Professional Documents
Culture Documents
Periodic Manteinance
Periodic Manteinance
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H [A227, B227]
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... Serial Number Data ...................................................................................................................................... How to Move Disabled YardMaster .............................................................................................................. How to Tow YardMaster............................................................................................................................ How to Put YardMaster on Blocks................................................................................................................ How to Raise Drive Tires .......................................................................................................................... How to Raise Steering Tires.......................................................................................................................... Maintenance Schedule....................................................................................................................................... Daily Inspections ........................................................................................................................................... First Inspection After First 100 Hours of Operation................................................................................... Periodic Maintenance Schedule .................................................................................................................... Boom Maintenance ........................................................................................................................................ Spreader Maintenance .................................................................................................................................. PPM Spreader Maintenance ......................................................................................................................... Maintenance Procedures Every 8 Hours or Daily............................................................................................ How to Make Checks With Engine Stopped................................................................................................. Tires and Wheels ....................................................................................................................................... Safety Labels ............................................................................................................................................. Fuel, Oil, or Coolant Leaks Check............................................................................................................ Drive Belts ................................................................................................................................................. Battery ....................................................................................................................................................... Engine Oil .................................................................................................................................................. Drain Water From Fuel Filter .................................................................................................................. Hydraulic System ...................................................................................................................................... Brake System Oil ...................................................................................................................................... Cooling System .......................................................................................................................................... Boom and Spreader ................................................................................................................................... Hook, Winch, and Boom (HR45H) ............................................................................................................ How to Make Checks With Engine Running................................................................................................ Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays.............................................................. Air Filter .................................................................................................................................................... Air Conditioning ........................................................................................................................................ Control Levers and Pedals........................................................................................................................ Electrical System....................................................................................................................................... Transmission Oil ....................................................................................................................................... Steering System ........................................................................................................................................ Service Brakes ........................................................................................................................................... Parking Brake ........................................................................................................................................... Engine Oil .................................................................................................................................................. Cooling System .......................................................................................................................................... Hydraulic System ...................................................................................................................................... Boom and Spreader Operation ................................................................................................................. Maintenance Procedures Every 50 Hours or Weekly....................................................................................... Boom............................................................................................................................................................... PPM Spreader................................................................................................................................................ Rotator and Extension Transmissions ..................................................................................................... Rotator Motor ............................................................................................................................................ Rotator Assembly ...................................................................................................................................... Twist Locks ................................................................................................................................................ Wear Pads (Extension Beam) ................................................................................................................... Sideshift Cylinders .................................................................................................................................... 1 1 1 2 2 2 2 3 3 5 5 7 8 10 12 12 12 12 13 13 13 14 14 14 15 15 15 15 15 15 18 18 18 18 18 19 19 19 19 19 19 19 20 20 20 20 20 20 21 21 21
Table of Contents
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Table of Contents
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General
General
This section contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your YardMaster. The recommendation for the time intervals are for 8 hours of operation per day. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: If the YardMaster is used more than 8 hours per day If the YardMaster must work in dirty operating conditions Your dealer for Hyster YardMasters has the equipment and trained personnel to do a complete program of inspection, lubrication, and maintenance. A regular program of inspection, lubrication, and maintenance will help your YardMaster give more efficient performance and operate for a longer period of time.
WARNING
Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments made on a YardMaster by people without authorization and training can make a dangerous operating condition. Do not operate a YardMaster that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operators area. Remove the key from the key switch. Some users have service personnel and equipment to do the inspection, lubrication, and maintenance shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster YardMasters to help users who do their own maintenance.
1. The first letter and number of the serial number indicates the design series and the model number of the Yardmaster. 2. The second letter identifies the manufacturing plant. Example: E=Nijmegen, the Netherlands. 3. The number series indicates the sequence of manufacture where the vehicle was made. 4. The letter indicates the year of manufacture starting with A=2003. The letter X=2000, Y=2001, Z=2002, L=2013, M=2014, and N=2015. (The letters I, O, and Q are not used.)
General
8000 SRM 780 2. Fully lower and retract boom. 3. Use a hydraulic jack under the side of the drive axle to raise tire from ground. Use a block under jack as necessary. Make sure that jack and block have a capacity of at least 36,000 kg (40 ton). 4. Put additional blocks under drive axle as support.
Maintenance Schedule
Maintenance Schedule
DAILY INSPECTIONS
Figure 2. Maintenance and Lubrication Points Table 1. Condition Check Item No. Item Boom, Rotator, and Spreader Fuel, Oil, or Coolant Leaks 1 10 Tires and Tire Pressure Drive Belts Engine Compartment 21 Radiators for Engine Coolant, Turbo Air, Hydraulic, and Transmission Oil Safety Labels Seat Belts and Seat Rails See Figure 2 for Item Nos. Procedure Inspect for damage, cracks and distortion. Check frame, boom, and spreader. See nameplate. Check tension. Remove combustible materials. Clean as necessary. See Parts Manual. Check operation.
Maintenance Schedule Table 2. Fluid Level Check Item No. 12 13 Item Hydraulic System Oil Brake System Oil (Until A227J 01587, B227J 01501, 01503, and 01504) Brake System Oil (Starting with A227J 01588, B227J 01502, and 01505) Fuel Coolant Battery Electrolyte Engine Oil Water Separator Windshield Washer Fluid See Figure 2 for Item Nos. J20C or equivalent SAE 10W, API CC, or CC/SE with 3 to 6% lubrisol Procedure
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7 22 4 28 8
Diesel No. 2 (520 liter) 50% Ethylene glycol, 50% water Distilled water See Maintenance Procedures Every 8 Hours or Daily and Engine Oil. Drain water. Add as necessary.
Table 3. Checks With Engine Running Item No. Item Air Conditioning Horn, Gauges, Lights, Alarms, Mirrors, and Control System Control Levers and Pedals Boom, Rotator, Spreader, Signal From Spreader, and Control System Steering System Service Brakes and Parking Brake Transmission 5 29 24 Transmission Oil Level Air Filter Hydraulic Oil Filter Procedure Operate at least once every 15 days for 10 minutes. Check operation.
Check operation. Check operation. Check operation. Add if necessary, J20C or equivalent. Clean or replace elements when indicator light is ON. Clean or replace when indicator light is ON.
Maintenance Schedule
Maintenance Schedule Table 6. Lubricate Item No. 23 18 17 Drive Shaft Steering Axle Pivot Pin Tie Rods King Pins Pedals, Levers, Seat Rails, and Hinges Doors, Window Seals, and Door Lock See Figure 2 for Item Nos. Item Interval 250 hr/1 mo 250 hr/1 mo 250 hr/1 mo 1000 hr/6 mo 2000 hr/1 yr Quantity 6 Fittings 2 Fittings 4 Fittings As necessary As necessary
Specification Multipurpose grease Multipurpose grease Multipurpose grease Engine oil Silicon spray
Table 7. Change Item No. 28 Engine Oil Item Interval 250 hr/1 mo Quantity 38 liter (40.2 qt) Procedure or Specification See Maintenance Procedures Every 8 Hours or Daily, Engine Oil. See Parts Manual See Parts Manual See Parts Manual See Parts Manual J20C or equivalent SAE 10W, API CC, or CC/SE Donax TD SAE 10W
27 8 6 24 5 13
Engine Oil Filter Fuel Filter Transmission Oil Filter Hydraulic System Filter Transmission Brake System Oil (Until A227J 01587, B227J 01501, 01503, and 01504) Brake System Oil (Starting with A227J 01588, B227J 01502, and 01505) Brake System Oil Filter Air Filter, Central Element Hydraulic Tank Breather Coolant Filter Hydraulic System Oil Drive Axle/Differential Oil Steer Wheel Hub Bearing Cavity
250 hr/1 mo 250 hr/1 mo 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo 1000 hr/6 mo
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1000 hr/6 mo
25 29 12 26 12 31 15
1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr
See Parts Manual See Parts Manual See Parts Manual See Parts Manual J20C or equivalent SAE 80W-90 Multipurpose grease
Maintenance Schedule
Table 7. Change (Continued) Item No. 29 22 Procedure or Specification See Parts Manual 50% ethylene glycol, 50% water Flush and replace.
BOOM MAINTENANCE
Figure 3. Maintenance and Lubrication Points for Boom Table 8. Inspect and Adjust Item No. 1 2 5 Boom Wear Pads Boom Side Wear Pads Hydraulic Accumulator Item Interval 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo Procedure Check wear, play, and fixation. Check wear, play, and fixation. See Accumulator 1800 SRM 1036.
Maintenance Schedule Table 9. Lubricate Item No. 3 4 6 7 1,2 Item Telescoping Cylinder Keys Boom Pivot Bearings Rotator Pivot Bearing Dampening Cylinders Boom Wear Pads Interval 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk Quantity 2 4 Fittings 1 Fitting 4 Fittings 10 Fittings
Specification Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease
SPREADER MAINTENANCE
Figure 4. Spreader Maintenance and Lubrication Points for ELME 817 Table 10. Initial 100-Hour Inspection Item No. 1 2 Item Rotator Brake Oil Rotator Transmission Oil Rotator Assembly 3 4 Rotator Bearing Rotator Gear Lubricate Lubricate 4 Fittings Multipurpose grease Apply exposed gear lube through 2 access holes. Procedure Change Change Quantity Specification SAE 80W-90 API GL5 SAE 80W-90 API GL5
8000 SRM 780 Table 11. Inspect and Adjust Item No. 5 7 8 10 Twist Locks Sideshift Slider Pads Extension Beams Wear Pads Extension Cylinder Wear Pads Item Interval 500 hr/3 mo 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo
Maintenance Schedule
Procedure Check condition. Check condition of the 4 pads. Check condition of the 24 pads. Check condition of the 4 pads.
Table 12. Lubricate Item No. Item Rotator Assembly 3 4 5 6 9 Bearing Gear Twist Locks Sideshift Cylinder Stop Cylinders 250 hr/1 mo 250 hr/1 mo 250 hr/1 mo 500 hr/3 mo 500 hr/3 mo 4 Fittings 4 Fittings 2 Fittings 4 Fittings Multipurpose grease Apply exposed gear lube through 2 access holes. Multipurpose grease Multipurpose grease Multipurpose grease Interval Quantity Specification
Table 13. Change Item No. 1 2 5 Item Rotator Brake Oil Rotator Transmission Oil Twist Locks Interval 2000 hr/1 yr 2000 hr/1 yr 5000 hr Quantity 2.6 liter (2.7 qt) 2.8 liter (3.0 qt) 4 Specification SAE 80W-90 API GL5 SAE 80W-90 API GL5 See Parts Manual
Maintenance Schedule
Figure 5. Maintenance and Lubrication Points for PPM Spreader Table 14. Initial 100-Hour Inspection Item No. 5 3 Item Rotator Transmission Oil Rotator Fixation Bolts Procedure Change Check torque Quantity 2 @ 2.6 liter (2.75 qt) 64 bolts M20 Specification SAE 80W-90 API GL5 500 Nm (368 lbf ft)
Table 15. Inspect and Adjust Item No. 8 5 4 1 8 3 5 Twist Locks Rotator Transmission Oil Extension Transmission Oil Extension Beams Horizontal Pads Extension Beams Side Wear Pads Rotator Gear Fixation Bolts Rotator Transmission Fixation Spreader Control System See Figure 5 for Item Nos. Item Interval 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 2000 hr/1 yr 2000 hr/1 yr Procedure Check wear and condition. Check level. Check level. Check progress of wear and fixation. Check condition, shimming, and fixation. Torque to 500 Nm (368 lbf ft) Torque 20 Bolts to 210 Nm (155 lbf ft) Check condition, adjustment, and fixation.
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8000 SRM 780 Table 16. Lubricate Item No. 3 3 3 8 9 7 1 Item Rotating Ring Gear Assembly Rotator Gear Bearing Rotator Gear Teeth Twist Locks Seated Pin Sideshift Cylinder Extension Beams Horizontal Pads 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 4 Fittings As required 4 Fittings 4 Fittings 2 Fittings 12 Fittings Interval Quantity
Maintenance Schedule
Specification
Multipurpose grease Exposed gear lube Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease
Table 17. Change Item No. 4 5 8 3 3 Item Extension Transmission Oil Rotator Transmission Oil Twist Locks Rotator Ring Gear Rotator Gear Fixation Bolts Interval 1000 hr/6 mo 1000 hr/6 mo 6000 hr 8000 hr 8000 hr Quantity 2.6 liter (2.7 qt) 5.2 liter (5.5 qt) 4 1 64 bolts, M20 Specification SAE 80W-90 SAE 80W-90 API GL5 See Parts Manual See Parts Manual See Parts Manual
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1. CHECK TIRE PRESSURE 2. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM TREAD) Figure 6. Check Tires Check tires for damage. Inspect tread and remove any objects that will cause damage. Check for bent or damaged rims. Check for loose or missing parts. Remove any wire, straps, or other material wrapped around axle.
CAUTION
Check all wheel nuts after 2 to 5 hours of operation: when new YardMasters begin operation and on all YardMasters when the wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 250 hours. Make sure wheel nuts are tight. Tighten wheel nuts as shown in Figure 25. The correct torque value is shown in the Maintenance Schedule.
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8000 SRM 780 Check that all safety labels are installed in correct locations on YardMaster. See the Parts Manual for the correct locations of the safety labels. If new labels must be installed, use the following procedures:
Maintenance Procedures Every 8 Hours or Daily acceptable. A drive belt with cracks that run the length of the belt or a belt with missing pieces is not acceptable. Check drive belt for correct tension.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. 1. Make sure surface is dry and has no oil or grease. Do not use solvent on new paint. Clean surface of old paint with cleaning solvent. 2. Remove paper from back of label. Do not touch adhesive surface. 3. Carefully hold label in correct position above surface. The label cannot be moved after it touches the surface. Put label on the surface. Make sure all air is removed from under label and corners and edges are tight.
1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 7. Drive Belt
Battery
A check of the battery electrolyte level is normally required only every 250 hours of operation. Heavy duty or high temperature operations will require more frequent checks. It is not necessary to check the electrolyte level on a maintenance-free battery. A low electrolyte level can cause the discharge indicator light to come on or cause battery damage during YardMaster operation.
WARNING
The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the eyes must be flushed with water immediately. Wear eye protection. Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flame away from the battery area. Do not make sparks from the battery connections. Disconnect the battery ground cable when doing maintenance. Keep battery and cable terminals clean. Check electrolyte level (unless maintenance-free battery). Keep electrolyte level above separators and plates. Use distilled water. Do not fill battery more than to bottom of internal filler neck.
Drive Belts
Make sure key is in OFF position and engine is stopped. Check drive belt for wear and damage. See Figure 7. Small cracks that run across belt are
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Maintenance Procedures Every 8 Hours or Daily If the battery becomes discharged and requires a booster battery to start engine, follow these procedures carefully when connecting jumper cables: 1. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal. 2. Always connect jumper cable that is the ground cable last.
CAUTION
Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. Verify that all of the cylinder are retracted. The hydraulic oil level gauge is on the outside of the hydraulic tank. See Figure 8. Keep the oil level between the two marks on the tube for the maximum oil level. Remove the hydraulic breather to add hydraulic oil to the reservoir. Check the hydraulic system for leaks and damaged or loose components.
CAUTION
Disposal of batteries must meet local environmental regulations. 3. Always connect jumper cables to discharged battery before connecting them to booster battery.
Engine Oil
Check oil level in engine daily. After engine has stopped, wait one minute before checking oil level. Keep oil at correct level as indicated on dipstick. Use correct oil as indicated below:
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WARNING
DO NOT let anyone use their hands to guide the cable on the winch drum. The moving cable can cause serious injury. 3. Inspect cable for wear or damage. Check for cuts, sharp bends, corrosion, or other damage to cable.
1. LEVEL INDICATOR
2. FILL CAP
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NOTE: NUMBERS ON THE FUSE PANEL CORRESPOND WITH THE NUMBERS LISTED BELOW. CIRCUIT BREAKERS F1 - ENGINE STOP (10 AMP) F2 - WINDSHIELD WIPER (20 AMP) F3 - WORKING LIGHT, CHASSIS (20 AMP) F4 - BOOM WORKING LIGHT (20 AMP) F5 - BEACON LIGHT (20 AMP) F6 - GEAR SELECTOR (15 AMP) F7 - HAZARD WARNING LIGHT (10 AMP) F8 - SPREADER/PIGGY BACK CONTROLS (15 AMP) F9 - SAFETY DEVICES AND FLOW SELECTIONS (15 AMP) F10 - PARKING LIGHTS (15 AMP) F11 - SPREADER/PIGGY BACK CONTROLS (10 AMP) F12 - HEADLIGHTS AND HORN (20 AMP) F13 - STARTER RELAY (10 AMP) F14 - NOT USED F15 - DASHBOARD LIGHTS (5 AMP) F16 - AIR CONDITIONER (35 AMP) F17 - NOT USED F18 - NOT USED
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NOTE: NUMBERS ON THE FUSE PANEL CORRESPOND WITH THE NUMBERS LISTED BELOW. F1 - BATTERY OFF SWITCH, 10A F2 - PARK BRAKE, 5A F3 - LH AND RH DOME LIGHT, 5A F4 - FRONT, REAR, AND ROOF WINDSHIELD WIPERS, 15A F5 - WINDSHIELD WASHER, ALARM, CONTROL LIGHTS, AND SENDERS, 5A F6 - CABIN, SPREADER, AND FRAME WORKING LIGHTS, 20A F7 - BRAKE LIGHTS, TURN SIGNAL INDICATOR LIGHTS, 15A F8 - CABIN, BOOM WORKING LIGHTS, 20A F9 - ROTATING BEACON, 20A F10 - REVERSE LIGHT, 5A F11 - AIR CONDITIONING, 15A F12 - SPREADER SIGNALS, SPREADER SENSORS, 15A F13 - SPREADER LEVELING, DERRICKING UP/DOWN, HYDRAULIC OIL COOLING, 15A F14 - CONDENSER, 15A F15 - TRANSMISSION, 20A F16 - DIRECTION INDICATOR LIGHTS, 15A F17 - SPREADER FUNCTIONS, 10A F18 - FRONT STABILIZERS, OPTIONAL, 5A F19 - SLIDING CAB, 10A F20 - DAMPENING NEUTRALIZATION, 10A F21 - SPREADER ROTATION, SIDESHIFT SPREADER, 10A F22 - CAB CONTROLLER SUPPLY, 10A F23 - ENGINE STOP, 5A F24 - HEADLIGHTS, HORN, 20A F25 - NOT USED F26 - NOT USED F27 - DIODE F28 - DIODE F29 - AIR CONDITIONING PROTECTION FUSES, 3A F30 - NOT USED F31 - NOT USED F32 - NOT USED F33 - NOT USED F34 - NOT USED F35 - NOT USED F36 - NOT USED F37 - NOT USED F38 - NOT USED F39 - BATTERY SHUTOFF, ENGINE START, 10A F40 - WARNING LIGHTS, 10A F41 - PARKING LIGHTS, 10A F42 - REVOLUTION COUNTER, HOURMETER, 5A F43 - CAR RADIO CONVERTER 24V/12V, 10A F44 - ELECTRONIC ENGINE CONTROLLER, 10A F45 - ELECTRONIC ENGINE CONTROLLER, 10A F46 - NOT USED F47 - NOT USED F48 - NOT USED F49 - NOT USED F50 - NOT USED F51 - NOT USED F52 - NOT USED F53 - NOT USED F54 - NOT USED F55 - NOT USED F56 - NOT USED F57 - NOT USED F58 - NOT USED
Figure 11. Circuit Breaker Panel Starting With Serial Number 01566
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Maintenance Procedures Every 8 Hours or Daily In the battery box there is an additional fuse panel. See Figure 12. This panel protects the indicated circuits shown below: PF100 (100 amp fuse) provides protection to all functions behind the battery shutoff. PF80 (80 amp fuse) provides protection to the starter motor behind the battery shutoff. PF50 (50 amp fuse) provides general protection for the direct battery supplies.
1. SECONDARY ELEMENT 2. RESTRICTION SENDER 3. PRIMARY ELEMENT Figure 13. Air Filter Assembly
Electrical System
Check voltmeter and discharge indicator light during operation. The discharge indicator light can come on during operation if the drive belt does not have the correct tension. Also check condition of battery.
Air Filter
Check indicator light for air filter during operation. Also, check restriction indicator with engine running at full speed. When the light comes on, filters are dirty. Clean or install a new air filter element(s) as necessary. See Figure 13. Replace secondary element every third time primary element is cleaned. Use compressed air to clean filter elements. Air pressure must be less than 2 bar (30 psi). Apply air from inside to outside of the filter element. Inspect filter elements. Put a bright light inside filter elements and look for holes or other damage. If a filter element is damaged, install a new filter element. Use a cloth with solvent to clean inside of canister before filter elements are installed.
Transmission Oil
Check gauges and indicator lights for transmission during operation. There are indicator lights for the oil pressure and oil temperature of the transmission. The light for the oil pressure is on when the oil pressure is too low for correct operation. The light for the oil temperature is on when the temperature is too high for correct operation. Make a visual check of transmission and check transmission oil level. See Figure 14. Apply parking brake. Put blocks on both sides (front and back) of drive tires to prevent movement of vehicle. Check oil level in transmission when engine is running at idle speed and transmission oil is at operating temperature. Put direction control lever in NEUTRAL position. Open lower petcock on righthand side of transmission. If oil does not drain from port, close petcock. Open upper petcock. Add correct oil as shown in the Maintenance Schedule at filler tube until oil drains from upper petcock. Close upper petcock.
Air Conditioning
It is recommended to operate the system at least once per 15 days for 10 minutes consecutively.
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Cooling System
1. OIL FILLER TUBE 2. OIL FILL PETCOCK 3. OIL LEVEL PETCOCK
CAUTION
Do not continue to operate vehicle when light is on during operation. For trucks before serial number 01566, check coolant temperature gauge and indicator light during operation. Do not operate vehicle when temperature is above 100 C (212 F). The red light is on when the coolant temperature is to low. Starting serial number 01567 and up, check the engine default code when the engine warning light is ON
Hydraulic System
Check hydraulic oil filter light during operation. The light is on when filters are dirty.
Service Brakes
Check operation of service brakes. Push on brake pedal. The service brakes must be applied before the brake pedal reaches the floor plate. The pedal must apply equally to each of both the drive wheel assemblies. The service brakes must not pull the YardMaster to either side of the direction of travel when they are applied.
Parking Brake
Check operation of parking brake. The parking brake, when in good condition and operating correctly will hold a YardMaster with a capacity load on a 15% grade. A 15% grade is a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft).
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Maintenance Procedures Every 50 Hours or Weekly Do the following checks and inspections: 1. Check for leaks in hydraulic system. Check condition of hydraulic hoses and tubes. 2. Slowly raise and lower boom several times without a load. Extend and retract boom at least once. The boom must raise and lower smoothly.
8000 SRM 780 3. Check that controls for boom and spreader operate the functions correctly. See symbols by each of the controls. 4. On HR45H units, check that controls for boom and winch operate the functions correctly. See symbols by each of the controls.
BOOM
Lubricate the fittings at the wear pads. For wear pads without grease fittings, lubricate the wear pad tracks with a brush and multipurpose grease. Lubricate the fittings at the boom pivots, the dampening cylinders, and at the rotator pivot bearing with multipurpose grease. Use a brush to lubricate the keys of the telescoping cylinder. Lubrication of the boom pivots is necessary to allow removal of the boom when required. See Figure 15.
Rotator Motor
Check oil level at motor assemblies. The oil level is correct when oil is visible in fill/check port (3, Figure 16).
1. 2. 3. 4.
FILL/CHECK PORT (ROTATOR BRAKE) DRAIN PORT (ROTATOR BRAKE) FILL/CHECK PORT (ROTATOR MOTOR) DRAIN PORT (ROTATOR MOTOR) Figure 16. Rotator Motor
Rotator Assembly
Lubricate rotator gears through access holes (Figure 17) in stop blocks. Be sure to use a lubricant for exposed gears. Rotate the gear completely in each direction and apply the grease to both sides of the teeth. Lubricate rotator assembly at grease fittings. There are four fittings for the rotator bearing. Rotate the ring four times, until all fittings have received one pump action of the grease gun.
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Twist Locks
Check the wear and the condition of the twist locks. Lubricate the fittings at the twist locks and seated pin.
Sideshift Cylinders
Lubricate the grease fittings at the end of the sideshift cylinder with multipurpose grease.
DRIVE BELTS
Check the tension of the drive belts for the engine and air conditioning.
STEERING AXLE
Use multipurpose grease to lubricate the four grease fittings at the king pins, the grease fittings at the tie rods, and the fittings at the two pins of the central pivot.
BATTERY
See procedures under Maintenance Procedures Every 8 Hours or Daily.
WHEEL NUTS
Check torque of the wheel nuts in the sequence shown in Figure 25. The correct torque value is in the Maintenance Schedule.
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Rotator Assembly
Lubricate the rotator gears through the access holes in the stop blocks. See Figure 17. Be sure to use a lubricant for exposed gears. Rotate the gear completely in each direction and apply the grease to both sides of the teeth. Lubricate the rotator assembly at the grease fittings. There are four fittings for the rotator bearing. Rotate the ring four times, a quarter of a turn each time, until all fittings have received one pump action of the grease gun.
1. DRAIN PLUG
2. FILL/CHECK PORT
Twist Locks
Check the wear and condition of the twist locks. Lubricate the fittings at the twist locks and seated pins.
GENERAL LUBRICATION
Lubricate any linkages, rod ends, levers, cab rails, hinges, and seat rails with engine oil.
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AIR FILTER
Replace the central air filter element every 500 hours. See Figure 13. See Maintenance Procedures Every 8 Hours or Daily for more information.
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NOTE: J REPRESENTS THE CLEARANCE BETWEEN THE CLAMP PLATE AND THE CYLINDER BRACKET. 1. CLAMP PLATE 2. CYLINDER BRACKET Figure 19. Centering the Rear of the Inner Boom Tighten the two clamp plates while verifying that are parallel with the cylinder, with clearance on each side between 3 mm (0.12 in.) and 6.5 mm (0.26 in.). To center the front of the inner boom, the lower portion of the inner boom must be centered in the outer boom. See Figure 20. To shim the side wear pads, loosen the adjustment bolt and insert a 1 mm (0.04 in.) shim between the outer boom and the side wear pad. Retighten the bolt to establish contact with the adjustment shim. Do not move the inner boom in the outer boom. Remove the shim and secure the position of the bolt by tightening the nut. Adjust the clearance for the upper side wear pads without moving the inner boom.
1. INNER BOOM 2. OUTER BOOM 3. DISTANCE BETWEEN INNER AND OUTER BOOM 4. LOWER WEAR PADS Figure 20. Centering the Front of the Inner Boom
SIDESHIFT CYLINDER
Lubricate two grease fittings at the end of each sideshift cylinder with multipurpose grease. See Figure 4.
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CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. Remove radiator cap and close shutoff valve at filter. See Figure 21. Clean area around filter head. Remove and discard coolant filter. Apply clean engine oil to gasket of new filter. Install new filter and turn filter until gasket touches, then tighten it 1/2 to 3/4 turn.
WARNING
Always use nitrogen only. Do NOT use air, which contains oxygen. Compressed oxygen may cause an explosion. 4. To increase the pressure, attach a nitrogen bottle with a pressure regulator and inflate until 50 bar has been reached. 5. After initial inflation, wait at least 30 seconds to allow the pressure to stabilize. Check and correct the pressure if necessary. 6. Close all valves and remove the connected bottle and inflator controller. 7. Verify that the controller bleed screw is completely closed.
1. SHUTOFF VALVE
2. COOLANT FILTER
CAUTION
Do not start engine with the coolant shutoff valve in the closed (OFF) position. The engine can be damaged when running with the valve closed.
DISC BRAKE
There is a disc brake assembly installed on the differential housing that is used for the parking brake. Inspect disc brake assembly every 1000 hours.
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WARNING
Brake linings can contain dangerous fibers. Breathing the dust from brake linings is a cancer or lung disease hazard. Do not create dust! Do not clean brake parts with compressed air or by brushing. Use vacuum equipment approved for dangerous fibers or follow the cleaning procedure in this section. Do not sand, grind, chisel, hammer, or change linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. Cleaning Procedures: 1. Do not release dust from brake linings into air when checking brakes. 2. Use a solvent to wet the lining dust on the parts of the brake. If a solvent spray is used, do not create dust with spray. 3. When lining dust is wet, clean parts. Put any cloth or towels in plastic bag or airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.
Inspect
Inspect brake lining and parts of brake assembly for wear or damage. If brake linings are worn or damaged, they must be replaced. Brake linings must be replaced in complete sets. Inspect brake rotor for wear or damage. Check caliper for leaks.
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Maintenance Procedures Every 2000 Hours or Yearly Change oil in the winch reduction unit. See Figure 18. Unwind cable to get access to ports on drum. Rotate drum until drain port is toward bottom. Remove plug to drain oil. When filling unit, check level at fill/check port.
COUNTERWEIGHT FIXATION
Verify the torque at 900 Nm (665 lbf ft).
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CAUTION
Do not permit dirt to enter the hydraulic system when the oil is checked or the filters are changed. 2. When the hydraulic oil has drained, install drain plug. Fill hydraulic tank with correct oil. Operate system and check for leaks.
VIBRATION DAMPER
Verify that the position of the damper has not moved. Replace the damper if the marker line has moved.
WARNING
If the coolant is hot, do not permit coolant to touch the skin and cause a burn. 2. Open the drain valve. Allow the coolant to drain into a container that will hold approximately 40 liter (42 qt). Remove the radiator cap. Flush the cooling system. Check hoses and fittings as needed.
TWIST LOCKS
Replace the twist locks. See the section Extendable Container Attachment (Elme) 5000 SRM 776.
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WARNING
Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. Completely remove the air pressure from the tire before it is removed from the YardMaster. If dual wheels are installed, remove the
B. DRIVE WHEELS 4. VALVE STEM 5. LOCK RING 6. SEAL RING Figure 23. Wheel Arrangements 7. RIM CLAMP 8. HUB 9. SPACER
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STEP 4. Loosen tire from other side of wheel rim. Remove side flange and seal ring as necessary. Remove rim from tire.
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Wheel and Tire Replacement in the correct position. The ends of the lock ring must not touch. 1. Clean and inspect all parts of wheel. If wheel has rust or corrosion, remove loose rust and corrosion and paint the parts.
WARNING
Do not lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can cause an explosion during inflation or use. 2. Apply rubber lubricant or soap solution to tire bead and tube. 3. Make sure that rim is correct size for tire. Lubricate the part of the wheel that contacts the bead. 4. Install wheel in tire as shown in Install Wheel in Tire.
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Wheel and Tire Replacement STEP 3. Install flange seat and seal ring.
STEP 5. Install lock ring. Make sure all parts are correctly aligned. When correctly installed, there will be a 13 to 25 mm (0.5 to 1.0 in.) clearance between ends of side ring and/or lock ring. Add air pressure to tire as described in Add Air to Tires.
5. Check that all wheel parts are correctly installed. If installation is not correct, remove all air pressure from tire. Remove valve core to make sure all air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be 13 to 25 mm (0.5 to 1.0 in.) when tire has the correct air pressure.
WARNING
Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). 1. Put tire in safety cage. See Figure 24. 2. Add 20 kPa (3 psi) air pressure to tire. 3. Check that all wheel parts are correctly installed. Hit lock ring to make sure it is in the seat. 4. If installation is correct, add correct air pressure to tire. (See Nameplate.) Figure 24. Add Air to Tires
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General Maintenance to 295 Nm (218 lbf ft) and finally to 375 Nm (277 lbf ft).
General Maintenance
SPREADER Twist Locks
Inspect twist locks for wear whenever twist locks are lubricated. Inspect heads of twist locks as shown in Figure 26. When the wear is more than 10 mm (0.4 in.), replace twist lock. It is recommended that twist locks are replaced after a maximum of 5000 hours of use. M24, grade 10.9 = 740 Nm (545 lbf ft) M12, grade 10.9 = 90 Nm (66 lbf ft) Check torque for mounting bolts for rotator motors. The correct torque for M12 bolts is 90 Nm (66 lbf ft).
Short-Term Storage
Figure 26. Twist Locks Do the following steps to prepare the YardMaster for storage from 1 to 6 months: 1. Check lubricant and fluid levels. Completely fill fuel tank. Make sure coolant mixture will protect cooling system and engine to lowest temperature expected during storage. Make sure all caps and dipsticks are installed correctly.
Rotator Assembly
Inspect rotator assembly for loose mounting bolts whenever parts are lubricated. Check torque at least twice a year. The correct torques for bolts for rotator ring gear are:
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General Maintenance 2. Fully lower and retract boom. Apply thin coat of engine oil to cylinder rods. 3. Check that all switches and accessories are in the OFF position. 4. If the YardMaster must be left on an incline, put blocks on down hill side of wheels so YardMaster cannot move - do not use parking brake. 5. Disconnect battery cables from batteries. Apply a protective coat to cable connectors and battery terminals to prevent corrosion. 6. Check tire pressure. Make sure tires have correct pressure (see Nameplate). 7. Clean engine compartment to prevent corrosion. 8. If YardMaster is not stored in a shelter, put a cover over YardMaster to prevent damage from weather. In wet conditions, a cover will not prevent corrosion to a YardMaster that is in longterm storage outside of a dry storage area.
8000 SRM 780 when traveling in the forward direction with steering wheel turned to move the YardMaster away from the edge of the dock, the rear will swing toward the edge. This can cause the YardMaster to fall off the dock.
WARNING
IF THE YardMaster FALLS OFF THE DOCK, DO NOT JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR FEET, AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT. Before YardMaster is moved on a transport, check the selected route to make sure there is enough clearance for YardMaster as loaded on the transport vehicle. Bridges, overpasses, power lines, and natural barriers can prevent clearance. Removal of the boom and/or spreader can be necessary. If a trailer is the method of transportation, use blocks in front and back of trailer tires to prevent movement of trailer when YardMaster is loaded and unloaded. If a loading ramp is used, make sure the ramp is the correct design and capacity. Lift YardMaster only at designated lifting points.
Long-Term Storage
Do the following steps to prepare the YardMaster for storage for 6 months or longer: 1. Complete all short-term storage procedures. 2. Wrap or cover all exterior lights, radiator grill, and air vents with a moisture barrier cover. Use tape to hold covers in position. 3. Remove batteries from YardMaster. Store batteries in an approved space. Be sure to follow local regulations. Batteries that are stored for long periods can become damaged. A recommendation is that batteries be used in service if possible. 4. Spray exterior surfaces and frame with preservative coating.
Loading
If boom and/or spreader must be removed for transport of the YardMaster, see the Service Manual for removal procedures. The operator must never leave YardMaster in a condition so that it can cause damage and injury. When YardMaster is loaded on the transport, do the following operations: 1. Apply parking brake. 2. Fully lower and retract boom. 3. Put direction control lever for transmission in NEUTRAL. 4. Turn key switch to OFF to stop engine. Check that all switches and accessories are turned off. 5. Put blocks in front and back of YardMaster tires to prevent YardMaster from moving. Make sure blocks are attached to load surface.
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General Maintenance
WARNING
The straps or chains used to fasten the YardMaster to the transport must be directly connected to the YardMaster frame or to a component (drive axle) that is solidly attached to the frame. Do not fasten a strap or chain to the boom or spreader to hold the YardMaster on the transport.
CAUTION
Make sure that any straps or chains used to fasten the YardMaster to the transport do not contact any tubes, hoses, hydraulic cylinders, or other parts of the truck that are easily damaged. If YardMaster is transported in severe weather or any other condition that can damage YardMaster, cover YardMaster. Make sure protective cover is designed for the application and is securely fastened.
Unloading
If components normally attached to YardMaster were removed for transport, see the Service Manual for installation procedures. 1. If used, remove any protective cover. 2. Make sure parking brake is applied. 3. Disconnect straps or chains. 4. Remove wheel blocks. 5. Check that all switches and accessories are turned off.
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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
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TECHNICAL PUBLICATIONS
8000 SRM 780 6/05 (11/03)(4/03)(2/03)(1/00) Printed in U.S.A.