Hyster B453 Service & Repair Manual Download Page 25

1. FORK

2. CARRIAGE

3. LOAD BACKREST

4. LOCK PIN

Figure 12. Hook-Type Fork

1. 

Inspect the welds on the mast and carriage for
cracks.  Make  sure  the  nuts  and  capscrews  are
tight.

  WARNING 

Always  wear  the  proper  protective  equipment  in-
cluding  eye  protection  and  petroleum-resistant
gloves  when  handling  hydraulic  oil.  Thoroughly
wash  oil  from  exposed  areas  of  skin  as  soon  as
possible.

Never  check  for  leaks  by  putting  hands  on  hy-
draulic  lines  or  components  under  pressure.  Hy-
draulic oil under pressure can be injected into the
skin.

Completely  lower  forks  to  relieve  hydraulic  pres-
sure  before  disassembling  any  part  of  the  lift
pump or disconnecting any hydraulic hoses.

2. 

Inspect  the  mast  header  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.

3. 

Inspect  the  channel  for  excessive  wear  in  the
areas  of  roller  contact.  Check  the  rollers  for
wear or damage.

4. 

Inspect  the  load  backrest  extension  for  cracks
and damage.

5. 

Inspect the forks for cracks and wear. See Fig-
ure  13.  
Check  that  the  fork  tips  are  aligned
within 

3% 

of 

each 

fork 

length

[32.00  mm  (1.26  in.)  for  a  standard
1067  mm  (42  in.)  fork].  Some  applications  can
require  closer  alignment.  Check  that  the  bot-
tom  of  the  fork  is  not  worn.  Check  that  the
thickness  of  the  fork  blade  (5,  Figure  13)  is  at
least  90%  of  the  thickness  of  the  fork  shank
(DIMENSION X). The fork's thickness can also
be checked using fork tool 3020387.

8000 SRM 1027

Maintenance Procedures Every 8 Hours or Daily

19

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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