Section 4.Scheduled Maintenance

Section 4.Scheduled Maintenance Model 4700 Maintenance Manual

Maintenance Guidelines

Maintenance Guidelines

Following a regularly scheduled maintenance program:

•promotes maximum truck performance

•prolongs truck life

•reduces costly down time

•avoids unnecessary repairs

Scheduled maintenance includes:

•lubrication

•cleaning

•inspection

•service

Perform all of the scheduled checks and maintenance during the suggested intervals. The time intervals given in this guide are based on Pump Hours under normal operating conditions.

When operating under Severe or Extreme conditions, perform these services more often as indicated in Table4-1.

Table 4-1.Maintenance Frequency Operating

Light to Moderate

Severe

An eight hour day of basic material handling

•Extended heavy duty operation

•Freezer operation

•Sudden temperature changes such as going from freezer to room temperature

Extreme•All UL Type EE rated lift trucks

•Dusty or sandy conditions such as in cement plants, lumber or flour mills, coal dust or stone-crushing areas

•High temperature areas such as in steel mills, foundries, or enclosed (TypeEE) applications

•Corrosive chemical atmosphere, such as:

• fish, meat, or poultry processing plants, tanneries, or any other similar applications

• chlorine or salt-sea air environments

•Adverse high humidity, wet, damp, or moist conditions

4-2

180 days or 500 pump hours, whichever comes first

60 days or 250 hours, whichever comes first

30 days or 100 hours, whichever comes first

Publication 1160093, Issued: 20 May 2013

Section 4.Scheduled Maintenance

Every 180 Days or 500 Pump Hours

Model 4700 Maintenance Manual

Every 180 Days or 500 Pump Hours

NOTE : For Severe or Extreme operating condition service intervals, refer to Table4-1, “Maintenance Frequency,” on page4-2

Perform the following tasks every 180 days/500 pump hours, whichever comes first.

Component

What to do Refer to Accelerator Pedal(s)Verify travel function is smooth and responsive through full range of acceleration.

BatteryCheck the weight stamped on the battery in the lift truck against the minimum and maximum allowable weights on the specification tag for the lift truck. Report any lift trucks that are running with batteries under the minimum or over the maximum allowable weight. Check for voltage leaks to frame. If cleaning does not remove voltage to frame, install a new battery. Inspect all battery connectors and leads for damage and cuts in protective coatings. Make sure the battery gates are in place and not damaged. Make sure the battery has no more than 0.5 in. (13 mm) free play in any direction.

Brakes In an open area, measure stopping distance. Traveling 2 to 3 mph (3.2 to 4.8km/h) empty, push the brake pedal. The empty lift truck should stop within 2 to 4 ft. (0.6 to 1.2 m). During normal operation, with a rated load and traveling at top speed, the lift truck should stop within approx. one and one-half truck lengths. Stopping distance depends on the load, floor, and tire condition. Check brake fluid reservoir level. Check for fluid leaks.

Single Traction Motor Trucks below S/N 10677 - Inspect brake shoe thickness.

Check parking brake for correct operation.

Chassis

General visual inspection of structural members for cracks.

Contactors Inspect contactor tips. Replace contactors with burnt or pitted contactor tips. Failure to replace the contactor may prevent the contactor from opening or closing causing unscheduled downtime. With the key switch OFF and the battery disconnected, check the plunger for smooth operation with no binding. If binding occurs, the lift truck may malfunction or exhibit intermittent fault codes.

Drain Holes

Make sure drain holes in battery compartment are not blocked.

Drive Units Check fluid level. Inspect for leaks.

Electrical CablesInspect all power cables for nicks or cuts. Replace any cable that is damaged or shows signs of excessive heat. Failure to do so will cause intermittent system shutdowns and/or electronic failures.

Forks

Examine for excessive wear, bends, cracks, welding arcs, excessive heat, or unauthorized modifications. Replace if found.

Hardware Check bolt torque of major components (motors, pump, brakes, drive units, manifolds, mast-to-chassis mounting bolts, steer cylinder mounting bolts). Tighten any loose hardware. Replace any broken or missing hardware.

Horn Check that horn sounds correctly when activated.

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Publication 1160093, Issued: 20 May 2013