Hyster E008 (H20.00F, H22.00F, H25.00F, H28.00F, H32.00F Europe) Forklift Service Repair Manual

Hyster E008 (H20.00F, H22.00F, H25.00F, H28.00F, H32.00F Europe) Forklift

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PERIODIC MAINTENANCE TIER 2/3 EMISSION ENGINE H20.00-32.00F/FS (H440-700F/FS) [E008]

PART NO. 1523596

8000 SRM 1023

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • 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 exceed 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 flammable. 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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Serial Number Data ......................................................................................................................................

How to Move Disabled Truck ........................................................................................................................

How to Tow Lift Truck...............................................................................................................................

How to Put Lift Truck on Blocks...................................................................................................................

How to Raise Drive Tires ..........................................................................................................................

How to Raise Steering Tires .....................................................................................................................

Maintenance Schedule.......................................................................................................................................

Maintenance Procedures Every 8 Hours or Daily............................................................................................

How to Make Checks With Engine Stopped.................................................................................................

Safety Labels .............................................................................................................................................

Operator Restraint System.......................................................................................................................

Tires and Wheels .......................................................................................................................................

Forks ..........................................................................................................................................................

Adjust.....................................................................................................................................................

Remove ..................................................................................................................................................

Low Mount Fork, Install.......................................................................................................................

High Mount Fork, Install .....................................................................................................................

Forks, Mast, and Lift Chains Inspection .................................................................................................

Cooling Fan................................................................................................................................................

Crankcase Breather Tube .........................................................................................................................

Air Filter ....................................................................................................................................................

Fuel, Oil, or Coolant Leaks, Check...........................................................................................................

Drive Belt...................................................................................................................................................

Air Intake Piping.......................................................................................................................................

Charge-Air Piping .....................................................................................................................................

Hydraulic System Oil ................................................................................................................................

Engine Oil ..................................................................................................................................................

Cooling System ..........................................................................................................................................

Battery .......................................................................................................................................................

Sealed Fuses ..............................................................................................................................................

Fuel System ...............................................................................................................................................

Fuel Filter/Water Separator .....................................................................................................................

How to Make Checks With Engine Running................................................................................................

Engine Fault Codes ...................................................................................................................................

Gauges, Lights, Horn, Fuses, Control Levers, and Pedals .....................................................................

Transmission Oil .......................................................................................................................................

Lift System Operation...............................................................................................................................

Hydraulic Oil Filters .................................................................................................................................

Brakes ........................................................................................................................................................

Steering System ........................................................................................................................................

Attachments ..............................................................................................................................................

Maintenance Procedures Every 250 Hours or Monthly...................................................................................

Empty Container Attachment ......................................................................................................................

Maintenance Procedures Every 250 Hours or 2 Months .................................................................................

Drive Shaft .....................................................................................................................................................

Steering Axle..................................................................................................................................................

Mast................................................................................................................................................................

Lift Chains .....................................................................................................................................................

Wear Check................................................................................................................................................

Lubrication ................................................................................................................................................

©2006 HYSTER COMPANY

1 1 1 2 2 2 3 4 12 12 12 12 13 13 14 14 14 14 14 16 16 16 17 17 18 18 18 19 20 21 22 22 22 23 23 32 33 33 33 34 34 34 34 34 34 34 34 35 35 35 36

i

Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued) Adjust .........................................................................................................................................................

Forks...............................................................................................................................................................

Wheel Nuts.....................................................................................................................................................

Drive Axle and Differential...........................................................................................................................

Maintenance Procedures Every 250 Hours or 3 Months .................................................................................

Fuel Pump......................................................................................................................................................

Maintenance Procedures Every 500 Hours or 3 Months .................................................................................

Engine Oil and Filter.....................................................................................................................................

Transmission Oil Filter .................................................................................................................................

Hydraulic Tank Breathers ............................................................................................................................

Maintenance Procedures Every 500 Hours or 6 Months .................................................................................

Air Filter, Heater ...........................................................................................................................................

Drive Belt .......................................................................................................................................................

Fuel Filter/Water Separator..........................................................................................................................

Tier 2 Coolant Filter ......................................................................................................................................

Maintenance Procedures Every 1000 Hours or 6 Months ...............................................................................

Steer Wheel Bearing Nut ..............................................................................................................................

Accumulator...................................................................................................................................................

Brakes ............................................................................................................................................................

Transmission Oil............................................................................................................................................

Mast................................................................................................................................................................

Other Lubrication ..........................................................................................................................................

Maintenance Procedures Every 1000 Hours or Yearly ....................................................................................

Coolant Fan Belt Tensioner ..........................................................................................................................

Belt Driven Fan Hub .....................................................................................................................................

Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................

Hydraulic System ..........................................................................................................................................

Differential and Drive Axle...........................................................................................................................

Maintenance Procedures Every 2000 Hours or 2 Years...................................................................................

Rubber Vibration Damper.............................................................................................................................

Engine Coolant ..............................................................................................................................................

Maintenance Procedures Every 5000 Hours ....................................................................................................

Container Handler.........................................................................................................................................

Maintenance Procedures Every 5000 Hours or 4 Years...................................................................................

Valve Adjustment ..........................................................................................................................................

Tilt Cab Operation .............................................................................................................................................

Raise Cab .......................................................................................................................................................

Lower Cab ......................................................................................................................................................

System Air Removal ..........................................................................................................................................

Safety Procedures When Working Near Mast..................................................................................................

Lift and Tilt System Leaks Check.....................................................................................................................

Lift System.....................................................................................................................................................

Tilt System .....................................................................................................................................................

Wheel and Tire Replacement ............................................................................................................................

Remove Wheels From Lift Truck ..................................................................................................................

Remove Tire From Wheel..............................................................................................................................

Install Tire on Wheel .....................................................................................................................................

Add Air to Tires .............................................................................................................................................

Wheels, Install ...............................................................................................................................................

ii

36 36 36 36 37 37 37 37 37 37 38 38 38 38 38 39 39 39 39 40 40 40 40 40 41 42 42 42 43 43 43 43 43 44 44 45 45 45 45 47 48 48 49 49 49 50 51 53 54

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS (Continued) This section is for the following models: H20.00-32.00F/FS (H440-700F/FS) [E008]

iii

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1023

General

General This section contains a Maintenance Schedule and the instructions for maintenance and inspection.

The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hourmeter and in calendar time. The recommendation is to use the interval that comes first.

The recommendation for the time intervals are for 8 hours of operation per day. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: • If the lift truck is used more than 8 hours per day • If the lift truck must work in dirty operating conditions

WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can make a dangerous operating condition.

WARNING Do not operate a lift truck that needs repairs.

Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operator’s area. Remove the key from the key switch.

Your dealer for Hyster lift trucks has the equipment and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A regular program of inspection, lubrication, and maintenance will help your lift truck give more efficient performance and operate for a longer period of time.

Some users have service personnel and equipment to do the inspection, lubrication, and maintenance shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster lift trucks to help users who do their own maintenance.

SERIAL NUMBER DATA The serial number for the lift truck is on the nameplate and also on the right-hand frame rail, near the counterweight. The serial number indicates the design series, manufacturing plant, and the year of manufacture.

Example:

E8

E

4369

N

(1)

(2)

(3)

(4)

(1) The first letter and number of the serial number indicates the design series and the model number of the lift truck.

Examples: E8 indicates the serial code for the H20.00-32.00F (H440-700F/FS) series of lift trucks.

(2) The second letter identifies the manufacturing plant.

Examples: B

= Northern Ireland

D

= Danville, IL, U.S.A.

E

= Nijmegen, The Netherlands

V

= Berea, KY, U.S.A.

(3) The number series indicates the sequence of manufacture where the lift truck was made.

(4) The letter indicates the year of manufacture starting with A=1980. The letter L=1990, M=1991, and N=1992. (The letters I, O, and Q are not used.)

HOW TO MOVE DISABLED TRUCK NOTE: If there is no hydraulic pressure to release the parking brake, the parking brake caliper (located on the drive shaft) must be manually released. Put blocks on each side (front and back) of the drive tires to prevent movement of the lift truck. To manually release the parking brake, remove the cotter pin and tighten the nut to compress the spring that applies the brake.

1

General

How to Tow Lift Truck WARNING Use extra care when towing a lift truck if there is a problem with any of the following: • Brakes do not operate correctly.

• Steering does not operate correctly.

• Tires are damaged.

• Traction conditions are bad.

• The lift truck must be towed on a slope.

If the engine cannot run, there is no power available for the hydraulic steering and brake systems. This condition can make the lift truck difficult to steer and stop. Poor traction can cause the disabled lift truck or towing vehicle to slide. A slope will also make the lift truck more difficult to stop.

Never lift and move a disabled lift truck unless the disabled lift truck MUST be moved and cannot be towed. A lift truck used to move a disabled lift truck MUST have a capacity rating equal to or greater than the weight of the disabled lift truck. The capacity of the lift truck used to move a disabled lift truck must have a load center equal to half the width of the disabled lift truck. See the nameplate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Put the weight center of the disabled lift truck on load center of the forks. Be careful to not damage the under side of the lift truck.

1. The towed lift truck must have an operator.

2. Tow the lift truck slowly.

3. Raise the carriage and forks approximately 30 cm (12 in.) from the surface. Install a chain to prevent the carriage and mast channels from moving.

4. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to tow the disabled lift truck. This half-capacity load will

2

8000 SRM 1023 increase the traction of the lift truck. Keep the load as low as possible.

5. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.

HOW TO PUT LIFT TRUCK ON BLOCKS WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions. a. Before removing the mast and drive axle, put blocks under the counterweight so that the lift truck cannot fall backward. b. Before removing the counterweight, put blocks under the mast assembly so that the lift truck cannot fall forward.

The surface must be solid, even, and level.

Make sure that any blocks used to support the lift truck are one-piece units. Put a steel plate on top of the block.

How to Raise Drive Tires 1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. See Figure 1.

2. Put the mast in a vertical position. Put a block under each outer mast channel.

3. Tilt the mast fully forward until the drive tires are raised from the surface.

4. Put additional blocks under the frame behind the drive tires.

5. If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the front. Make sure that the jack has a capacity equal to at least half the weight of the lift truck.

See the nameplate.

8000 SRM 1023

General

How to Raise Steering Tires 1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 1.

2. Use a hydraulic jack to raise the steering tires.

Make sure that the jack has a capacity of at least

1. DRIVE TIRES

2/3 of the total weight of the lift truck as shown on the nameplate.

3. Put the jack under the steering axle or frame to raise the lift truck. Put blocks under the frame to support the lift truck.

2. STEERING TIRES Figure 1. Put Lift Truck on Blocks

3

Maintenance Schedule

8000 SRM 1023

Maintenance Schedule NOTE: Portions reproduced by permission of Cummins Inc.

Figure 2. Maintenance Points (Tier 2)

4

8000 SRM 1023

Maintenance Schedule

Figure 3. Maintenance Points (Tier 3) Table 1. Daily Inspections Item No.

Condition Check

Item

Procedure

Safety Labels

Replace if necessary. See Parts Manual.

Seat Belt and Seat Rails

Check condition and operation.

Tires

Check condition.

Tire Pressure

See nameplate.

11

Mast, Carriage, and Attachment

Check condition and operation.

14

Lift Chains

Check condition and Lubricate.

Cooling Fan

Check for damage and loose rivets.

Crankcase Breather Tube

Check for sludge and ice.

Air Filter, Restriction Indicator, and Pre-Cleaner

Check, replace, and clean as necessary.

Fuel, Oil, Coolant Leaks

Check for leaks.

Drive Belt

Check condition. See Parts Manual.

Air Intake Piping and Charge Air Piping

Check for wear points, damage to the piping, leaks, loose clamps or loose connections.

Coolant Hoses

Inspect for cracks, cuts, and collapsing.

10

3

15

See Figure 2 and Figure 3 for Item Nos.

5

Maintenance Schedule

8000 SRM 1023

Table 1. Daily Inspections Item No.

Condition Check (Continued)

Item

Procedure

Radiator Section for Engine Coolant, Charge Air Cooler, and Hydraulic Oil

Check fins and clean if necessary. Check hoses and tube connections for leakage.

Engine Compartment

Remove combustible materials.

See Figure 2 and Figure 3 for Item Nos.

Table 2. Daily Inspections Item No. 1

Fluid Level Check

Item

Procedure

Hydraulic System Oil

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

Add if needed. 10W API CC or CC/SE/SF/SG, -18 C (0 F) and up.

4

Engine Oil

Add if needed.

SAE 10W 30 28 to 20 C ( 18 to 68 F) SAE 15W 40 18 C (0 F) and up.

API CH-4/SJ

6

Coolant System

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

Add if needed. 50% ethylene glycol, 50% water.

8

Battery Electrolyte

Add distilled water if needed.

9

Fuel Filter/Water Separator

Drain water/sediment.

17

Windshield Washer Fluid

Add if needed.

See Figure 2 and Figure 3 for Item Nos.

6

8000 SRM 1023

Maintenance Schedule Table 3. Daily Inspections

Item No.

Checks With the Engine Running

Item

Procedure or Specification

Engine Fault Codes

Check fault code warning lights.

Control Levers, Switches, and Pedals

Check operation as described in Operating Manual.

7

Fuel Level

Add if needed. Diesel No. 2.

2

Hydraulic System Oil Filters

Check indicator.

5

Transmission Oil

Add if needed. John Deere JDM J20C

Horns, Gauges, Lights, Alarms, Mirrors, and Control System

Check operation.

Steering System

Check operation.

Service Brakes

Check operation.

Parking Brake

Check operation.

Transmission

Check operation.

12

13

See Figure 2 and Figure 3 for Item Nos.

Table 4. First Inspection After First 100 Hours of Operation Item No.

Item

Procedure

Quantity

Specification

29

Engine Oil Filter

Change

1

See Parts Manual.

14

Lift Chains

Lubricate

2

Engine oil.

9

Fuel Filter/Water Separator

Change

1

See Parts Manual.

30

Fuel Filter

Change

1

See Parts Manual.

31

Tier 2 Coolant Filter

Change

1

See Parts Manual.

32

Transmission Oil Filter

Change

1

See Parts Manual.

26

Planetary Drive Axle

Change oil.

Clean magnetic plugs.

20 - 25 Ton, each side 28 - 32 Ton, each side

2

3.8 liter (4 qt)

SAE80W-90 or SAE85W-140.

API GL-5

5.2 liter (5.5 qt)

Differential

Change

22.7 liter (24 qt)

SAE80W-90 or SAE85W-140.

API GL-5

Hydraulic System Oil Filter

Change

2

See Parts Manual

Brake System Filter Element

Change

1

See Parts Manual

See Figure 2 and Figure 3 for Item Nos.

7

Maintenance Schedule

8000 SRM 1023

Table 5. Periodic Maintenance Schedule Item No. 27

Item

Inspect and Adjust

Interval

Wheel Nuts

Procedure Check torque.

Drive Wheels

250 hr/2 mo

305 to 340 N•m (225 to 251 lbf ft)

Steer Wheels

250 hr/2 mo

270 to 340 N•m (199 to 251 lbf ft)

Mounting Hardware (Fuel Injection Pump)

250 hr/3 mo

Inspect.

Coolant Concentration

500 hr/6 mo

Check antifreeze concentration and coolant level.

15

Drive Belt

500 hr/6 mo

Check tension.

12

Service Brakes and Parking Brakes

1000 hr/6 mo

Check wear values. See the sections Parking Brake 1800 SRM 1037 and Service Brake 1800 SRM 1038.

25

Steering Wheel Bearing Nut

1000 hr/6 mo

Check torque. See Steer Wheel Bearing Nut.

37

Accumulator

1000 hr/6 mo

See the section Accumulator 1800 SRM 1036.

Belt Driven Fan Hub

1000 hr/1 yr

Inspect condition.

Coolant Fan Belt Tensioner

1000 hr/1 yr

Inspect for damage and proper alignment.

Cab Lift Pump

2000 hr/1 yr

Check level. John Deere JDM J20C

Vibration Damper Inspection

2000 hr/2 yr

Check index lines.

36

Engine Valve Adjustment

Check with coolant temperature below 60 C (140 F).

Inlet (cold)

5000 hr/4 yr

0.305 mm (0.012 in.)

Exhaust (cold)

5000 hr/4 yr

0.559 mm (0.022 in.)

See Figure 2 and Figure 3 for Item Nos.

Table 6. Periodic Maintenance Schedule Item No.

Item

Interval

Quantity

Lubricate Specification

14

Lift Chains

250 hr/2 mo

2

16

Sideshift Carriage Bushing

250 hr/2 mo

2 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

18

Drive Shaft

250 hr/2 mo

3 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

19

Mast Pivots

250 hr/2 mo

2 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

Engine oil

See Figure 2 and Figure 3 for Item Nos.

8

8000 SRM 1023

Maintenance Schedule

Lubricate (Continued)

Table 6. Periodic Maintenance Schedule Item No.

Item

Interval

20

Mast Fork Pins and Guides

250 hr/2 mo

21

Mast Tilt Cylinder Pins

250 hr/2 mo

8 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

22

Mast Chain Sheaves

250 hr/2 mo

2 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

24

Steering Axle Tie Rods

250 hr/2 mo

8 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

23

Steering Axle Pivots

250 hr/2 mo

2 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

Pedals, Levers, Linkages, Cables, Hinges, and Seat Rails

1000 hr/6 mo

33

Mast Load Rollers and Side Rollers

1000 hr/6 mo

8 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

34

Carriage Rollers, Load Rollers, Side Rollers, and Sideshift Rollers

1000 hr/6 mo

8 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

35

Steering Axle King Pins

1000 hr/6 mo

4 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide

Tie Bar Stub

2000 hr/1 yr

Quantity

Specification Engine oil.

Engine oil.

Multipurpose grease with 2 to 4% molybdenum disulfide

See Figure 2 and Figure 3 for Item Nos.

Table 7. Periodic Maintenance Schedule Item No. 4

Item

Interval

Engine Oil

500 hr/3 mo

Change

Quantity 19 liter (20 qt)

Specification SAE 10W 30 28 to 20 C ( 18 to 68 F) SAE 15W 40 18 C (0 F) and up API CH-4/SJ

29

Engine Oil Filter

500 hr/ 3 mo

1

See Parts Manual.

32

Transmission Oil Filter

500 hr/ 3 mo

1

See Parts Manual.

28

Hydraulic Tank Breather Element

500 hr/3 mo

2

See Parts Manual.

Heater Air Filter

500 hr/6 mo

1

See Parts Manual.

See Figure 2 and Figure 3 for Item Nos.

9

Maintenance Schedule

8000 SRM 1023

Table 7. Periodic Maintenance Schedule Item No.

Item

Change (Continued)

Interval

Quantity

Specification

9

Fuel Filter/Water Separator

500 hr/6 mo

1

See Parts Manual.

30

Fuel Filter

500 hr/ 6 mo

1

See Parts Manual.

31

Tier 2 Coolant Filter

500 hr/6 mo

1

See Parts Manual.

3

Air Filter

1000 hr/6 mo

1

See Parts Manual.

5

Transmission Oil

1000 hr/6 mo

25.5 liter (27 qt)

Cab Air Filter

1000 hr/6 mo

1

Hydraulic System Oil

2000 hr/1 yr

325 liter (85.8 gal)

1

John Deere JDM J20C See Parts Manual.

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

10W API CC or CC/SE/SF/SG 18 C (0 F) and up

2

Hydraulic System Oil Filters

26

Planetary Drive Axle

6

2000 hr/1 yr

2

20 - 25 Ton, each side

2000 hr/1 yr

3.8 liter (4 qt)

28 - 32 Ton, each side

2000 hr/1 yr

5.2 liter (5.5 qt)

Differential

2000 hr/1 yr

22.7 liter (24 qt)

Brake System Filter Element

2000 hr/1 yr

1

Cooling System

2000 hr/2 yr

Tier 2

See Parts Manual.

Clean magnetic plugs.

SAE80W-90 or SAE85W-140.

API GL-5 Clean magnetic plugs.

SAE80W-90 or SAE85W-140.

API GL-5 See Parts Manual

40 liter (42.3 qt)

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

Tier 3

35.4 liter (37.4 qt)

50% ethylene glycol, 50% water.

See Figure 2 and Figure 3 for Item Nos.

10

8000 SRM 1023

Maintenance Schedule

Figure 4. Container Attachment Maintenance Table 8. Container Attachment Maintenance Item No.

Item

Interval

Quantity

Lubricate Specification

2

End Beams and Twist Locks

250 hr/1 mo

8 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide.

1

Wear Pads for Main Extension Beams and Extending Beams

500 hr/3 mo

24 lube points

Multipurpose grease with 2 to 4% molybdenum disulfide.

4

Slew/Sideshift Cylinders

500 hr/3 mo

6 fittings

Multipurpose grease with 2 to 4% molybdenum disulfide.

3

Stop Cylinders

1000 hr/6 mo

2 lube points

Multipurpose grease with 2 to 4% molybdenum disulfide.

5

Tracks and Wear Pads for Extension Cylinder Support

1000 hr/6 mo

4 tracks

Multipurpose grease with 2 to 4% molybdenum disulfide.

See Figure 4 for Item Nos.

Table 9. Container Attachment Maintenance Item No. 2

Item Twist Locks

Interval

Quantity

5000

2

Replace Specification See Parts Manual.

See Figure 4 for Item Nos.

11

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1023

Maintenance Procedures Every 8 Hours or Daily HOW TO MAKE CHECKS WITH ENGINE STOPPED WARNING Do not operate a lift truck that needs repairs.

Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operator’s area. Remove the key from the key switch.

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

3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label and the corners and edges are tight.

Operator Restraint System The seat belt, seat, and mounting are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly and is in good condition. See Figure 5.

Put the lift truck on a level surface. Lower the carriage and forks, stop the engine, and apply the parking brake. Open the hood and check for leaks and conditions that are not normal. Clean any oil or fuel spills. Verify all surfaces are free of oil, lubricants, or other foreign objects.

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the Frame section of the Service Manual for the correct location of the safety labels.

If new labels must be installed, use the following procedures:

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

12

1. SEAT BELT RETRACTOR

2. SEAT BELT LATCH 3. SEAT RAIL

Figure 5. Seat Check The seat belt must latch securely. Make sure the seat belt extends and retracts smoothly and is not damaged or torn. If the seat belt cannot be pulled from the retractor assembly, remove the screw that keeps the cover on the retractor. Push the bar to release the spool. Straighten the belt so that it pulls out and retracts smoothly. The belt must latch securely. See Figure 6.

Make sure the seat rails are not loose. The seat rails must lock securely in position, but move freely when unlocked. The seat rails must be securely attached to the mounting surface.

8000 SRM 1023

Maintenance Procedures Every 8 Hours or Daily Check for bent or damaged rims. Check for loose or missing hardware. Remove any wire, strapping, or other material that is wrapped around the axle.

Keep the tires at the correct air pressure. (See the Nameplate.) Check the air pressure with a gauge when the tires are cold. If it is necessary to add air to a tire that is warm, check one of the other tires on the same axle and add air to the tire that has low pressure so that the air pressures are equal. The air pressure of warm tires must always be equal to or greater than air pressures specified for cold tires.

1. COVER OPEN 2. SEAT BELT RETRACTOR

3. SEAT BELT 4. BAR

Figure 6. Release Jammed Seat Belt

Tires and Wheels WARNING Air pressure in tires can cause tire and wheel parts to explode. The explosion of wheel parts can cause serious injury or death.

Remove the air pressure from the tires before the wheels are removed from the lift truck.

If the air pressure is less than 80% of the correct pressure, the tire and wheel must be removed before air is added. Put the tire and wheel in a safety cage when adding air pressure to the tire. Follow the procedures under Add Air to Tires.

1. CHECK TIRE PRESSURE 2. CHECK FOR DAMAGE Figure 7. Tires Check

Forks The identification of a fork is determined by how it is connected to the carriage. See Figure 8. These lift trucks have pin forks. Pin forks are fastened to the carriage with large fork pins.

When air is added to the tires, a remote air chuck must be used so that the person adding air can stand to the side and not in front of the tire.

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 drive wheels have been removed and installed. Tighten the nuts as shown in Figure 53. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 250 hours.

Check the tires for damage. See Figure 7. Inspect the tread and remove any objects that will cause damage.

1. HIGH MOUNT FORKS 2. LOW MOUNT FORKS Figure 8. Types of Forks

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