Hyster B453 Service & Repair Manual Download Page 22

1. NEGATIVE CONNECTION

2. POSITIVE CONNECTION

3. 200-OHM, 2-WATT RESISTOR

4. INSULATED JUMPER WIRES

Figure 9. Discharging Controller

HOW TO MAKE CHECKS WITH KEY

SWITCH OFF

Safety Labels

  WARNING 

If  labels  that  have  warnings  or  instructions  are
damaged, they must be replaced immediately.

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  necessary,  see  the  PARTS  MANUAL  for
your lift truck for the correct location of the labels.

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. If labels are missing or damaged,
replace.  See  the  Parts  Manual  for  label  replace-
ment for your lift truck.

Put the lift truck on a level surface. Lower the forks
and turn the key switch to the OFF position. Dis-
connect  the  battery.  Open  the  drive  unit  compart-
ment cover. On the W25/30/40ZC, also open the hy-
draulic  compartment  cover  located  in  the  front  of
the  truck.  Check  for  leaks  and  conditions  that  are
not normal. Clean any oil leaks or spills. Make sure
that  lint,  dust,  paper,  and  other  materials  are  re-
moved from the compartment(s).

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1027

16

Summary of Contents for B453

Page 1: ......

Page 2: ...PERIODIC MAINTENANCE W30 40ZA B453 W20 30ZR B455 W25 30 40ZC B454 PART NO 1524253 8000 SRM 1027...

Page 3: ...dic Maintenance 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 ma...

Page 4: ...lic System 21 How to Make Checks With Key Switch ON 21 Check for Leaks in Lift System 21 Control Buttons 22 Direction Speed Control and Switches 22 Gauges Horn Fuses 23 Maintenance Procedures Every 35...

Page 5: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 6: ...38 Equalizing Charge 38 How to Change the Battery 39 Standard Battery Spacer Adjustment 39 Changing the Battery With an Overhead Crane 40 Remove 40 Install 41 Changing Battery With Rollers 41 Remove...

Page 7: ...repairs Your Hyster lift truck dealer has the trained personnel and equipment to do a complete program of inspection lubrication and maintenance This complete program will help your lift truck operat...

Page 8: ...the lift truck to prevent it from moving 2 Turn the key switch to the OFF position 3 Disconnect and separate the battery connectors 4 Remove drive unit cover to allow access to wiring harness 5 Locat...

Page 9: ...lock in front and back of the tires touching the ground to prevent movement of the lift truck DO NOT raise the lift truck by attaching an overhead lifting device to areas that can be damaged Some of t...

Page 10: ...2 FORK END 3 STRAP Figure 2 Lifting Points W30 40ZA W20 30ZR 4 Install additional blocks under the frame near the drive tire See Figure 3 and Figure 4 Figure 3 Putting Lift Truck on Blocks W30 40ZA an...

Page 11: ...ift both ends at once 3 To raise the fork end of the lift truck hook a lift strap through each load wheel opening in the top of each fork and lift together See Figure 2 Raise the outriggers only enoug...

Page 12: ...all parts of mast that move are fully low ered Push lift lower control button and make sure there is no movement in mast OR 2 If parts of the mast must be in raised position install a safety chain to...

Page 13: ...n the Mast Legend for Figure 5 A TWO STAGE MAST B THREE STAGE MAST 1 OUTER WELDMENT 2 INNER WELDMENT 3 INTERMEDIATE WELDMENT 4 HOOK 5 FREE LIFT CYLINDER 6 CARRIAGE 8000 SRM 1027 Safety Procedures When...

Page 14: ...ating in non standard or severe appli cations may require special optional environmen tal packages additional maintenance procedures more frequent service intervals and or special lu bricants The main...

Page 15: ...Figure 6 Maintenance Points W30 40ZA 8000 SRM 1027 Maintenance Schedule 9...

Page 16: ...Figure 7 Maintenance Points W20 30ZA Maintenance Schedule 8000 SRM 1027 10...

Page 17: ...Figure 8 Maintenance Points W25 30 40ZC 8000 SRM 1027 Maintenance Schedule 11...

Page 18: ...ultipurpose Grease1 Wear Plugs X and L Clean and Lubricate Multipurpose Grease1 22 Lift Chains4 X Check Condition SAE 20W or 30W Motor Oil X2 and L Clean Check and Lubricate 4 Forks X Check Condition...

Page 19: ...Horn and Fuses X Check Condition Replace as required 15 Control Handle X Check Operation Smooth No Binding Pivot Shaft L 1 Lube Fitting Multipurpose Grease1 11 Articulating Chain Anchors Carriage L 2...

Page 20: ...nd Wire Sheaves L Check Condition Clean and Lubricate SAE 20W or 30W Motor Oil 14 Drive Tire Wheel Bolt Torque X Tighten if Required 200 N m 148 lbf ft 13 Drive Unit Gear Oil X C 1 75 liter 1 85 qt SA...

Page 21: ...capacitors in the controller by con necting a load such as a 200 ohm 2 watt resis tor across the controller s B and B terminals DO NOT use a screwdriver to discharge the trac tion motor controller Se...

Page 22: ...talled 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 If labels are missing or damaged replace See...

Page 23: ...electrolyte has stabilized Check the electrolyte level on all cells every week Fill to the correct level The correct level is generally halfway between the top of the plates and the bottom of the fil...

Page 24: ...ct the tread and remove any objects that will cause damage See Figure 11 Inspect the wheels for loose or missing parts Remove any wire strap ping or other material wound around the axles 1 REMOVE NAIL...

Page 25: ...der hoses and fittings for hydraulic leaks Check the hose cover for cracks or exposed reinforcement Check for broken or defective clamping devices Repair or replace any damaged components as necessary...

Page 26: ...k is equipped with a sideshift car riage or attachment inspect the parts for cracks and wear 8 Check that the lift chains are correctly lubrica ted 9 Inspect the lift chains for cracks or broken links...

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