PERIODIC MAINTENANCE

MANUAL
V30ZMU
C1.0 - C1.3 - C1.3 LWB
[B463]
V35ZMU
C1.3 80 - C1.5 SWB - C1.5 MWB - C1.5
[B464]

PART NO. 1638867 8000 SRM 2202

 Table of Contents

TABLE OF CONTENTS
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR.............................................................................. 2
Safety decals maintenance....................................................................................................................................3
Frame maintenance...............................................................................................................................................4
Motor maintenance................................................................................................................................................5
Reduction unit maintenance................................................................................................................................. 6
Braking system maintenance ...............................................................................................................................9
Cab and controls instruments.............................................................................................................................10
Electrical system maintenance........................................................................................................................... 12
Hydraulic system maintenance.......................................................................................................................... 13
Mast, platform, pantograph, forks and lift chains maintenance...................................................................... 15
Operator compartment maintenance................................................................................................................. 17
Wheel maintenance............................................................................................................................................. 18
Battery maintenance........................................................................................................................................... 19
Greasing............................................................................................................................................................... 21

©2021 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 2202

1
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR 8000 SRM 2202

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.
• 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage. On the lift truck, the WARNING
symbol and word are on orange background. The CAUTION symbol and
word are on yellow background.

2
 8000 SRM 2202 Safety decals maintenance

Safety decals maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check conditions of visible warning and information plates and decals ●
(1) ■

General cleaning of all warning and information plates and decals ■ ●

(1)
Replace, if necessary. Check that all safety labels are installed in the
correct locations on the lift truck. Make sure that all
labels are not damaged and that they can be read. If
WARNING necessary, see the Parts Manual for your lift truck
If labels that have warnings or instructions are for the correct location of the labels.
damaged, they must be replaced immediately.
Make sure all safety labels are installed in the Safety labels are installed on the lift truck to give
correct locations on the lift truck. Make sure all information about possible hazards. It is important
labels are not damaged and that they can be read. that all safety labels are installed on the lift truck
and can be read. See the Parts Manual for label
CHECK CONDITIONS AND CLEANING OF
placement for your lift truck.
LABELS AND DECALS

3
 Frame maintenance 8000 SRM 2202

Frame maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance Intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 year
Check the tightening of the screws and bolts ●
Check the motor compartment cover hinges ●
Check the traverse frame rollers ●
Check the main welds ●
General cleaning ●

CHECK THE TIGHTENING OF THE SCREWS WELDING CHECK

AND BOLTS
Visually inspect the weldings. Check they have no
Check the screws and the bolts are well tightened. signs of wear or break.

MOTOR COMPARTMENT HINGES GENERAL CLEANING

Visually inspect the hinges of the motor Use dry air, cloths moistened with water, or
compartment. If needed, lubricate them with degreasing cleaning products.
Multipurpose Grease with 2 to 4% Molybdenum
Disulfide.
CAUTION
Do not use water jets, vapours, solvents or
TRAVERSE FRAME ROLLERS flammable products that may damage the truck or
Visually inspect the traverse frame rollers. If that can be dangerous for the operator.
needed, lubricate them with Multipurpose Grease
with 2 to 4% Molybdenum Disulfide.

4
 8000 SRM 2202 Motor maintenance

Motor maintenance

● = check and maintenance, ■ = operator check, x = replacement Maintenance intervals

Every 8
Every 1000, Every 3000,
Operation description hours,
1 year 3 year
1 day
Check motor insulation ●
Check cable connection ●
Check fixing nut connection ●
Check bearing noise ●
General cleaning ●

MOTOR INSULATION CHECK

Remove the motor compartment bonnet. Check the
screws securing the traction motor unit to the
support plate are well tightened. Check the cables
WARNING
are properly connected.
Before starting work, ensure that you are wearing
suitable protective clothing. Move the truck to a
safe place, away from areas of transit of other BEARING NOISE CHECK
vehicles and all pedestrians. Set the key switch to
OFF and disconnect the battery. Check that the bearing does not make abnormal
noise during operation.
To measure the motor insulation resistance,
disconnect the phase wires (U, V, W) . Connect one
of the tester probes to the U phase and the other GENERAL CLEANING
probe to the bodywork in an unpainted zone. The To clean the motor, please use only dry air at low
resistance reading (Ω) on the tester should be pressure and a clean dry brush.
infinity (~). Otherwise, the motor is not insulated
and must be replaced immediately. Repeat the
operation with the other two phases (V, W). CAUTION
Do not use wet rags, water jets, vapour, solvents
or flammable products that may damage the truck
CABLE AND FIXING NUT CONNECTION or that may be dangerous for the operator.
CHECK

WARNING
Before starting work, ensure that you are wearing
suitable protective clothing. Move the truck to a
safe place, away from areas of transit of other
vehicles and all pedestrians. Set the key switch to
OFF and disconnect the battery.

5
 Reduction unit maintenance 8000 SRM 2202

Reduction unit maintenance

● = check and maintenance, ■ = check by the operator, x = Maintenance intervals

replacement Every 8 Every 1000 Every 3000,
hours, hours, hours,
Operation description
1 day 1 year 3 years
Check for oil leaks ■ ●
Check steering crown gear and steering pinion wear ●
Change oil in reduction unit x
General cleaning ●

OIL LEAK CHECK

Check for leaks by looking for oil under the lift truck WARNING
and where the lift truck has been parked. Visually Do not dispose of used oil in the ground or by
inspect the hydraulic system and hoses. Small oil pouring it down the drain. Contact a waste
leaks may appear as wet, oily leaks or unusually disposal company specialised in the disposal and
dirty areas where dirt and dust sticks to oil that has recycling of industrial oils.
slowly leaked out.
Procedure
Phase 1
CHECK STEERING CROWN GEAR AND
STEERING PINION WEAR Clean the area near the filling and drain screws
carefully. Place the oil tank with proper dimensions
Unscrew and remove the fastening screws on the
under the drain screw. Using the Allen wrench
motor compartment cover Remove the cover.
loosen the oil filling screw (ref. A figure 1. and
Visually inspect the steering crown gear and the figure 2.), remove the filling screw and the O-ring.
steering pinion. Check they have no signs of wear. Always using the Allen wrench loosen the oil drain
screw (ref. B figure 1 and figure 2), remove the
screw and the O-ring.
CHANGE THE REDUCTION UNIT OIL
Drain the oil in the tank completely. Clean the
drain screw from the impurities gathered during the
WARNING reduction unit working.
Before starting work, ensure that you are wearing
suitable protective clothing. Move the truck to a
safe place, away from areas of transit of other
vehicles and pedestrians. Lower the forks to the
ground, push the forks against an obstacle in
order to keep the truck blocked when it is lifted
using the hydraulic jack , position the ignition key
on OFF and disconnect the battery.

WARNING
Use caution as the oil in the reduction unit will be
hot after use of the truck. Wear oil resistant gloves
capable of withstanding high temperatures.

6
8000 SRM 2202 Reduction unit maintenance

Figure 1. Figure 2.

NOTE: Screw the plug with a new O-ring 22 Nm

driving torque.
Phase 2
In models KG30, loosen and remove the upper plug
with its O-ring and use a syringe to fill the oil
(figure 3.), which allows the oil to be filled easily
and quickly.

7
Reduction unit maintenance 8000 SRM 2202

Figure 3.
Figure 4.
In models KG40, loosen and remove the upper plug
with its O-ring and use a funnel with hose to fill the
oil (figure 4.) Use the type of oil contained in the table below
The right level and quantity of oil are reached when
the oil surface is on the lower edge of the oil filling GK 30 GK400
Model
hole or when the oil goes from the oil filling hole at Oil type Oil Oil
Use
the latest. qty qty
Standa SHELL SPIRAX S3 4.6
7 liter
rd AX 80-W90 liter
Cold SHELL SPIRAX S6 4.6 7 liter
store AXME 75W-90 liter

8
 8000 SRM 2202 Braking system maintenance

Braking system maintenance

● = check and maintenance, ■ = operator check, x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check service braking operation ■ ●
Check reverse braking operation ■ ●
Check release braking operation ■ ●
Check ermegency braking operation ■ ●
Electromagnetic parking brake and coil efficiency check ●
Brake lining wear check ●
General cleaning ●

REVERSE BRAKING CHECK

CAUTION Drive the machine forward and reverse the direction
Before carrying out all the maintenance operations with the direction of travel selector.
described in this chapter ensure that the truck is
on a flat surface, with no load.
EMERGENCY BRAKING CHECK
Drive the machine forward and press the emergency
WARNING switch.
Never allow people to stand around anywhere near
the truck when testing the braking action.
ELECTROMAGNETIC PARKING BRAKE,
Never carry out tests where damage could be COIL EFFICIENCY AND LINING WEAR
caused by a lenghty braking action CHECK
NOTE: Perform the following checks on a stretch of Check the operation of the brake. The brake is
road that is level, dry and obstacle-free and applied when the truck is stopped. The brake must
sufficiently long to allow stopping in case of non not let the lift truck move if parked on an incline.
operation of the brakes. The brake, when in good condition and correctly
adjusted, will hold the lift truck with a capacity load
on a 5% grade [a slope of 0.5 meters in 10 meters (a
RELEASE BRAKING CHECK slope of 0.5 ft in 10 ft)]. If the brake does not hold
Drive the machine forward and release the drive the truck on a grade, the brake needs to be checked
control. by authorized service personnel.

9
 Cab and controls instruments 8000 SRM 2202

Cab and controls instruments

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check all the truck functions by actuating controls ■ ●
Check the steering system ■ ●

foot switch depressed. All electrical circuits must

NOT operate.
WARNING
Make sure the area around the lift truck is clear Lift System Operation
before moving the lift truck or checking for correct
operation. Be careful when making the checks.
WARNING
NOTE: None of the electrical controls will operate Lower the lift mechanism completely. Never allow
until the power circuit is energized by the key anyone under a raised platform or the forks. Do
switch. not put any part of your body in or through the lift
mechanism unless all parts of the mast and
CHECK ALL THE TRUCK FUNCTIONS USING
platform are completely lowered and the key
THE CONTROLS
switch is in the OFF position. Remove the key.
Check the operation of all controls and
Before making any repairs, completely lower the
instrumentation.
platform or use chains on the mast weldments and
Gauges and horn platform so they cannot move. Make sure the
Check the operation of the gauges and horn. The moving parts are fastened to the parts that cannot
key switch must be in the ON position to operate move.
the horn. The hourmeter display operates during Do not try to find hydraulic leaks by putting hands
startup. The battery meter operates whenever the on hydraulic components under pressure.
truck is ON. Hydraulic oil can be injected into the body by
The battery meter correctly indicates the condition pressure.
of the battery.
1. Slowly raise and lower the forks and the
There are two power fuses in the electrical platform several times without a load. All
compartment. The power fuses have the following moving components must raise and lower
ratings: smoothly.
Large chassis truck only 2. The platform and the forks must lower
completely.
Traction Motor - 300 amps
3. Raise the platform 1 m (3 ft), with a capacity
Hydraulic Pump Motor - 500 amps load. The inner weldment and platform must
raise smoothly. Lower the platform and forks.
Make sure the fuses are the correct size and are not All moving components must lower smoothly.
burned. Some types of fuses must be checked with
4. Make sure the tops of the forks are 70 to 77
an ohmmeter. If any of the fuses are bad, disconnect
mm (2.75 to 3.00 in.) above the floor. If the
the battery before replacing the fuse. clearance is not correct, the chain anchors
Lift/Lower and Direction/Speed Control must be adjusted.
Make sure the foot switch and Direction/Speed Emegency devices
control operate correctly. Check the operation of all emergency devices.
Check the operation of the Power Disconnect switch.
Push the button with the key switch ON and the

10
8000 SRM 2202 Cab and controls instruments

CHECK THE STEERING SYSTEM

Make sure that the steering system operates
smoothly and gives good steering control.
WARNING
There is NO steering if there is no electrical power.
To prevent injury or damage, make sure the
electric power steering is operating correctly
before moving the lift truck.

WARNING
When the truck is started, the steering system will
automatically rotate the drive unit to the straight-
ahead position. Keep hands, feet, and tools clear
of the mechanism while this is happening.

11
 Electrical system maintenance 8000 SRM 2202

Electrical system maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Battery plug/socket integrity check ■ ●
Check conditions of the electrical power connections ●
Fixing nut condition check ●
Electrical wiring check ●
Sensor operation check ●
General cleaning of electrical panel ●

BATTERY PLUG/SOCKET INTEGRITY

CHECK
ELECTRICAL WIRING CHECK
Check the integrity of the battery socket and plug.
Visually inspect the electrical wiring. Check the
The plug must be securely attached to the truck and
wiring is correct and have no signs of wear.
the handle for quick removal must be securely
attached to the socket.
SENSOR EFFICIENCY CHECK
ELECTRICAL CONNECTION CHECK With key switch turned on, enable each sensor
installed on the truck to check its operating.
Visually inspect the electrical connections. Check
the cables are properly connected and have no signs
of wear. Check for loose or broken electrical GENERAL CLEANING OF ELECTRICAL
connections and damaged wires or cables. PANEL
To clean the electrical panel use only dry air at low
WARNING pressure and a clean dry brush.
Broken electrical connections, damaged wires or
cables can cause the electrical controls to operate
incorrectly.
CAUTION
Do not use wet rags, water jets, vapour, solvents
or flammable products that may damage the truck
or that may be dangerous for the operator.
FIXING NUT CONDITION CHECK
By using the proper tool, check the fixing nut is well
tightened.

12
 8000 SRM 2202 Hydraulic system maintenance

Hydraulic system maintenance

● = check and maintenance, ■ = operator check, x = replacement Maintenance intervals

Every 8 hours Every 1000 Every 3000
Operation description 1 day hours, hours,
1 year 3 years
Check for oil leaks ■ ●
Check for smooth operation of valves ■ ●
Check oil level in tank ●
Tank oil change x
(1) x
Change oil filter
Check the conditions of the hydraulic tank breather ●
General cleaning ●

(1)
Change hydraulic filters after first 100 hours of platform must be lowered and the key switch must
operation be OFF. If the oil level is not visible at the sight
gauge, the oil level is above or below the sight
gauge. Open the door of the hydraulic compartment
to check for the correct level and to fill the tank if
WARNING necessary (see figure 5.).
Do not permit hot hydraulic oil to touch the skin
and cause a burn. When hydraulic oil is at
operating temperature, it is HOT.

CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

CHECK FOR OIL LEAKS

Check for leaks by looking for oil under the lift truck
and where the lift truck has been parked. Visually
inspect the hydraulic system and hoses. Small oil
leaks may appear as wet, oily leaks or unusually
dirty areas where dirt and dust sticks to oil that has Figure 5.
slowly leaked out.
If it is necessary to top up the oil, unscrew the
breather cap and fill with the proper oil (see table
VALVES OPERATION CHECK below).
Check that all the valves mounted on the truck If too much hydraulic oil is added, the oil will leak
operate correctly. from the breather during operation.

CHECK OIL LEVEL IN TANK

Check the hydraulic oil level at the sight gauge
when the oil is at operating temperature. The

13
Hydraulic system maintenance 8000 SRM 2202

Extract the housing from the filter (ref. B figure

Applicatio Cold Trade 7). Extract the filter from the valve unit seat (ref.C
Std Type
n store mark figure 8) and replace it
Oil for ● TELLUS
Shell
lubrication S2 V 46
of the AEROSHE
hydraulic ● Shell LL FLUID
circuit 41

REPLACEMENT OF THE OIL CONTAINED IN

THE TANK
To drain the oil, put the lift truck on a level surface.
Completely lower the mast and the forks. Use a Figure 7.
container with a 100 liter (25 gal) capacity near the
supply hose of the hydraulic tank to hold the oil.
Turn the key switch to the OFF position and
disconnect the battery.
NOTE: The hydraulic oil must be drained or
replaced by authorized service personnel only.

REPLACEMENT OF THE OIL FILTER

Figure 8.
WARNING
Before starting work, ensure that you are wearing NOTE: The valves must be tightened using a torque
suitable protective clothing. Move the truck to a wrench to a torque of 110 Nm.
safe place, away from areas of transit of other
vehicles and all pedestrians. Set the key switch to
OFF and disconnect the battery. CHECK THE CONDITION OF THE
HYDRAULIC TANK BREATHER
Put on the oil proof gloves, place the tank under the
Visually inspect the condition of the tank breather.
filter housing. By means of the Allen wrench loosen
Clean it by flushing with solvent and check it has no
the four fastening screws of the filter housing (ref.
damages and signs of wear.
A figure 6.).

Figure 6.

14
 8000 SRM 2202 Mast, platform, pantograph, forks and lift chains maintenance

Mast, platform, pantograph, forks and lift chains maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check conditions of forks and the fork pins ■ ●
Check conditions of the bearings ●
Check conditions of the lifting chains ■ ●
Check conditions of the shaves ●
Check conditions of pantograph pins ●
Check conditions of the sliding surfaces and the rollers ●
Check mast and platform welds and nuts tightening ■ ●

A. TIP ALIGNMENT
WARNING B. FORK PIN DAMAGE
NEVER work under a raised carriage or forks. Replace any damaged or broken parts that are used
Lower the carriage or use chains on the mast to keep the forks locked in position.
weldments and platform so that they cannot move.
When chains are used, make sure the moving
parts are fastened to a part that cannot move. WARNING
Do not try to correct alignment of the fork tips by
CHECK CONDITION OF FORKS bending the forks. Use shims to align the fork tips.
Check that there are no cracks in the structure of Replace damaged forks.
the forks and particularly at welded joins. If any
cracks are visible, replace the fork. Do not attempt
any repairs by welding. CHECK CONDITIONS OF BEARINGS
Check the mast does not make abnormal noise
WARNING during operation.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special
CHECK THE LIFTING CHAINS
procedures. Replace damaged forks. Always
replace forks in pairs. Check all lift chains for the correct lubrication. In
case lubricate with engine oil.
Make sure the fork tips are aligned within 13 mm
Inspect the lift chains for cracks or broken lines and
(0.5 in.) of each other. See (ref. A figure 6.). Add or
pins (figure 7.)
remove shims for alignment.

Figure 9.

15
Mast, platform, pantograph, forks and lift chains maintenance 8000 SRM 2202

NOTE: If the chains need repair or adjustment, it

must be done by authorized personnel.

CHECK CONDITIONS OF THE SHEAVES

Visually inspect the sheaves. Check they have no
signs of wear.

CHEK CONDITIONS OF PANTOGRAPH PINS

Visually inspect the pantograph pins. Lubricate
Figure 10. them every 500 working hours with Multipurpose
Grease with 2 to 4% Molybdenum Disulfide.
1. WORN PIN
2. CRACKS
CHECK CONDITIONS OF THE SLIDING
3. EDGE WEAR SURFACES AND ROLLERS
4. HOLE WEAR Inspect the channel for wear in the areas where the
5. LOOSE LEAVES rollers travel. Inspect the rollers for wear or
6. DAMAGED PIN damage.
7. RUST If needed, lubricate the sliding surface with
Multipurpose Grease with 2 to 4% Molybdenum
Inspect the chain anchors and pins for cracks and Disulfide.
damage. Make sure the lift chains are adjusted so
they have equal tension. Check tension by pulling
horizontally on both chains and making sure they CHECK MAST AND PLATFORM WELDS AND
move the same amount NUTS TIGHTENING
Replace the chains if they have stretched beyond 2% Inspect the welds on the mast and platform for
of their length or if the links, hinge pins or chain cracks.
tensioner are worn to such an extent that
replacement is indispensable. Check the nuts and bolts are well tightened

16
 8000 SRM 2202 Operator compartment maintenance

Operator compartment maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check the seat conditions and operation ■ ●
OPERATOR COMPARTMENT

Check seat belt conditions and operation ■ ●

Check the emergency lowering device/kit ●

Check the personal fall protection system (PFPS)

■ ●
V30ZMU - V35ZMU only

CHECK THE PERSONAL FALL PROTECTION

Make sure the emergency lowering device is always
SYSTEM
kept in the protective casing.
Check all parts of the device before using.
Do not use defective components.
WARNING
Never apply oil or grease to the emergency lowering
The Personal Fall Protection System is specially
device.
made to lessen the shock of a fall. Do not
The components of the emergency lowering device
substitute other types of ropes or straps.
must be inspected by a safety officer after each use,
1. Inspect the lanyard for wear, deformation, and at regular intervals no longer than 12 months.
excessive elongation, cuts, or damage. Inspect NOTE: For more detailed information on the
the clips for cracks, broken hardware, duration of use refer to the manuals of the
corrosion, and proper operation. Replace as individual components contained in the kit.
necessary.
2. Inspect the full body harness or body belt for
fraying, cracks, cuts, deformation, or wear. WARNING
Inspect any hardware for cracks, broken These durations are purely indicative. A rope can
hardware, corrosion, and proper operation. be damaged irreparably the first time it is used.
Replace as necessary.
Inspection will establish whether or not the
CHECK THE EMERGENCY LOWERING product can continue to be used. It is essential to
DEVICE/KIT look after the rope properly as long as it is in use.
A rope should never remain in use for more than
10 years. Maximum rope life (storage prior to use +
WARNING duration of use) is limited to 15 years.
The operator must be instructed in the use of the
emergency lowering device, which is stored in the
compartment below the seat. This device must
only be used to bring down the operator when it is
not possible to lower the cab with the manual
lowering valve.

17
 Wheel maintenance 8000 SRM 2202

Wheel maintenance

● = check and maintenance; ■ = Operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Check condition and wear of drive wheel (replace if necessary) ■ ●
Check condition and wear of load wheels (replace if necessary) ■ ●
Check condition of load wheel bearings (replace if necessary) ●
Check drive wheel fixing nut tightness ●

CHECK THE CONDITION AND WEAR OF 2. REMOVE NAILS, GLASS, AND ALL METAL
DRIVE WHEEL, LOAD WHEELS
Inspect the drive tire and load wheels for damage. CHECK CONDITION OF THE LOAD WHEEL
Inspect the tread and remove any objects that will BEARINGS
cause damage. Inspect the wheels and casters for
loose or missing parts. Remove any wire, strapping, Check the load wheel bearings do not make
or other material wound around the axles or the abnormal noises during operation.
casters.
Visually inspect the wheels have no signs of wear CHECK DRIVE WHEEL FIXING NUT
(see figure 8.). TIGHTNESS
By using the proper tool, check the the drive weel
fixing nuts are well tightened
The torque riquired is 140 Nm

CAUTION
If the wheels have been removed and installed,
check all wheel nuts after 2 to 5 hours of
operation. Tighten the nuts in a cross pattern to
the correct torque value (140 Nm). When the nuts
Figure 11. stay tight for eight hours, the interval for checking
the torque can be extended to 500 hours
1. MAKE SMOOTH EDGES

18
 8000 SRM 2202 Battery maintenance

Battery maintenance

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Battery charge level check ■ ●
Cable connection check ●
Liquid leaks check ■
Electrolyte density check ●
Electrolyte level check ●
Battery insulation check ●
General cleaning ●

come into contact with flames or sparks. In the

WARNING case of forced ventilation, flues also used for the
extraction of combustion products may not be
Failure to follow the instructions in this chapter
used.
and the information of the battery and charger
instruction manuals, can cause serious damage to In case the battery needs to be charged:
persons or property in relation to the danger level
of the batteries.
WARNING
The element caps are provided with vents. Before
WARNING recharging the battery, make sure the holes are not
It is recommended to wear safety footwear, gloves, obstructed.
safety glasses and suitable clothing when working
with the batteries. The container is acid resistant 1. Take the truck to a recharge area.
and must be kept in a vertical position (or as close 2. Switch off the truck.
to vertical as possible): it must never be turned 3. Open the battery compartment cover.
upside down in order to avoid electrolyte spillage.
The acid present in the solution can cause serious 4. Check that the voltage and the polarity are
correct so as to avoid causing serious damage
injury. to the battery and the battery charger.
BATTERY CHARGE CHECK 5. Disconnect the battery socket from the truck
plug and connect it to the battery charger
Check the battery charge level shown on the battery plug.
charge indicator located on the truck display.
6. Disconnect the battery socket from the
If the battery needs to be recharged, take the truck battery charger and connect it to the truck
in a recharge area, allow the battery to cool down plug when the charging is completed.
after taking it out of service and before starting to 7. Re-close the battery compartment cover.
recharge.
NOTE: The battery compartment cover must be
kept open at all times during recharging operations
WARNING in order to allow gases generated by chemical
The battery should be recharged in a special well reactions inside the battery elements to disperse.
ventilated room separated from the working
environment because the batteries generate
flammable gases that may cause explosions if they

19
Battery maintenance 8000 SRM 2202

NOTE: The battery socket and truck plug must only NOTE: After connecting the clamps to the
be separated when the truck is switched off. battery poles, apply some Vaseline grease to
prevent the risk of oxidation.
The battery socket and charger plug must only be
connected and separated when the charger is LIQUID LEAKS CHECK
switched off.
Open the battery housing and check there are no
fluid leaks.
WARNING
The acid in the electrolyte can cause injury. Use ELECTROLYTE DENSITY AND LEVEL
water to flush the area and make the acid neutral CHECK
with a solution of soda and water (one pound of
baking or commercial soda to one gallon of water). Check the electrolyte level daily on a minimum of
Acid in the eyes must be flushed with water. one cell and on all cells every week. Fill to the
correct level according to the battery manufacturer's
Batteries generate explosive fumes during the recommendations. Add only distilled water. Use a
charging operation. Keep fire, sparks, and burning hydrometer to check that the battery is not
material away from the charging area. When discharged below the minimum specific gravity
charging the battery, keep the vent caps clear. given by the manufacturer and has enough charge
Avoid sparks or open flame. Provide ventilation. to complete a work period.
Open the battery cover if equipped. Disconnect the
battery during servicing.
WARNING
The acid in the electrolyte can cause injury. If the
CABLE CONNECTION CHECK electrolyte is spilled, use water to flush the area
and make the acid neutral with a solution of soda
Check for loose or broken electrical connections and
and water (one pound of baking or commercial
damaged wires or cables.
soda to one gallon of water). Acid in the eyes must
be flushed with water. Have a doctor check the
WARNING eyes.
Broken electrical connections, damaged wires or
cables, and leakage or corrosion from the battery
can cause the electrical controls of the truck to BATTERY INSULATION CHECK
operate incorrectly. By using a multimiter check the battery is correctly
insulated.
Check the right cable connection to the battery
considering that the positive battery terminal is
identified with the redmarking or the symbol + , GENERAL CLEANING
while the negative pole is identified with
bluemarking or the symbol - . The battery connector Keep the battery case, top cover, and battery areas
cables are in turn marked with a red tag for the clean and painted. Use a water and soda solution to
connection to the positive pole and a blue tag for the clean the battery and the battery area. Keep the top
connection to the negative pole. of the battery clean, dry, and free of corrosion.

20
 8000 SRM 2202 Greasing

Greasing

● = check and maintenance; ■ = operator check; x = replacement Maintenance intervals

Every 8 Every 1000 Every 3000
Operation description hours, hours, hours,
1 day 1 year 3 years
Lubricate lifting chains ●
Lubricate with grease the reduction unit outer gear (steering wheel, ●
crown and pinion)
Lubricate with grease the battery tray sliding blocks ●
Lubricate with grease the bearings for the forks carriage cylinder ●
joint
Lubricate with grease the forks carriage sliding bearings guides ●
Lubricate with grease the mast bearings slide guides ●
Lubricate with grease the side shift ●

*See the operator manual (Maintenance/Battery

section) to know the correct lubricant in use.

21
 TECHNICAL PUBLICATIONS

8000 SRM 2202 10/21 (10/20)(8/20)(12/18)