflowthroughthevalveandairhose.
A bad PCV system will cause one or more of the
followingconditions:
1.Roughidle
2.Oil intheaircleanerduct
3.Oilleaks
4.Engineoilwillbecomedirtymorequickly
thannormal
A.Loosen ventscrewA atthefuel injectorpump.
B.Loosenvent screw B atthepump.
C.Operatetheleverunder thefuelpump.Whenfuel
that is without air bubbles comes from each screw,
closetheventscrewsin thefollowingsequence.
1.Vent screwB
2.Ventscrew A
D.Loosenthetop nut C for the fueltubeatthe fuel
injectorpump.
E. Operate the lever under the fuel pump until fuel
withoutbubblescomesoutofthethreads.Tightenthe
nut.
FIGURE16.REMOVING AIR FORM THE
DIESELFUEL SYSTEM

PCV VALVE (GAS ENGINE) (Item 24)
Change the PCV valve. Make sure air will flow
throughthesystem. ThePCV system willneed ser-
vicemorefrequentlyduringthefollowingconditions:
l.Operationofthelifttruckindustyconditions
2.Engine operatesatidle forlong periods
3. Engine operates at cool temperatures for
short periods and does not reach operating
temperature
PCV VALVE (DIESEL ENGINE)
(Item 24)
Clean or change the PCV valve. Remove the PCV
valve from the engine for cleaning. Seal the small
breatherhole(l) topreventfillingthecavitywithsol-
vent.Flushthevalvepassagewithkeroseneordiesel
fuel.Check thatthebreatherholeis clean.
EVERY 2000 HOURS OR YEARLY
FIGURE17.PCV VALVE
FIGUREl8. PCVVALVE (DIESELENGINE)

DIFFERENTIAL (Item 21 or 22)
Checktheoillevelfortheoilclutchtransmissionand
differential.Removethe plug for theoillevelhole.
Theoillevelmustbeevenwiththebottomofthehole.
Addthecorrectoilthroughtheholeifthelevelislow.
Installandtightentheplug.
Checktheoil levelforthe differential forlifttrucks
withpowershift transmissions.Remove theplug for
theoillevelhole.The oillevelmustbeevenwiththe
bottom of the hole. Add the correct oil through the
holeifthelevelislow.Installandtightentheplug.
FIGURE 19. CLUTCH LINKAGE ADJUSTMENT
ADJUSTING THE OIL CLUTCH
PEDAL
Theclutchpedal must be adjustedsothatthe pedal
armdoes nottouchthebottomofthefloorplate.See
Figure19.Theremustbe1.6mm(0.0625inch)clear-
ance between the top of the pedal arm and the bot-
tom of the floor plate. The distance from the top of
thefloorplatetothe bottomofthepedalpadmustbe
136mm(5.38inch).Toadjusttheheightofthepedal,
loosen the lock nut that is on the capscrew on the
shaftbracket.Turnthecapscrewuntilthepedalheight
iscorrect.Tightenthelocknut.
When the clutch pedal height is correct, adjust the
clutchreleaselinkage. The pedalmustmove freely
13mm(0,5inch)fromitsstop tothe pointwherethe
release bearing touches the pressure plate levers.
Removethepedal returnspring. Move thepedal up
anddownandmeasurethetravelbetween thepoints
ofresistance.Adjustthelengthofthethreadedrodto
changetheamountofmovementofthepedal.Loosen
thelocknut on therod.Remove the cotterpinfrom
the dowel on the pedal arm. Pull the rod from the
dowel.Turn the rodtochange its length. Installthe
rod on the dowel and measure the pedal travel. In-
stallanewcotterpinwhenthepedaltraveliscorrect.
Installthepedalreturnspring.
HYDRAULIC SYSTEM (Item 1 and
25)
Changing The Hydraulic Oil Filter
Thehydraulicfilterhastwoelements:Ascreenwhich
can be cleaned and a paper element which must be
replaced.
A.Remove thecapscrewsthatholdthefilterheadto
thetank.Remove thefilterassembly fromthetank.
Removethefittingfromthefilterhead.
WARNING
A spring pushes on the filter head and
bowl.Be carefulwhenremovingthefour
screws.
B.Removethe4 screws that hold the filterbowlto
thehead.See Figure 20.

Changing The Hydraulic Oil
A.Put thelifttruckona levelsurface. Lowerthe lift
cylinder.Putadrainpanunderthelifttruck.Anaddi-
tionaldrain panisused toreplace thefirstpan when
thefirst isfull.A containerwith a49.2litre (13 gal-
lon)capacityisneededasareservoirfor theusedoil.
WARNING
The hydraulic oil can be hot. Be careful
whendraining theoil.
B.Putthe pan under thedrainplug of thehydraulic
tank.Removethedrainplug.
C.Whentheoilhasdrained,installthedrainplug.Fill
the tank as described in CHECKING THE HY-
DRAULICOIL.
CHANGING THE GASOLINE FUEL
FILTER
Replace the filter element for gasoline every 2000
hours.SeeFigure 3.
CHANGING THE FUEL FILTER
FOR LPG
Removethe filterfromthefilterunit asdescribed in
theLPGSYSTEM.
FIGURE20. HYDRAULICOILFILTER
C.Remove thepaperelement.Removethenutfrom
thebolt inthecenter. Removeandclean thescreen.
D.Installthescreenandfilterholder.Installthepaper
element.Usenew gasketsandO-ringsandinstallthe
filterbowland cap.Pushonthefilterheadandinstall
the4screws.
E.Installa newgasketand install filterassemblyin
thetank. Tightenthe capscrews. FIGURE21.LPG SYSTEM