Hyster A244 Service & Repair Manual
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Hyster A244 Service & Repair Manual

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Hyster A244 (BE80ZHD, BE100ZHD) Forklift

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  • Page 1 Hyster A244 (BE80ZHD, BE100ZHD) Forklift...
  • Page 2 PERIODIC MAINTENANCE BE80ZHD, BE100ZHD [A244] PART NO. 4110886 8000 SRM 1705...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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.

  • Page 4: Table Of Contents

    Change Gear Oil ............................23 Check Oil Level .............................23 Drive Tire Check ............................... 24 Maintenance Procedures Every 2000 Hours or Yearly ..................24 Lubrication ................................ 24 Repack Load Wheel Bearings ........................24 Hydraulic System ..............................24 Oil Change ..............................24 ©2015 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more 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 please write to me: admin@servicemanualperfect.com...
  • Page 6 Preparation for Storage ............................29 Short-Term Storage (1 to 6 months) ........................ 29 Long-Term Storage (6 months or longer) ......................29 Preparation for Use ...............................29 Preparation After Shipment ..........................29 Preparation After Storage ..........................29 This section is for the following models: (BE80ZHD, BE100ZHD) [A244]...

  • Page 7: General

    Your Hyster lift truck dealer has the trained personnel and equipment to provide a complete program of inspection, lubrication, and maintenance.

  • Page 8: Install

    General 8000 SRM 1705 3. Remove four capscrews and front pad from frame. See Figure 3. Install NOTE: Install pads in reverse order that they were removed. 1. Using four capscrews, install front pad onto frame. See Figure 3. NOTE: Prior to installing hip pad, make sure capscrews are finger tight to prevent them from coming out during install and operation of lift truck.

  • Page 9: Operator's Compartment Console

    8000 SRM 1705 General Operator's Compartment Console 5. Disconnect all electrical wiring from under console cover. Tag wiring to assist when reinstalling steering handle assembly. Remove 1. Turn key to the OFF position. 6. Remove console cover from lift truck. See Figure 4.

  • Page 10: Install

    General 8000 SRM 1705 Console Tray Remove 1. Remove four capscrews and four washers from console tray. See Figure 6. 2. Remove console tray from heat shield and frame assembly. See Figure 6. 3. Remove heat shield from frame assembly. See Figure 6.

  • Page 11: Drive Unit Compartment Door

    8000 SRM 1705 General DRIVE UNIT COMPARTMENT DOOR Legend for Figure 7 1. DRIVE UNIT COMPARTMENT DOOR Open the drive unit compartment door by lifting up 2. LATCH on latch handle. Pull the door open on its hinges. 3. FRAME To close, push the door closed until latch catches.

  • Page 12: How To Tow The Lift Truck

    General 8000 SRM 1705 How to Tow the Lift Truck 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 WARNING weight to the forks. Additional weight on the Stay clear of the tow chain, towing vehicle, and forks may DECREASE the traction of the drive the lift truck during the towing operation to...

  • Page 13: How To Raise Load Wheels

    8000 SRM 1705 General Figure 8. Putting Lift Truck on Blocks 2. Use an overhead crane and web sling under the How to Raise Load Wheels forks to raise the load wheels. Another lift truck can also be used to raise the forks. Make WARNING sure that the crane and sling or other lift truck Never raise the forks any higher than necessary...

  • Page 14: Welding Repairs

    Special Precautions 8000 SRM 1705 Legend for Figure 9 1. CONTROLLER 2. POSITIVE CONNECTION 3. INSULATED JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR 5. NEGATIVE CONNECTION Figure 9. Discharging Capacitors Welding Repairs around the area to be welded. Use local ventila- WARNING tion, and/or supplied-air respiratory protection.

  • Page 15: Maintenance Schedule

    8000 SRM 1705 Maintenance Schedule Maintenance Schedule The Maintenance Schedule is divided into four time vere operation and require the 3-month/500-hour intervals which call for particular maintenance pro- checks to be performed at 1 month/200 hours. The cedures to be performed. The intervals are 1 Day or approximate locations of the items listed in the 8 Hours, 6 Weeks or 250 Hours, 3 Months or 500 Maintenance Schedule are shown in Figure 10.
  • Page 16 Maintenance Schedule 8000 SRM 1705 Table 1. Maintenance Schedule Item Item 1 yr/ Procedure or Specification 2000 Quantity Check Charge Battery Charge or Change Out Status Electrolyte Check Level Distilled Water Check Restraint Panels Repair as Necessary Condition Check Power Disconnect Repair as Necessary Operation Check...
  • Page 17 8000 SRM 1705 Maintenance Schedule Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification 2000 Quantity Check Level (Full Mark on Hydraulic Oil Tank) Hydraulic Oil Change Inspect / Hydraulic Oil Replace as See Parts Manual Strainer Necessary Check Lift and Lower Linkage...
  • Page 18 Maintenance Schedule 8000 SRM 1705 Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification 2000 Quantity Check Load Wheels Replace as Necessary Condition Wheels and Bearings Lube Fitting Multipurpose Grease (Greasable Option) Axle (Greasable Anti-seize Lube Option) Lubricant Check Listen for Abnormal...
  • Page 19 8000 SRM 1705 Maintenance Schedule Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification 2000 Quantity Use ISO VG 46 (conventional) antiwear (HCE-140) for Standard and Cooler/Freezer configurations. Use ® Exxon Univis HVI 26 (synthetic) for Sub-Zero and Corrosion/Washdown configurations. Replace after first 500 hours of service and check every 2000 hours or yearly thereafter.

  • Page 20: Maintenance Procedures Every 8 Hours Or Daily

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1705 Maintenance Procedures Every 8 Hours or Daily The battery must fit the battery compartment so WARNING the battery restraint panels will operate correctly. DO NOT operate a lift truck that needs repairs. If a Use spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any direction.

  • Page 21: Hydraulic Leaks

    8000 SRM 1705 Maintenance Procedures Every 8 Hours or Daily Hydraulic Leaks If the drive tire has recently been installed, check to ensure the lug nuts are properly tightened to 140 N•m (103 lbf ft). When installing, snug all the WARNING nuts, then tighten to half the torque value, then Always wear the proper protective equipment in-...

  • Page 22: Checks With Key Switch Turned On

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1705 The key switch (or toggle switch) is a two position WARNING switch located on the right side of the dash display. The first position is OFF (marked "O"). The second In normal operation, the casters should continu- position is ON (marked "I").
  • Page 23 8000 SRM 1705 Maintenance Procedures Every 8 Hours or Daily for proper operation. If the brake will not re- WARNING lease or fails to apply or will not hold the lift truck, the brake assembly must be replaced. If any function does not operate or operates incor- When the controller senses the truck has come rectly, remove the truck from operation and attach to a complete stop, the brake is applied and acts...

  • Page 24: Maintenance Procedures Every 250 Hours Or Every 6 Weeks

    Excess rocking is often a sign of under adjus- bearings or different grease fitting configurations. ted casters. This may occur when a new drive tire is Contact your Hyster dealer for information on op- installed. Loss of traction may be caused by over tional packages.

  • Page 25: Caster Adjust Procedure

    8000 SRM 1705 Maintenance Procedures Every 250 Hours or Every 6 Weeks 4. A truck that appears to be leaning more than the specified amount should be adjusted promptly. 5. Do not use the drive frame or operator compart- ment as a point of reference for measuring the height difference, as this may vary due to man- ufacturing tolerances.

This manual is also suitable for:

Be80zhdBe100zhd

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