Professional Documents
Culture Documents
Manual de Serviço h360
Manual de Serviço h360
MAINTENANCE
H8-12XM-6, H10XMS-6
(H190-280HD2, H230HDS2) [L007];
H13-16XM-6, H6-7XM-12EC
(H210-250-48HD2, H300-360HD2, H360HD2-EC)
[K019]
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Serial Number Data ............................................................................................................................................1
Truck Handling Procedures ....................................................................................................................................2
Moving and Towing a Lift Truck ........................................................................................................................2
Precautions ..................................................................................................................................................... 2
Moving the Truck ............................................................................................................................................2
Putting a Lift Truck on Blocks ...........................................................................................................................3
Raising the Drive Tires .................................................................................................................................. 3
Raising the Steering Tires ............................................................................................................................. 3
Cleaning a Lift Truck ..........................................................................................................................................4
Safety Procedures Before Starting Maintenance .................................................................................................. 5
Making Checks From the Driver Seat with Engine Running .......................................................................... 5
Fire Hazard .....................................................................................................................................................5
Hydraulic Service Switch ................................................................................................................................... 6
Transmission Calibration Switch .......................................................................................................................6
Wait 100 Seconds Before Disconnecting Battery .............................................................................................. 6
Periodic Maintenance Schedule ..............................................................................................................................7
Daily Inspection .................................................................................................................................................. 8
Daily Condition Checks ..................................................................................................................................8
Daily Fluid Level Checks ............................................................................................................................... 9
Daily Checks from the Driver Seat with Engine Running .........................................................................10
Initial Inspection ...............................................................................................................................................11
First Inspection after First 100 Hours of Operation .................................................................................. 11
Periodic Maintenance ....................................................................................................................................... 11
Inspect and Adjust ........................................................................................................................................11
Lubricate ....................................................................................................................................................... 15
Change ...........................................................................................................................................................16
Periodic Maintenance Schedule - ELME 580 Series Container Attachment .....................................................17
Periodic Maintenance ....................................................................................................................................... 18
Inspect and Adjust ........................................................................................................................................18
Lubricate ....................................................................................................................................................... 18
Change ...........................................................................................................................................................19
Periodic Maintenance Procedures ........................................................................................................................ 19
Air Conditioning System .................................................................................................................................. 19
Attachment ........................................................................................................................................................19
Brake Cooling Filter ......................................................................................................................................... 19
Brake System Accumulator ..............................................................................................................................20
Cab Air Filter .................................................................................................................................................... 20
Cab Door Hinges ............................................................................................................................................... 20
Control Levers, Switches, and Pedals ..............................................................................................................20
Cooling System ..................................................................................................................................................21
Coolant Hoses ............................................................................................................................................... 21
Coolant Level ................................................................................................................................................ 21
Coolant Quality .............................................................................................................................................21
Cooling Fan ................................................................................................................................................... 22
Cooling Fan Belt ........................................................................................................................................... 22
Cooling Fan Belt Tensioner and Pulleys ..................................................................................................... 22
Bearing Condition .................................................................................................................................... 22
Pulley Alignment ......................................................................................................................................22
Tensioner Condition ................................................................................................................................. 23
ii
Table of Contents
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 1939 General
General
This section contains a Periodic Maintenance Some lift truck users have service personnel and
Schedule and the Periodic Maintenance Procedures equipment to do the inspection, lubrication, and
for L007 and K019. maintenance shown in the Periodic Maintenance
Schedule. Service Manuals are available from your
The Periodic Maintenance Schedule has hour dealer for HYSTER lift trucks to help users who do
intervals for inspection, lubrication, and component their own maintenance.
replacement for your lift truck.
SERIAL NUMBER DATA
When in addition to the hour intervals a calendar
interval is mentioned, then the first expiring The serial number for the lift truck is on the
interval must be observed. nameplate and also on the right hand frame rail,
near the counterweight. The serial number
It may be necessary to apply shorter maintenance indicates the design series, manufacturing plant,
intervals under circumstances, such as continuous and the year manufactured.
heavy rain, dusty environment and extreme
temperatures.
WARNING
Example: L007 or K019 E 4369 N
Do not make repairs or adjustments unless you
have both authorization and training. Repairs and (1) (2) (3) (4)
adjustments made on a lift truck by people
without authorization and training can make a (1) The first letter and number of the serial number
dangerous operating condition. indicates the design series and the model number
of the lift truck.
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair (2) The second letter identifies the manufacturing
is necessary, put a DO NOT OPERATE tag in the plant. In this example: E = Nijmegen, The
operators area. Remove the key from the key Netherlands.
switch.
(3) The number series following the second letter
CAUTION indicates the sequence of manufacture where the
lift truck was made.
Maintenance procedures have to be executed with
the engine OFF, unless indicated otherwise.
(4) The letter following the number series indicates
the year of manufacture starting with A=2003. The
letter B=2004, N = 2015, and so on.
1
General 8000 SRM 1939
NOTE: If the parking brake is manually released, 1. The towed lift truck must have an operator.
it will need to be adjusted before the lift truck is re-
turned to service. With hydraulic pressure applied 2. Make sure transmission oil level is above mini-
to the parking brake, adjust play between brake mum. Observe a maximum towing speed of 5
disc and park brake pads to 1.0 mm (0.04 in.). km/hr and a maximum towing distance of 5 km
(3 miles).
The parking brake caliper is mounted on a support
bracket at the differential carrier assembly. To
manually release the parking brake, perform the
following steps:
2
8000 SRM 1939 Truck Handling Procedures
3. Use a lifting device to raise the carriage and NOTE: Some lift trucks have lifting eyes. Truck
forks approximately 30 cm (12 in.) from the sur- lifting eyes can be used to raise the lift truck and
face. Install a chain around the mast cross- put the truck on blocks.
member and the carriage to prevent the car-
riage and mast channels from moving.
Raising the Drive Tires
4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or 1. Put blocks on each side (front and rear) of the
larger capacity than the disabled lift truck. In- steering tires to prevent movement of the lift
stall an approximate half-capacity load on the truck. See Figure 3.
forks of the lift truck that is being used to tow
the disabled lift truck. This half-capacity load 2. Slightly tilt the mast towards the operators
will increase the traction of the lift truck. Keep cab. Put a block with steel plates under each
the load as low as possible. outer mast channel.
5. Use a towing link made of steel that fastens to 3. Tilt the mast fully forward until the drive tires
both lift trucks. Connect the towing link to an are raised from the surface.
adequate provision, such as a towing pin or lift-
ing eye. 4. Put blocks with steel plates under the drive
axle mounting. Make sure the steel plates do
6. After towing is completed, place blocks on both not damage hoses, cables or hardware.
sides (front and rear) of all drive and steering
tires and re-apply the parking brake. 5. If the hydraulic system does not operate, use a
hydraulic jack under the side of the frame near
PUTTING A LIFT TRUCK ON BLOCKS the drive axle. Make sure that the jack has a
capacity of at least half the weight of the lift
truck. See the nameplate.
WARNING
The lift truck must be put on blocks for some Raising the Steering Tires
types of maintenance and repair. The removal of
the following assemblies will cause large changes 1. Apply the parking brake. Put blocks on both
in the center of gravity: drive axle, engine, trans- sides (front and rear) of the drive tires to pre-
mission and the counterweight. When the lift vent movement of the lift truck. See Figure 3.
truck is put on blocks, put additional blocks in the
2. Put blocks between the steering axle and
following positions to maintain stability:
frame. See Figure 4.
a. Before removing the mast and drive axle,
put blocks under the counterweight to pre- 3. Use a hydraulic jack to raise the steering tires.
vent the lift truck from falling backward. Make sure that the jack has a capacity of at
least 2/3 of the weight of the lift truck. See the
b. Before removing the counterweight, put
nameplate.
blocks under the mast assembly to prevent
the lift truck from falling forward. 4. Put the jack under the steering axle to raise the
lift truck. Put blocks under the frame to sup-
The surface must be solid, even, and level when
port the lift truck.
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid, one 5. Put blocks with steel plates under the LH and
piece units. Put a steel plate on top of the block. RH side of the steering axle. Lower the jack un-
til the steering axle is supported by the blocks.
Before putting the lift truck on blocks, check the
presence of components, hoses or wires mounted
under the frame, to prevent damage to these
parts.
3
Truck Handling Procedures 8000 SRM 1939
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
CAUTION
Units may be washed with a non-heated pressure
washer. Steam cleaning is not recommended in
most instances, as condensation may form in
1. FRAME electrical components causing damage or erratic
2. BLOCKS BETWEEN FRAME AND AXLE behavior.
3. SUPPORT BLOCKS
4. STEERING AXLE Use the following guidelines when cleaning a fork-
5. WHEEL
6. AXLE PIVOT POINT lift truck:
Figure 4. Steering Axle on Blocks 1. Assure truck components have cooled down be-
fore starting the cleaning procedure.
4
8000 SRM 1939 Truck Handling Procedures
5. Be sure to avoid directing the spray into electri- • Armrests with electrical components.
cal panel compartment. Ensure overspray does
not come in contact with electrical components; 7. Clean the battery compartment by using a
DO NOT spray water directly at electrical com- clean cloth to wash the battery with water. Dry
ponents, wiring connectors, or electrical enclo- with compressed air.
sures. Even sealed connectors may allow water
8. DO NOT use a pressure washer to clean the
egress under pressure or if connector is dam-
battery.DO NOT use hot water.
aged.
9. DO NOT use a pressure washer to clean lift
6. Avoid spraying in areas containing electrical
chains, sheaves, or load rollers in the mast as-
components such as:
sembly.
• Floor Plates.
• Battery Compartment. 10. After cleaning, immediately start and run the
lift truck to dry out components.
• Dash/cowl assembly.
5
Safety Procedures Before Starting Maintenance 8000 SRM 1939
FASTEN YOUR SEAT BELT! The seat belt is DO NOT FORGET to return the switch up to the
installed to help the operator stay on the transmission symbol when putting the truck back
truck if the lift truck tips over. into service. Hydraulic functions do not operate
when the switch is in the down position.
Make sure that the area around the lift truck is
clear before starting the engine or making any op- WAIT 100 SECONDS BEFORE
erational checks. Be careful when making the DISCONNECTING BATTERY
checks. If the lift truck is stationary during a check,
apply the parking brake and put the transmission DO NOT operate the battery disconnect switch un-
in NEUTRAL. Make the checks carefully. til 100 seconds after key switch is in OFF position
to avoid damage to the DEF system and to the dif-
HYDRAULIC SERVICE SWITCH ferent controllers.
The Hydraulic Service Switch allows operation of Early disconnect will prohibit the DEF system to
hydraulic functions for service purposes only, with- finish the purge cycle, possibly resulting in crystal-
out an operator being present in the seat. Move the lization of the DEF injection nozzle and damage
switch to the spanner symbol when operation of hy- caused by freezing.
draulic functions is desired during truck servicing.
See Figure 65 for location. Early disconnect of controllers may trigger fault co-
des and prohibit a memory reset.
DO NOT FORGET to return the switch to the hy-
draulic symbol when putting the truck back into See Figure 65 for location of the Battery Disconnect
service. If the switch is NOT returned into its nor- Switch.
mal position, the transmission will remain disa-
bled.
6
8000 SRM 1939 Periodic Maintenance Schedule
7
Periodic Maintenance Schedule 8000 SRM 1939
DAILY INSPECTION
8
8000 SRM 1939 Periodic Maintenance Schedule
9
Periodic Maintenance Schedule 8000 SRM 1939
Table 3. Daily Checks from the Driver Seat with Engine Running
10
8000 SRM 1939 Periodic Maintenance Schedule
Table 3. Daily Checks from the Driver Seat with Engine Running (Continued)
INITIAL INSPECTION
PERIODIC MAINTENANCE
11
Periodic Maintenance Schedule 8000 SRM 1939
12
8000 SRM 1939 Periodic Maintenance Schedule
13
Periodic Maintenance Schedule 8000 SRM 1939
14
8000 SRM 1939 Periodic Maintenance Schedule
Lubricate
Table 6. Lubricate
15
Periodic Maintenance Schedule 8000 SRM 1939
Change
Table 7. Change
16
8000 SRM 1939 Periodic Maintenance Schedule
17
Periodic Maintenance Schedule - ELME 580 Series Container Attachment 8000 SRM 1939
PERIODIC MAINTENANCE
Lubricate
Table 9. Lubricate
18
8000 SRM 1939 Periodic Maintenance Schedule - ELME 580 Series Container Attachment
Change
Table 10. Change
ATTACHMENT
19
Periodic Maintenance Procedures 8000 SRM 1939
Check the precharge pressure of the Brake System The cab air filter is located at the left rear corner of
Accumulator. the cab.
1. Place the lift truck on a solid, level surface. Move the locks to each other and pull the cab air
filter for inspection. Clean the element if possible.
2. Apply the parking brake.
Replace the filter when necessary.
3. Lower the mast completely.
4. Tilt the mast completely forward. After the filter has been installed, push the locks
into the locked position. See Figure 8.
5. Switch the engine OFF.
CAB DOOR HINGES
6. Shut down the engine.
7. Place blocks in front of and behind the tires to Every 1,000 Hours
prevent movement of the lift truck.
There are four grease fittings on the cab door
8. Raise (side tilt) the cab to the fully open posi- hinges, two on each hinge. Lubricate the cab door
tion to gain access to the main control valve. hinges. See Approved Oils, Fluids, and Grease.
9. Remove the cap from check port M ACC on the CONTROL LEVERS, SWITCHES, AND
main control valve.
PEDALS
10. Connect a 0 to 30 MPa (0 to 4,351 psi) hy-
draulic pressure gauge at port M ACC. Daily
11. Lower the cab until it is in the fully lowered Check that the control levers for the transmission,
and latched position. mast, attachment, and the pedals operate as descri-
bed in the Operating Manual.
12. Apply the brake pedal and observe the gauge
reading. Repeat this procedure until the brake
pedal pressure nears the accumulator pressure.
A sudden sharp pressure drop will be observed.
The gauge reading immediately before the
sharp pressure drop represents the precharge
pressure of the accumulator.
20
8000 SRM 1939 Periodic Maintenance Procedures
COOLING SYSTEM Check the cooling system for leaks if more than 1 li-
ter (0.26 gal) of coolant must be added per 3,000
Coolant Hoses running hours.
Verify if coolant hoses are collapsed when the en- Every 2,000 Hours
gine is cold. Collapsed hoses indicate a malfunc-
tioning radiator cap. Replace the radiator cap as re- Measure and record acidity and ethylene glycol con-
quired. tent of the coolant.
Inspect the condition of the coolant hoses by look- Compare measurement with earlier records and
ing for cracks, leakage or other damage. take appropriate action.
CAUTION
Additives in the coolant may damage the cooling
system. Before using additives, contact your local
HYSTER dealer.
Also add coolant when the Coolant Level Warning 1. RADIATOR CAP
2. EXPANSION TANK
Light is ON during operation of the truck. 3. "MIN" MARK
4. "MAX" MARK
If coolant must be added, use an OAT (Organic 5. COOLANT LEVEL SWITCH
Acid Technology) type coolant. Add coolant until
just below the 'MAX' mark on the expansion tank. Figure 9. Cooling System
See Figure 9.
21
Periodic Maintenance Procedures 8000 SRM 1939
Pulley Alignment
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 10. Drive Belt Inspection
22
8000 SRM 1939 Periodic Maintenance Procedures
Tensioner Condition 3. Check the tensioner pulley and body for cracks.
If any cracks are noticed, the tensioner must be
1. Check that neither the top nor bottom ten- replaced. See Figure 15.
sioner arm stop is touching the cast boss on the
tensioner body. If either of the stops is touching
a cast boss, the drive belt must be replaced.
Make sure that the correct belt part number is
being used if either condition exists. See Fig-
ure 13.
23
Periodic Maintenance Procedures 8000 SRM 1939
1. DEF PUMP
2. FILTER SCREW CAP
Replace the DEF Pump Filter and filter insert us- 1. DEF PUMP
ing the filter removal tool. See Figure 18. 2. FILTER
3. FILTER REMOVAL TOOL
1. Remove the cover using a wrench. Figure 19. DEF Pump Filter Remove
24
8000 SRM 1939 Periodic Maintenance Procedures
3. Insert the filter insert into the filter element. DEF Tank Suction Filter
See Figure 20.
Every 5,000 Hours
1. FILTER INSERT
2. FILTER ELEMENT
25
Periodic Maintenance Procedures 8000 SRM 1939
3. Remove the filter from the suction tube. See • The situation is normal if a fine powder has
Figure 24. been collected.
Every 250 Hours Change the oil for differential and drive axle. To
drain the oil, remove the plugs from the planetary
Remove magnetic oil plugs in differential and plan- covers and the plug at the bottom of the differential
etary drives to check oil level and verify size of housing. Verify particle size on the magnetic plugs
wear particles. and clean the magnetic plugs. Fill the drive axle
with the oil specified in Approved Oils, Fluids, and
• If particles are large shine chips, check for
Grease. Fill slowly to the bottom of the fill plug
damages on bearings and gears before con-
holes. After filling, operate the lift truck to make
tinuing operation.
sure the oil level is even. Check the oil level again
• If particles are course, check wheel bearing and check for leaks.
pre-tension.
26
8000 SRM 1939 Periodic Maintenance Procedures
Every 500 Hours Replace the safety element every third time the
main element is replaced. Clean the inside of the
Check the end beam slider pads for excessive play. housing when changing filters.
Maintain a play of 1 to 2 mm (0.039 to 0.079 in.)
between slider pads and end beam. Re-shim or re- Every 500 Hours or at least Every 12 Months
place the slider pads as required. See Figure 25.
Verify maintenance records to establish if normal
air filter replacement is due. Make sure the Tier 3/
Stage IIIA Air Filter sensor performs properly.
27
Periodic Maintenance Procedures 8000 SRM 1939
ENGINE COMPARTMENT
1. MOUNTING BRACKET
2. RUBBER MOUNT
3. LARGE WASHER
4. NUT
5. CAP SCREW
6. FRAME BRACKET
Figure 28. Engine Mounts
28
8000 SRM 1939 Periodic Maintenance Procedures
WARNING
Long-term exposure to used engine oil can cause
skin irritation or cancer. Use caution when check-
ing or adding oil to the engine. If oil comes in con-
tact with skin, wash with detergent and water.
CAUTION
DO NOT permit dirt to enter the engine when the
oil level is checked or the filter is changed.
NEVER operate the engine without oil. The opera-
1. MOUNTING BRACKET
2. WASHER tion of the engine without oil will damage the en-
3. CAP SCREW gine.
4. WASHER
5. NUT Every 500 Hours
6. NUT
7. BOLT
8. WASHER Change engine oil and replace the engine oil filter.
9. METAL CORE
10. RUBBER MOUNT
11. BRACKET
Figure 29. Transmission Mounts
ENGINE OIL
WARNING
Long-term exposure to used engine oil can cause
skin irritation or cancer. Use caution when check-
ing or adding oil to the engine. If oil comes in con-
tact with skin, wash with detergent and water.
CAUTION
DO NOT permit dirt to enter the engine when the
oil level is checked or the filter is changed.
NEVER operate the engine without oil. The opera-
tion of the engine without oil will damage the en- 1. ENGINE OIL FILTER
gine. 2. ENGINE OIL DIPSTICK
Figure 30. Engine Oil Filter and Dipstick
Daily and Every 250 Hours
29
Periodic Maintenance Procedures 8000 SRM 1939
CAUTION
Engine coolant temperature should be lower than
60°C (140°F).
1. BARRING TOOL
30
8000 SRM 1939 Periodic Maintenance Procedures
5. With the engine in this position, lash can be 7. While holding the adjusting screw in place with
checked on the following rocker arms: 1l, 1E, 2l, a screwdriver to prevent losing the proper ad-
3E, 4l, and 5E. See Table 11. justment, torque the locknut to
24 N•m (18 lbf ft) to set the adjustment, then
Table 11. Valve Adjust Limits measure the lash again with the feeler gauge.
Repeat Step 4 through Step 9 until the proper
Valve Adjust Limits
lash adjustment is acquired.
"MIN"
0.152 mm (0.006 in.) 8. Using a barring tool, rotate the crankshaft 360
Intake
"MAX" degrees and repeat Step 4 through Step 7 for
0.559 mm (0.022 in.) rocker arms 2E, 3l, 4E, 5l, 6l, and 6E. Reset the
lash, if out of specification.
"MIN"
0.381 mm (0.015 in.) 9. Install the press-in gasket. See Figure 35.
Exhaust
"MAX"
0.813 mm (0.032 in.) • Press the molded gasket into the corners
of the rocker lever cover.
• Press the gasket around the cap screw
6. Measure lash by inserting a feeler gauge be- mounting holes.
tween the crosshead and the rocker lever ball
insert and socket while lifting up on the end of • Press the remaining gasket into the
the rocker arm. If the lash measurement is out rocker lever cover.
of specification, loosen the locknut while hold- 10. Install the rocker lever cover and cap screws.
ing the adjusting screw with a screwdriver and Torque cap screws to 12 N•m (106 lbf in).
adjust the lash to the nominal specification as
indicated on the engine identification plate. See 11. Install the crankcase breather tube onto the
Figure 31. rocker lever cover.
NOTE: Lash resets are only required at the inter- 12. Install the variable geometry turbocharger ac-
val specified in the Maintenance Schedule, when tuator air supply line, if equipped.
lash is measured and found out of specification, or
when engine repairs cause removal of the rocker
arms and/or loosening of the adjusting screws.
1. WRENCH ON LOCKING NUT Figure 35. Rocker Lever Cover Gasket Installation
2. FEELER GAUGE
3. SCREWDRIVER
Figure 34. Locking Nut and Feeler Gauge
31
Periodic Maintenance Procedures 8000 SRM 1939
EXTENSION BEAM WEAR PADS If a fault appears, report the fault immediately. DO
NOT operate the lift truck until the fault is correc-
Every 500 Hours ted. When all faults have been cleared or repaired,
the hourmeter/fault code display will show engine
1. Inspect the wear pads for wear. See Figure 36. running hours again.
FORKS
WARNING
DO NOT try to correct the alignment of the fork
tips by bending the forks or adding shims. Never
repair damaged forks by heating or welding.
Forks are made of special steel using special pro-
cedures. If either fork is damaged, replace the
1. WEAR PAD forks as a set.
2. WEAR PAD SHIM
3. CAP SCREW NOTE: Also perform below checks immediately af-
4. WASHER
5. WEAR PAD BRACKET ter any collision of the truck, load or attachment.
6. EXTENSION BEAM
Daily and Every 250 Hours
Figure 36. Extension Beam Wear Pads
Replace the forks as a set if any of the below re-
quirements is not met.
2. Replace the wear pads if thickness is
18 mm (0.709 in.) or less. When replacing wear 1. Check that the fork angle is less than 93°.
pads, simultaneously replace all pads that are
fitted in the same plane. (All lower pads, all up- 2. Check that the fork tips are aligned within 3%
per pads or all side pads). Using wear pads of fork length.
with a different thickness will twist and dam-
age the extension beam weldment. 3. Check for absence of cracks at fork pin connec-
tion.
3. Check torqueing of the hardware that retain
the wear pad brackets. The required torque is 4. Check for absence of cracks at fork heel. See
63 N•m (46 lbf ft). Figure 37.
4. Grease the tracks for the wear pads. Replace any damaged or broken part that is used
to keep forks locked in position.
FAULT CODES
Every 250 Hours
Daily and Every 250 Hours
Make sure the bottom of the fork is at least 90% of
If the engine, transmission or hydraulic controller the original thickness.
detects a fault, the hourmeter/fault code display
will show a fault code instead of engine running If either fork is worn, replace the forks as a set.
hours, and the central warning lights will be ON.
32
8000 SRM 1939 Periodic Maintenance Procedures
WARNING
Lower the lift mechanism completely. Never allow
any person under a raised carriage. DO NOT put
any part of your body in or through the lift mecha-
nism unless all parts of the mast are completely
lowered and the engine is STOPPED.
33
Periodic Maintenance Procedures 8000 SRM 1939
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
Daily
34
8000 SRM 1939 Periodic Maintenance Procedures
Figure 40. Fuel Tank Breather For location of fuses and relays, see Table 14 and
Figure 66.
35
Periodic Maintenance Procedures 8000 SRM 1939
36
8000 SRM 1939 Periodic Maintenance Procedures
Hydraulic Oil Replacement 10. Loosen the supply hose connections at the hy-
draulic pumps to bleed the air from the hoses.
CAUTION
CAUTION
Never start the engine when the hydraulic pumps
Disposal of lubricants and fluids must meet local are not filled with hydraulic oil. Make sure that the
environmental regulations. hydraulic pumps are filled with oil by disconnect-
ing the drain hoses and filling the pump chambers
CAUTION through the drain port on each hydraulic pump.
Failure to comply can result in serious damage
DO NOT permit dirt to enter the hydraulic system
and loss of durability to the hydraulic pump(s).
when the hydraulic oil is checked or the filters are
changed or lift truck damage may occur. 11. Disconnect the drain hoses and fitting from the
hydraulic pumps and fill the pump chambers
CAUTION with clean hydraulic oil through the drain port
on each hydraulic pump. See Figure 42.
Additives in the hydraulic system oil may damage
the hydraulic system. Before using additives, con- 12. Connect the drain hoses to the hydraulic
tact your local Hyster dealer. pumps.
Every 3,000 Hours or according oil test re- 13. Start the engine while operating the lift func-
port. tion. Keep engine speed at idle.
9. Fill the hydraulic tank with clean hydraulic oil 1. SUPPLY HOSES
as specified in Approved Oils, Fluids, and 2. DRAIN PORT
Grease.
Figure 42. Hydraulic Pump Fill
37
Periodic Maintenance Procedures 8000 SRM 1939
14. Lift the mast until it has almost reached its end HYDRAULIC TANK RETURN FILTER
of stroke.
Every 3,000 Hours or at hydraulic oil replace-
15. Lower the mast and keep the engine at idle for
ment.
about one minute.
16. Return to Step 14 if the pump has produced a Replace the hydraulic tank return filter when re-
sound that relates to cavitation. placing hydraulic oil.
17. Raise engine speed to high idle (1,000 – 1,200 Measure filter back pressure if excessive back pres-
rpm) and lift the mast until it has almost sure is suspected.
reached its end of stroke.
To measure filter back pressure, heat hydraulic oil
18. Lower the mast and keep the engine at idle for temperature to at least 60°C (140°F). Connect a
about one minute. pressure gauge at check port MRF. Run the engine
at full throttle while lowering the mast at maxi-
19. Return to Step 17 if the pump has produced a
mum lowering speed. Replace the tank return filter
sound that relates to cavitation.
if the measured value is 250 kPa (36 psi) or higher.
20. Operate each hydraulic function in both direc-
tions twice, at high engine speed (1,600 – 1,900 Replace the hydraulic return filter by removing the
rpm). Release the function when it has reached 4 bolts and the filter head from the hydraulic tank.
its end of stroke.
Remove the spring and the filter.
21. Switch the engine OFF, check oil level and
check for leaks. Install a new filter, the spring and the filter head.
Tighten the four bolts to 20 N•m (14.7 lbf ft).
HYDRAULIC TANK BREATHER
INCHING PEDAL SENSOR CALIBRATION
CAUTION
Every 2,000 Hours
DO NOT remove the complete hydraulic oil
breather cap assembly to avoid dirt from entering Calibrate the inching pedal sensor to compensate
the hydraulic system. for normal wear.
Daily and Every 250 Hours Normal wear may cause that the signal from the
sensor to the transmission controller moves outside
1. Check if the yellow indicator on the hydraulic of the acceptable range. This causes the controller
oil breather cap is raised. See Figure 41. to shift the transmission into neutral and to show
2. If the indicator is fully raised or almost fully fault code t0211 on the display.
raised, replace the filter element in the hy-
draulic oil breather. See Transmission Operations and Diagnostics
1300SRM1455 for calibration procedure.
3. Before replacing the element, push the yellow
indicator down to release pressure from the hy- LIFT CHAINS
draulic oil breather cap.
Check and Lubricate Lift Chains
4. Remove the hydraulic oil breather cap and
clean the inside of the breather cap.
WARNING
5. Install a new filter element and replace the hy-
draulic oil breather cap. Lower the lift mechanism completely. Never allow
anyone under a raised carriage. DO NOT put any
6. Push the yellow indicator down. part of your body in or through the lift mechanism
unless all parts of the mast are completely low-
ered and the engine is STOPPED.
38
8000 SRM 1939 Periodic Maintenance Procedures
Before making any repairs, use chains to secure 5. Allow sufficient time for the oil to penetrate
the mast weldments and carriage into position so before the chains are put under tension
that they cannot move. Make sure the moving again.
parts are attached to a part that does not move. 6. Wipe excess oil.
DO NOT repair a worn lift chain. Replace both lift
chains when one or both lift chains are worn. Adjust Lift Chains
When the oil film is still intact, check absence of 5. Turn large nuts on both chain anchors. Make
following conditions: sure that both forks have at least 1 cm (0.40
in.) clearance with ground.
1. Broken, damaged or missing chain link
plates. 6. Align the vertical carriage bar with the inner
mast channel by tightening the large nut of
2. Damaged, turned or protruding link pins. the anchor chain that is in lowest position.
Make sure that the vertical carriage bar runs
Have both lift chains replaced if any of the above parallel with the inner mast channel. Apply
conditions is observed. an accuracy of 0.5 mm per 50 cm (0.025 in.
per 2 feet). See Figure 44.
Check the chain anchors and chain pins for cracks
and damage. Replace if cracked or damaged. 7. Adjust fork height by turning both chain an-
chor nuts with the same angle until the re-
First 100 Hour inspection and Every 250 quired ground clearance has been obtained.
Hours Make sure that the ground clearance of both
forks is between 10 and 20 mm (0.4 and
Lubricate both lift chains: 0.8 in.).
1. Slacken the chains. This may require setting 8. After adjustments are completed, bend fin-
the forks or attachment on a support such as gers of securing plates around large nut and
a wooden block or container. tighten lock nut.
39
Periodic Maintenance Procedures 8000 SRM 1939
40
8000 SRM 1939 Periodic Maintenance Procedures
Inspect Lift Chains Compare the length with the chart in Figure 46.
Replace the chain if the length of 20 links of the
worn section is longer than the wear limit. For re-
WARNING placement procedures see 2-Stage Mast
Lower the lift mechanism completely. Never allow 4000SRM1647.
anyone under a raised carriage. DO NOT put any
part of your body in or through the lift mechanism
unless all parts of the mast are completely low-
ered and the engine is STOPPED.
A. CHAIN PITCH
Figure 45. Lift Chain Pitch
41
Periodic Maintenance Procedures 8000 SRM 1939
Lift Chain Wear and Damage Connect a nitrogen filling device and refill the accu-
mulator with nitrogen gas at approximately
Every 250 Hours 20°C (68°F) to the required precharge pressure of
9.00 MPa (0.75 psi). For the correct nitrogen gas re-
Inspect and replace if any of the following condi- filling procedure, refer to Hydraulic System
tions occur, see Figure 47: 1900SRM1934.
1. Wear of any plate exceeds 5% of the original
dimension. See Figure 47. LOAD ROLLERS
2. Wear of any pin exceeds 5% of the original
Carriage Load Rollers
dimension.
3. Broken, damaged or missing chain link Every 250 Hours
plates.
4. Damaged, turned or protruding link pins. Add grease through the grease nipple until grease
escapes from the sides of the load roller. See Ap-
5. Stiff articulation between chain links.
proved Oils, Fluids, and Grease and Figure 48.
6. Presence of lubricant, which is brown colored
by rust. Inner Mast Load Rollers
For replacement procedures see 2-Stage Mast Every 250 Hours
4000SRM1647.
Raise the inner mast until the holes in the sides of
the outer mast provide access to the lube fittings of
the rollers. Add grease through the grease fitting
until grease escapes from the sides of the load
roller. See Approved Oils, Fluids, and Grease and
Figure 48.
1. MOVED PIN
2. RUST
3. LOOSE LEAVE
4. PIN WEAR (MAX 5%)
5. CRACK
6. HOLE WEAR
7. EDGE WEAR (MAX 5%)
Figure 47. Lift Chain Check
42
8000 SRM 1939 Periodic Maintenance Procedures
Daily and Every 250 Hours Daily and Every 250 Hours
1. Slowly raise and lower the mast several NOTE: Check correct operation of the Operator
times without a load. Raise the mast to its Presence System.
full extension height at least once. The mast
components must raise and lower smoothly 1. Run the engine and verify normal operation
in the correct sequence. of transmission and hydraulic functions.
2. Check proper tracking of header hoses. 2. Raise yourself from the seat for more than
3. Check for excessive play of rollers and bear- 2.5 sec.
ing blocks. 3. Verify that hydraulic lift, lower and tilt func-
4. The inner weldment and the carriage must tions do not operate as long as you are raised
lower completely. from the seat.
5. Check for leaks of hydraulic components. 4. Verify that the transmission has been disen-
gaged.
6. Raise the mast 1 m (3 ft) with a capacity
load. The inner weldment and the carriage 5. Verify that hydraulic lift, lower and tilt func-
must raise smoothly. Lower the mast. All tions operate again after you have re-seated.
moving components must lower smoothly. 6. Verify that the transmission can be re-en-
7. Lower the load to approximately 0.3 m (1 ft) gaged.
from the floor. Tilt the mast forward and
backward. The mast must tilt smoothly and To re-engage the transmission the operator must
all tilt cylinders must stop evenly. either:
8. Check that the controls for the attachment • Depress the inching brake pedal more than
operate the functions of the attachment cor- 75%.
rectly as described in the Operating Man- • Move the gear selector into the NEUTRAL
ual. See the symbols by each of the controls. position and then move the gear selector into
9. Perform Leak Checks for lift cylinders and travel mode.
tilt cylinders if excessive creep is suspected. • Make a direction change using the MONO-
TROL® pedal.
Repair and adjust as required. For procedures, see
2-Stage Mast 4000SRM1647. If the Operator Presence System does not work,
first check if the Hydraulic Service Switch is in the
MAST PIVOT PINS correct position. The Hydraulic Service Switch is lo-
cated behind the fuse panel.
Every 250 Hours
The Hydraulic Service Switch must be moved to the
Lubricate the fittings for the mast pivot pins, under hydraulic symbol for normal truck operation.
no load conditions. For proper lubrication, the mast
should be lifted. Place blocks under the mast and The Hydraulic Service Switch must be moved to the
tilt the mast forward until the drive tires start lift- spanner symbol for servicing, to allow operation of
ing off of the ground. The carriage and the mast hydraulic functions without an operator being
must stay in the lowered position during this proce- present in the seat. See Figure 64.
dure. See Approved Oils, Fluids, and Grease.
43
Periodic Maintenance Procedures 8000 SRM 1939
The seat belt, seat, seat mounting and steering col- Daily and Every 250 Hours
umn are all part of the operator restraint system.
Each item must be checked to make sure it is at- Make sure the latch for the steering column oper-
tached securely, functions correctly, and is in good ates correctly. The latch must NOT allow the col-
condition. umn to move unless the latch is released. Repair as
required.
Seat Belt and Seat Rails
PARKING AND SERVICE BRAKES
Daily and Every 250 Hours
Make sure the seat belt is in good condition and the CAUTION
end of the seat belt fastens correctly in the latch. Always apply the parking brake when the truck is
Make sure the seat belt pulls and retracts from the parked. A parking brake that is not applied will
retractor assembly smoothly. Pull the seat belt with drain the batteries.
a sudden jerk to verify that the retractor assembly
will lock the seat belt. Daily and Every 250 Hours
Replace the seat belt assembly when it is worn or Check the operation of the parking brake.
damaged, or when the retractor does not function
correctly. See Figure 49. The parking brake must apply when the knob for
the parking brake is pulled, and must release when
Make sure the seat rails lock securely in position, the knob is pushed.
but move freely when unlocked. Make sure the seat
rails attach securely to the seat suspension. The The park brake must be able to hold the truck with
seat suspension must be securely bolted to the cab a capacity load on a 15% grade (a slope that raises
floor. Repair as required. 1.5 m every 10 m (1.5 ft every 10 ft)). Repair the
parking brake if it fails these requirements.
44
8000 SRM 1939 Periodic Maintenance Procedures
1. Clean the radiator with compressed air or NOTE: The lift truck has hydraulic power steering.
water as required. Be careful not to bend the Steering is not possible when the engine is not run-
radiator fins. ning due to hydraulic pressure not being supplied
2. Inspect the radiator sections and hose con- to the steering system.
nections for leakage. Repair as required.
Check operation of the steering system.
SIDE SHIFT BEARING PADS (ECH)
Make sure the steering system operates smoothly
Every 500 Hours and steering control is good. Check for leaks.
Check upper and lower bearing pads. Replace bear- Repair as required.
ing pads if thickness is 18 mm (0.709 in.) or less.
King Pins
45
Periodic Maintenance Procedures 8000 SRM 1939
Figure 51. Steering Wheel Hub Bearings 7. Align the castle nut with the cotter pin hole at
first alignment position at or above
34 N•m (25 lbf ft) and install and lock the cot-
ter pin.
46
8000 SRM 1939 Periodic Maintenance Procedures
The tilt cylinder pivot pins have four grease fit- After each transmission oil change the transmis-
tings, two fittings per tilt cylinder. The grease fit- sion must be recalibrated to compensate for the dif-
tings are located at the end of each pivot pin. Apply ference in oil viscosity between used oil and new
grease until it escapes from the bushings. See Ap- transmission oil.
proved Oils, Fluids, and Grease and Figure 52.
For calibration procedure, see Transmission Op-
erations and Diagnostics 1300SRM1455.
WARNING
At operating temperature, the transmission oil is
hot. DO NOT permit the hot oil to touch the skin
and cause severe burns. Let transmission cool
before performing any maintenance.
WARNING
1. GREASE FITTING DO NOT permit dirt to enter the transmission
2. TILT PIVOT PIN
when the oil level is checked or the filter is
Figure 52. Tilt Cylinder Pivot Pin changed. Dirt can cause damage to transmission
components.
47
Periodic Maintenance Procedures 8000 SRM 1939
Transmission Oil and Oil Filter 9. Recalibrate the transmission. For procedure see
Transmission Operations and Diagnostics
1300SRM1455.
WARNING
At operating temperature, the transmission oil is TWIST LOCKS
hot. DO NOT permit the hot oil to touch the skin
and cause severe burns. Let transmission cool Every 250 Hours
before performing any maintenance.
Inspect and lubricate the two twist Locks.
WARNING Inspect
DO NOT permit dirt to enter the transmission
when the oil level is checked or the filter is Inspect the twist locks for wear and damage.
changed. Dirt can cause damage to transmission
components.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
48
8000 SRM 1939 Periodic Maintenance Procedures
Lubricate Replace
Each twist lock has two grease fittings. Lubricate Replace twist locks.
the grease fittings and sleeves using EP2/3 grease.
For procedures see Extendable Container At-
tachment (Elme) 5000SRM1221.
CAUTION
The silicone fluid in the vibration damper will be-
come solid after extended service, which makes
the vibration damper inoperative. An inoperative
vibration damper can cause major engine or
driveline failures. Replace the damper at overhaul.
49
Periodic Maintenance Procedures 8000 SRM 1939
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
Figure 56. Vibration Damper Damage 1. Make sure the surface is dry and has no oil or
Identification grease. Do not use solvent on new paint. Clean
the surface of the old paint with a cleaning sol-
vent.
To establish maximum deformation, measure and
record the thickness of the vibration damper at four 2. Partially remove the paper from the back of the
places. Replace the vibration damper if its thick- label. Do not touch the adhesive surface.
ness has increased, or varies by more than
3. Carefully hold the label in the correct position
6.35 mm (0.25 in.). See Figure 57.
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface and remove the rest of the paper at the
back. Make sure that all air is removed from
under the label and the corners and edges are
tight.
Daily
Figure 57. Vibration Damper Measure Points WINDSHIELD WASHER FLUID LEVEL
50
8000 SRM 1939 Periodic Maintenance Procedures
WHEELS AND TIRES Air pressure in pneumatic tires can cause tire and
wheel parts to explode. The explosion of wheel
Wheels, Tires, and Tire Pressure parts can cause serious injury or death. Remove
all of the air from the tires before the tires are re-
moved from the lift truck.
WARNING
The type of tire and tire pressure are shown on
the nameplate. Make sure the nameplate is correct
for the type of tires on the lift truck.
51
Periodic Maintenance Procedures 8000 SRM 1939
Daily and Every 250 Hours Remove Wheels from Lift Truck
WARNING
Lift truck wheels are heavy and can cause per-
sonal injury.
52
8000 SRM 1939 Periodic Maintenance Procedures
1. SIDE FLANGE
2. WHEEL RIM FOR SOLID TIRE
3. FLANGE SEAT
4. WHEEL RIM FOR PNEUMATIC TIRE
5. LOCK RING
WARNING
Completely remove the air pressure from the tire before it is removed from the lift truck. If dual wheels are
installed, remove the air from both tires. Air pressure in the tires can cause the tire and rim to explode
causing serious injury or death.
WARNING
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause serious injury. See Figure 61.
STEP 1.
For tubeless tires, remove the air valve by rotating it 60 degrees until the valve releases from the valve slot
STEP 2.
Loosen the tire bead from the side ring and/or lock
ring.
53
Periodic Maintenance Procedures 8000 SRM 1939
STEP 3.
Put the tire tool into the slot between the side ring
and/or lock ring and the wheel rim. Remove the
side ring and/or lock ring.
STEP 4.
Turn the tire over. Separate the tire from the
wheel rim.
STEP 5.
For tires with an inner tube, push the air valve
through the rim opening into the tire.
STEP 6.
Remove the wheel rim from the tire. Remove the
inner tube and flap.
54
8000 SRM 1939 Periodic Maintenance Procedures
WARNING
Wheels can explode and cause injury or death if the following procedures are not followed:
• Clean and inspect all parts of the wheel before installing the tire.
• Inspect all wheel components for deformation, corrosion and fractures.
• Look for fractures at the contact area between tire and wheel parts in particular.
• Unacceptable deformation includes progressed wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the above defects, and replace by new ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.
• Check with your dealer whether a specific tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure that the lock ring is in the correct position. The ends of the lock ring must not
touch. The clearance at the ends of the lock ring will be approximately 4 to 14 mm (0.15 to 0.55 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to cause
serious injury.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 61.
STEP 1.
Clean and inspect all parts of the wheel. If the 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
STEP 2.
Apply a rubber lubricant or a soap solution to the
tire bead and tube.
55
Periodic Maintenance Procedures 8000 SRM 1939
STEP 3.
Make sure that the wheel is the correct size for
the tire. Lubricate the part of the wheel that is in
contact with the bead and flap.
STEP 4.
For tire with inner tube, install the inner tube and
the tire flap in the tire. For tubeless tires, install
the bead seal in the tire.
STEP 5.
For tires with inner tube, align the valve slot in
the rim with the air valve and install the wheel
rim in the tire. Guide the air valve through the
valve slot in the rim. For tubeless tires, align the
valve slot hole in the rim with the valve bead hole
in the valve bead, and install the wheel rim in the
tire.
STEP 6.
Turn over the rim and tire. Put a block under the
rim so that the rim is 8 to 10 cm (3.15 to 3.94 in.)
above the floor. Install the side ring and the lock
ring. When correctly installed, there will be a 4 to
14 mm (0.15 to 0.55 in.) clearance between the
ends of the side ring and the lock ring.
WARNING
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury.
STEP 7.
For tubeless tires insert the air valve into the
bead seal and rotate the valve 60 degrees until the
air valve locks into the valve slot.
56
8000 SRM 1939 Periodic Maintenance Procedures
Adding Air Pressure to Pneumatic Tires 4. If installation is correct, add air pressure to the
tire. The correct pressure is shown on the
Nameplate.
WARNING
Add air pressure to the tires only in a safety cage. 5. Check that all wheel parts are correctly instal-
Inflating or adjusting tire pressure outside of a led. If installation is not correct, remove all of
cage is allowed only if residual air pressure ex- the air pressure from the tire. Remove the
ceeds 80% of the pressure as indicated on the valve core to make sure all of the air pressure
nameplate. has been removed and make adjustments. The
clearance at the ends of the lock ring will be 4
Inspect the safety cage for damage before use. to 14 mm (0.15 to 0.55 in.) when the tire has
the correct air pressure.
Always use a tire inflator with a clip-on chuck
when inflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in length.
During inflation the technician must stand away
from the safety cage. See Figure 62.
WARNING
Wheels can explode and cause injury or death if
the above procedures are not followed.
57
Periodic Maintenance Procedures 8000 SRM 1939
WARNING
Completely remove the air pressure from the tire
before it is removed from the lift truck. If dual
wheels are installed, remove the air from both
tires. Air pressure in the tires can cause the tire
and rim to explode causing serious injury or
death.
STEP 1.
Put the wheel rim on the bed of the press. Put the
cage in position on the tire. Use the press to push
the tire away from the side ring.
STEP 2.
Put the tire tool into the slot between the side ring
and/or lock ring and the wheel rim. Remove the
side ring, lock ring, and wedge band.
STEP 3.
Turn the tire over. Put a support under the wheel
rim. Make sure the wheel rim is at least 150 to
200 mm (6 to 8 in.) from the bed of the press.
58
8000 SRM 1939 Periodic Maintenance Procedures
STEP 4.
Put the cage in position on the tire. Use the press
to push the tire from the wheel rim.
59
Periodic Maintenance Procedures 8000 SRM 1939
WARNING
Wheels can explode and cause injury or death if
the following procedures are not followed:
• Clean and inspect all parts of the wheel be-
fore installing the tire.
• Inspect all wheel components for deforma-
tion, corrosion and fractures.
• Look for fractures at the contact area be-
tween tire and wheel parts in particular.
• Unacceptable deformation includes pro-
gressed wear, buckling, twisting or pres-
ence of dents.
• Discard all wheel components showing any
of the above defects, and replace by new
ones.
• DO NOT use any damaged or repaired
wheel parts.
• Make sure that all parts of the wheel are the
correct parts for that wheel assembly.
• DO NOT mix parts between different types
or manufacturers of wheels.
• DO NOT mix types of tires, type of tire
tread, or wheel assemblies of different man-
ufacturers on any one lift truck.
• Check with your dealer whether a specific
tire is approved for use on this lift truck.
CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.
60
8000 SRM 1939 Periodic Maintenance Procedures
STEP 1.
Lubricate the wheel rim and the inner surface of
the tire with tire lubricant or soap.
STEP 2.
Put the wheel rim on the bed of the press. Put the
tire over the wheel rim. Put the cage in position
on the tire. Use the press to install the tire on the
wheel rim.
STEP 3.
Remove the cage and put the wedge band, the side
ring, and the lock ring in position on the wheel as-
sembly. Install the cage on the tire. Use the press
to push the tire onto the wheel rim so that the
wedge band and side ring can be installed.
STEP 4.
While the cage is holding the tire on the wheel
rim, install the lock ring. Use a tire tool to make
sure the lock ring is in the correct position. Slowly
release the press and verify that the clearance at
the ends of the lock ring will be 4 to 14 mm (0.15
to 0.55 in.) when the cage almost loses contact
with the tire.
61
Periodic Maintenance Procedures 8000 SRM 1939
CAUTION
Check all wheel nuts after 2 to 5 hours of operation, when new lift trucks begin operation, and on all lift
trucks when the wheels have been removed and installed. Tighten the nuts as shown in Figure 63. When
the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 250 Hours.
Start with the wheel nut at the top and tighten the nuts to 68 to 136 N•m (50 to 100 lbf ft) in the sequence
shown in Figure 63. Check to make sure that the wheel(s) is tight against the hub, then tighten the nuts to
615 to 710 N•m (454 to 524 lbf ft).
62
8000 SRM 1939 Capacities and Specifications
Engine WWFC Diesel Sulfur Content ASTM D975 Emission Engine Oil
Emission Fuel Legislation
Legislation
Non-Compliance Category 1 <5000 mg/kg S5000 <5000 mg/kg ACEA E7 API
CI-4 (see Notes)
NOTE:
• Diesel Category 1 is not allowed in countries with Tier 3/Stage IIIA or more stringent emission
legislation.
• When using Diesel Category 1, the factory-filled CJ-4 engine oil must be replaced at initial 250 hours
by API CI-4 specification oil.
• When using Diesel Category 1, engine oil specification API CI-4 must be used to allow 500-hour oil
change intervals.
• Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content does not
exceed 5 percent of total volume.
63
Capacities and Specifications 8000 SRM 1939
Chain lubricant must be a mineral or synthetic en- If an electrical component does not function prop-
gine oil. Oil viscosity must match ambient tempera- erly, also check the main electrical supply, relays
ture, so that oil remains viscous and can penetrate and fuses.
to the contact area between link pin and intermedi- • Components for main electrical supply are
ate links. shown in Figure 64.
• Use SAE 20W to 30W oil in ambient temper- • Fuses and relays are shown in Table 14 and
atures of −30 to 5°C (−22 to 41°F). Figure 66.
• Use SAE 15W-40 oil in ambient tempera- Before replacing a failed fuse or relay, first repair
tures of -10 to 35°C (14 to 95°C). the defect that caused the fuse or relay to fail. Have
• Use SAE 40 oil in ambient temperatures of 5 any failed component replaced.
to 45°C (41 to 113°F).
• Use SAE 50 oil in ambient temperatures
above 45°C (113°F).
64
8000 SRM 1939 Capacities and Specifications
65
Capacities and Specifications 8000 SRM 1939
66
8000 SRM 1939 Capacities and Specifications
67
Capacities and Specifications 8000 SRM 1939
1. MAIN POWER
2. LIGHTS
3. HORN
4. OPS
5. START ENABLE
6. IGN
7. HYDRAULIC CONTROLLER
8. TWISTLOCK
9. START INHIBIT
10. NEUTRAL
11. 12V RELAY
12. OVERRIDE
13. AC 3
14. REVERSE LIGHTS & ALARM
15. FLASHER UNIT
16. AC 1
17. AC 2
68
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