PERIODIC

MAINTENANCE
B60Z AC [B230];
B80Z AC [B233]

PART NO. 1644779 8000 SRM 1298

 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 when making repairs,
or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are 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

2006 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Unloading....................................................................................................................................................... 23
Preparation for Storage ..................................................................................................................................... 24
Short-Term Storage (1 to 6 months) ............................................................................................................. 24
Long-Term Storage (6 months or longer) ..................................................................................................... 24
Preparation for Use............................................................................................................................................ 24
Preparation After Shipment ......................................................................................................................... 24
Preparation After Storage............................................................................................................................. 24

This section is for the following models:

B60Z AC [B230];
B80Z AC [B233]

ii
8000 SRM 1298
General
WARNING
DO NOT make repairs or adjustments unless
you have been properly trained and authorized
to do so. Repairs and adjustments that are in-
correct can create dangerous operating condi-
tions.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, attach a DO
NOT OPERATE tag on the control handle. Re-
move the key from the key switch.
This section contains the instructions for periodic
maintenance and inspection, and a Maintenance
Schedule.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and periodic maintenance. The
time intervals are based on a normal operation. A
normal 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.
NOTE: The front end of the lift truck is the control
handle end. Forward travel is movement with the
forks trailing. Rear travel is movement in the direc-
tion of the forks. The right-hand side of the lift truck
is to the operators right hand, facing the truck from
the control handle end in the position for operating
the controls.
Your Hyster lift truck dealer has the trained person-
nel and equipment to provide a complete program of
inspection, lubrication, and maintenance. This com-
plete program will help your lift truck operate prop-
erly over a longer period of time.
Some users have service personnel and facilities to
do the items listed in the Maintenance Schedule.
Service Manuals are available from your Hyster lift
truck dealer to help users who do their own repairs.
HOW TO MOVE A DISABLED TRUCK
This lift truck is not normally towed. If the traction
system will not operate, make repairs at the location
General
if possible. If the lift truck must be towed, refer to
How to Tow the Lift Truck in this section.
WARNING
Never carry a disabled lift truck unless the lift
truck MUST be moved. 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 capacity plate on
the disabled lift truck for the approximate total
weight. The forks must extend the full width
of the disabled lift truck. Put the weight of
the disabled lift truck at the center of the forks
and be careful not to damage the under side of
the disabled lift truck. Tilt the mast back and
travel slowly.
Make sure no one except the driver is near the
lift trucks during towing. Both the tow truck
and the disabled truck can cause a personal in-
jury during towing.
To avoid personal injury, use extra care when
moving a lift truck during the following condi-
tions:
Brake does not operate correctly
Steering does not operate correctly
Tire is damaged
Traction conditions are bad
CAUTION
Never carry the lift truck faster than the speed
of a person walking. Steering can be difficult
and motor damage can occur at higher speeds.
Always travel smoothly without sudden starts.
The electric brake must be released before the lift
truck can be moved. If there is not sufficient battery
power, placing the control handle in the operating
position will not release the electric brake. Refer to
Towing The Lift Truck of the Maintenance Manual.
Use the control handle to steer the lift truck while it
is being towed. Use one hand and walk to one side
of the lift truck. DO NOT walk or stand between the
towing vehicle and the lift truck.
1
General
How to Tow the Lift Truck
WARNING
Stay clear of the tow chain, towing vehicle, and
the lift truck during the towing operation to
prevent personal injury.
Make sure no one, except the driver, is near the
lift trucks during towing. Both the tow truck
and the disabled truck can cause personal in-
jury during towing.
CAUTION
Travel slowly and DO NOT tow on grades.
NEVER tow the lift truck faster than a normal
walking speed. Always tow smoothly, without
sudden starts or stops.
Until repairs are complete, keep a tag on the
control handle stating DO NOT OPERATE. Re-
move the key.
1. Disconnect the battery, and fasten the chain to
the lift truck. Make sure the tow chain has the
capacity to tow the weight. Carefully fasten the
tow chain completely around the drive unit com-
partment and battery compartment over top of
the forks. The chain must not cause damage to
either lift truck.
2. The electric brake must be released before the
lift truck can be towed. If there is not sufficient
battery power, placing the control handle in the
operating position will not release the electric
brake.
On B60Z AC models, two 1/4 1 inch capscrews
may be used to manually release the brake. In-
stall the two screws into the service ports of the
brake assembly and tighten alternately in small
increments until the brake releases. When there
is no alternative, the brake assembly may be re-
moved from the traction motor to allow towing.
For brake removal procedures see Brakes 1800
SRM 1285.
3. Steer the lift truck with the control handle while
it is being towed. Use one hand and walk to one
side of the lift truck. DO NOT walk or stand
between the towing vehicle and the lift truck.
4. Tow the lift truck slowly.
2
8000 SRM 1298
5. If counterbalanced style, lift truck configured
with the drive wheels nearest to the forks is
used to tow the disabled lift truck. The lift truck
must have weight added to the forks. The total
weight of the lift truck and load must be equal
to or greater than the weight of the disabled lift
truck. Install a load of approximately half the
maximum capacity on the forks of the lift truck
that is used for towing. This load will increase
the traction of the lift truck. Keep the load on
the forks lowered as much as possible.
If counterbalanced style, lift truck configured
with the drive wheel(s) furthest from the forks
is used to tow the disabled lift truck. DO NOT
add weight to the forks. Additional weight on
the forks may DECREASE the traction of the
drive wheel(s). Make sure that the lift truck
used has a total weight equal to or greater than
the weight of the disabled lift truck.
HOW TO PUT A LIFT TRUCK ON BLOCKS
WARNING
DO NOT put the lift truck on blocks unless the
surface is solid, even, and level. Make sure that
any blocks used to support the lift truck are
solid, one-piece units. Put a block in front and
back of the tires touching the ground to pre-
vent movement of the lift truck.
DO NOT raise the lift truck by attaching an
overhead crane to areas that will be damaged.
Some of these points are not designed to sup-
port the weight of the lift truck. The lift truck
can be damaged or it can fall, causing serious
personal injury. Attach the chain or sling to a
support structure of the lift truck frame.
See Figure 1.
How to Raise Drive/Steer Tire
1. Put blocks on each side (front and back) of the
load wheels to prevent movement of the lift truck.
2. Use a special low clearance hydraulic jack, crane,
or another lift truck to raise the drive tire. Make
sure that the jack, crane, or other lift truck has
the correct capacity rating. The capacity must
equal to 2/3 the weight of the lift truck, including
the battery. See the capacity plate.
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.

ACCESSING THE DRIVE UNIT

COMPARTMENT
The drive unit compartment is concealed behind a
molded cover which fits securely around the drive
unit and steer support to the frame. The floormat
fits snugly in the operator platform after the drive
unit cover is installed.

To remove the drive unit cover, first lift the corners of

the floormat and pull it out away from the drive unit.
See Figure 2. Next, reach under the side of the drive
unit cover near the bottom and find the grip slot. See
Figure 3. With both hands, pull up and away from
the truck until the bottom of the cover kicks out from
the retaining clips. Repeat this for the other side of
the cover. Work around the edge of the cover until
free from the truck.

A. PUTTING TRUCK ON BLOCKS (DRIVE TIRE)

B. PUTTING TRUCK ON BLOCKS (LOAD WHEELS)

Figure 1. Putting Lift Truck on Blocks

How to Raise Load Wheels

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
1. DRIVE UNIT COMPARTMENT COVER
2. RETAINER TABS
3. GRIP SLOT
4. FRAME
Figure 3. Drive Unit Compartment Cover
Special Precautions
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can
hold an electrical charge even after the battery
is disconnected. To prevent electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any compo-
nent. Wear safety glasses. Make certain the
battery has been disconnected. DO NOT use
a screwdriver to discharge the traction motor
controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
4
8000 SRM 1298
To install the drive unit cover, make sure the floor-
mat is pulled away from the drive unit and place the
bottom of the drive unit cover onto the operator plat-
form and position the lower edges partially into the
lower retaining clips. Push the top of the cover par-
tially into the upper retaining clips. DO NOT push
either edge of the cover in completely before start-
ing all edges into the proper place. When the cover
is aligned and started properly, press the cover com-
pletely into the retaining clips and place the floormat
into the operator platform around the cover.
and connecting or disconnecting a handset or
PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.
1. Turn the key switch to the OFF position and dis-
connect the battery.
2. Remove the drive unit compartment cover to ac-
cess the controller. See Accessing the Drive Unit
Compartment.
8000 SRM 1298 Special Precautions

3. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across
the controllers B+ and B terminals using in-
sulated jumper wires. See Figure 4. DO NOT
attempt to discharge the capacitors by creating
a short across the motor controller terminals
with a screwdriver or jumper wire. Remove the
200-ohm, 2-watt resistor before reconnecting the
battery.

1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION

Figure 4. Discharging Controller - B60Z AC and

B80Z AC

5
Maintenance Schedule
Welding Repairs
WARNING
Disconnect the battery connector and remove
the battery before welding. Welding can cause
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.
Forklift truck frames and components may
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position of the paint may release isocyanates.
These chemicals are allergic sensitizers to
skin and respiratory tract and overexposure
may occur without odor warning. When per-
forming work, utilize good industrial hygiene
Maintenance Schedule
The Maintenance Schedule is divided into four time
intervals which call for particular maintenance pro-
cedures to be performed. The intervals are 1 Day
or 8 Hours, 6 Weeks or 250 Hours, 3 Months or 500
Hours, and 1 Year or 2000 Hours for normal opera-
tion (whichever comes first). Normal operation is
considered one 8-hour shift per day, in a relatively
clean environment, on an improved surface. Op-
erating a lift truck for more than eight hours per
Figure 5. Maintenance Points
6
8000 SRM 1298
practices, including removal of all paint (prime
and finish coats) to the metal around the area
to be welded. Use local ventilation, and/or
supplied-air respiratory protection.
CAUTION
Always disconnect the battery connector to
prevent damage to circuit components when
welding. Connect the welding ground clamp
as close to the weld area as possible to prevent
welding current from damaging bearings.
Observe the previous WARNING and CAUTION be-
fore performing any welding repairs.
day is considered Heavy operation and requires
the 3-month/500-hour checks to be performed at 2
months/350 hours. Lift trucks operating in freezer
environments or dirty conditions are considered
Severe operation and require the 3-month/500-hour
checks to be performed at 1 month/200 hours. The
approximate locations of the items listed in the
Maintenance Schedule are shown in Figure 5.
8000 SRM 1298 Maintenance Schedule

Table 1. Maintenance Schedule

Item Item 1 6 3 1 yr/ Procedure or Specification

No. day/ wk/ mo/ 2000 Quantity
8 hr 250 500 hr
hr hr
1 Check Charge Charge or Change
Battery X1
Status Out
Electrolyte X Check Level Distilled Water
Restraint Panels X Check Condition Repair as Necessary
Check
Power Disconnect X Repair as Necessary
Operation
2 Check
X Repair as Necessary
Operation
Parking Brake
Hold on Grade Capacity Load on
X
Test 10% Grade
3 Check
Control Handle and Horn X Repair as Necessary
Operation
4 BDI, Horn, Key Switch, and Check
X Repair as Necessary
Electrical Circuits Operation
5 Hydraulic System X Check for Leaks Repair as Necessary
Visually Inspect
X Repair as Necessary
for Leaks
Hydraulic Hoses and
Fittings Check for Hose
Repair or Replace
X Damage and
as Necessary
Loose Fittings

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

Table 1. Maintenance Schedule (Continued)

Item Item 1 6 3 1 yr/ Procedure or Specification

No. day/ wk/ mo/ 2000 Quantity
8 hr 250 500 hr
hr hr
8 Check
Standard Steer X Repair as Necessary
Operation
Repack Multipurpose
Steer Bearings L
Bearings Grease 2
8 Check
Power Assist Steer X Repair as Necessary
Operation
CRC 3-36
Steering Gears L Spray Lubricant
Lubricant
9 Frame X Visually Inspect Repair as Necessary
10 Casters and Load Wheels X Check Condition Repair as Necessary
Check Adjust With Shims
Caster Adjustment X
Adjustment Gap as Necessary
Multipurpose
Caster Swivel STD L7 L Lube Fitting
Grease 2
Multipurpose
Caster Wheel HD L7 L Lube Fitting
Grease 2
11 Replace as
Load Wheels X Check Condition
Necessary
Multipurpose
Wheels and Bearings L Lube Fitting
Grease 2
Axle Bolts (Food Process-
L Lube Antiseize Lubricant
ing)
12 Check
Master Drive Unit X Repair as Necessary
Operation
CRC 3-36 Spray
MDU Steering Gear L Apply to Gear
Lubricant
Check
MDU Gearcase X Repair as Necessary
Operation
Oil X Check Level
AC
B60Z 1.7 liter (1.8 qt) Gear Oil 6
C5
B80Z AC 2.0 liter (2.1 qt)
X=Check C=Change L=Lubricate

8
8000 SRM 1298 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 1 6 3 1 yr/ Procedure or Specification

No. day/ wk/ mo/ 2000 Quantity
8 hr 250 500 hr
hr hr
13 Drive Wheel and Tire X Check Condition Repair as Necessary
Smooth Edges/
Inspect for
Tire X Remove Embedded
Damage
Objects
Inspect for Oil Remove Wrapped
Axle Seal X
Leaks Debris
Wheel Bolts (B60Z AC) Tighten as 191 to 210 Nm
X4
Lug Nuts (B80Z AC) Required (141 to 155 lbf ft)
1
Equalization charge approximately each month, but not more than each week.
2
Use Mobilgrease 28 synthetic extra-protection grease (clay) for standard, freezer, and cold storage
configurations.
Use Amsoil GHD synthetic multipurpose grease (lithium complex) with 2 to 4% molybdenum disulfide for
arctic and food processing configurations and for standard steer bearings on all configurations.
3
Use ISO VG 46 (conventional) antiwear (HCE-140) for standard, freezer, and cold storage configurations.
Use Exxon Univis HVI 26 (synthetic) for arctic and food processing configurations.
4
Apply antiseize at installation and check every 2 to 5 hours until nuts/bolts stay tight for an entire 8-hour
shift. Check tightness every 3 months or 500 hours thereafter.
5
Replace after the first 500 hours of service and every 2000 hours or yearly thereafter.
6
Use conventional 80W-90 (GL-5) for standard, freezer, and cold storage configurations.
Use synthetic 75W-90 (GL-5) for arctic and food processing configurations.
7
Lubricate every 8 hours if using in a food processing or corrosive environment.
X=Check C=Change L=Lubricate

9
Maintenance Procedures Every 8 Hours or Daily
Maintenance Procedures Every 8 Hours or Daily
WARNING
DO NOT operate a lift truck that needs repairs.
If a repair is necessary, attach a DO NOT OPER-
ATE tag to the control handle and disconnect
the battery.
Inspect the lift truck every 8 hours or daily before
use. Put the lift truck on a level surface. Lower the
carriage and forks, and turn the key switch to OFF.
If repair is required, attach a DO NOT OPERATE
tag to the control handle and disconnect the battery.
DO NOT operate a lift truck until the problems are
corrected.
CHECKS WITH KEY SWITCH TURNED OFF
Make the following checks:
Electrolyte and specific gravity of the battery
Make sure the battery is clean and the correct size
and weight for the lift truck
Check that the battery restraint plates are in place
Leaks in the hydraulic system
Condition of the casters, load wheels, drive tire,
and frame
Battery
WARNING
DO NOT lay tools on top of the battery.
The acid in the electrolyte can cause injury. If
the electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution
of sodium bicarbonate (baking soda). Acid in
the eyes must be flushed with water continu-
ously for fifteen minutes then seek medical at-
tention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT
make a spark from the battery connections.
Disconnect the battery when doing mainte-
nance.
The battery must fit the battery compartment
so the battery restraint panels will operate cor-
rectly. Use spacers to prevent the battery from
moving more than 13 mm (0.5 in.) in any direc-
tion.
10
8000 SRM 1298
CAUTION
Disposal of batteries must meet local environ-
mental regulations.
Make sure the battery weight is within the maximum
and minimum weight shown on the nameplate.
Keep the battery case, top cover, and the area for the
battery clean and painted. Leakage and corrosion
from the battery can cause a malfunction in the elec-
tric controls of the lift truck. Use a water and sodium
bicarbonate solution (soda) to clean the battery and
the battery area. Keep the top of the battery clean,
dry, and free of corrosion.
Make sure the battery is charged and has the correct
voltage and ampere hour rating for the lift truck. See
the nameplate.
Inspect the battery case, connector, and cables for
damage, cracks, or breaks. Contact your local bat-
tery dealer to discuss repair options for the battery
case. Check the level of the electrolyte daily on a
minimum of one cell. The correct level is halfway be-
tween the top of the plates and the bottom of the fill
hole. Add only distilled water.
Make certain the battery restraint panels are prop-
erly installed.
WARNING
Make sure the key switch is OFF and the brake
is set before connecting the battery.
If the lift truck was operated with a discharged
battery, check the contactor for welded tips be-
fore a charged battery is connected.
The battery should have an equalization charge each
month, but not more than each week.
Hydraulic Leaks
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
8000 SRM 1298
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper
amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil
levels will damage the pump.
Check for leaks by looking for oil under the lift truck
and where the lift truck has been parked. Visually in-
spect the hydraulic system and hoses. Small oil leaks
may appear as wet, oily leaks or unusually dirty ar-
eas where dirt and dust sticks to oil that has slowly
leaked out.
Drive Tire, Load Wheels, Casters, and
Frame
WARNING
When the drive tire has been installed, check
all wheel nuts after 2 to 5 hours of operation.
When the nuts stay tight after an 8-hour check,
the interval for checking the torque can be ex-
tended to 500 hours. Refer to the Maintenance
Schedule in this section.
If the drive tire has recently been installed, check to
ensure the lug nuts are properly tightened to 191 to
210 Nm (141 to 155 lbf ft). When installing, snug all
the nuts, then tighten to half the torque value, then
tighten to the full torque value. Tighten the nuts in
a cross pattern to properly seat the wheel to the hub.
Inspect the tire for embedded rocks, glass, wire,
pieces of metal, holes, cuts, and other damage. See
Figure 6. Remove any object that will cause damage.
Check for loose or missing nuts and broken studs.
Remove any wire strapping or other material that is
Maintenance Procedures Every 8 Hours or Daily
wrapped around the axle to prevent damage to the
axle seal.
1. REMOVE EMBEDDED OBJECTS
2. CHECK FOR CUTS, SPLITS, AND OTHER
DAMAGE
Figure 6. Tire Check
Inspect the frame for structural damage and
loose/missing hardware. Make certain all covers
are in place and secured before operating the lift
truck. Inspect the load wheels. Loose or crooked
load wheels may indicate a bearing failure. If failure
is suspected, raise the lift truck slightly and check
that the load wheels are secure on the axles and
rotate smoothly. See How to Put a Lift Truck on
Blocks. Repair or replace as necessary.
WARNING
In normal operation, the casters should con-
tinuously contact the floor. As the drive tire
wears, the frame will move closer to the floor
and the casters will carry more of the load. If
the caster shims are not periodically adjusted,
they will bear too much of the lift truck weight
and reduce the necessary load on the drive tire.
This can interfere with the ability of the drive
tire to control steering and stopping functions
of the truck.
To check for proper adjustment:
1. Position the lift truck on a level surface.
2. Ensure the caster wheel is oriented toward the
battery compartment.
3. Remove the battery from the lift truck.
11
Maintenance Procedures Every 8 Hours or Daily
4. The caster should be in contact with the floor. If
there is a gap between the floor and the bottom
of the caster wheel, the gap should not exceed
1.50 mm (0.06 in.) for poly drive tires or 3.00 mm
(0.12 in.) for rubber drive tires.
NOTE: DO NOT over shim the caster when adding
shims.
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.
6. Measure the gap between the caster round bar
and the frame of the caster wheel.
7. The gap should measure no greater than
4.50 mm (0.19 in.).
NOTE: DO NOT under shim the caster when remov-
ing shims.
8. Remove excess shims if gap exceeds specification.
WARNING
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.
Check that all safety labels are installed in the cor-
rect locations on the lift truck. See the Parts Man-
ual or the section Frame 100 SRM 960 for the proper
locations of the safety labels.
Check the frame channel for excessive wear in the
areas of roller contact. Check the rollers for wear
or damage. Check the load backrest extension for
cracks and damage. Make sure the nuts and bolts
for the load backrest extension are tight.
CHECKS WITH KEY SWITCH TURNED ON
Operation
WARNING
Make sure the area around the lift truck is
clear before moving the lift truck. Always look
12
8000 SRM 1298
in the direction that you intend to move the
lift truck. Be careful when making checks or
servicing the lift truck.
Make sure a properly charged battery of the correct
voltage is installed and connected. Turn the key
switch to the ON position. Move the directional
butterfly switch on the control handle head to test
for proper forward and reverse travel operation.
WARNING
Use the battery power disconnect to shut down
the truck only in an emergency.
The key switch (or toggle switch) is a two position
switch located on the right side of the dash display.
The first position is OFF (marked "O"). The second
position is ON (marked "I"). The key switch should
be used as the primary means of shutting down the
truck.
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower the forks to relieve hydraulic
pressure before disassembling any part of the
lift pump or disconnecting any hydraulic
hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
Never put your hands on pressurized hydraulic
components. Highly pressurized hydraulic oil
escaping through pin-hole leaks can be in-
jected into the skin. Visually inspect to find
hydraulic leaks.
8000 SRM 1298
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper
amount of oil in the hydraulic system. Operat-
ing the hydraulic pump with low oil levels will
damage the pump.
1. Raise the forks slowly without a load. Check for
smooth operation and mechanical interference.
Mechanical interference is caused by damaged or
worn linkage or shafts or by incorrect adjustment
of the tension rods.
2. Check for damaged or worn linkage bushings or
shafts.
3. Check for missing or loose shaft pins.
4. Check load wheels and support bearings, shafts,
and shaft pins for wear, damage, or missing
parts.
WARNING
If any function does not operate or operates in-
correctly, remove the truck from operation and
attach a DO NOT OPERATE tag to the control
handle. Remove the key and disconnect the
battery.
Test the lift truck operation in an area that is
clear of personnel and equipment.
5. Check the operation of the key switch. Functions
should not operate with the key in the OFF posi-
tion. Turn the key to the ON position. Lower the
control handle to the operating (BRAKE OFF)
position. The horn, hydraulic functions, traction
functions, and brake should be operational.
Maintenance Procedures Every 8 Hours or Daily
6. Check the operation of the brake switch. Release
the control handle to allow it to return to the ver-
tical position. Rotate the directional control (but-
terfly) switch without lowering the control han-
dle. The traction system must not operate under
these conditions.
7. Check the operation of the directional control
(butterfly) switch. Lower the control handle to
release the brake. Slowly rotate the directional
control (butterfly) switch in either direction. The
lift truck must accelerate smoothly. Rotate the
switch in the opposite direction. The lift truck
must stop smoothly and then change direction.
Check the control handle return spring. The
control arm should return to the full vertical
position when the control handle is released.
8. Check the operation of the lift and lower func-
tions. Push the lift button and then the lower
button. Check that the forks raise and lower
smoothly.
9. Check the operation of the traction reverse func-
tion. Slowly rotate the directional control (but-
terfly) switch in the reverse direction. Push the
traction reverse button without changing the po-
sition of the directional control (butterfly) switch.
The horn must sound and the lift truck must stop
and accelerate in the opposite direction. Once
the lift truck changes direction and moves with
the control handle trailing, release the traction
reverse button. The lift truck should not resume
movement in the direction of the control handle
until the directional control (butterfly) switch is
cycled back to the neutral position and then ro-
tated in either direction or until the control han-
dle is moved to the BRAKE ON position and then
back to the BRAKE OFF position.
10. Check the steering function. Move the control
handle to the right and left. Check for smooth
movement of the drive tire in the same direc-
tion. Steering will require more effort on stan-
dard steer models if the lift truck is stationary.
13
Maintenance Procedures Every 250 Hours or Every 6 Weeks 8000 SRM 1298

Maintenance Procedures Every 250 Hours or Every 6 Weeks

CASTER LUBRICATION Legend for Figure 7
1. SWIVEL MOUNT
CAUTION 2. GREASE FITTING
Use only the recommended lubricants for your 3. SPRINGS
4. CASTER WHEEL
application. Refer to Capacities and Specifica-
tions 8000 SRM 1299 for lubrication specifica- The heavy-duty caster has one grease fitting in the
tions for your lift truck. end of the caster wheel axle which lubricates the
caster wheel bearings. See Figure 8.
Wipe grease fittings clean before greasing.

NOTE: Some optional packages may utilize sealed

bearings or different grease fitting configurations.
Contact your Hyster dealer for information on op-
tional packages.

The casters should be lubricated every 250 hours or 6

weeks during normal operation. The standard caster
has one grease fitting above the springs which pro-
vides lubrication to the swivel bearing. See Figure 7.

1. SWIVEL MOUNT
2. SPRINGS
3. CASTER WHEEL
4. GREASE FITTING

Figure 8. Heavy-Duty Caster

Figure 7. Standard Caster

14
8000 SRM 1298 Maintenance Procedures Every 500 Hours or Every 3 Months

Maintenance Procedures Every 500 Hours or Every 3 Months

HYDRAULIC SYSTEM
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
Hydraulic Reservoir Breather
Check the condition of the breather cap. The
breather cap is located on the side of the hydraulic
reservoir of the oil pump and motor assembly, inside
the drive unit compartment. Unscrew the cap from
the oil fill elbow. Clean the breather cap with a suit-
able cleaning solution, blow dry with compressed air,
and reinstall. If the breather cap cannot be cleaned
so air will flow through it easily, or it is damaged, it
must be replaced.
STEERING SYSTEM

The hydraulic oil is hot at normal operating Power Assist Steering

temperatures. Be careful when draining the
oil. CAUTION
Never check for leaks by putting hands on Use caution to prevent spray from drifting onto
hydraulic lines or components under pressure. parking brake or drive tire.
Hydraulic oil under pressure can be injected
The steer support gear should be lubricated by re-
into the skin.
moving the gear cover from the support base and
spraying the gear with CRC 3-36 lubricant. See Fig-
CAUTION ure 9.
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

Never operate the pump without the proper

amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil
levels will damage the pump

Perform the following checks:

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.

Check the hydraulic oil level when the oil is at normal

operating temperature and forks are in the lowered
position.

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
motor gear for dirt or buildup. Brush clean with a
wire brush and apply CRC 3-36 lubricant on all vis-
ible gears. See Figure 10.
500 hours or 3 months unless the lift truck is being
operated in a food processing/corrosive environment
which requires daily lubrication. Load wheel axles
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

b. Position a sheet of paper under one of the

caster wheels and lower the lift truck.

c. Slowly raise the lift truck again while try-

ing to pull the paper from under the caster
wheel. Stop raising the truck as soon as the
paper can be removed from under the caster
wheel.

d. Loosen the two capscrews securing the extra

shims to the frame of the operator platform.
See Caster Shim Adjust.

e. Remove one shim by sliding it off the top of

the stack. Place a shim flat on the floor be-
side the drive wheel and try to push the shim
under the drive tire.
1. CAPSCREW f. If the shim slides under the drive tire, a shim
2. LOCKWASHER should be removed from between each side
3. WASHER
4. EXTRA SHIMS STACK of the caster and the frame. If two shims
5. SHIM SLOT IN FRAME stacked can be slid under the drive tire, two
6. TOP OF CASTER shims should be removed from between each
7. LOCKWASHER side of the caster and the frame.
8. CAPSCREW
g. If a shim cannot be slid under the drive tire,
Figure 11. Caster Shims the caster wheel is properly adjusted. Repeat
checks for other caster.
b. Remove one shim by sliding it off the top of
the stack.
Caster Shim Adjust
c. Place a shim flat on the floor beside the caster
1. Park on a smooth and level surface with the
wheel and try to push the shim under the
control handle centered and with no load on the
wheel.
forks. Lower the forks completely.
d. Repeat for the other caster.
2. Turn the key switch to the OFF position and dis-
e. If the shim slides under the caster wheel, connect the battery (DO NOT remove the bat-
a shim should be added between each side tery). Remove the floormat and the drive unit
of the caster and the frame. If two shims compartment cover.
stacked can be slid under the wheel, two
3. Check to determine if the casters need shims
shims should be added between each side of
added or removed for each caster. Refer to Caster
the caster and the frame. See Caster Shim
Shim Check.
Adjust.
4. Position a floor jack centered under the drive end
f. If the caster wheel is not touching the floor
of the lift truck. Raise the casters off the floor.
but a shim cannot be slid under the caster
wheel, the caster is properly adjusted. Re- 5. Loosen the four capscrews and lockwashers se-
peat checks for other caster. curing one caster to the frame. See Figure 11.
6. If the caster wheel is touching the floor, check 6. Loosen the two capscrews securing the extra
caster for over shimming: shims to the frame of the operator platform.
a. Position a floor jack centered under the drive 7. Add or remove the proper amount of shims be-
end of the lift truck. Raise the casters off the tween each side of the caster and the frame. In-
floor and verify jack position using the level. sert or remove shims through the shim slot in
the frame. Use shims from the extra shim stack

17
Maintenance Procedures Every 500 Hours or Every 3 Months 8000 SRM 1298

to augment or store extra shims in the stack for
later use. See Figure 12.
Operate the lift truck MDU for several minutes to
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.

Refer to the section Master Drive Unit 630 SRM

961 for MDU repair procedures.

Check Oil Level

Check gear oil level. Position the truck on a level sur-
face, turn the key switch to the OFF position, and
disconnect the battery. Remove the drive unit com-
partment cover. Turn the control handle arm to ac-
cess the oil fill plug in the MDU housing. Remove oil
fill plug. It may be necessary to roll the drive wheel
either forward or backward to line holes in the gear
up with the fill hole to visually check the oil level.
See Figure 13. Add gear oil through oil fill plug, if
1. SHIM SLOT 4. TRUCK FRAME necessary, until oil is level with bottom or halfway to
2. SWIVEL 5. SHIMS
3. CASTER WHEEL the top of the gear. Install fill plug. DO NOT OVER-
FILL.
Figure 12. Caster Mounting

8. Tighten the four capscrews and lockwashers se-

curing the caster to the frame.

9. Repeat for other caster.

10. Tighten the two capscrews securing the extra

shims to the frame of the operator platform.

11. Lower the lift truck and check for proper adjust-
ment.

12. Reinstall the floormat, connect the battery, and

turn the key switch to the ON position. Test for
proper operation.

MASTER DRIVE UNIT

Change Gear Oil
NOTE: The oil used in the master drive unit should
be drained and replaced after the initial 500 hours
break-in period in accordance with the Maintenance 1. MDU HOUSING 3. OIL LEVEL
2. OIL FILL HOLE
Schedule. After the initial oil change, the MDU
gear oil should be changed every 2000 hours. Refer Figure 13. Oil Level
to Maintenance Procedures Every 2000 Hours or
Yearly.

18
8000 SRM 1298
DRIVE TIRE CHECK
WARNING
When the drive tire has been installed, check
all wheel bolts after 2 to 5 hours of operation.
When the wheel bolts stay tight after an 8-hour
check, the interval for checking the torque can
be extended to 500 hours.
Check to ensure the wheel bolts are properly tight-
ened to 135 Nm (100 lbf ft). Inspect the tire for
Maintenance Procedures Every 2000 Hours or Yearly
LUBRICATION
Repack Load Wheel Bearings
Disassemble, clean, and inspect for wear or damage.
Lubricate the bearings with the proper grease type
specified in the Maintenance Schedule using a stan-
dard bearing packing device. Some lift trucks use
load wheels with sealed bearings. These bearings
may be wiped clean with a cloth, but cannot be lubri-
cated and must be replaced if not operating smoothly.
Apply a thin coat of antiseize lubricant to the sealed
bearing axles during installation.
Repack Steer Bearings (Manual Steer
Only)
Remove, clean, and inspect bearings for wear or
damage. Under normal conditions it is not neces-
sary to remove the bearing cups (races) from the
support. Clean and inspect the race surfaces for
wear or damage. Clean the bearing cones. Pack the
steer bearings with the proper grease type speci-
fied in the Maintenance Schedule using a standard
bearing packing device. Place a liberal coating of
grease on the surface of the races before installing
the bearings to ensure proper coverage.
HYDRAULIC SYSTEM
Oil Change
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Maintenance Procedures Every 2000 Hours or Yearly
embedded rocks, glass, wire, pieces of metal, holes,
cuts, and other damage. Remove any object that will
cause damage. Check for loose or missing nuts and
wheel bolts. Remove any wire strapping or other
material that is wrapped around the axle to prevent
damage to the axle seal. Make sure the wheel bolts
are tight.
When installing the tire and wheel, snug the wheel
bolts, then tighten to half the torque value, then
tighten to the full torque value. Tighten the nuts in
a cross pattern to properly seat the wheel to the hub.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper
amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil
levels will damage the pump.
NOTE: The hydraulic oil should be changed after the
initial 500 hour break-in period and then every 2000
hours thereafter.
Lower the forks, turn the key switch to the OFF
position, and disconnect the battery. Remove drive
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
and motor assembly to remove. Recover the reservoir
O-ring. Empty hydraulic oil into a suitable container
and discard in accordance with local regulations.
Clean hydraulic reservoir using a suitable clean-
ing solution and dry with compressed air. Clean
and inspect strainer. Replace strainer if clogged
19
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1298

or damaged. Clean and check reservoir O-ring for ELECTRICAL

brittleness or damage. Replace as necessary.
Make sure reservoir is clean and dry. Lubricate the
O-ring with a thin coating of grease and position it
around the lip of the reservoir as removed. Install
reservoir into the pump flange. If the O-ring shifts
out of place during installation; stop, reposition the
O-ring, and resume installation. Install retaining
clamps and secure using screws as removed. Add
hydraulic oil through breather filler pipe until at
Max mark on reservoir. Install breather cap and
tighten. Raise and lower forks several times to
bring the oil to normal operating temperature. Then
recheck hydraulic oil level. DO NOT OVERFILL.
Reconnect the battery, turn the key switch to the ON
position, and fully cycle the lift and lower functions
several times to expel air from the hydraulic system.
Recheck the hydraulic oil level and add as necessary.
Reinstall the drive unit compartment covers and
return to service.
BRAKE
Inspect all visible electrical wiring and terminals
when performing these checks. Repair any areas
where rubbing has frayed wiring. For more informa-
tion on electrical systems, refer to section Electrical
System 2200 SRM 1287.
MDU
Oil Change
Operate the lift truck MDU for several minutes to
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. See Figure 15. Replace drain
plug. Add gear oil through oil fill plug until oil is level
with bottom or halfway to the top of the gear. It may
be necessary to roll the drive wheel either forward or
backward to line holes in the gear up with the fill hole
to visually check the oil level. See Figure 15. Replace
oil fill plug. DO NOT OVERFILL.

A spring-applied, electrically-released brake is

mounted to the top of the traction motor to hold the
lift truck stationary when the traction motor is not
being operated. Check the brake for proper opera-
tion. If the brake will not release or fails to hold the
lift truck plus a capacity load on a 10-percent grade
[1 m rise in 10 m (3 ft rise in 30 ft)] with the forks
facing uphill, the brake assembly must be repaired
or replaced. See Figure 14. For information on
repairing or replacing the brake, refer to the section
Brakes 1800 SRM 1285.

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

Figure 14. Hold On Grade Test

20
8000 SRM 1298
Battery Maintenance
HOW TO CHARGE THE BATTERY
WARNING
The acid in the electrolyte can cause personal
injury. If electrolyte is spilled, flush the area
with water. Use a solution of sodium bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
WARNING
Batteries generate explosive hydrogen when
they are being charged. Keep fire, sparks,
and burning material away from the battery
charger area. Prevent sparks from the battery
connectors. Open the battery cover to disperse
explosive gas.
WARNING
Charge batteries only in the special area for
charging batteries. When charging the bat-
teries, keep the vent caps clean. The battery
charger area must have ventilation so that
explosive fumes are removed. Move the key to
the OFF position and disconnect the battery
when doing cleaning and maintenance.
WARNING
If the lift truck has been operated using a
battery that is almost discharged, inspect
for welded contacts BEFORE connecting a
charged battery. A contactor with welded
contacts can cause operations that are not
expected and possible personal injury when
a charged battery is connected. Check the
battery connector for damage.
CAUTION
Never connect the battery charger plug to the
plug of the lift truck. You can damage the
traction control circuit. Always make sure the
charger voltage is the correct voltage for the
battery.
Correct use of the hydrometer and proper operation
of the battery charger is important. Operate the
battery charger according to the instructions of
the charger manufacturer. Never let the battery
discharge below the minimum value given by the
battery manufacturer. A fully charged battery will
Battery Maintenance
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
that will raise the electrolyte temperature above
49 C (120 F). Never permit a battery to stay dis-
charged for long periods.
Table 2. Specific Gravity Corrections
Specific
Electrolyte Correction Correct
Gravity
Temperature Points Value
Reading
1.210 31 C (88 F) +0.003 1.213
1.210 27 C (81 F) +0.001 1.211
1.210 25 C (77 F) +0.000 1.210
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).
Base Value (Degrees C 1.8) + 32 = Degrees F.
Equalizing Charge
This charge is at a low rate and balances the charge
in all of the cells. The equalizing charge is normally
given approximately once a month. It is a charge at
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
gravity measurement for a charged battery will be af-
ter an equalizing charge. If the difference in specific
gravity is more than 0.020 between cells of a battery
after an equalizing charge, there may be a cell that
has a malfunction. Consult your battery dealer.
NOTE: Many customers have battery chargers that
can follow a program to automatically charge a
battery according to recommendations of the bat-
tery manufacturer. Use the recommendations of
the battery manufacturer for charging the battery.
Use only battery chargers approved by the battery
manufacturer or dealer.
Normal Charge
This charge is normally given to a battery that is
discharged from normal operation. Many customers
charge the battery at regular intervals that depend
on use. This procedure will keep the battery correctly
charged if the battery is not discharged below the
limit. Always use a hydrometer to check the battery
21
Battery Maintenance 8000 SRM 1298

if the battery is charged at regular intervals. Fre-
quent charging of a battery that has a 2/3 or more
charge can decrease the life of the battery.
HOW TO CHANGE THE BATTERY
WARNING
Batteries are heavy and can cause personal in-
jury or property damage. DO NOT put hands,
arms, feet, or legs between the battery and
a solid object. Make sure the capacity of the
crane and spreader bar is greater than the
weight of the battery. The weight of the bat-
tery is normally shown on the battery case.
The maximum battery weight is shown on the
lift truck capacity plate. The spreader bar
must NOT be made of metal or it must have
insulated straps.
3. Loosen and remove buckle and strap from around
battery.
4. Lift the battery out of the truck. DO NOT allow
the battery to shift from side to side. Make sure
the battery cables have clearance.
5. Before installing a new battery, make sure the
battery is the correct size and weight for the lift
truck. Make sure the battery has clearance for
installation. Check that the battery connector
can be attached to the lift truck connector with-
out pulling during lifting and lowering opera-
tions. DO NOT damage the battery cables dur-
ing installation. Install the battery.
6. Replace buckle and strap and tighten to prevent
the battery from moving.
7. Remove the blocks from under the truck.

WARNING 8. Connect the battery. Test the operation of the

Put blocks under both sides of the frame in the motorized hand truck before returning the truck
area of the battery compartment. The blocks to service.
must prevent the lift truck from falling and
causing personal injury or property damage.

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
WARNING
Maintain a safe distance from the edge of
docks, ramps, platforms, and other similar
working surfaces. Watch the "tailswing." Re-
member, when traveling in the forward direc-
tion, and the steering wheel is turned to move
the lift truck away from the edge of the dock,
the rear will swing toward the edge. This can
cause the lift truck to fall off the dock.
If the lift truck falls off the dock, DO NOT jump
off! Hold firmly to the steering wheel, brace
your feet, and lean forward and away from the
point of impact.
Before the lift truck is transported, check the se-
lected route to make sure there is adequate clearance
for the lift truck as loaded on the transport vehicle
(bridges, overpasses, power lines, and natural bar-
riers).
If a trailer is the method of transportation, use blocks
in front and back of the trailer tires to prevent move-
ment of the trailer when the lift truck is loaded and
unloaded. If a loading ramp is used, make sure that
the ramp is the proper design and capacity.
Use approved lifting eyes to lift the truck. If the lift
truck is not equipped with approved lifting eyes, DO
NOT lift the truck by attaching a lifting device to any
other part of the lift truck for the purposes of loading
or unloading.
LOADING
The operator must never leave a lift truck in a condi-
tion so it can cause damage or injury. When parking
the lift truck, do the following operations:
1. After the lift truck has been loaded, apply the
parking brake.
2. Turn the key switch to OFF to stop the engine.
Transporting
3. Check that all switches and accessories are
turned off.
4. Put blocks in front and back of the lift truck tires
to prevent any movement of the lift truck. Make
sure the blocks are attached to the transport sur-
face.
WARNING
The straps or chains used to attach the lift
truck to the transporter must be directly at-
tached to the lift truck frame or to a component
(drive axle, tow pin) that is solidly attached to
the frame. DO NOT attach the straps or chains
to the mast or any attachment.
CAUTION
Make sure that any straps or chains used to at-
tach the lift truck to the transporter DO NOT
contact any tubes, hoses, hydraulic cylinders,
or other parts of the lift truck that are easily
damaged.
5. If the lift truck is transported in severe weather
or any other condition that can damage the lift
truck, cover the lift truck. Make sure the tarp
or protective material is designed for the appli-
cation and is securely attached.
UNLOADING
1. If used, remove any covering.
2. Make sure the park brake is applied.
3. Disconnect the straps or chains.
4. Remove the wheel blocks.
5. Check that all switches and accessories are
turned off.
6. Unload the lift truck.
23
Preparation for Use
Preparation for Storage
The following storage procedures are guidelines for
conditions and temperatures above 0 C (32 F). Ad-
just these procedures to meet local conditions as well
as any expected change in conditions during storage.
Determine the amount of preparation necessary for
storage based on the following:
Length of Storage. Short-term storage is from 1 to
6 months. Long-term storage is over 6 months.
Storage Locations. A lift truck stored indoors will
not require as much external protection as a lift
truck stored outdoors.
SHORT-TERM STORAGE (1 TO 6 MONTHS)
CAUTION
Make sure all caps, lids, and dipsticks are in-
stalled correctly.
1. Check lubricants and fluid levels.
2. Check that all switches and accessories are off.
3. Disconnect battery cables from the batteries. Ap-
ply corrosion preventive to battery terminals.
Preparation for Use
After being transported or stored, the lift truck must
be prepared for service and checked for proper opera-
tion. Refer to Maintenance Schedule in this section.
PREPARATION AFTER SHIPMENT
1. Complete the unloading procedures.
2. Inspect the lift truck for damage and missing
components.
PREPARATION AFTER STORAGE
1. Remove all tape, covers, and preservation mate-
rials.
24
8000 SRM 1298
4. Put blocks at the front and rear of the drive
tire when parked. DO NOT rely on the parking
brake.
5. Clean dust and dirt from interior surfaces and
exterior surfaces. Clean frame to remove sand or
road salt. Allow frame to air dry.
6. If lift truck is parked outside, cover with a tarp
or protective material to keep direct sunlight out
of the operators compartment and water out of
the controls.
LONG-TERM STORAGE (6 MONTHS OR
LONGER)
1. Complete all short-term storage procedures.
2. Wrap or cover all exterior lights and air vents
with moisture barrier paper and tape closed.
3. Remove the batteries from the lift truck. Put the
batteries in storage. Be sure to follow local fire
regulations.
4. Spray exterior surfaces and frame with preser-
vative coating.
2. Check the lift truck for damaged or missing com-
ponents. Repair damage and/or replace missing
components.
3. Clean battery cables. Check the battery volt-
age. If the voltage is less than nominal, charge
the battery. Connect the cables to battery and
tighten.
 TECHNICAL PUBLICATIONS

8000 SRM 1298 11/06 Printed in U.S.A.