Hyster G118 User manual

Hyster G118 (R30XM2, R30XMA2, R30XMF2) Forklift

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R30XMS2 [D174];
R30XM2/XMA2/XMF2 [G118]
PART NO. 1490103 8000 SRM 924

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 whenmaking 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), andDiesel 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!

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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 the Drive Tire ..................................................................................................................... 2
How to Raise the Load Wheels................................................................................................................. 3
Maintenance Schedule....................................................................................................................................... 4
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 6
How to Make Checks With Key Switch in the OFF Position...................................................................... 6
Hydraulic System...................................................................................................................................... 6
Battery....................................................................................................................................................... 7
Mast, Platform, Forks, and Lift Chains................................................................................................... 7
Tether Line and Belt ................................................................................................................................. 8
Pallet Clamp.............................................................................................................................................. 8
Tire, Wheels, and Caster........................................................................................................................... 8
How to Make Checks With Key Switch in the ON Position........................................................................ 9
Gauges, Lights, Horn, and Fuses............................................................................................................. 9
Fuses.......................................................................................................................................................... 9
Switches and Direction/Speed Control..................................................................................................... 10
Lift System Operation............................................................................................................................... 11
Brake.......................................................................................................................................................... 11
Steering System ........................................................................................................................................ 11
Maintenance Procedures Every 350 Hours or 2 Months................................................................................. 11
Brake.............................................................................................................................................................. 11
Electrical Cable Sheaves............................................................................................................................... 11
Hydraulic Tank Breather.............................................................................................................................. 11
Electrical Inspection...................................................................................................................................... 12
Contactors.................................................................................................................................................. 12
Motor Brushes........................................................................................................................................... 12
Safety Labels.................................................................................................................................................. 13
Mast................................................................................................................................................................ 13
Check for Leaks in Lift System..................................................................................................................... 14
Check Lift Cylinders for Leaks................................................................................................................. 14
Lift Chains ..................................................................................................................................................... 14
Maintenance Procedures Every 2000 Hours or Yearly.................................................................................... 16
Master Drive Unit ......................................................................................................................................... 16
Steering Chain............................................................................................................................................... 16
Wheels and Bearings..................................................................................................................................... 16
How to Change Hydraulic Oil and Filter ..................................................................................................... 16
Battery Maintenance......................................................................................................................................... 18
How to Charge Battery.................................................................................................................................. 18
How to Change the Battery........................................................................................................................... 19
General....................................................................................................................................................... 19
Battery, Remove ........................................................................................................................................ 19
Battery, Install........................................................................................................................................... 19
Wheels and Tires................................................................................................................................................ 21
How to Change Drive and Steer Tires.......................................................................................................... 21
How to Replace Load Wheels........................................................................................................................ 22
©2002 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
This section is for the following models:
R30XMS2 [D174];
R30XM2/XMA2/XMF2 [G118]
ii

8000 SRM 924 General
General
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance. The time
intervals are based on a normal operation. A nor-
mal operation is considered to be one 8-hour shift
per day, in a relatively clean environment, on an im-
proved surface. Multiple shifts, dirty operating con-
ditions, etc., will require a reduction in the recom-
mended time periods in the Maintenance Schedule.
Some users have service personnel and facilities to
do the items listed in the Maintenance Schedule.
ServiceManualsareavailablefromyourHyster
lift truck dealer to help users who do their own
maintenance.
Your Hyster lift truck lift truck dealer has the per-
sonnel and equipment to do a complete program of
inspection, lubrication, and maintenance. Periodic
maintenance will help your lift truck operate better
over a longer period.
WARNING
Do not make repairs or adjustments unless
you have both authorization and training.
Repairs and adjustments that are not correct
canbemadeonalifttruckbypeoplewith-
out authorization and training. Repairs and
adjustments that are not correct can make a
dangerous operating condition.
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
in the operator’s area. Remove the key from
the key switch.
Put the lift truck on a level surface. Lower the plat-
form and forks, apply the parking brake, and turn
the key switch to the OFF position. Open the ac-
cess panels and check for leaks and conditions that
are not normal. Clean any oil or other spills. Make
sure that lint, dust, paper, and other materials are
removed from the compartments.
HOW TO MOVE A DISABLED TRUCK
WARNING
To avoid personal inury or property damage,
use extra care when moving a lift truck if there
is a problem with any of the following condi-
tions:
•Brakes do not operate correctly.
•Steering does not operate correctly.
•Tires are damaged.
•Traction conditions are bad.
•The lift truck must be towed on a steep grade.
Poor traction can cause the disabled lift truck
or towing vehicle to slide. Steep grades will
increase the required brake effort.
NOTE: Always remember there may be problems
with more than one of the above areas of the truck.
Do not tow the lift truck if you have not identified
all problem areas.
The best way to move the lift truck is to use another
lifttrucktoraisethedrivetireofftheground.This
willallowthelift truckto betowedorpushed around.
Whatever method is used, the important thing to re-
member is to travel slowly.
If there is no electrical power, there is no steering
and the brake will be applied. If the lift truck is in-
operable, the brake will have to bereleased using two
1/4-20 × 1-1/2 inch bolts. Poor traction can cause the
disabled lift truck or towing vehicle to slide. Steep
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 ex-
tend the full width of the disabled lift truck. Center
theweightofthedisabledlifttruckontheforksand
be careful not to damage the underside of the dis-
abled lift truck. Tilt the mast back and travel slowly.
1

General 8000 SRM 924
How to Tow the Lift Truck
CAUTION
Do NOT tow the lift truck by fastening a towing
device to the attachment or base arms. Make
sure the guidance sensors are not damaged
when connecting a chain to the lift truck.
1. If the lift truck must be towed, the operator must
be on the lift truck to release the brake and steer
the lift truck. If the lift truck is inoperable, re-
lease the brake using two 1/4-20 × 1-1/2 inch
bolts.
2. Tow the lift truck slowly.
3. Raise the platform approximately 30 cm (12 in.)
from the surface. Install a chain to prevent the
platform and mast channels from moving.
4. 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.
Ifthelifttruckusedfortowinghasa masterdrive
unit or drive unit similar to the R30XM2/XMA2/
XMF2/XMS2, do NOT add weight to the forks.
Additional weight on the forks will 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.
5. Make sure the tow chain has the capacity to tow
the weight. Carefully fasten the tow chain to the
drive unit end of the lift truck. Make sure the
chain is fastened so that the chain will not cause
damage to either lift truck.
HOW TO PUT A LIFT TRUCK ON BLOCKS
How to Raise the Drive Tire
WARNING
Thelifttruckmustbeputonblocksforsome
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, battery,
and master drive unit.
Do NOT put the lift truck on blocks if the sur-
face isnotsolid, even, andlevel. Makesure 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 the overhead guard or areas
of the mast that will be damaged. Some of
these components and other lift points are
not designed to support the weight of the lift
truck. The lift truck can be damaged or it can
fall on someone causing serious injury. Attach
the chain or sling to a support structure of the
lift truck frame.
CAUTION
Make sure the sensors are not damaged on
trucks that have wire guidance.
1. Put blocksoneachside(frontandback)ofthe
loadwheelstopreventmovementofthelifttruck.
See Figure1.
2. Usea speciallow clearancehydraulic jack, crane,
or another lift truck to raise the drive tire. Make
sure that the jack, crane, or other lift truck has
the correct minimum capacity rating. The capac-
ity must equal at least 2/3 the weight of the lift
truck including the battery. See the nameplate.
3. Raise the lift truck only enough to suspend the
drive tire. Install additional blocks under the
frame near the drive tire.
2

8000 SRM 924 General
How to Raise the Load Wheels
WARNING
Never raise the base arms any higher than nec-
essary 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.
CAUTION
Make sure the sensors are not damaged on
trucks that have wire guidance.
1. Putblocksonbothsides(frontandback)ofthe
drive tire to prevent movement of the lift truck.
SeeFigure1.
2. Use a hydraulic jack, crane, or another lift truck
to lift the base arms. Make sure that the jack,
crane, or other lift truck has a capacity equal to
at least half the weight of the lift truck including
the battery.
3. Put blocks under the base arm at the rear of the
load wheel to support the lift truck.
NOTE: R30XMS2 IS ON THE LEFT, R30XM2/XMA2/XMF2 IS ON THE RIGHT.
1. DRIVE/STEER WHEEL 2. LOAD WHEEL
Figure 1. How to Put Lift Truck on Blocks
3

Maintenance Schedule 8000 SRM 924
Maintenance Schedule
Figure 2. Maintenance Points
Table 1. Maintenance Schedule
Item
No. Item 8hr/
1day 350 hr/ 2mo 2000 hr/ 1yr Procedure or Quantity Specification
1Hydraulic Oil (Full Mark)
(Approximate)
R30XM2/XMA2/XMF2
R30XMS2
Oil Leaks
X
XC1
C1
8.5liter(2.25gal)
14.65 liter (3.87 gal)
Check for leaks
−18 to 38 C (0 to 100 F)
SAE 10W API SC/CC
2Battery
Panels - Latches
Disconnect Switch
X
X
X
2Check level
Check operation
Check operation
See Battery
Specifications
3Drive Tire and Wheels X Check condition See Parts Manual
4Forks X C Check condition See Parts Manual
5Lift Chains X L Check condition SAE-30
6Mast and Platform X Check condition
7Brake XCheck operation Hold On 5% Grade
8Gauges and Horn XCheck operation
9Steering X L Check operation Multipurpose Grease3
X=Check C=Change L=Lubricate IR=Initial Replacement
1Change oil after first 350 hours. Change oil every 1000 hours or 6 months with corrosion/freezer option.
2Equalization Charge approximately once each month but not more than once each week.
3Multipurpose Grease with 2-4% Molybdenum Disulfide.
NOTE: Never use steam to clean electrical parts.
4

8000 SRM 924 Maintenance Schedule
Table 1. Maintenance Schedule (Continued)
Item
No. Item 8hr/
1day 350 hr/ 2mo 2000 hr/ 1yr Procedure or Quantity Specification
10 Direction/Speed Control X L Check operation MIL-G-7711A or
equivalent
11 Hydraulic Tank Breather XClean or replace See Parts Manual
13 Hydraulic Pump Coupling LClean and lube Multipurpose Grease3
12 Contactor Tips XCheck condition See Parts Manual
13 Motor Brushes XCheck condition See Parts Manual
14 Safety Labels (not shown) XReplace if necessary See Parts Manual
6
4
5
16
Mast and Platform
Fork Pin and Guides
Lift Chains and Sheaves
Sliding Surfaces
L
X,L
L
As required
As required
As required
SAE 30 Oil
SAE 30 Oil
Multipurpose Grease3
17 Wheel Nut Torque XTighten if required 136 N•m (100 lbf ft)
18 Master Drive Unit X,IR C3.8 liter (1 gal) SAE 80W-90 or 85W
19 Steering Chain LAs required Multipurpose Grease3
20 Hydraulic Filter IR C1ea. See Parts Manual
21 Electrical Cable Sheaves LAs required SAE 30 Oil
22 Base Arm Bearings LAs required SAE 30 Oil
23 Pallet Clamp LAs required SAE 30 Oil
Misc. LAs required Hyster Part No. 328388
X=Check C=Change L=Lubricate IR=Initial Replacement
1Change oil after first 350 hours. Change oil every 1000 hours or 6 months with corrosion/freezer option.
2Equalization Charge approximately once each month but not more than once each week.
3Multipurpose Grease with 2-4% Molybdenum Disulfide.
NOTE: Never use steam to clean electrical parts.
5

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 924
Maintenance Procedures Every 8 Hours or Daily
HOW TO MAKE CHECKS WITH KEY
SWITCH IN THE OFF POSITION
Hydraulic System
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
in the operator’s area. Remove the key from
the key switch.
WARNING
Do not permit the hot hydraulic oil to touch the
skin and cause a burn. When the hydraulic oil
is at operating temperature, it is HOT.
CAUTION
Donotpermitdirttoenterthehydraulicsys-
tem when the filter is changed.
CAUTION
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.
Park the lift truck on a level surface. Completely
lower the mast and the forks.
Check the hydraulic oil level at the sight gauge when
the oil is at operating temperature. See Figure 3.
If the oil level is not visible at the sight gauge, the
oil level is above or below the sight gauge. Open
the door of the hydraulic compartment to check for
the correct level and fill the tank if necessary. If too
much hydraulic oil is added, the oil will leak from the
breather during operation. Clean the breather and
fill cap by removing the fill cap and flushing it with
solvent. Make sure the breather and fill cap are free
of solvent. Install and tighten the fill cap.
To drain the oil, put the lift truck on a level surface.
Completely lower the mast and forks. Use a con-
tainer with a 38 liter (10 gal) capacity near the sup-
ply hose of the hydraulic tank. Turn the key switch
to the OFF position and disconnect the battery.
Inspect the hydraulic system for leaks and damaged
or loose components.
1. FILL/BREATHER
2. PLATE ASSEMBLY
3. HOSE
CONNECTOR
4. SIGHT GAUGE
5. HYDRAULIC TANK
6. TUBE
7. FILTER ELEMENT
8. GROMMET
Figure 3. Hydraulic Checks
6

8000 SRM 924 Maintenance Procedures Every 8 Hours or Daily
Battery
WARNING
Do not put tools on the battery. Tools on the
battery can cause a short circuit and possible
damage or injury.
The acid in the electrolyte can cause injury.
If the electrolyte leaks, 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.
WARNING
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 lift truck and battery stand MUST be on a
level surface to remove the battery.
Check the level of theelectrolytedailyon a minimum
of one cell. Add only distilled water if the cell is low.
The correct level is halfway between the top of the
plates and the bottom of the fill hole. To check and
add water to the cells, the battery must be out of the
battery compartment.
Remove the battery as described in How to Change
the Battery. 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
painted. 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.
Check that the correct spacer is installed across the
mast side of the battery compartment. The spacer
must allow the battery to move not more than 13 mm
(0.5 in.) toward the front or rear of the compart-
ment. Checkthatthebatterycannot movemorethan
13 mm (0.5 in.) across the width of the lift truck.
Ifthebatterycanmovemorethanthemaximum
amount, make sure the battery is the correct weight
and the correct spacers are installed for that battery.
See your Hyster lift truck dealer for the correct spac-
ers. The correct battery is in Table 4 of Battery Main-
tenance at the end of this section. Check that each
battery compartment panel fits correctly and is not
bent.
Mast, Platform, Forks, and Lift Chains
WARNING
To avoid personal injury or property damage,
NEVER work under a raised platform or forks.
Lower the platform or use chains on the mast
weldments and platform so they cannot move.
When chains are used, make sure the moving
parts are fastened to a part that cannot move.
WARNING
Never repair damaged forks. Do not heat, weld,
or bend forks. Replace damaged forks.
Check the attachment points of the forks with a pen-
etrant or magnetic particle inspection.
CAUTION
Do not try to correct alignment of the fork tips
by bending the forks. Use shims to align the
fork tips. Replace damaged forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
dures. Replace damaged forks. Always replace forks
in pairs.
1. Inspect the welds on the mast and platform for
cracks. Make sure the nuts and bolts are tight-
ened.
2. Inspect the channels for wear in the areas where
the rollers travel. Inspect the rollers for wear or
damage.
3. Check all lift chains for the correct lubrication.
Lubricate the lift chains using the oil specified in
the Maintenance Schedule.
4. Inspect the lift chains for cracks or broken links
and pins.SeeFigure4.
7

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 924
1. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. RUST
Figure 4. Inspect Lift Chains and Cables
5. Inspect the chain anchors and pins for cracks or
damage.
6. Make sure the lift chains are adjusted so they
have equal tension. Check tension by pulling
horizontally on both chains and checking that
they move the same amount. If the chains need
repair or adjustment, it must be done by autho-
rized personnel.
7. Check that the fork tips are aligned within
13 mm (0.5 in.) of each other. See (1, Figure 5).
Add or remove shims for alignment.
8. Inspect forks for cracks and wear.
9. Replace any damaged or broken parts that keep
the forks locked in position.
1. TIP ALIGNMENT 2. CRACKS 3. FORK PIN DAMAGE
Figure 5. How to Inspect Forks
Tether Line and Belt
WARNING
To help avoid personal injury, the tether line is
specially made to lessen the shock of a fall. Do
not substitute other types of rope.
1. Inspect the tether line for wear, cuts, or damage.
Inspect the clips for cracks and proper operation.
2. Inspect the belt for cracks, cuts, or wear. The
operator must fasten the belt snuglywith the "D"
ring in the center of the back.
Pallet Clamp
Check for correct operation of the pallet clamp. Put
an empty pallet on the forks. With the forks raised
so the pallet is supported by the forks, stand on the
cornersofthepalletfarthestfrom theoperator’splat-
form. Some movement may occur, but the board un-
der the opposite fork must not raise enough to con-
tactthefork. Usemultipurposegreasetolubricate
the pawls of the pallet clamp.
Tire, Wheels, and Caster
Inspect the drive tire and load wheels for damage.
Inspect the tread and remove any objects that will
causedamage. SeeFigure6. Smoothanycutsor
tears to prevent further damage. Inspect the wheels
8

8000 SRM 924 Maintenance Procedures Every 8 Hours or Daily
and caster for loose or missing parts. Remove any
wire, strapping, or other material wound around the
axles or caster.
CAUTION
If the wheels have been removed and installed,
check all wheel nuts after 2 to 5 hours of opera-
tion. Tighten thenuts (in a crosspattern) to the
correct torque value shown in the Maintenance
Schedule table. When the nuts stay tight after 8
hours, the interval for checking the torque can
be extended to 350 hours.
Makesure thewheelnutsaretightenedto thecorrect
torque value. Tighten the nuts (in a cross pattern) to
the correct torque value shown in the Maintenance
Schedule table.
1. MAKE SMOOTH EDGES
2. REMOVE NAILS, GLASS, AND ALL METAL
Figure 6. Inspecting Tire and Wheels
HOW TO MAKE CHECKS WITH KEY
SWITCH IN THE ON POSITION
Gauges, Lights, Horn, and Fuses
WARNING
Make sure the area around the lift truck is
clear before moving the lift truck or checking
for correct operation. Be careful to avoid
injury or damage when making the checks.
NOTE: None of theelectrical controls will operateun-
til the power disconnect circuit is energized by the
key switch. See Figure 2 and Table 1.
Check that all the instruments and controls operate
as described in the Operating Manual.Checkthe
operation of the gauges and horn. The key switch
must be in the ON position to operate the horn. The
key switch must be ON and the foot switch must be
depressed for the hourmeter to operate. The battery
meter operates whenever a charged battery is con-
nected.
The battery meter correctly indicates the condition of
the battery. If the battery meter LED is illuminated
red, charge the battery. There must be a current flow
from the battery before the "lift interrupt" indicator
will be reset. Normal operation, after connecting a
charged battery, will reset the indicator.
Fuses
There are seven fuses on this truck and they are all
found on the Contactor Panel. Ratings of the fuses
are shown in Table 2.
Table 2. Fuses
Fuses Circuit Rating
FU-1 Traction 300A
FU-2 Pump 300A
FU-3 Start Circuit 5A
FU-4 Operator Compartment
light Fan and Flashing
Light
15A
FU-5 APS Power 15A
FU-6 APS Power 15A
FU-7 MCU, LS3, WGU,
and Indicator 5A
Power for the APS Steering Motor Controller is sup-
plied by fuses FU-5 and FU-6. They are wired in par-
allel to provide 30 amps to the controller so that if one
blows, the other may too. Without this current, the
controller will be disabled. The MCU will sense that
the steering controller is disabled and will not allow
thedrivemotortowork.
All the fuses are located in the electrical compart-
ment. See Figure 7. Remove the cover over the elec-
trical compartment for access. The condition of some
fuses can be checked by looking at them. Other fuses
do not change in looks and must be checked with an
ohmmeter to determine continuity. Disconnect the
battery before checking fuses.
9

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 924
Figure 7. Fuse Locations
Check that the fuses are the correctsizes and are not
burned. Some types of fuses must be checked with an
ohmmeter. If any of the fuses are bad, disconnect the
battery before replacing the fuse.
Switches and Direction/Speed Control
Check that the Direction/Speed control and the
switches for Lift and Lower operate as described in
Table 1 of the Operating Manual.Checkthatthe
foot switch and Direction/Speed control operate as
described in the Operating Procedures section of the
Operating Manual.
Check the operation of the Power Disconnect Switch.
ThelocationoftheswitchisshowninFigure8.Push
theswitchwiththekeyswitchintheON positionand
the foot switch depressed. All electrical circuits must
NOToperate. MovethekeytotheOFF,START,and
ON positions to reset the power disconnect circuit.
1. STEERING CONTROL (RETURN TO CENTER
SHOWN)
2. POSITION INDICATOR (MULTITURN STEERING)
3. GUIDANCE BUTTON (OPTIONAL)
4. FANSWITCH(OPTIONAL)
5. LIFT LIMIT SWITCH (OPTIONAL)
6. BATTERY INDICATOR/HOURMETER
7. BATTERY DISCONNECT SWITCH
8. KEY SWITCH
9. CONSOLE ADJUSTMENT RELEASE
(OPTIONAL)
10. DIRECTION/SPEED CONTROL ASSEMBLY
Figure 8. Instruments and Controls
10

8000 SRM 924 Maintenance Procedures Every 350 Hours or 2 Months
Lift System Operation
WARNING
Lower the lift mechanism completely. Never al-
low anyone under a raised platform or forks.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
and platform are completely lowered and the
key switch is in the OFF position. Remove the
key.
Before making any repairs, completely lower
the platform or use chains on the mast weld-
ments and platform so they cannot move. Make
sure the moving parts are fastened to the parts
that cannot move.
Do not try to find hydraulic leaks by putting
hands on hydraulic components under pres-
sure. Hydraulic oil can be injected into the
body by pressure.
1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
2. Slowlyraiseandlowertheforks andtheplatform
several times without a load. All moving compo-
nents must raise and lower smoothly.
3. The platform and the forks must lower com-
pletely.
4. Raise the platform 1 m (3 ft) with a capacity
load. The inner weldment and platform must
raise smoothly. Lower the platform and forks.
All moving components must lower smoothly.
5. Check the operation of the limit switches on the
mast. Themaximumtravelspeedmustbe slower
when the platform is above 1524 mm (60 in.).
Maximum travel speed with the platform below
1524 mm (60 in.) is 9.7 km/h (6.0 mph). It should
noticeably slower above 1524 mm (60 in.).
6. If necessary, have the lift truck checked and ad-
justed by authorized service personnel.
Brake
Check the operation of the brake. The brake, when
in good condition and correctly adjusted, will hold the
lift truck with a capacity load on a 5% grade [a slope
of 0.5 m in 10 m (1.6 ft in 33 ft)]. If the brake does not
hold the lift truck on the grade, the brake needs to be
checkedbyauthorizedservicepersonnel. Refertothe
procedures for the Brake in Maintenance Procedures
Every 350 Hours or 2 Months of this section.
Steering System
WARNING
There is NO steering if there is no electrical
power. To prevent injury or damage, make
sure the electric power steering is operating
correctly before moving the lift truck.
Make sure that the steering system operates
smoothly and has good steering control.
Maintenance Procedures Every 350 Hours or 2 Months
NOTE: Do thefollowingproceduresinaddition tothe
8-hour checks.
BRAKE
The brake, when in good condition and correctly ad-
justed, will hold the lift truck with a capacity load
on a 5% grade [a slope of 0.5 m in 10 m (1.6 ft in
33 ft)]. If the brake will not hold the lift truck on
the grade as described, have the adjustment checked
by authorized personnel. See the manual Electric
Brake 1800 SRM 305 and 1800 SRM 761 to check or
repair the brake or to replace the friction disc.
ELECTRICAL CABLE SHEAVES
Lubricate the cable sheaves at the top of the mast
andcylinderheadusingSAE30Oil.
HYDRAULIC TANK BREATHER
The fill cap and breather assembly are in the hy-
drauliccompartmentatthetopofthe hydraulictank.
SeeFigure3.Removethefillcapassemblyfromthe
hydraulic tank and clean the filter material of the
breather in solvent. Replace the fill cap and breather
assembly if air will not flow through it easily.
11

Maintenance Procedures Every 350 Hours or 2 Months 8000 SRM 924
ELECTRICAL INSPECTION
Contactors
WARNING
Disconnect the battery connector before mak-
ing any inspections or repairs. Personal injury
or equipment and tool damage can occur if the
battery is not disconnected.
CAUTION
If the lift truck has been operated using a
low battery or de-energized with the power
disconnect circuit, inspect for welded contacts
BEFORE connecting a charged battery. The
Power Disconnect circuit will not reset and
lifttruckoperationcannotbecontrolledifthe
contacts are welded.
CAUTION
Low battery voltage makes motors use high
currents for a longer time to do the same work.
The high currents can damage motors and
weld contactor contacts. Never try to repair
contactor contacts that are welded. Always
replace welded contacts. Do not operate the
lift truck using a battery that has a specific
gravity of 1.130 or less.
Thecontactsurfacesofthecontactorareasilveralloy
over a copper base. In normal operation, the contact
surfaces become a dark color and rough. Cleaning is
not necessary. Do not use a file or emery cloth on the
contacts. Replace the contacts when the surface is
worn to the base material. Always replace the con-
tacts in sets (two pairs). If necessary, disassemble
the contactor to inspect the contacts.
Open the electrical compartment for access to the
contactors.
Motor Brushes
WARNING
Disconnect the battery before making any
checks on the motors. Personal injury or
equipment and tool damage can occur if the
battery is not disconnected.
CAUTION
Low battery voltage makes motors use high
currents for a longer time to do the same
work. The high currents can damage motors
and contactor contacts. Do not operate the
lift truck using a battery that has a specific
gravity of 1.130 or less.
Open the front compartment doors for access to the
motors.
To check the motor brushes, disconnect the battery
and get access to the motor. Check motor brushes
using the following procedure:
1. Visually inspect the commutator and brushes ev-
ery350hoursontheHydraulicandDrivemotors.
See Figure 9. Remove the brush cover. Move the
brush spring to remove a brush from the holder.
Pull the brush from the holder. Make sure the
surface of the commutator is good and the opera-
tion of the motor is correct. Replace brushes be-
foretheyarewornto thevaluesshowninTable3.
Table 3. Motor Brush Minimum Dimensions
Motor Dimension A
Traction Motor 16 mm (0.63 in.)
Lift Pump Motor 14 mm (0.55 in.)
NOTE: Measure brush from armature side to
spring side. Use smallest measurement.
2. Inspect the brush holders for burns or damage.
Make sure the brush holder is fastened tightly
to the mounts. Make sure the brushes will move
freely and smoothly in the brush holders and do
nothavewirebreaks.
3. Check the brush springs for damage from heat
(color changes) and corrosion. Replace a dam-
aged brush spring.
4. Use dry compressed air under low pressure to
remove any brush dust.
NOTE: See the section DC Motor Maintenance
620 SRM 294 for additional information for repair of
the commutator and brushes.
12

8000 SRM 924 Maintenance Procedures Every 350 Hours or 2 Months
1. TRACTION MOTOR 2. LIFT PUMP MOTOR 3. ACCESS COVER EE ONLY
Figure 9. Inspect the Motor Brushes
SAFETY LABELS
WARNING
If labels that have warnings or instructions are
damaged, they must be replaced immediately.
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.
MAST
WARNING
To avoid injury or damage, never work under
a raised platform or forks. Lower the platform
and the forks or use chains on the mast weld-
ments and carriage so they cannot move. When
chains are used, make sure the moving parts
are fastened to a part that cannot move.
1. Inspect the surfaces in the channels where the
load rollers travel. A scraper and solvent can be
used to clean dirt from the mast channels.
Make sure all safety labels are installed in the
correct location on the lift truck. Make sure
all labels are not damaged and that they can
be read. If necessary, see the Frame section or
the PARTS MANUAL for your lift truck for the
correct location of the labels. See the Frame
section for the installation procedures.
CAUTION
Be careful when steam or high-pressure water
is used to clean the mast channels. Do NOT
permit the steam or water to be used on the
load rollers, sheaves, or lift chains. The steam
or water will damage the bearings in the load
rollers and sheaves, and will cause corrosion in
the lift chains.
2. Apply a thin layer of multipurpose grease to the
surfaces in the channels of the inner mast where
theloadrollerstravel.Applythegreasetoboth
the roller surfaces and the thrust surfaces in the
mast.
13

Maintenance Procedures Every 350 Hours or 2 Months 8000 SRM 924
NOTE: The mast and platform load rollers have
sealed bearings that do not need additional lubrica-
tion.
3. Use multipurpose grease to lubricate all sliding
surfaces and the chain sheaves at the top of the
masts.
4. Lubricate the liftchains using the oil specified in
the Maintenance Schedule.
CHECK FOR LEAKS IN LIFT SYSTEM
WARNING
Never allow anyone under a raised platform or
forks. Do not put any part of your body in or
through either lift mechanism unless all parts
of the mast and carriage are completely low-
ered and the key is in the OFF position.
Before making any repairs, use chains on the
mast weldments and carriage so they cannot
move. Make sure the moving parts are fastened
to the parts that cannot move.
Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.
During test procedures for the hydraulic sys-
tem, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel
away from the lift truck during the tests.
Check the hydraulic system for internal leaks after
every 350 hours of operation.
Check Lift Cylinders for Leaks
1. Operate the hydraulic system. Put a capacity
load on the forks and raise and lower the load
several times. Check for leaks.
2. Raise the carriage and load 1 m (3 ft). If the car-
riage slowly lowers when the control valve is in
the neutral position, there are leaks inside the
hydraulic system. The maximum speed that the
forks can slowly lower when there are internal
leaks is 50 mm (2 in.) per 10 minutes. This max-
imum leak rate is specified for an oil temperature
of 30 C(90F).Ifthetemperatureofthehydraulic
oil is 70 C(160F), the specification increases to
150 mm (6 in.) per 10 minutes.
3. If there are leaks in the hydraulic system, check
the lift cylinders for internal leaks.
4. Completely lower the forks. Install a gate valve
at the base of each main lift cylinder. Raise the
load. Close the gate valve at the base of one main
lift cylinder. Move the Lift/Lower knob to lower
themast.Iftheloadslowlylowers,thesealsin
onemaincylinderleak. Thecylinderthathas
the leak is the cylinder with the closed valve.
Openthegatevalveofthefirstmaincylinderand
close the gate valve at the base of the other main
cylinder. Repeat the check for the other main lift
cylinder.
5. If the load does not lower with either gate valve
closed, open the gate valve and check the move-
ment again. If the load lowers when the gate
valve is open, check for leaks in the hydraulic
lines and fittings. If no leaks are found, the low-
ering valve can have a malfunction. Remove the
load from the forks.
6. Completely lower the forks. Remove all gate
valves and connect the hydraulic lines to the
cylinders.
LIFT CHAINS
CAUTION
Do not repair a worn lift chain. Replace a worn
lift chain with a new lift chain. Both chains
must be replaced if one lift chain needs replac-
ing.
Lubricate the lift chains using the oil specified in the
Maintenance Schedule.
If a section of chain is 3% longer than a similar sec-
tion of new chain, replace the worn chain.
If a chain scale is available, check the lift chains as
shown in Figure 10. If a chain scale is not available,
measure 20 links of chain. Compare the lengths with
thechartinFigure10. Replacethechainifthelength
of 20 links of the worn section is more than the max-
imum wear limit.
14