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PERIODIC

MAINTENANCE
H8-12XM-6, H10XMS-6
(H190-280HD2, H230HDS2) [L007];
H13-16XM-6, H6-7XM-12EC
(H210-250-48HD2, H300-360HD2, H360HD2-EC)
[K019]

PART NO. 4133481 8000 SRM 1939


SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

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

©2016 HYSTER COMPANY i


Table of Contents

TABLE OF CONTENTS (Continued)


Crankcase Breather Element (Tier 4F/Stage IV Only) ...................................................................................24
Diesel Exhaust Fluid (DEF) System ................................................................................................................24
DEF Pump Filter .......................................................................................................................................... 24
DEF Tank Fill Cap ....................................................................................................................................... 25
DEF Tank Suction Filter ..............................................................................................................................25
Drive Axle and Differential .............................................................................................................................. 26
Check Oil level .............................................................................................................................................. 26
Change Oil .................................................................................................................................................... 26
Drive Shaft ........................................................................................................................................................ 27
End Beam Slider Pads ...................................................................................................................................... 27
Engine Air Filter ...............................................................................................................................................27
Engine Air Intake Piping and Charge Air Piping ........................................................................................... 28
Engine and Transmission Mounts ................................................................................................................... 28
Engine Compartment ....................................................................................................................................... 28
Engine Oil ..........................................................................................................................................................29
Engine Oil Level ........................................................................................................................................... 29
Engine Oil and Engine Oil Filter .................................................................................................................29
Engine Valve Adjustment .................................................................................................................................30
Extension Beam Wear Pads ............................................................................................................................. 32
Fault Codes ........................................................................................................................................................32
Forks .................................................................................................................................................................. 32
Fork Pins, Carriage Pins, and Carriage Sliding Surfaces .............................................................................. 33
Frame, Mast, Carriage and Attachment ......................................................................................................... 33
Fuel, Oil, DEF, or Coolant Leaks .....................................................................................................................34
Fuel/Water Separator and Final Fuel Filter ................................................................................................... 34
Fuel Tank Breather .......................................................................................................................................... 35
Header Hose Assembly ..................................................................................................................................... 35
Horn, Gauges, Lights, Alarms and Control System ........................................................................................35
Hydraulic System Oil ........................................................................................................................................36
Hydraulic Oil Testing Procedures ............................................................................................................... 36
Hydraulic Oil Replacement .......................................................................................................................... 37
Hydraulic Tank Breather ................................................................................................................................. 38
Hydraulic Tank Return Filter ..........................................................................................................................38
Inching Pedal Sensor Calibration .................................................................................................................... 38
Lift Chains .........................................................................................................................................................38
Check and Lubricate Lift Chains .................................................................................................................38
Adjust Lift Chains ........................................................................................................................................ 39
Inspect Lift Chains ....................................................................................................................................... 41
Chain Elongation ......................................................................................................................................41
Lift Chain Wear and Damage ..................................................................................................................42
Lift System Accumulator (Optional) ................................................................................................................42
Load Rollers .......................................................................................................................................................42
Carriage Load Rollers ...................................................................................................................................42
Inner Mast Load Rollers ...............................................................................................................................42
Mast, Carriage, and Attachment ..................................................................................................................... 43
Mast Pivot Pins ................................................................................................................................................. 43
Operator Presence System ............................................................................................................................... 43
Operator Restraint System .............................................................................................................................. 44
Seat Belt and Seat Rails ...............................................................................................................................44
Steering Column Latch ................................................................................................................................ 44

ii
Table of Contents

TABLE OF CONTENTS (Continued)


Parking and Service Brakes ............................................................................................................................. 44
Radiator Assembly ............................................................................................................................................ 45
Side Shift Bearing Pads (ECH) ........................................................................................................................ 45
Signals from the Spreader Control System ..................................................................................................... 45
Steering Axle Grease Fittings .......................................................................................................................... 45
King Pins .......................................................................................................................................................45
Tie Rod Pins .................................................................................................................................................. 45
Steering System ................................................................................................................................................ 45
Steering Wheel Hub Bearings ..........................................................................................................................46
Remove and Disassemble ............................................................................................................................. 46
Clean and Inspect ......................................................................................................................................... 46
Assemble and Install .................................................................................................................................... 46
Tilt Cylinder Pivot Pins .................................................................................................................................... 47
Transmission .....................................................................................................................................................47
Transmission Clutch Calibration ................................................................................................................ 47
Transmission Oil Level ................................................................................................................................ 47
Transmission Oil and Oil Filter ...................................................................................................................48
Twist locks .........................................................................................................................................................48
Inspect ........................................................................................................................................................... 48
Lubricate ....................................................................................................................................................... 49
Replace .......................................................................................................................................................... 49
Vibration Damper (Viscous) ............................................................................................................................. 49
Warning and Safety Labels .............................................................................................................................. 50
Windows and Mirrors ....................................................................................................................................... 50
Windshield Washer Fluid Level .......................................................................................................................50
Wheels and Tires ...............................................................................................................................................51
Wheels, Tires, and Tire Pressure .................................................................................................................51
Remove Wheels from Lift Truck .................................................................................................................. 52
Remove Pneumatic Tire from Wheel ........................................................................................................... 52
Install Pneumatic Tire on Wheel ................................................................................................................. 55
Adding Air Pressure to Pneumatic Tires .................................................................................................... 57
Remove Solid Rubber Tire from Wheel ....................................................................................................... 58
Install Solid Rubber Tire on Wheel ............................................................................................................. 60
Install Wheels on Lift Truck ........................................................................................................................ 61
Wheel Nuts on Drive and Steer Wheels ...................................................................................................... 62
Capacities and Specifications ............................................................................................................................... 62
Approved Fuel and Engine Oils ....................................................................................................................... 62
Approved Oils, Fluids, and Grease .................................................................................................................. 63
Engine Oil Viscosity ..........................................................................................................................................64
Lift Chain Lubricant Requirements ................................................................................................................ 64
Fuses and Relays .............................................................................................................................................. 64
Main Electrical Supply .................................................................................................................................66
Relays ............................................................................................................................................................ 68

This section is for the following models:

H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS2) [L007];


H13-16XM-6, H6-7XM-12EC (H210-250-48HD2, H300-360HD2, H360HD2-EC)
[K019]

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.

The Periodic Maintenance Procedures are placed in


alphabetical order. The relevant page number is
mentioned in the Maintenance Schedule and in the
Table of Contents.

Your dealer for HYSTER lift trucks 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 lift
truck perform more efficiently and extend its
lifetime. Figure 1. Truck Nameplate

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

Truck Handling Procedures


MOVING AND TOWING A LIFT TRUCK Use extra caution when moving a lift truck if any
of the following conditions exist:
Precautions • Brakes do not operate correctly.
• Steering does not operate correctly.
While the lift truck is being towed the engine must
stay running in order to generate sufficient hy- • Tires are damaged.
draulic oil pressure. Without hydraulic pressure • Traction conditions are bad.
the steering system and service brake system do • The lift truck must be towed on a slope.
not operate, and the park brake will automatically
apply. The parking brake can be manually released If the engine cannot run, there is no hydraulic
if no hydraulic pressure is available. pressure available for the steering system and
service brake system. This can make the control
of the lift truck difficult. Poor traction can cause
WARNING the disabled lift truck or towing vehicle to slide.
When the parking brake is manually released, the Steep grades will increase the required brake ef-
lift truck does not have any parking brake func- fort.
tion. Block the wheels to prevent the lift truck
from moving. If the wheels are not blocked, seri- NEVER lift and move a disabled lift truck unless
ous personal injury and damage to components the disabled lift truck MUST be moved and cannot
can occur. be towed.

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:

1. Place blocks on both sides (front and rear) of


the drive and steering tires to prevent move-
ment of the lift truck.

2. Remove the plastic screw cap. See Figure 2.

3. Loosen the lock nut.

4. Turn the adjustment bolt or socket counter-


clockwise until the brake disc is free.

5. Tighten the lock nut and install the plastic


screw cap hand tight.

Moving the Truck 1. PLASTIC SCREW CAP


2. ADJUSTMENT BOLT OR SOCKET
3. LOCK NUT
WARNING
DO NOT tow the lift truck if a load is attached. Figure 2. Releasing the Parking Brake

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

1. STEER AXLE / STEER TIRES 2. DRIVE AXLE / DRIVE TIRES

Figure 3. Putting Lift Truck on Blocks

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.

CLEANING A LIFT TRUCK 2. Disconnect the battery.

3. Remove accumulated debris using a com-


WARNING pressed air line and nozzle.
Engine, exhaust system components, and other 4. Lightly spray a noncorrosive cleaning agent
components are hot after using the truck. Be sure onto the areas to be cleaned. This will help
lift truck components have cooled down before loosen grime, so close contact direct spraying
starting inspection and cleaning, or personal in- will not be necessary.
jury may occur.

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.

Safety Procedures Before Starting Maintenance


• DO NOT use diesel engines indoors where
WARNING soot can accumulate.
DO NOT operate a lift truck that needs repairs. Re- • If engines are operated in confined spaces,
port the need for repairs immediately. If repair is maintain adequate ventilation or vent ex-
necessary, put a DO NOT OPERATE tag in the op- haust to the outside. DO NOT exceed appli-
erators area. Remove the key from the key switch. cable air contaminant limits.
1. Put the lift truck on a level surface. • Follow the inspection and maintenance
schedule and procedures in this manual.
2. Lower the carriage and forks. DO NOT alter exhaust, ignition, or fuel sys-
tems.
3. Switch the engine OFF.

4. Apply the parking brake.


Fire Hazard
5. Open the hood and check for leaks and condi-
tions that are not normal. The hot engine surfaces and exhaust of inter-
nal combustion engine-powered lift trucks
6. Clean any oil or fuel spills. can present fire hazards when operating in
areas containing flammable gases, vapors, liq-
7. Verify all surfaces are free of oils, lubricants,
uids, dusts, or fibers. Engine and exhaust
fuel, and organic dust or fibers (paper, wood,
component surface temperatures can exceed
cotton, wool, agricultural grass/grain, etc.).
the ignition temperatures of common sol-
MAKING CHECKS FROM THE DRIVER vents, fuels, oil, paper, and other organic ma-
terials (wood, wheat, cotton, etc.). Exhaust-
SEAT WITH ENGINE RUNNING emitted sparks can ignite these materials as
well. Engine and exhaust surface tempera-
WARNING tures increase after engine shutoff, present-
Exhaust from internal combustion engines con- ing increased fire hazard. Check the engine
tains carbon monoxide and other harmful chemi- compartment immediately following the lift
cals. Carbon monoxide is a colorless, odorless truck operation in areas containing combusti-
poison and can cause unconsciousness or death ble dusts, fibers, or paper and remove any for-
without warning. Long-term exposure to exhaust eign material.
or chemicals in the exhaust can cause cancer,
birth defects, and other reproductive harm. Avoid Operate the lift truck only in areas that have
exposure to engine exhaust: been approved for lift truck operation.

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.

TRANSMISSION CALIBRATION SWITCH

The Transmission Calibration Switch must be


moved down to the spanner symbol during calibra-
tion. See Figure 65 for location.

6
8000 SRM 1939 Periodic Maintenance Schedule

Periodic Maintenance Schedule


NOTE: Portions reproduced by permission of Cum- REMARK: Periodic greasing of the axle pivot pin
mins Inc. and the chain sheave is NOT required. Greasing of
these items is only required at assembly.

1. FORK PINS 11. DEF PUMP AND SUCTION FILTER


2. LIFT CHAIN 12. ENGINE OIL FILTER
3. CARRIAGE LOAD ROLLER 13. TIE ROD PINS AND KING PINS
4. MAST LOAD ROLLER 14. STEER WHEEL HUB
5. MAST PIVOT PIN 15. FUEL FILTER
6. TILT CYLINDER PIVOT PIN 16. CRANKCASE BREATHER
7. DRIVE SHAFT 17. HYDRAULIC RETURN FILTER
8. FUEL TANK BREATHER 18. HYDRAULIC TANK BREATHER
9. WATER SEPARATOR 19. BRAKE COOLING FILTER
10. TRANSMISSION OIL FILTER

Figure 5. Filters and Lubrication Points

7
Periodic Maintenance Schedule 8000 SRM 1939

DAILY INSPECTION

Daily Condition Checks


Table 1. Daily Condition Checks

Daily Condition Checks Procedure Page


Warning and Safety Labels • Check for presence and readability. See page 50.
For position and replacement, see Parts Manual.
Frame, Mast, Carriage, and • Make sure retaining hardware is tightened and in See page 33.
Attachment good condition.
• Check for cracks and deformation. In particular
after any collision or when any unusual noise is
heard.
Repair as required.
Forks • Check condition and fork tip alignment. See page 32.
Replace as required.
Lift Chains • Check proper lubrication. See page 38.
• Make sure both chains are slack during parking.
• Check condition of link plates and pins.
Replace chains as required. See Parts Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves. See page 35.
Replace as required. See Parts Manual.
Wheels, Tires, and Tire • Check condition and absence of damage. See page 51.
Pressure • Check pressure as specified on nameplate.
Correct or replace as required.
Wheel Nuts on Drive and • Re-torque 2 - 5 hours after replacement of a See page 62.
Steer Wheels wheel, or 8 hours after a nut could be turned at
re-torqueing.
Torque to 615 to 710 N•m (454 to 524 lbf ft).
Hydraulic Tank Breather • Inspect restriction indicator. See page 38.
Replace elements as required. See Parts
Manual.
Fuel, Oil, DEF or Coolant • Check for leaks. See page 34.
Leaks Repair as required.
Engine Air Intake Piping and • Check for air leaks and loose connections. See page 28.
Charge Air Piping Repair as required.
Cooling Fan Belt • Check tension and condition. See page 22.
Replace as required.
Radiator Assembly • Check that radiator is clean and not obstructed. See page 45.
• Check radiator, hoses and connections for
leakage.
Clean and repair as required.

8
8000 SRM 1939 Periodic Maintenance Schedule

Table 1. Daily Condition Checks (Continued)

Daily Condition Checks Procedure Page


Engine Compartment • Remove combustible materials. See page 28.
• Remove all foreign materials.
Windows and Mirrors • Clean windows, wipers and mirrors. See page 50.
Adjust and replace as required. See Parts
Manual.

Daily Fluid Level Checks


Table 2. Daily Fluid Level Checks

Daily Fluid Level Checks Procedure Page


Windshield Washer Fluid • Check level in reservoir. See page 50.
Level Add fluid as required.
Hydraulic System Oil • Check level indicator with mast fully lowered. See page 36.
• Add hydraulic oil as required through the tank
return filter and record added volume and hour
meter reading.
Use JDM-J20C ISO VG46.
Coolant Level • Check level at the expansion tank. See page 21.
• Add coolant as required and record added volume
and hour meter reading.
For coolant see Approved Oils, Fluids, and
Grease.
Engine Oil Level • Maintain level at two/thirds of full range on See page 29.
dipstick when cold.
See Approved Fuel and Engine Oils for required
specifications.

9
Periodic Maintenance Schedule 8000 SRM 1939

Daily Checks from the Driver Seat with


Engine Running
NOTE: First read Safety Procedures Before Start-
ing Maintenance and Daily Checks from the Driver
Seat with Engine Running.

Table 3. Daily Checks from the Driver Seat with Engine Running

Daily Checks from the Procedure Page


Driver Seat with Engine
Running
Operator Restraint System • Check condition and operation of seat belt, seat See page 44.
rails and steering column latch.
Repair as required.
Horn, Gauges, Lights, Alarms • Visual and audible verification. See page 35.
and Control System Repair as required.
Fault Codes • The display should be free of fault codes. The See page 32.
central warning light will be ON when a fault
code is shown.
• Stop the engine when the Engine Stop Warning
Light is ON.
Report any fault code to have the fault diagnosed
and repaired.
Engine Air Filter • Replace Main Filter Element when warning light See page 27.
is ON, and record hour meter reading. •
• Also replace the Safety Element at every third
replacement of the Main Filter Element.
See Parts Manual.
Fuel/Water Separator and • Drain water/sediment when the warning light is See page 34.
Final Fuel Filter ON.
Coolant Level • Add coolant when warning light is ON, and See page 21.
record added volume and hour meter reading.
For details, see Approved Oils, Fluids, and
Grease.
Fuel Level • Avoid low fuel level. Refuel in time.
Diesel Exhaust Fluid (DEF) • Avoid low DEF level. Refuel in time. See page 24.
For details, see Approved Oils, Fluids, and
Grease.
Control Levers, Switches, and • Check operation as described in the Operating See page 20.
Pedals Manual.
Repair as required.
Parking and Service Brakes • Check operation. Repair as required. See page 44.
Steering System • Check operation. See page 45.
Repair as required.
Mast, Carriage, and • Check proper tracking of header hoses. See page 43.
Attachment • Check smooth operation.
Repair as required.

10
8000 SRM 1939 Periodic Maintenance Schedule

Table 3. Daily Checks from the Driver Seat with Engine Running (Continued)

Daily Checks from the Procedure Page


Driver Seat with Engine
Running
Signals from the Spreader • Check operation. See page 45.
Control System (ECH) Repair as required.
Transmission • Check operation. See page 47.
Repair as required.
Operator Presence System • Check operation. See page 43.
Repair as required.
Transmission Oil • Check oil level and add ZF TE-ML 03 oil as See page 47.
required.

INITIAL INSPECTION

First Inspection after First 100 Hours of


Operation
Table 4. First Inspection after First 100 Hours of Operation

Initial 100 Hours Inspec- Procedure Page


tion
Lift Chains • Lubricate and adjust lift chains. See page 38.
• Make sure chains are slack during parking.
Transmission Oil Filter • Replace filter. See Parts Manual. See page 48.

PERIODIC MAINTENANCE

Inspect and Adjust


Table 5. Inspect and Adjust

Inspect and Adjust Procedure Page


Every 250 Hours
Warning and Safety Labels • Check for presence and readability. See page 50.
• For position and replacement, see Parts Manual.
Frame, Mast, Carriage, and • Make sure retaining hardware is tightened and in See page 33.
Attachment good condition. Re-torque or replace as required.
• Look for deformations in the material and
irregular lines in welds. Repair as required.
Forks • Check condition and fork tip alignment. See page 32.
Replace as required. See Parts Manual.

11
Periodic Maintenance Schedule 8000 SRM 1939

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page


Lift Chains • Check proper lubrication and adjustment. See page 38.
• Check condition of link plates and pins.
Replace as required. See Parts Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves. See page 35.
• Check proper tracking during operation.
Replace as required. See Parts Manual.
Wheel, Tires, and Tire • Check condition and absence of damage. See page 51.
Pressure • Check pressure as specified on nameplate.
Correct or replace as required.
Wheel Nuts on Drive and • Make sure all nuts are properly torqued. See page 62.
Steer Wheels Required torque is 615 to 710 N•m (454 to
524 lbf ft).
Hydraulic Tank Breather • Inspect restriction indicator. See page 38.
Replace element when indicator is raised. See
Parts Manual.
Fuel, Oil, DEF, or Coolant • Check for leaks. See page 34.
Repair as required.
Engine Air Intake Piping and • Check for leaks and proper installation. See page 28.
Charge Air Piping Repair as required.
Coolant Hoses • Inspect for cracks, cuts, and collapsing. See page 21.
Repair as required.
Cooling Fan Belt • Check tension and condition. See page 22.
Repair as required.
Radiator Assembly • Check radiator, hoses and connections for See page 45.
leakage.
Clean and repair as required.
Engine Compartment • Remove combustible materials. See page 28.
• Remove all foreign materials.
DEF Tank Fill Cap • Check cap sealing and membrane breathing See page 25.
capabilities.
• Rinse off DEF crystals as necessary.
Drive Axle and Differential • Inspect magnetic plugs and oil level. See page 26.
• If oil is added, check for leaks and record added
volume and hour meter reading.
• Inspect wear parts on plugs, clean plugs and
reinstall.
For details, see Approved Oils, Fluids, and
Grease.

12
8000 SRM 1939 Periodic Maintenance Schedule

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page


Windshield Washer Fluid • Check level in reservoir and add fluid as required. See page 50.
Level For details, see Approved Oils, Fluids, and
Grease.
Hydraulic System Oil • Check level indicator. See page 36.
• Add hydraulic oil as required through the
hydraulic return filter.
• If oil is added, check for leaks, and record added
volume and hour meter reading.
For details, see Approved Oils, Fluids, and
Grease.
Coolant Level • Inspect level at the expansion tank. See page 21.
• If level is below “MIN” mark, inspect for leaks,
repair as required, and add coolant to the “MAX”
mark. Record added volume and hour meter
reading.
For coolant see Approved Oils, Fluids, and
Grease.
Engine Oil Level • Maintain level at two/thirds of full range on See page 29.
dipstick when cold.
See Approved Fuel and Engine Oils.
Fuel/Water Separator and • Drain water until clear fuel flows from the filter. See page 34.
Final Fuel Filter
Operator Restraint System • Check condition and operation of seat belt, seat See page 44.
rails and steering column latch.
Repair as required.
Horn, Gauges, Lights, Alarms • Visual and audible verification. See page 35.
and Control System Repair as required.
Fault Codes • Check fault code warning lights. The display See page 32.
should be free of fault codes.
• Diagnose and repair the cause of any fault code.
Control Levers, Switches, and • Check operation as described in the Operating See page 20.
Pedals Manual.
Repair as required.
Parking and Service Brakes • Check condition and operation. See page 44.
Repair as required.
Steering System • Check operation. See page 45.
Repair as required.
Operator Presence System • Check operation. See page 43.
Repair as required.

13
Periodic Maintenance Schedule 8000 SRM 1939

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page


Mast, Carriage, and • Check smooth operation. See page 43.
Attachment • Check tracking of header hoses.
Repair as required.
Signals from the Spreader • Check operation. See page 45.
Control System (ECH) Repair as required.
Transmission Oil • Check oil level and add ZF TE-ML 03 oil as See page 47.
required.
If oil is added, check for leaks and record added
volume and hour meter reading.
Every 500 Hours
Cab Air Filter • Check and clean element. See page 20.
Replace filter when required. See Parts Manual.
Engine Air Filter • Verify maintenance records to establish if normal See page 27.
air filter replacement is due. Make sure Tier 3 air
filter sensor performs properly.
• If required, replace the Main Filter Element,
clean the inside of the housing and record filter
replacement.
• At every third replacement of the Main Filter
Element, also replace the Safety Filter Element.
Cooling Fan • Check for cracks and damage. See page 22.
Replace fan when required. See Parts Manual.
Every 2,000 Hours
Coolant Quality • Measure and record acidity and freezing point. See page 21.
• Compare measurement with earlier records and
take appropriate action.
For coolant see Approved Oils, Fluids, and
Grease.
Cooling Fan Belt Tensioner • Verify if the bearings for the hubs and pulleys See page 22.
and Pulleys produce more noise during operation than
normal.
• Check tension and belt condition.
Replace or repair as required. See Parts
Manual.
Brake System Accumulator • Make sure pre-charge pressure is 9.0 See page 20.
±0.5 MPa (1305.3 ±72.5 psi).
Re-charge or replace accumulator as required.
Transmission Clutch • Perform clutch calibration at each transmission See page 47.
Calibration oil change.
Inching Pedal Sensor • Check calibration value and adjust as required. See page 38.
Calibration

14
8000 SRM 1939 Periodic Maintenance Schedule

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page


Lift System Accumulator • Make sure pre-charge pressure is 9 See page 42.
(Optional) ±0.5 MPa (1300 ±38 psi).
Correct if required.
Crankcase Breather Element • Check element. See page 24.
Replace when required. See Parts Manual.
Engine and Transmission • Check isolators and hardware. See page 28.
Mounts Replace as required. See Parts Manual.
Vibration Damper • Check for fluid loss and deformation. See page 49.
Replace as required. See Parts Manual.
Every 5,000 Hours
Engine Valve Adjustment • Check valve clearance. See page 30.
See engine identification plate for valve
adjustment.

Lubricate
Table 6. Lubricate

Lubricate Procedure Page


Every 250 Hours
Lift Chains • Lubricate every 250 Hours, but at least every 3 See page 38.
Months.
• Make sure chains are slack during re-lubrication.
Use engine oil SAE 15W-40.
Mast Pivot Pins • Lubricate 2 fittings under no load condition. See page 43.
Use multipurpose grease with MoS2 additive. For
details, see Approved Oils, Fluids, and Grease.
Tilt Cylinder Pivot Pins • Lubricate 4 fittings. See page 47.
Use multipurpose grease.
Fork Pins, Carriage Pins, and • Lubricate pins and surfaces. See page 33.
Carriage Sliding Surfaces Use multipurpose grease.
Inner Mast Load Rollers • Lubricate 4 fittings. See page 42.
Use multipurpose grease.
Carriage Load Rollers • Lubricate 4 fittings. See page 42.
Use multipurpose grease.
Every 500 Hours
Drive Shaft • Lubricate 3 fittings. See page 27.
Use multipurpose grease.
Steering Axle Tie Rod Pins • Lubricate 4 fittings. See page 45.
Use multipurpose grease.

15
Periodic Maintenance Schedule 8000 SRM 1939

Table 6. Lubricate (Continued)

Lubricate Procedure Page


Steering Axle King Pins • Lubricate 4 fittings. See page 45.
Use multipurpose grease.
Every 1,000 Hours
Cab Door Hinges • Lubricate 4 fittings. See page 20.
Use multipurpose grease.

Change
Table 7. Change

Change Procedure Page


Every 500 Hours
Engine Oil • Change engine oil. See page 29.
For details, see Approved Fuel and Engine Oils.
Engine Oil Filter • Replace filter. See page 29.
See Parts Manual.
Fuel/Water Separator • Replace filter. See page 34.
See Parts Manual.
Final Fuel Filter • Replace filter. See page 34.
See Parts Manual.
Every 1,500 Hours
Drive Axle and Differential • Change oil. See page 26.
For details, see Approved Oils, Fluids, and
Grease.
Every 2,000 Hours
Crankcase Breather Element • Inspect and replace crank case breather element See page 24.
as required.
See Parts Manual.
Transmission Oil • Change transmission oil. See page 47.
For details, see Approved Oils, Fluids, and
Grease.
Transmission Oil Filter • Replace filter. See page 48.
See Parts Manual.
Brake Cooling Filter • Replace filter. See page 19.
See Parts Manual.
Every 3,000 Hours
Hydraulic System Oil • Take oil sample and follow instructions from the See page 36.
laboratory report.
For details, see Approved Oils, Fluids, and Grease
when replacing oil.
Hydraulic Tank Return Filter • Replace filter at each hydraulic oil change. See page 38.
See Parts Manual.

16
8000 SRM 1939 Periodic Maintenance Schedule

Table 7. Change (Continued)

Change Procedure Page


Every 5,000 Hours
Fuel Tank Breather • Replace filter. See page 35.
See Parts Manual.
DEF Pump Filter • Replace filter. See page 24.
See Parts Manual.
DEF Tank Suction Filter • Replace filter. See page 25.
See Parts Manual.
Steering Wheel Hub Bearings • Replace multipurpose grease and re-adjust bear- See page 46.
ing preload.
Air Conditioning System • Contact certified AC specialist for replacing See page 19.
dryer, lubricant and refrigerant.
For Dryer, see Parts Manual.
For Lubricant, see Compressor Nameplate.
For Refrigerant use 1300 ±50 grams (2.87
±0.11 lb) of R134a.

Periodic Maintenance Schedule - ELME 580 Series Container


Attachment

1. TWIST LOCK 4. SIDE SHIFT WEAR PAD


2. SLIDER PAD 5. CARRIAGE ROLLERS
3. EXTENSION BEAM WEAR PAD

Figure 6. Container Attachment Maintenance Points

17
Periodic Maintenance Schedule - ELME 580 Series Container Attachment 8000 SRM 1939

PERIODIC MAINTENANCE

Inspect and Adjust


Table 8. Inspect and Adjust

Inspect and Adjust Procedures Page


Daily
Attachment • Check for damage, cracks and distortion. See page 19.
• Check spreader control system and spreader
operation.
• Check for hydraulic leaks.
Repair as required.
Every 250 Hours
Attachment • Check for damage, cracks and distortion. See page 19.
• Check spreader control system and spreader
operation.
• Check for hydraulic leaks.
Repair as required.
Twist Locks • Monitor wear and check for possible damage. See page 48.
Repair as required.

Lubricate
Table 9. Lubricate

Lubricate Procedures Page


Every 500 Hours
Twist Locks • Lubricate 2 or 4 fittings. See page 48.
Use multipurpose grease. For details, see Ap-
proved Oils, Fluids, and Grease.
Extension Beam Wear Pads • Replace wear pads if thickness is 18 mm (0.7 in) See page 32.
or less.
• Check torqueing of retention hardware.
• Lubricate tracks at wear pads for extension
beams.
Use multipurpose grease.
End Beam Slider Pads • • Monitor maximum play and retention. See page 27.
Replace as required.
Side Shift Wear Pads • Apply lubricant to fittings at two central greasing See page 45.
points.
Use multipurpose grease.
Carriage Load Rollers • Lubricate fitting at each carriage roller. See page 42.
Use multipurpose grease.

18
8000 SRM 1939 Periodic Maintenance Schedule - ELME 580 Series Container Attachment

Change
Table 10. Change

Change Procedures Page


Every 5,000 hours
Twist Locks • Replace twist locks. See page 48.
See Parts Manual.

Periodic Maintenance Procedures


AIR CONDITIONING SYSTEM BRAKE COOLING FILTER

Every 2,000 Hours


CAUTION
Contact certified AC trained technician for extract- Remove and replace the filter element.
ing and refilling refrigerant.
1. Lower the mast.
Every 5,000 Hours or 36 Months
2. Switch the engine OFF.
Have a new dryer installed and refill with new lu-
bricant and refrigerant. 3. Apply the parking brake.

4. Use a wrench to loosen the bowl that holds the


For Dryer, see Parts Manual. filter cartridge. See Figure 7.
For Lubricant, see Compressor Nameplate. 5. Remove and replace the filter cartridge and re-
install the bowl. Torque to
For Refrigerant, use 1300 ± 50 grams (2.87 ± 0.11 20 N•m (177.02 lbf in).
lb) of R134a.

ATTACHMENT

Daily and Every 250 Hours

Make sure that retaining hardware is tightened


and in good condition.

Check the controls and the attachment functions


for correct operation as described in the Operating
Manual. See the symbols at each of the controls.

Every 250 Hours

Check the attachment for damage, cracks and dis-


tortion. Look for deformations in the material and
irregular lines in welds. Repair as required.
1. FILTER BOWL
Check for hydraulic leaks. Make sure wear pad re- 2. FILTER ADAPTOR
tainers are tightened to 63 N•m (46.4 lbf ft).
Figure 7. Brake Cooling Filter

19
Periodic Maintenance Procedures 8000 SRM 1939

BRAKE SYSTEM ACCUMULATOR CAB AIR FILTER

Every 2,000 Hours Every 500 Hours

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.

13. Refill the accumulator with nitrogen gas at ap-


proximately 20°C (68°F) to the required pre-
charge pressure of 9.00 MPa (1,305.34 psi).

14. After refilling the accumulator, raise (side tilt)


the cab to the fully open position to gain access
to the main control valve.

15. Remove the pressure gauge from port M ACC.


1. CAB AIR FILTER
16. Install the cap on check port M ACC on the 2. LOCK
main control valve.
Figure 8. Cab Air Filter

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.

Every 250 Hours Coolant Quality

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.

Replace damaged hoses. Replace factory filled coolant if pH level is lower


than 7.7.
Coolant Level
If pH level is above 7.7, make a judgement when
actual pH level will probably reach 7.7.
WARNING
DO NOT remove the radiator cap when the engine See Cooling System 0700SRM1595 for coolant re-
is hot. When the radiator cap is removed from the placement procedures.
expansion tank, the pressure is released from the
system. If the system is hot, the steam and boiling
coolant can cause burns.

CAUTION
Additives in the coolant may damage the cooling
system. Before using additives, contact your local
HYSTER dealer.

Daily and Every 250 Hours

Check coolant level in the expansion tank when


cold. Coolant level must be between the 'MIN' and
'MAX' mark on the expansion tank.

Add coolant when level is at or below the ‘MIN’


mark.

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.

When coolant has been added, make a note of the


date and added quantity.

21
Periodic Maintenance Procedures 8000 SRM 1939

Measure ethylene glycol content with a refractome- Bearing Condition


ter. Maintain ethylene glycol content between 40%
and 50%. Certain freezing conditions may require Remove the belt and rotate each hub and pulley to
an ethylene glycol level that is higher than 50%. verify smooth rotation and absence of play. See Fig-
Add ethylene glycol to raise ethylene glycol content. ure 11.
Add distilled water to lower ethylene glycol con-
tent. Verify whether the alternator bearings are the
source for the noise.
Cooling Fan
Replace components or bearings as necessary.
Every 500 Hours
Reinstall the fan belt.
Check the fins for cracks and damage. Replace the
fan when required.

Cooling Fan Belt

Daily and Every 250 Hours

Check that the key is in the OFF position and the


engine is stopped. Check the drive belt for wear
and damage. Small cracks that run across the belt
are acceptable. A drive belt with cracks that run
the length of the belt or missing pieces are not ac-
ceptable. Check proper belt tension. See Figure 10.

Figure 11. Drive Belt

Pulley Alignment

Use a straightedge and an inclinometer to establish


misalignment between the belt and the different
pulleys. Maximum misalignment is 3 degrees. See
Figure 12.

1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 10. Drive Belt Inspection

Cooling Fan Belt Tensioner and Pulleys

Every 2,000 Hours

Verify if the bearings for the hubs and pulleys pro-


duce more noise during operation than normal. If
there is excessive noise, check condition of the pul-
ley bearings, pulley alignment, and functioning of Figure 12. Pulley Alignment
the belt tensioner.

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.

Figure 15. Tensioner Pulley Inspection

4. Check the tensioner for dirt build up. If this


condition exists, the tensioner must be removed
and steam cleaned.
Figure 13. Cooling Fan Belt Tensioner Arm Stops
with Drive Belt 5. Inspect the tensioner for evidence of the pivot-
ing tensioner arm contacting the stationary cir-
cular base. If there is evidence of these two
2. Remove the drive belt from the tensioner. Ver- areas touching, the pivot tube bushing has
ify that the bottom tensioner arm stop is in con- failed and the tensioner must be replaced. See
tact with the bottom tensioner arm stop boss on Figure 16.
the tensioner body. If these two are not touch-
ing, the tensioner must be replaced. See Fig-
ure 14.

Figure 16. Tensioner Inspection

Figure 14. Cooling Fan Belt Tensioner Arm Stops


without Drive Belt

23
Periodic Maintenance Procedures 8000 SRM 1939

CRANKCASE BREATHER ELEMENT


(TIER 4F/STAGE IV ONLY)

Every 2,000 Hours

Remove the crankcase breather element for inspec-


tion and replace as required. Check the breather
ventilation tube and crankcase breather tube for
deposits and clean as necessary to ascertain suffi-
cient ventilation capacity. See Figure 17.

1. DEF PUMP
2. FILTER SCREW CAP

Figure 18. DEF Pump

2. Use the filter tool to pull the filter from the


pump. See Figure 19.

1. CRANKCASE VENTILATION HOSE


2. CRANKCASE BREATHER
3. OIL DRAIN TUBE
4. CRANKCASE BREATHER TUBE

Figure 17. Crankcase Breather

DIESEL EXHAUST FLUID (DEF) SYSTEM

DEF Pump Filter

Every 5,000 Hours

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

Replace the DEF Tank Suction Filter.

1. Remove the DEF Tank Unit from the DEF


Tank. See Figure 22.

1. FILTER INSERT
2. FILTER ELEMENT

Figure 20. DEF Pump Filter Set

4. Install the filter in the DEF pump, install the


screw cap and tighten by hand.

DEF Tank Fill Cap

Every 250 Hours

Check the DEF tank fill cap sealing and membrane


breathing capabilities. If required, clean the fill cap
by soaking it in water and rinse off DEF crystals.
See Figure 21. Figure 22. DEF Tank Unit

2. Remove the filter retention screw. See Fig-


ure 23.

1. DEF TANK FILL CAP


1. DEF SUCTION FILTER
Figure 21. DEF Tank Fill Cap 2. RETENTION SCREW

Figure 23. DEF Suction Filter Screw

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.

Gear oil level in differential and planetary gears


must be checked separately.

The gear oil level in the differential is correct when


the gear oil is even with the plug at the front of the
housing.

The gear oil level in the planetary gears is correct


when the "level line" on the planetary cover is par-
allel to the floor and oil is even with the plug.

Add clean gear oil as required. See Approved Oils,


Fluids, and Grease.

Check for leaks if oil must be added.

Record added volume and hour meter reading.

Every 500 Hours


1. HEATER TUBE FIN
2. DEF SUCTION TUBE Lubricate the three grease fittings on the drive
3. RETENTION SCREW HOUSING shaft. See Approved Oils, Fluids, and Grease.
4. DEF SUCTION TUBE HOUSING
5. DEF SUCTION FILTER
Two of these fittings are located on the universal
Figure 24. DEF Suction Filter joints at each end of the drive shaft. The third fit-
ting is on the slip yoke at the center of the drive
shaft.
4. Position the new filter on the suction tube hous-
ing onto the bottom of the suction tube and
Check that the universal joints are tightened and
press the filter against the bottom of the heater
not damaged. Check the drive shaft for damage. If
tube fin.
any of the components are loose or damaged they
5. Install the DEF Tank Unit in the DEF Tank. must be replaced.

DRIVE AXLE AND DIFFERENTIAL Change Oil

Check Oil level Every 1,500 Hours

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

DRIVE SHAFT ENGINE AIR FILTER

Every 500 Hours


CAUTION
Lubricate the three grease fittings on the drive If the air filter container is not cleaned during
shaft. See Approved Oils, Fluids, and Grease. maintenance or replacement of the air filter, dirt
will gradually build up in the filter housing. This
Two of these fittings are located on the universal may cause the filter unit to function incorrectly. If
joints at each end of the drive shaft. The third fit- the filter element has been forced into place, the
ting is on the slip yoke at the center of the drive filter housing can crack over time, allowing dirt to
shaft. enter into and damage the engine.

Check that the universal joints are tightened and Daily


not damaged. Check the drive shaft for damage. If
any of the components are loose or damaged they Replace the main filter element, when the Air Flow
must be replaced. Restriction Indicator Light on the instrument panel
is ON. Record the hour meter reading at replace-
END BEAM SLIDER PADS ment.

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.

If required, replace the filter element, clean the in-


side of the housing and record filter replacement.
See Parts Manual.

At every third replacement of the Main Element,


also replace the Safety Filter Element.

For Tier 3/Stage IIIA engines, test functioning of


the Air Filter Warning Light, if it is suspected to
malfunction. The vacuum switch should switch ON
at a vacuum of 6.3 kPa (0.91 psi). Replace as re-
quired.

The air filter housing should not be opened until an


air filter element replacement or an inspection is
1. BRACKET required. See Figure 26.
2. SLIDER PAD

Figure 25. End Beam Slider Pads

27
Periodic Maintenance Procedures 8000 SRM 1939

ENGINE AND TRANSMISSION MOUNTS

Every 2,000 Hours

Inspect all rubber mounts for ageing and damage.


Look for traces, which indicate excessive relative
movement between the frame supports and the en-
gine and transmission brackets.

Check that mounting bolts are torqued to


165 N•m (122 lbf ft). Replace any damaged part.
See Figure 28 and Figure 29.

ENGINE COMPARTMENT

Daily and Every 250 Hours

Open the hood and check for leaks and abnormal


1. PRECLEANER
2. RETAINING CLIP conditions. Clean any oil or fuel spills. Make sure
3. AIR FILTER HOUSING COVER all surfaces are free of oil, lubricants, fuel, and or-
4. AIR FILTER HOUSING ganic dust or fibers (paper, wood, cotton, wool, etc.).
5. AIR RESTRICTION SENDER
Remove all foreign materials.
Figure 26. Engine Air Filter (Tier 4F/Stage IV
shown)

ENGINE AIR INTAKE PIPING AND


CHARGE AIR PIPING

Daily and Every 250 Hours

Inspect the intake and charge air piping for wear


points and leakage. Look for loose clamps and
punctures that can allow ingress of dirt into the en-
gine. See Figure 27.

1. MOUNTING BRACKET
2. RUBBER MOUNT
3. LARGE WASHER
4. NUT
5. CAP SCREW
6. FRAME BRACKET
Figure 28. Engine Mounts

Figure 27. Air Intake Piping and Charge Air Piping

28
8000 SRM 1939 Periodic Maintenance Procedures

Check engine oil level after the engine has stopped


for more than a minute.

Keep the oil level at two thirds of the full range on


the dipstick. See Figure 30. When adding oil, use
the correct oil as shown in Approved Oils, Fluids,
and Grease.

Engine Oil and Engine Oil Filter

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

Engine Oil Level

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

The engine oil filter is installed at the left-hand


side of the engine. See Figure 30. Replace spin-off
filter element. Fill the filter element with the oil
specified in the Approved Fuel and Engine Oils and
apply clean oil to the gasket of the new filter. Turn
the filter until the gasket touches oil filter housing,
then tighten ½ to 3/4 turn further by hand.

Place a suitable container that can hold 19 li-


ter (20 qt) under the engine oil pan, remove the
drain plug and drain the oil. Install the drain plug
and refill the engine with new oil as specified in
Approved Oils, Fluids, and Grease.

ENGINE VALVE ADJUSTMENT

Every 5,000 Hours

Adjust the engine valves according the values listed


on the engine serial number plate on the valve
cover. See Figure 31.
1. MOUNTING NUT AND ISOLATOR
2. EGR CONNECTION TUBE
3. EXHAUST PRESSURE SENSOR

Figure 32. Rocker Lever Cover Removal

4. Use a barring tool to rotate the crankshaft to


Figure 31. Serial Number Plate on Valve Cover align the top dead center marks on the gear
cover and the fuel pump gear. See Figure 33.

CAUTION
Engine coolant temperature should be lower than
60°C (140°F).

1. Remove the mounting nuts and isolators that


secure the rocker lever cover.

2. Remove the connector from the exhaust pres-


sure sensor. See Figure 32.

3. Remove the rocker cover and gasket under-


neath the EGR connection tube.

1. BARRING TOOL

Figure 33. 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. ROCKER LEVER COVER GASKET


2. ROCKER LEVER COVER

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.

See Cummins Engine Fault Code Guide


0600SRM1101 for engine fault codes.

See Transmission Operations and Diagnostics


1300SRM1455 for ZF transmission fault codes.

See Hydraulic Control System 2200SRM1935


for hydraulic system fault codes.

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

Reposition forks and carriage to make sure the en-


tire area of travel is lubricated. See Approved Oils,
Fluids, and Grease.

FRAME, MAST, CARRIAGE AND


ATTACHMENT

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.

Daily and Every 250 Hours

1. Make sure all retaining hardware for carriage,


mast pivots end tilt cylinder rod ends is tight-
ened and in good condition.

2. Check welds for cracks immediately when any


Fork Tip Alignment
unusual noise is heard during lifting or maneu-
Length of Forks 3% Dimension vering of a load. An immediate check must be
1,220 mm (48 in.) 37 mm (1.5 in.) made also after any collision of the truck, load
or attachment.
1,830 mm (72 in.) 55 mm (2.2 in.)
2,440 mm (96 in.) 74 mm (3.0 in.) NOTE: Early detection and repair of cracks will
prevent major structural failures and will limit the
1. ORIGINAL DIMENSION associated cost of repairs. Applications involving
2. TIP ALIGNMENT WITHIN 3% poor ground conditions, floating or offset loads,
3. NO CRACKS overloading, or other circumstances that influence
4. MUST BE AT LEAST 90% OF ORIGINAL DI- structural integrity, will require more frequent
MENSION
5. FORK WEAR MAX 10% servicing and inspection. At your request, your
6. 93° MAXIMUM ANGLE Hyster dealer will advise you of the appropriate
Figure 37. Check the Forks service intervals based on an application survey.

Every 250 Hours


FORK PINS, CARRIAGE PINS, AND
Look for deformations in the material and irreg-
CARRIAGE SLIDING SURFACES
ular lines in welds.
Every 250 Hours Remove dirt and grease from the surrounding
surface and check for cracked paint and any rust
Replace a fork pin, or a side shift apron pin, if showing up through the paint.
found bent or damaged. See 2-Stage Mast
4000SRM1647. If abnormalities are detected, notify qualified
maintenance personnel for further evaluation.
Lubricate the fork pin area with grease where the
forks and fork guides travel. For side shift car-
riages, lubricate the fitting on the apron brackets.

33
Periodic Maintenance Procedures 8000 SRM 1939

FUEL, OIL, DEF, OR COOLANT LEAKS Every 250 Hours

Drain water from the fuel/water separator.


WARNING
All fuels are very flammable and can burn or Every 500 Hours
cause an explosion. DO NOT use an open flame to
check the fuel level or to check for leaks in the Replace the fuel/water separator and the final fuel
fuel system. If there is a leak in the fuel system, filter.
extra care must be used during the repair. DO • Close the fuel shutoff valve on the fuel tank.
NOT operate the lift truck until the leak is re-
paired. Fuel leaks MUST be repaired IMMEDI- • Remove the final fuel filter, which is located
ATELY. at the right-hand side of the engine, near the
transmission dipstick and fill-tube. See Fig-
Daily and Every 250 Hours ure 39. Fill the new filter element with clean
diesel fuel and install.
Make a visual check for leaks in the engine com- • Remove the electrical connector from the
partment and under the lift truck. Start checking fuel/water separator and remove the filter.
the underside of reservoirs, filters, radiators, hy- • Install the new fuel/water separator and re-
draulic valves and radiators. All hoses and hose connect the connector.
connections should be dry on the outside.
• Open the fuel shutoff valve.
Check the condition of radiator and heater hoses. • Rotate the handpump at the filter head until
Soft or cracked hoses need to be replaced before a it springs open.
leak occurs. • Operate the handpump at the filter head un-
til fuel escapes from the de-aeration plug.
Be aware of internal leaks. Although no outside
leakage is visible, it is possible that fluids from one • Push and rotate the handpump to lock the
system (coolant, brake oil) leak into a different sys- hand pump.
tem (engine sump, planetary gear). Always make a
note of the volumes being topped up.

FUEL/WATER SEPARATOR AND FINAL


FUEL FILTER

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

Daily

Drain water from the fuel/water separator when


the warning light on the instrument panel is ON
during operation. The fuel/water separator is loca-
ted at the left-hand side of the truck. See Figure 38.
1. FUEL/WATER SEPARATOR
1. Open the drain valve by turning the valve coun- 2. HANDPUMP
ter clockwise until draining occurs. 3. DRAIN VALVE
4. ELECTRICAL CONNECTOR
2. Drain water into a cup until clean fuel flows 5. SHUTOFF VALVE
from the valve.
Figure 38. Fuel/Water Separator
3. Close the valve.

34
8000 SRM 1939 Periodic Maintenance Procedures

HEADER HOSE ASSEMBLY

Daily and Every 250 Hours

1. Check if hoses are aged, kinked, crushed or


twisted.

2. Check the hose covers for cuts, cracks, or ex-


posed reinforcement.

3. Check proper hose tension.

4. Check hoses and fittings for hydraulic leaks.

5. Check the clamps and sheaves for defective or


broken parts.
1. FINAL FUEL FILTER
6. Check proper tracking during operation.
Figure 39. Final Fuel Filter
Adjust, or replace components as required. For
procedures see 2-Stage Mast 4000SRM1647.
FUEL TANK BREATHER HORN, GAUGES, LIGHTS, ALARMS AND
CONTROL SYSTEM
Every 5,000 Hours
Daily and Every 250 Hours
Use a spanner to remove and replace the breather.
See Figure 40.
Turn the key to the ON position. Verify that all
warning lights and indicator lights will light up. Af-
ter two seconds all warning lights will be OFF, ex-
cept for the Wait to Start Light , Central Warning
Lights, Brake System Low Pressure Warning
Light, and the Parking Brake Warning Light. Start
the engine after the Wait to Start Light is OFF.

With the engine running at idle, check the gauges


and indicator lights for correct operation. See the
Controls, Instruments, Indicators, and Switches
section in the Operating Manual.

Have any failed light gauge, horn or alarm repaired


immediately.
1. FUEL TANK BREATHER
2. FUEL TANK FILL CAP Check for presence of fault codes on the display and
3. FUEL TANK rectify as required.

Figure 40. Fuel Tank Breather For location of fuses and relays, see Table 14 and
Figure 66.

35
Periodic Maintenance Procedures 8000 SRM 1939

HYDRAULIC SYSTEM OIL Alternative sampling methods (extraction


pump) are not recommended.

WARNING 2. Send the sample to a specified laboratory for in-


At operating temperature, hydraulic oil is hot. DO vestigation.
NOT permit oil to contact the skin and cause a
3. Oil can be used for another 1000 hours if it
burn.
passes following tests:
- Particle count according ISO 4406, the
CAUTION result may not exceed 21/17/14
DO NOT permit dirt to enter the hydraulic system - Kinematic Viscosity 40°C (104°F) per
when the hydraulic oil level is checked or the filter ASTM D445
is changed. Never operate the hydraulic pumps
without hydraulic oil in the hydraulic system. The - (Total) Acid Number (TAN) per ASTM
operation of the hydraulic pumps without hy- D664
draulic oil will cause damage to the pumps.
Oil has to be replaced if it fails the test or if
Only use the hydraulic oil specified in Approved there are no possibilities to test the oil.
Oils, Fluids, and Grease.
Replace the hydraulic tank return filter when re-
Additives in the hydraulic system oil may damage placing hydraulic oil.
the hydraulic system. Before using additives, con-
tact your local Hyster dealer.

Daily and Every 250 Hours

Check hydraulic oil level at the level indicator


when the carriage is lowered and the engine stop-
ped. See Figure 41.

Hydraulic oil level is correct when it is in the green


area.

If hydraulic oil level is in the yellow area, there is a


risk that during operation hydraulic oil will leak
from the hydraulic tank breather cap.
• If hydraulic oil level is in the red area, add
clean hydraulic oil through the fill plug at
the return filter and check the hydraulic sys-
tem for leaks. Record added volume and hour
meter reading.

Hydraulic Oil Testing Procedures 1. LEVEL INDICATOR


2. HYDRAULIC TANK
Every 3,000 Hours 3. BATTERY BOX
4. RIGHT-HAND PANEL
When oil life is 3,000 Hours, but when it has not 5. HYDRAULIC TANK BREATHER
6. HYDRAULIC FILL PLUG
yet reached 6,000 hours, oil can be tested if it com-
plies with the requirements for extended usage. Figure 41. Hydraulic System

1. Take an oil sample at port Mp, which is located


on the main valve.

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.

WARNING Once the air is removed and hydraulic oil is present


At operating temperature, the hydraulic oil is hot. at the supply hose and hydraulic pump connections,
DO NOT permit the hydraulic oil to contact the tighten the supply hose connections.
skin and cause a burn.

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.

Replace hydraulic oil.

1. Put the lift truck on a level surface.

2. Put the mast in a vertical position and lower


the carriage completely.

3. Shut the engine OFF.

4. Apply the parking brake.

5. Put a container with a capacity of approxi-


mately 200 liter (52.8 gal) under the hydraulic
tank.

6. Remove the drain plug to drain the hydraulic


oil.

7. Replace the hydraulic tank return filter.

8. When the hydraulic oil is drained, install the


drain plug.

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

First 100 Hour inspection and Every 250


WARNING Hours
Adjustment or repair of the lift chains must be
done by authorized personnel. Adjust the lift chains as necessary to align the car-
riage with the inner mast and correct the fork
Daily height.
1. Put mast in a vertical position and lower car-
Check that the oil film on the outside of the lift riage completely.
chains is intact and that the oil at the links is still
free flowing. Make sure both chains are slack dur- 2. Side shift the carriage until it is at the center
ing parking. line of the mast.
3. Move both forks into maximum extended po-
If oil is not sufficiently present, or if lift chains pro- sition.
duce noises under operation, there is an increased 4. Loosen chain anchor lock nut and bend fin-
risk for chain failure. Call a mechanic to have the gers of the securing plate to release large
lift chains inspected and re-lubricated. nut. See Figure 43.

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.

2. Clean the chains as necessary to allow pene-


tration of oil into the chain links. Remove
debris, grease and thick oil.
3. Make sure that any trapped water or conden-
sation is removed.
4. Apply engine oil onto the chains. Do not use
grease.

39
Periodic Maintenance Procedures 8000 SRM 1939

1. SPLIT PIN A. MEASURING POINT


2. CHAIN PIN B. MEASURING POINT B
3. WASHER
4. CHAIN ANCHOR 1. CARRIAGE
5. LARGE NUT 2. INNER MAST
6. SECURING PLATE 3. OUTER MAST
7. LOCK NUT
8. NUT Figure 44. Lift Chain Adjustment
9. WASHER
10. CAP SCREW
Figure 43. Chain Anchor on Carriage

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.

Before making any repairs, use chains to secure


the mast weldments and carriage into position so
that they cannot move. Make sure the moving
parts are attached to a part that does not move.

DO NOT repair a worn lift chain. Replace both lift


chains when one or both lift chains are worn.

Every 250 Hours

Depending on the application, the chains will have


to be removed from the truck periodically for clean-
ing, inspection and re-lubrication. Cleaning must
allow thorough visual inspection and result in the
removal of wear particles and used oil at the pin
contact area.
1. CHAIN WEAR SCALE
Chain Elongation
Pitch Total Length of Wear Limit -
Inspect and replace both lift chains if any chain has 20 Links Maximum
elongated 3% or more. (Pitches) of Length of 20
New Chain Links
NOTE: The instructions for measuring chain elon-
gation are also shown on the Figure 46. 31.75 mm 635 mm (25 in.) 654 mm
(1.25 in.) 762 mm (30 in.) (27.75 in.)
If a chain scale is not available, measure the length 38.10 mm 785 mm
of 20 links of chain. Measure from the center of a (1.50 in.) (30.9 in.)
pin to the center of another pin which is 20 pitches 44.45 mm 889 mm (35 in.) 916 mm
away. See Figure 45. (1.75 in.) (36.1 in.)

Figure 46. Measuring Chain Elongation

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

LIFT SYSTEM ACCUMULATOR 1. MAST LOAD ROLLER GREASE POINT


2. CARRIAGE LOAD ROLLER GREASE NIPPLE
(OPTIONAL)
Figure 48. Load Roller Lubrication
Every 2,000 Hours

42
8000 SRM 1939 Periodic Maintenance Procedures

MAST, CARRIAGE, AND ATTACHMENT OPERATOR PRESENCE SYSTEM

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

OPERATOR RESTRAINT SYSTEM Steering Column Latch

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.

Check the operation of the service brakes.

The service brake must apply when pushing the


brake pedal and/or the inching pedal.

The service brake must be able to hold the truck


with a capacity load on a 20% grade when applying
108 N•m (24.28 lbf ft) to the brake pedal. A 20%
grade is a slope that raises 1 m every 5 m (1 ft ev-
ery 5 ft).

Repair the service brake if it fails these require-


ments.

1. SEAT BELT RETRACTOR


2. SEAT BELT LATCH
3. SEAT RAIL

Figure 49. Safety Belt and Seat Rails

44
8000 SRM 1939 Periodic Maintenance Procedures

RADIATOR ASSEMBLY Tie Rod Pins

Every 500 Hours


CAUTION
Compressed air can move particles so that they Lubricate the tie rods at both ends of the steering
cause injury to the user or to other personnel. axle. Each tie rod has two grease fittings. See Fig-
Make sure that the path of the compressed air is ure 50.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. STEERING SYSTEM
Daily and Every 250 Hours Daily and every 250 Hours

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.

Make sure that retaining hardware is torqued to


63 N•m (46 lbf ft).

SIGNALS FROM THE SPREADER


CONTROL SYSTEM

Daily and Every 250 Hours

Check that the control lights on the spreader and


on the TWIST module work correctly for the posi-
tions: seated, locked and unlocked. Repair the
spreader if any of the control lights is blinking or
does not work correctly.

STEERING AXLE GREASE FITTINGS

King Pins

Every 500 Hours


1. KINGPIN GREASE FITTING
There are two grease fittings at each kingpin of the 2. TIE ROD GREASE FITTING
steering axle. See Figure 50.
Figure 50. Kingpin and Tie Rod Grease Fittings

45
Periodic Maintenance Procedures 8000 SRM 1939

STEERING WHEEL HUB BEARINGS Clean and Inspect

Every 5,000 Hours


WARNING
Remove and disassemble the steering wheel hub Cleaning solvents can be flammable and toxic and
bearings to replace the lubricant and adjust wheel can cause skin irritation. When using cleaning
bearing pre-torque. solvents, always follow the recommendations of
the manufacturer.
Remove and Disassemble 1. Clean all parts with solvent. Make sure bear-
ings are clean and dry.
1. Remove the wheel. See Wheels and Tires, Re-
move Wheels from Lift Truck. 2. Inspect the bearings, bearing cups and seal. Re-
place as required. Use appropriate pushers
2. Remove grease cap from hub. See Figure 51.
when replacing cups with a press.
3. Remove cotter pin, castle nut and washer from
3. Inspect spindle and hub for cracks and damage.
spindle.
Ensure spindle and hub do not have any rough
NOTE: The hub assembly for this truck model or sharp areas that would prevent the bearings
weighs about 60 kg (135 lb). Use a lifting device from being correctly installed. If required,
when removing the hub assembly. smoothen any rough or sharp areas before in-
stalling the bearings.
4. Remove outer bearing cone and hub from spin-
dle and put on a flat clean surface. 4. Inspect the contact surface between spindle and
seal. Smoothen as required.
5. Remove seal and inner bearing cone from hub.
Assemble and Install
1. Apply grease and install inner bearing cone and
seal on hub. See Approved Oils, Fluids, and
Grease. Install the seal in the hub until it al-
most touches the face of the inner bearing cone.

2. Fill the cavity inside the hub with grease.

NOTE: The hub assembly for this truck model


weighs about 60 kg (132 lb). Use a lifting device
when installing the hub assembly on the spindle.

3. Use a lifting device to position the hub on the


spindle.

4. Install the outer bearing cone, washer and cas-


1. STEERING AXLE tle nut.
2. SPINDLE
3. SEAL 5. Install washer and castle nut. Tighten castle
4. OUTER BEARING CONE nut to 203 N•m (150 lbf ft) while rotating
5. HUB wheel hub in both directions to properly seat
6. INNER BEARING CONE the bearings. Loosen castle until wheel hub
7. WASHER
8. COTTER PIN turns freely with no end play.
9. CASTLE NUT
10. GREASE CAP 6. Tighten castle nut to 34 N•m (25 lbf ft).

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

8. Completely fill hub cap with grease and install TRANSMISSION


cap in hub.
Daily and every 250 Hours
9. Install wheel on hub. Be careful not to damage
threads on studs.
Inspect for leaks and check the condition of all ho-
10. Start with wheel nut at the top and tighten ses and external components of the transmission.
nuts to 65 to 130 N•m (48 to 96 lbf ft) in se- Make sure the transmission is shifting smoothly. If
quence shown. Make sure there is no dirt be- a problem is present, report the problem immedi-
tween wheel and hub. The wheel must fit over ately.
the pilot surface and be tight against the hub.
Tighten nuts to 615 to 710 N•m (454 to Do not operate the lift truck until the problem is
524 lbf ft). See Figure 63. corrected.

TILT CYLINDER PIVOT PINS Transmission Clutch Calibration

Every 250 Hours Every 2,000 Hours

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.

During calibration the Transmission Calibration


Switch must be moved down to the spanner symbol.
See Figure 65 for location.

Make sure the switch is returned up to the trans-


mission symbol when putting the truck back into
service. No hydraulic pressure is available if the
switch is in the down position.

Transmission Oil Level

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

6. Install the new filter and tighten by hand.


CAUTION
Disposal of lubricants and fluids must meet local 7. Fill transmission with 20 liter (5.3 gal) ZF TE-
environmental regulations. ML 03 oil.

Daily and every 250 Hours CAUTION


When restarting the engine, DO NOT exceed en-
Check transmission oil level with the engine run-
gine low idle speed during the first 5 seconds. Af-
ning at idle and the park brake applied.
ter filter change the initial low oil pressure may
damage the transmission.
For the location of the dipstick and fill tube, see
Figure 53. Keep oil level at the "FULL" mark on NOTE: Check for leaks during operation.
the dipstick.
8. Start the engine and allow the lift truck to
Add transmission oil as required. See Approved reach normal operating temperature, recheck
Oils, Fluids, and Grease. the transmission oil level with the engine run-
ning. If necessary, add more oil to fill the trans-
Check for leaks if oil must be added and record mission to the correct level. For the location of
added volume and hour meter reading. the dipstick and fill tube, see Figure 53.

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.

Initial 100 Hours and Every 2,000 Hours

1. Put a suitable container under the transmis-


sion.

2. Remove and clean the drain plug.

3. Reinstall the drain plug when all oil has


drained. Torque the plug to 45 N•m (35 lbf ft). 1. TRANSMISSION OIL FILTER
2. DIPSTICK AND FILL TUBE
4. Remove and discard the old filter.
Figure 53. Transmission Oil Filter and Dipstick
5. Apply clean transmission oil to the gasket of
the new filter.

48
8000 SRM 1939 Periodic Maintenance Procedures

Replace the twist lock if the top area has worn


6 mm (0.24 in.) or more, and if the remaining thick-
ness of the twist lock head is 25 mm (1.00 in.) or
less. See Figure 54.

A. TWIST LOCK WEAR TOP AREA B. TWIST LOCK HEAD THICKNESS

Figure 54. Twist Lock Wear Check

Lubricate Replace

Every 250 Hours Every 5,000 Hours

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.

VIBRATION DAMPER (VISCOUS)

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.

Every 2,000 Hours

Inspect the vibration damper and replace it when


evidence is found of fluid loss, dents, cracks, raised
surfaces, eccentricity, and shake. See Figure 56.

1. NIPPLE FOR SLEEVE


2. NIPPLE FOR TWIST LOCK

Figure 55. Twist Lock Lubrication

49
Periodic Maintenance Procedures 8000 SRM 1939

Check that all safety labels are installed at the cor-


rect location on the lift truck and can be read. See
the Parts Manual for part numbers and correct lo-
cation.

If new labels must be installed, use the following


procedure:

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.

WINDOWS AND MIRRORS

Daily

Make sure the windows of the cab are clean, and


the window wipers operate correctly.

Have the mirrors correctly adjusted.

A. THICKNESS Replace components as required.

Figure 57. Vibration Damper Measure Points WINDSHIELD WASHER FLUID LEVEL

Daily and Every 250 Hours


WARNING AND SAFETY LABELS
The reservoir is located at the left rear corner of the
WARNING operator's cab. Check the level in the reservoir
through the three holes in the operator's cab. Add
Safety labels are installed on the lift truck to give
fluid as necessary through the fill opening outside
information about operation and possible haz-
the operator's cab.
ards. It is important that all safety labels are in-
stalled on the lift truck and can be read.

Daily and Every 250 Hours

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.

Wheels and tires must be changed and repaired


by trained personnel only.

Always wear safety glasses.

Always use a tire inflator with a clip-on chuck


when deflating 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 deflation or when adjusting the tire pres-
sure, the technician must not stand in-line with
the axis of the wheel. See Figure 58.

If the air pressure is less than 80% of the correct


air pressure, the tire must be removed before air 1. ACCURATE IN-LINE PRESSURE GAUGE
is added. Follow the procedures described in the
Figure 58. Adjusting and Deflating Position
section: Remove Wheels from Lift Truck and the
section: Adding Air Pressure to the Tires.

Adjusting tire pressure is allowed only if residual


air pressure exceeds 80% of the pressure as indi-
cated on the nameplate.

If the tire is removed from the truck and flat on the


ground, the technician should not have any body
part within the diameter of the tire when adjusting
the tire pressure. See Figure 59.

Wheels can explode and cause injury or death if


the above procedures are not followed.

1. HOSE LONG ENOUGH FOR USER TO STAND


OUTSIDE POTENTIAL TRAJECTORY OF EX-
PLOSION

Figure 59. Adjusting Tire Pressure Position

51
Periodic Maintenance Procedures 8000 SRM 1939

Daily and Every 250 Hours Remove Wheels from Lift Truck

Keep the tires at the correct air pressure as speci-


fied on the lift truck name plate. Using a tire pres- CAUTION
sure gauge, check the tire pressure when the tires Lift truck wheels are very heavy, use caution
are at ambient temperature. If it is necessary to when removing wheels or personal injury may oc-
add air to a tire that is warm, check one of the cur.
other tires on the same axle and add air to the tire
that has lowest pressure so that the air pressures 1. Raise the lift truck as described in Putting a
are equal. The air pressure of warm tires must al- Lift Truck on Blocks.
ways be equal to or greater than the specification
2. Attach a tire inflator as described above. Note
for air pressure for cold tires.
tire pressure. After air is drained from tire,
check the tire pressure to ensure there is no re-
Check the tires for damage. See Figure 60. Inspect
sidual pressure. Remove chuck. Remove the
the tread and remove any objects that will cause
tire stem valve core. Push a wire through the
damage. Remove any wire, straps, or other mate-
valve stem to make sure that the stem does not
rial wrapped around the axle. Check for loose or
have a blockage causing a flow restriction. For
missing hardware. Check for bent or damaged
dual tires, remove air pressure from both tires
rims. Inspect wheel components for deformation,
using the described procedure before loosening
corrosion and fractures.
the wheel nuts.

WARNING
Lift truck wheels are heavy and can cause per-
sonal injury.

3. Remove the wheel nuts and remove the wheel


from the lift truck. Be careful NOT to damage
the studs when removing the wheels.

4. Use a tire jack to remove the wheel assembly.

1. CHECK TIRE PRESSURE


2. CHECK FOR DAMAGE
Figure 60. Tire Check

Remove Pneumatic Tire from Wheel


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.

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

Figure 61. Types of Wheels

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

Install Pneumatic Tire on Wheel

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.

Do not use a hammer to try and correct the posi-


tion of the side flange or lock ring when the tire
has air pressure greater than 20 kPa (3 psi).

WARNING
Wheels can explode and cause injury or death if
the above procedures are not followed.

1. Put the tire in a safety cage. See Figure 62.

2. Add 20 kPa (3 psi) of air pressure to the tire.

3. Check that all wheel parts are correctly instal-


led. Hit the side ring and/or lock ring lightly to 1. QUICK-RELEASE COUPLING
make sure that it is in the seat.
Figure 62. Adding Air Pressure to the Tire
Position

57
Periodic Maintenance Procedures 8000 SRM 1939

Remove Solid Rubber Tire from Wheel

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.

Keep tire tools in firm contact with the wheel. If


the tool slips, it can move with enough force to
cause serious injury. See Figure 61.

Always use a cage when removing the solid rub-


ber tire from the rim or personal injury may occur.

NOTE: There are two types of wheels used on this


series of lift trucks. If pneumatic shaped solid rub-
ber tires are installed, the four-piece wheel assem-
blies must be used. If pneumatic tires are installed,
the three-piece wheel assemblies must be used. See
Figure 61.

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

Install Solid Rubber Tire on Wheel

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.

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 cor-
rect 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.

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 rub-
ber tires are installed, the four-piece wheel assem-
blies must be used. If pneumatic tires are installed,
the three-piece wheel assemblies must be used. See
Figure 61.

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.

Install Wheels on Lift Truck

Align and Install the wheel(s) and tire(s) on the


hub. Tighten the nuts according to Wheel Nuts on
Drive and Steer Wheels.

61
Periodic Maintenance Procedures 8000 SRM 1939

Wheel Nuts on Drive and Steer Wheels

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.

Daily and Every 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).

Figure 63. Wheel Nut Tightening Sequence

Capacities and Specifications


APPROVED FUEL AND ENGINE OILS
Engine WWFC Diesel Sulfur Content ASTM D975 Emission Engine Oil
Emission Fuel Legislation
Legislation
Tier 4F/Stage IV Category 4 <10 mg/kg S15 <15 mg/kg ACEA E9 - API
Engines CJ-4
Category 4 <10 mg/kg S15 <15 mg/kg ACEA E7, or E9
- API CI-4, or
Tier 3/Stage IIIA CJ-4
Engines
Category 2 <500 mg/kg S500 <500 mg/kg ACEA E7 API
CI-4

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.

APPROVED OILS, FLUIDS, AND GREASE


Fluid Specification Truck/Engine Type Quantity
Oils
Air Conditioner – See Compressor
PAG
Compressor Oil Nameplate
Chain Oil 15W-40 Engine oil – As required
Differential Oil MIL-L-2105D, API-GL-5, – 21 liter (5.5 gal)
SAE 80W-90
ACEA E7 API CI-4 QSB 6.7 Tier 3/Stage IIIA 16 liter (17 qt)
Engine Oil: ACEA E9 API CJ-4 QSB 6.7 Tier 4F/Stage IV 14 liter (15 qt)
ACEA E9 API CJ-4 QSB 4.5 Tier 4F/Stage IV 10.5 liter (11 qt)
H8-12XM-6 / 151 liter (39.9 gal)
John Deere JDM-J20C H170-280HD2
Hydraulic System Oil
ISO VG46 H13-16XM-6 /
172 liter (45.4 gal)
H300-360HD2
H8-12XM-6 / 4.4 liter (4.7 qt)
MIL-L-2105D, API-GL-5, H170-280HD2
Planetary Gear Oil
SAE 80W-90 H13-16XM-6 /
5.0 liter (5.3 qt)
H300-360HD2
Transmission Oil ZF TE-ML 03 – 20 liter (5.28 gal)
Fuel
H8-9XM-6 / H190-210 108 liter (28.5 gal)
HD2
See Approved Fuel and H10-12XM-6 / 140 liter (37 gal)
Fuel
Engine Oils H210-280HD2
H13-16XM-6 / 158 liter (41.7 gal)
H300-360HD2

63
Capacities and Specifications 8000 SRM 1939

Fluid Specification Truck/Engine Type Quantity


Fluids
Air Conditioner – 1300 +/- 50 grams (45.8
R134a
Refrigerant +/- 1.8 oz)
3174102 - Shell Rotella Tier 3/Stage IIIA 25.5 liter (26.9 qt)
ELC, 3116456 – Eurol 22 liter (23 qt)
Coolant Coolant XL-NM, Or
equivalent OAT type Tier 4F/Stage IV
coolant
Diesel Exhaust Fluid – 18.9 liter (5 gal)
AUS 32, ISO 22241-1
(DEF)
Windshield Washer Fluid Clean water with – 5 liter (5.3 qt)
detergent and anti-freeze
as required.
Grease
EP2/3
Multipurpose Grease – –
EP2/3 with 2–4% MoS2

ENGINE OIL VISCOSITY


Ambient Temperature Temperature Range Oil Viscosity
All Season -15°C (5°F) and above 15W-40
Winter Conditions -20°C (-4°F) to 20°C (68°F) 10W-30
Arctic Conditions Below 0°C (32°F) 0W-30

LIFT CHAIN LUBRICANT REQUIREMENTS FUSES AND RELAYS

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

Figure 64. Main Electrical Supply

Table 13. Legend for Main Fuses and Relays


1. BATTERY DISCONNECT SWITCH
2. BATTERY DISCONNECT SWITCH LOCK
3. BATTERY
4. POWERBOARD
Name Value Description
5. F1 125A ALTERNATOR
6. R1 --- RELAY GRID HEATER
7. F2 125A CAB SUPPLY
*8. F4 15A DEF HOSE HEATING
9. F3 150A GRID HEATER
10. F5 10A SPARE
*11. F6 10A DEF UNIT
12. F7 7.5A SPARE
13. F8 10A SPARE
14. F11 15A SPARE
*15. R4 --- RELAY DEF HOSE 3
*16. R5 --- RELAY DEF MODULE HEATER
*17. R3 --- RELAY DEF HOSE CPS 141
*18. R2 --- RELAY DEF HOSE CPS 140
19. F10 30A ENGINE ECM SUPPLY
20. F9 30A CAB TILT
* Tier 4F/Stage IV only.

65
Capacities and Specifications 8000 SRM 1939

Main Electrical Supply

1. FUSE PANEL 1 (TABLE 14) 7. RELAYS (FIGURE 66)


2. FUSE PANEL 2 (TABLE 14) 8. TRANSMISSION CONTROLLER
3. FUSE PANEL 3 (TABLE 14) 9. HYDRAULIC CONTROLLER
4. FUSE PANEL 4 (TABLE 14) 10. IFAK CONNECTOR
5. HYDRAULIC SERVICE SWITCH 11. 24 VOLT SERVICE CONNECTOR
6. TRANSMISSION CALIBRATION SWITCH 12. ECO-ELO HIP SWITCH

Figure 65. Main Electrical Supply

66
8000 SRM 1939 Capacities and Specifications

Table 14. Fuse Locator

FUSE PANEL 1 FUSE PANEL 2


30A ENGINE START 30A FLOOD LIGHTS
5A ECM IGN 5A STROBE LIGHT B+
5A BRAKE PRESSURE WARNING 10A BRAKE LIGHTS
7.5A TRANSMISSION 15A FRONT DRIVE LIGHTS
7.5A TRANSMISSION B+ 5A INTERIOR LIGHTS
30A HYDRAULIC CONTROLLER 15A MAST/ATTACHMENT LIGHTS
15A ATTACHMENT CONTROLS 10A DIRECTION INDICATORS
5A PARK BRAKE SOLENOID 10A SIDE/TAIL LIGHTS
10A INSTRUMENTATION 10A REAR DRIVE LIGHTS
5A ALTERNATOR ON 10A REVERSE LIGHTS/ALARM/STROBE
FUSE PANEL 3 FUSE PANEL 4
10A FRONT SCREEN WASH/WIPE 10A POWER SOCKET 12V
10A ROOF WASH/WIPE 10A RADIO/CB/INTERCOM
10A REAR WASH/WIPE 10A 12V CONVERTER ACCESSORIES
10A HORN 10A HAZARD LIGHTS
5A SPED POWER IGN 25A SPED POWER B+
10A AUTOMATIC GREASING (OPT) 3A 12V RELAY
15A SEAT SUSPENSION COMPRESSOR 3A OPS SYSTEM
25A HEATER/AC/VENTILATION 10A EAS SENSOR
30A AC CONDENSOR FANS 15A POWER SOCKET 24V B+
5A PARK BRAKE WARNING BUZZER 5A POWER SOCKET 24V IGN

67
Capacities and Specifications 8000 SRM 1939

Relays Legend for Figure 66

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

Figure 66. Relays

68
TECHNICAL PUBLICATIONS

8000 SRM 1939 10/16 (12/15)(7/15)