Professional Documents
Culture Documents
MAINTENANCE
B60Z AC [B230];
B80Z AC [B233]
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.
Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
How to Move a Disabled Truck ..................................................................................................................... 1
How to Tow the Lift Truck ........................................................................................................................ 2
How to Put a Lift Truck on Blocks................................................................................................................ 2
How to Raise Drive/Steer Tire .................................................................................................................. 2
How to Raise Load Wheels ....................................................................................................................... 3
Accessing the Drive Unit Compartment ...................................................................................................... 3
Special Precautions............................................................................................................................................ 4
Discharging the Capacitors........................................................................................................................... 4
Welding Repairs ................................................................................................................................................. 6
Maintenance Schedule....................................................................................................................................... 6
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 10
Checks With Key Switch Turned OFF.......................................................................................................... 10
Battery ....................................................................................................................................................... 10
Hydraulic Leaks ........................................................................................................................................ 10
Drive Tire, Load Wheels, Casters, and Frame ........................................................................................ 11
Checks With Key Switch Turned ON ........................................................................................................... 12
Operation ................................................................................................................................................... 12
Maintenance Procedures Every 250 Hours or Every 6 Weeks ........................................................................ 14
Caster Lubrication......................................................................................................................................... 14
Maintenance Procedures Every 500 Hours or Every 3 Months ..................................................................... 15
Hydraulic System .......................................................................................................................................... 15
Hydraulic Oil ............................................................................................................................................. 15
Hydraulic Reservoir Breather .................................................................................................................. 15
Steering System............................................................................................................................................. 15
Power Assist Steering ............................................................................................................................... 15
Lift Linkage and Load Wheels...................................................................................................................... 16
Casters ........................................................................................................................................................... 16
Caster Shim Check.................................................................................................................................... 16
Caster Shim Adjust ................................................................................................................................... 17
Master Drive Unit ......................................................................................................................................... 18
Change Gear Oil ........................................................................................................................................ 18
Check Oil Level ......................................................................................................................................... 18
Drive Tire Check............................................................................................................................................ 19
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 19
Lubrication..................................................................................................................................................... 19
Repack Load Wheel Bearings ................................................................................................................... 19
Repack Steer Bearings (Manual Steer Only) .......................................................................................... 19
Hydraulic System .......................................................................................................................................... 19
Oil Change ................................................................................................................................................. 19
Brake .............................................................................................................................................................. 20
Electrical ........................................................................................................................................................ 20
MDU ............................................................................................................................................................... 20
Oil Change ................................................................................................................................................. 20
Battery Maintenance ......................................................................................................................................... 21
How to Charge the Battery ........................................................................................................................... 21
Equalizing Charge..................................................................................................................................... 21
Normal Charge .......................................................................................................................................... 21
How to Change the Battery........................................................................................................................... 22
Transporting....................................................................................................................................................... 23
Loading........................................................................................................................................................... 23
B60Z AC [B230];
B80Z AC [B233]
ii
8000 SRM 1298 General
General
if possible. If the lift truck must be towed, refer to
WARNING How to Tow the Lift Truck in this section.
DO NOT make repairs or adjustments unless
you have been properly trained and authorized
WARNING
to do so. Repairs and adjustments that are in-
correct can create dangerous operating condi- Never carry a disabled lift truck unless the lift
tions. truck MUST be moved. The lift truck used to
lift the disabled lift truck MUST have a rated
DO NOT operate a lift truck that needs repairs. capacity equal to or greater than the weight of
Report the need for repairs to your supervisor the disabled lift truck. The capacity must be
immediately. If repair is necessary, attach a DO for a load center equal to half the width of the
NOT OPERATE tag on the control handle. Re- disabled lift truck. See the capacity plate on
move the key from the key switch. the disabled lift truck for the approximate total
weight. The forks must extend the full width
This section contains the instructions for periodic of the disabled lift truck. Put the weight of
maintenance and inspection, and a Maintenance the disabled lift truck at the center of the forks
Schedule. and be careful not to damage the under side of
the disabled lift truck. Tilt the mast back and
The Maintenance Schedule has time intervals for in- travel slowly.
spection, lubrication, and periodic maintenance. The
time intervals are based on a normal operation. A Make sure no one except the driver is near the
normal operation is considered to be one 8-hour shift lift trucks during towing. Both the tow truck
per day in a relatively clean environment on an im- and the disabled truck can cause a personal in-
proved surface. Multiple shifts, dirty operating con- jury during towing.
ditions, etc., will require a reduction in the recom-
mended time periods in the Maintenance Schedule. To avoid personal injury, use extra care when
moving a lift truck during the following condi-
NOTE: The front end of the lift truck is the control tions:
handle end. Forward travel is movement with the Brake does not operate correctly
forks trailing. Rear travel is movement in the direc- Steering does not operate correctly
tion of the forks. The right-hand side of the lift truck Tire is damaged
is to the operators right hand, facing the truck from Traction conditions are bad
the control handle end in the position for operating
the controls.
CAUTION
Your Hyster lift truck dealer has the trained person- Never carry the lift truck faster than the speed
nel and equipment to provide a complete program of of a person walking. Steering can be difficult
inspection, lubrication, and maintenance. This com- and motor damage can occur at higher speeds.
plete program will help your lift truck operate prop- Always travel smoothly without sudden starts.
erly over a longer period of time.
The electric brake must be released before the lift
Some users have service personnel and facilities to truck can be moved. If there is not sufficient battery
do the items listed in the Maintenance Schedule. power, placing the control handle in the operating
Service Manuals are available from your Hyster lift position will not release the electric brake. Refer to
truck dealer to help users who do their own repairs. Towing The Lift Truck of the Maintenance Manual.
Use the control handle to steer the lift truck while it
HOW TO MOVE A DISABLED TRUCK is being towed. Use one hand and walk to one side
of the lift truck. DO NOT walk or stand between the
This lift truck is not normally towed. If the traction towing vehicle and the lift truck.
system will not operate, make repairs at the location
1
General 8000 SRM 1298
How to Tow the Lift Truck 5. If counterbalanced style, lift truck configured
with the drive wheels nearest to the forks is
WARNING used to tow the disabled lift truck. The lift truck
must have weight added to the forks. The total
Stay clear of the tow chain, towing vehicle, and
weight of the lift truck and load must be equal
the lift truck during the towing operation to
to or greater than the weight of the disabled lift
prevent personal injury.
truck. Install a load of approximately half the
Make sure no one, except the driver, is near the maximum capacity on the forks of the lift truck
lift trucks during towing. Both the tow truck that is used for towing. This load will increase
and the disabled truck can cause personal in- the traction of the lift truck. Keep the load on
jury during towing. the forks lowered as much as possible.
2
8000 SRM 1298 General
3. Raise the lift truck only enough to suspend the 3. Raise the forks only enough to suspend the
drive tire. Install additional blocks under the wheels. Install blocks under the forks at the rear
frame near the drive tire. of the wheels to support the lift truck.
WARNING
Never raise the forks any higher than neces-
sary to change the load wheels. Always raise
both forks at the same time. Raising the forks
too high can make the lift truck tip over and
cause property damage or personal injury.
1. FLOORMAT
1. Put blocks on both sides (front and back) of the 2. DRIVE UNIT COMPARTMENT COVER
drive tire to prevent movement of the lift truck. 3. FRAME
4. CASTER MOUNTING ACCESS
2. Use an overhead crane and web sling under the
Figure 2. Floormat
forks to raise the load wheels. Another lift truck
can also be used to raise the forks. Make sure
that the crane and sling or other lift truck has a
capacity of at least 2/3 the total weight of the lift
truck, as shown on the capacity plate.
3
Special Precautions 8000 SRM 1298
Special Precautions
DISCHARGING THE CAPACITORS and connecting or disconnecting a handset or
PC.
WARNING
The capacitor in the transistor controller can CAUTION
hold an electrical charge even after the battery To avoid controller damage, always disconnect
is disconnected. To prevent electrical shock the battery. Discharge the capacitor and never
and personal injury, discharge the capacitor put power to the controller with any power
before inspecting or repairing any compo- wire disconnected. Never short any controller
nent. Wear safety glasses. Make certain the terminal or motor terminal to battery. Make
battery has been disconnected. DO NOT use sure to use proper procedures when servicing
a screwdriver to discharge the traction motor the controller.
controller.
1. Turn the key switch to the OFF position and dis-
connect the battery.
WARNING
To avoid personal injury and prevent electrical 2. Remove the drive unit compartment cover to ac-
shock, perform the following steps before per- cess the controller. See Accessing the Drive Unit
forming any troubleshooting or adjustments, Compartment.
4
8000 SRM 1298 Special Precautions
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
5
Maintenance Schedule 8000 SRM 1298
Welding Repairs
practices, including removal of all paint (prime
WARNING and finish coats) to the metal around the area
Disconnect the battery connector and remove to be welded. Use local ventilation, and/or
the battery before welding. Welding can cause supplied-air respiratory protection.
a fire and/or an explosion. Make sure there is
no fuel, oil, or grease near the weld area. Make
sure the area is well ventilated. CAUTION
Always disconnect the battery connector to
Forklift truck frames and components may prevent damage to circuit components when
have polyurethane paint. Welding, burning, or welding. Connect the welding ground clamp
other heat sufficient to cause thermal decom- as close to the weld area as possible to prevent
position of the paint may release isocyanates. welding current from damaging bearings.
These chemicals are allergic sensitizers to
skin and respiratory tract and overexposure Observe the previous WARNING and CAUTION be-
may occur without odor warning. When per- fore performing any welding repairs.
forming work, utilize good industrial hygiene
Maintenance Schedule
The Maintenance Schedule is divided into four time day is considered Heavy operation and requires
intervals which call for particular maintenance pro- the 3-month/500-hour checks to be performed at 2
cedures to be performed. The intervals are 1 Day months/350 hours. Lift trucks operating in freezer
or 8 Hours, 6 Weeks or 250 Hours, 3 Months or 500 environments or dirty conditions are considered
Hours, and 1 Year or 2000 Hours for normal opera- Severe operation and require the 3-month/500-hour
tion (whichever comes first). Normal operation is checks to be performed at 1 month/200 hours. The
considered one 8-hour shift per day, in a relatively approximate locations of the items listed in the
clean environment, on an improved surface. Op- Maintenance Schedule are shown in Figure 5.
erating a lift truck for more than eight hours per
6
8000 SRM 1298 Maintenance Schedule
Check Level
X (Full Mark on
Hydraulic Oil Tank) Hydraulic Oil 3
C5 Change
Inspect / Replace
Hydraulic Oil Strainer X/C See Parts Manual
as Necessary
6 Check
Lift and Lower Linkage X Repair as Necessary
Operation
Multipurpose
Load Roller Linkage L Lube Fittings
Grease 2
Forks to Drive End Frame Multipurpose
L Lube Fittings
Linkage Grease 2
7 Replace if
Safety Labels and Operating
X Missing or See Parts Manual
Manual
Damaged
X=Check C=Change L=Lubricate
7
Maintenance Schedule 8000 SRM 1298
8
8000 SRM 1298 Maintenance Schedule
9
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1298
10
8000 SRM 1298 Maintenance Procedures Every 8 Hours or Daily
Completely lower forks to relieve hydraulic wrapped around the axle to prevent damage to the
pressure before disassembling any part of axle seal.
the lift pump or disconnecting any hydraulic
hoses.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper 1. REMOVE EMBEDDED OBJECTS
amount of oil in the hydraulic system. The 2. CHECK FOR CUTS, SPLITS, AND OTHER
operation of the hydraulic pump with low oil DAMAGE
levels will damage the pump.
Figure 6. Tire Check
Check for leaks by looking for oil under the lift truck
and where the lift truck has been parked. Visually in- Inspect the frame for structural damage and
spect the hydraulic system and hoses. Small oil leaks loose/missing hardware. Make certain all covers
may appear as wet, oily leaks or unusually dirty ar- are in place and secured before operating the lift
eas where dirt and dust sticks to oil that has slowly truck. Inspect the load wheels. Loose or crooked
leaked out. load wheels may indicate a bearing failure. If failure
is suspected, raise the lift truck slightly and check
Drive Tire, Load Wheels, Casters, and that the load wheels are secure on the axles and
rotate smoothly. See How to Put a Lift Truck on
Frame
Blocks. Repair or replace as necessary.
WARNING
When the drive tire has been installed, check
WARNING
all wheel nuts after 2 to 5 hours of operation. In normal operation, the casters should con-
When the nuts stay tight after an 8-hour check, tinuously contact the floor. As the drive tire
the interval for checking the torque can be ex- wears, the frame will move closer to the floor
tended to 500 hours. Refer to the Maintenance and the casters will carry more of the load. If
Schedule in this section. the caster shims are not periodically adjusted,
they will bear too much of the lift truck weight
If the drive tire has recently been installed, check to and reduce the necessary load on the drive tire.
ensure the lug nuts are properly tightened to 191 to This can interfere with the ability of the drive
210 Nm (141 to 155 lbf ft). When installing, snug all tire to control steering and stopping functions
the nuts, then tighten to half the torque value, then of the truck.
tighten to the full torque value. Tighten the nuts in
a cross pattern to properly seat the wheel to the hub. To check for proper adjustment:
Inspect the tire for embedded rocks, glass, wire, 1. Position the lift truck on a level surface.
pieces of metal, holes, cuts, and other damage. See
2. Ensure the caster wheel is oriented toward the
Figure 6. Remove any object that will cause damage.
battery compartment.
Check for loose or missing nuts and broken studs.
Remove any wire strapping or other material that is 3. Remove the battery from the lift truck.
11
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1298
4. The caster should be in contact with the floor. If in the direction that you intend to move the
there is a gap between the floor and the bottom lift truck. Be careful when making checks or
of the caster wheel, the gap should not exceed servicing the lift truck.
1.50 mm (0.06 in.) for poly drive tires or 3.00 mm
(0.12 in.) for rubber drive tires. Make sure a properly charged battery of the correct
voltage is installed and connected. Turn the key
NOTE: DO NOT over shim the caster when adding switch to the ON position. Move the directional
shims. butterfly switch on the control handle head to test
for proper forward and reverse travel operation.
5. If the gap between the floor and the bottom of the
caster wheel is greater than specification, add
shims to adjust the caster to the floor. WARNING
Use the battery power disconnect to shut down
6. Measure the gap between the caster round bar the truck only in an emergency.
and the frame of the caster wheel.
The key switch (or toggle switch) is a two position
7. The gap should measure no greater than switch located on the right side of the dash display.
4.50 mm (0.19 in.). The first position is OFF (marked "O"). The second
position is ON (marked "I"). The key switch should
NOTE: DO NOT under shim the caster when remov- be used as the primary means of shutting down the
ing shims. truck.
8. Remove excess shims if gap exceeds specification.
WARNING
WARNING Always wear the proper protective equipment
including eye protection and petroleum-resis-
Safety labels are installed on the lift truck to
tant gloves when handling hydraulic oil. Thor-
give information about possible hazards. It is
oughly wash oil from exposed areas of skin as
important that all safety labels are installed on
soon as possible.
the lift truck and can be read.
Completely lower the forks to relieve hydraulic
Check that all safety labels are installed in the cor-
pressure before disassembling any part of the
rect locations on the lift truck. See the Parts Man-
lift pump or disconnecting any hydraulic
ual or the section Frame 100 SRM 960 for the proper
hoses.
locations of the safety labels.
The hydraulic oil is hot at normal operating
Check the frame channel for excessive wear in the
temperatures. Be careful when draining the
areas of roller contact. Check the rollers for wear
oil.
or damage. Check the load backrest extension for
cracks and damage. Make sure the nuts and bolts Never put your hands on pressurized hydraulic
for the load backrest extension are tight. components. Highly pressurized hydraulic oil
escaping through pin-hole leaks can be in-
CHECKS WITH KEY SWITCH TURNED ON jected into the skin. Visually inspect to find
hydraulic leaks.
Operation
WARNING
Make sure the area around the lift truck is
clear before moving the lift truck. Always look
12
8000 SRM 1298 Maintenance Procedures Every 8 Hours or Daily
13
Maintenance Procedures Every 250 Hours or Every 6 Weeks 8000 SRM 1298
1. SWIVEL MOUNT
2. SPRINGS
3. CASTER WHEEL
4. GREASE FITTING
14
8000 SRM 1298 Maintenance Procedures Every 500 Hours or Every 3 Months
Hydraulic Oil
NOTE: The hydraulic oil should be changed after the
initial 500 hour break-in period and then every 2000
hours thereafter. Refer to Maintenance Procedures
Every 2000 Hours or Yearly for oil change procedures
for the initial 500 hour change.
Remove drive unit cover. Remove breather cap from 1. STEER SWIVEL 5. PINION GEAR
2. WASHER 6. GEAR COVER
hydraulic pump and reservoir. Add hydraulic oil, if 3. SCREW 7. SUPPORT BASE
necessary, through the breather filler pipe until oil is 4. STEER SUPPORT 8. TILLER SENSOR
at Full mark on reservoir. Install breather cap and GEAR
tighten. DO NOT OVERFILL.
Figure 9. Gear Cover
15
Maintenance Procedures Every 500 Hours or Every 3 Months 8000 SRM 1298
Check the lower pinion, MDU steer gear and steer 500 hours or 3 months unless the lift truck is being
motor gear for dirt or buildup. Brush clean with a operated in a food processing/corrosive environment
wire brush and apply CRC 3-36 lubricant on all vis- which requires daily lubrication. Load wheel axles
ible gears. See Figure 10. without grease fittings are used on units with sealed
load wheel bearings. These bearings may be wiped
clean with a cloth, but cannot be lubricated and must
be replaced if not operating smoothly. Apply a thin
coat of antiseize lubricant to the sealed bearing axles
during installation.
CASTERS
Caster Shim Check
Periodically, the casters must be adjusted to compen-
sate for drive tire wear/replacement. Excess rock-
ing is often a sign of under shimmed casters. This
may occur when a new drive tire is installed. Loss
of traction may be caused by over shimmed casters.
This may occur when the drive tire diameter has de-
creased because of regular wear. The casters ideally
should be level with the bottom of the drive tire (just
touching the floor). A gap of not more than 1.50 mm
(0.06 in.) between the caster wheels and the floor is
acceptable, as is the casters being compressed to the
floor not more than 1.50 mm (0.06 in.). Refer to the
following instructions for the proper caster checking
and adjustment procedures.
1. LOWER PINION SHAFT (NOTCH FORWARD)
2. LOWER PINION 1. Park on a smooth and level surface with the
3. LOWER PINION
4. STEER MOTOR GEAR control handle centered and with no load on the
5. MOUNTING SCREWS forks. Lower the forks completely.
6. STEER GEAR
7. DRIVE UNIT HOUSING 2. Turn the key switch to the OFF position and dis-
8. TRACTION MOTOR connect the battery (DO NOT remove the bat-
9. STEERING MOTOR tery). Remove the floormat from the operator
platform.
Figure 10. Lower Pinion Mounting
3. Position a small level across the operator plat-
LIFT LINKAGE AND LOAD WHEELS form to verify the lift truck is level.
The lift linkage must be lubricated regularly to 4. Slide a sheet of paper under one of the caster
ensure smooth operation and to prevent component wheels to determine if it is touching the floor.
wear. The linkage is equipped with grease fittings If the caster wheel is touching the floor, skip to
near the load wheels accessible from the top of the Step 6.
forks. The linkage is also equipped with grease
fittings accessible from beneath the frame near the 5. If the caster wheel is not touching the floor, check
battery compartment. Wipe all grease fittings clean the caster for under shimming:
and check for damage to lift linkage components
before greasing. a. Loosen the two capscrews securing the extra
shims to the frame of the operator platform.
Some load wheel axles are also fitted with a grease See Figure 11.
fitting. These load wheels should be greased every
16
8000 SRM 1298 Maintenance Procedures Every 500 Hours or Every 3 Months
17
Maintenance Procedures Every 500 Hours or Every 3 Months 8000 SRM 1298
to augment or store extra shims in the stack for Operate the lift truck MDU for several minutes to
later use. See Figure 12. warm the gear oil. Elevate truck to access drive unit.
Keep truck level. Remove drive unit cover. Remove
both drain and oil fill plugs and drain gear oil into a
suitable container. Replace drain plug. Add gear oil
through oil fill plug until oil is level with top of gear
without covering gear. Replace oil fill plug. DO NOT
OVERFILL.
11. Lower the lift truck and check for proper adjust-
ment.
18
8000 SRM 1298 Maintenance Procedures Every 2000 Hours or Yearly
DRIVE TIRE CHECK embedded rocks, glass, wire, pieces of metal, holes,
cuts, and other damage. Remove any object that will
WARNING cause damage. Check for loose or missing nuts and
wheel bolts. Remove any wire strapping or other
When the drive tire has been installed, check
material that is wrapped around the axle to prevent
all wheel bolts after 2 to 5 hours of operation.
damage to the axle seal. Make sure the wheel bolts
When the wheel bolts stay tight after an 8-hour
are tight.
check, the interval for checking the torque can
When installing the tire and wheel, snug the wheel
be extended to 500 hours.
bolts, then tighten to half the torque value, then
Check to ensure the wheel bolts are properly tight- tighten to the full torque value. Tighten the nuts in
ened to 135 Nm (100 lbf ft). Inspect the tire for a cross pattern to properly seat the wheel to the hub.
HYDRAULIC SYSTEM Lower the forks, turn the key switch to the OFF
position, and disconnect the battery. Remove drive
Oil Change unit compartment cover. Remove the screws secur-
ing retaining brackets to the bottom of the lift pump.
Slightly twist the reservoir from the hydraulic pump
WARNING and motor assembly to remove. Recover the reservoir
Always wear the proper protective equipment O-ring. Empty hydraulic oil into a suitable container
including eye protection and petroleum-resis- and discard in accordance with local regulations.
tant gloves when handling hydraulic oil. Thor- Clean hydraulic reservoir using a suitable clean-
oughly wash oil from exposed areas of skin as ing solution and dry with compressed air. Clean
soon as possible. and inspect strainer. Replace strainer if clogged
19
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1298
1. MDU HOUSING
2. OIL FILL HOLE
3. OIL LEVEL
1. CAPACITY LOAD
2. 10-PERCENT GRADE Figure 15. Oil Fill Hole
3. FORKS UPHILL
20
8000 SRM 1298 Battery Maintenance
Battery Maintenance
HOW TO CHARGE THE BATTERY have a specific gravity of 1.265 to 1.310 at 25 C
(77 F). See Table 2. Never charge a battery at a rate
WARNING that will raise the electrolyte temperature above
49 C (120 F). Never permit a battery to stay dis-
The acid in the electrolyte can cause personal
charged for long periods.
injury. If electrolyte is spilled, flush the area
with water. Use a solution of sodium bicarbon- Table 2. Specific Gravity Corrections
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately. Specific
Electrolyte Correction Correct
Gravity
Temperature Points Value
WARNING Reading
Batteries generate explosive hydrogen when 1.210 31 C (88 F) +0.003 1.213
they are being charged. Keep fire, sparks,
and burning material away from the battery 1.210 27 C (81 F) +0.001 1.211
charger area. Prevent sparks from the battery 1.210 25 C (77 F) +0.000 1.210
connectors. Open the battery cover to disperse
explosive gas. 1.210 18 C (64 F) 0.004 1.206
+0.001 for each 1.7 C (35 F) from the 25 C (77 F).
WARNING Base Value (Degrees C 1.8) + 32 = Degrees F.
Charge batteries only in the special area for
charging batteries. When charging the bat- Equalizing Charge
teries, keep the vent caps clean. The battery
charger area must have ventilation so that This charge is at a low rate and balances the charge
explosive fumes are removed. Move the key to in all of the cells. The equalizing charge is normally
the OFF position and disconnect the battery given approximately once a month. It is a charge at
when doing cleaning and maintenance. a slow rate for 3 to 6 hours in addition to the regular
charging cycle. DO NOT give an equalizing charge
more than once a week. The most accurate specific
WARNING gravity measurement for a charged battery will be af-
If the lift truck has been operated using a ter an equalizing charge. If the difference in specific
battery that is almost discharged, inspect gravity is more than 0.020 between cells of a battery
for welded contacts BEFORE connecting a after an equalizing charge, there may be a cell that
charged battery. A contactor with welded has a malfunction. Consult your battery dealer.
contacts can cause operations that are not
expected and possible personal injury when NOTE: Many customers have battery chargers that
a charged battery is connected. Check the can follow a program to automatically charge a
battery connector for damage. battery according to recommendations of the bat-
tery manufacturer. Use the recommendations of
the battery manufacturer for charging the battery.
CAUTION Use only battery chargers approved by the battery
Never connect the battery charger plug to the manufacturer or dealer.
plug of the lift truck. You can damage the
traction control circuit. Always make sure the Normal Charge
charger voltage is the correct voltage for the
battery. This charge is normally given to a battery that is
discharged from normal operation. Many customers
Correct use of the hydrometer and proper operation charge the battery at regular intervals that depend
of the battery charger is important. Operate the on use. This procedure will keep the battery correctly
battery charger according to the instructions of charged if the battery is not discharged below the
the charger manufacturer. Never let the battery limit. Always use a hydrometer to check the battery
discharge below the minimum value given by the
battery manufacturer. A fully charged battery will
21
Battery Maintenance 8000 SRM 1298
if the battery is charged at regular intervals. Fre- 3. Loosen and remove buckle and strap from around
quent charging of a battery that has a 2/3 or more battery.
charge can decrease the life of the battery.
4. Lift the battery out of the truck. DO NOT allow
HOW TO CHANGE THE BATTERY the battery to shift from side to side. Make sure
the battery cables have clearance.
WARNING 5. Before installing a new battery, make sure the
Batteries are heavy and can cause personal in- battery is the correct size and weight for the lift
jury or property damage. DO NOT put hands, truck. Make sure the battery has clearance for
arms, feet, or legs between the battery and installation. Check that the battery connector
a solid object. Make sure the capacity of the can be attached to the lift truck connector with-
crane and spreader bar is greater than the out pulling during lifting and lowering opera-
weight of the battery. The weight of the bat- tions. DO NOT damage the battery cables dur-
tery is normally shown on the battery case. ing installation. Install the battery.
The maximum battery weight is shown on the
lift truck capacity plate. The spreader bar 6. Replace buckle and strap and tighten to prevent
must NOT be made of metal or it must have the battery from moving.
insulated straps.
7. Remove the blocks from under the truck.
CAUTION
If the lift truck was operated using a low bat-
tery, inspect for welded contacts BEFORE con-
necting a charged battery. The circuit will not
reset and lift truck operation cannot be con-
trolled if the contacts are welded. Prevent side-
to-side movement of the battery by adjusting
the brackets on each side of the battery and
tighten the capscrews, lockwashers, and nuts
to retain the batteries.
CAUTION
The replacement battery must fit the battery
compartment. Make sure the battery cables
have clearance to move during lifting and
lowering of the forks. Make sure that the re-
placement battery is the correct voltage and
weight as shown on the capacity plate. See
Figure 16.
1. CRANE
1. Move the key to the OFF position. Disconnect 2. SPREADER BAR
the battery. Use a spreader bar and lifting device 3. INSULATOR STRAPS
to remove the battery. 4. BATTERY
2. Position blocks under both sides of the truck in Figure 16. Changing the Battery
the area of the battery compartment.
22
8000 SRM 1298 Transporting
Transporting
3. Check that all switches and accessories are
WARNING turned off.
Maintain a safe distance from the edge of
docks, ramps, platforms, and other similar 4. Put blocks in front and back of the lift truck tires
working surfaces. Watch the "tailswing." Re- to prevent any movement of the lift truck. Make
member, when traveling in the forward direc- sure the blocks are attached to the transport sur-
tion, and the steering wheel is turned to move face.
the lift truck away from the edge of the dock,
the rear will swing toward the edge. This can WARNING
cause the lift truck to fall off the dock. The straps or chains used to attach the lift
If the lift truck falls off the dock, DO NOT jump truck to the transporter must be directly at-
off! Hold firmly to the steering wheel, brace tached to the lift truck frame or to a component
your feet, and lean forward and away from the (drive axle, tow pin) that is solidly attached to
point of impact. the frame. DO NOT attach the straps or chains
to the mast or any attachment.
Before the lift truck is transported, check the se-
lected route to make sure there is adequate clearance CAUTION
for the lift truck as loaded on the transport vehicle
Make sure that any straps or chains used to at-
(bridges, overpasses, power lines, and natural bar-
tach the lift truck to the transporter DO NOT
riers).
contact any tubes, hoses, hydraulic cylinders,
If a trailer is the method of transportation, use blocks or other parts of the lift truck that are easily
in front and back of the trailer tires to prevent move- damaged.
ment of the trailer when the lift truck is loaded and
5. If the lift truck is transported in severe weather
unloaded. If a loading ramp is used, make sure that
or any other condition that can damage the lift
the ramp is the proper design and capacity.
truck, cover the lift truck. Make sure the tarp
Use approved lifting eyes to lift the truck. If the lift or protective material is designed for the appli-
truck is not equipped with approved lifting eyes, DO cation and is securely attached.
NOT lift the truck by attaching a lifting device to any
other part of the lift truck for the purposes of loading UNLOADING
or unloading.
1. If used, remove any covering.
LOADING 2. Make sure the park brake is applied.
The operator must never leave a lift truck in a condi- 3. Disconnect the straps or chains.
tion so it can cause damage or injury. When parking
the lift truck, do the following operations: 4. Remove the wheel blocks.
1. After the lift truck has been loaded, apply the 5. Check that all switches and accessories are
parking brake. turned off.
2. Turn the key switch to OFF to stop the engine. 6. Unload the lift truck.
23
Preparation for Use 8000 SRM 1298
2. Check that all switches and accessories are off. 3. Remove the batteries from the lift truck. Put the
batteries in storage. Be sure to follow local fire
3. Disconnect battery cables from the batteries. Ap- regulations.
ply corrosion preventive to battery terminals.
4. Spray exterior surfaces and frame with preser-
vative coating.
PREPARATION AFTER SHIPMENT 3. Clean battery cables. Check the battery volt-
age. If the voltage is less than nominal, charge
1. Complete the unloading procedures. the battery. Connect the cables to battery and
tighten.
2. Inspect the lift truck for damage and missing
components.
24
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