Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Forklift Service Repair Manual

Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XMH52.00XM-16CH Europe) Forklift

PERIODIC MAINTENANCE H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]; H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]

PART NO. 1616443

8000 SRM 1237

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 Lift 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.......................................................................................................................................

Spreader Maintenance ..................................................................................................................................

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

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

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

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

Safety Belt and Seat Rails....................................................................................................................

Steering Column Latch.........................................................................................................................

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

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

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

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

Low Mount Forks, Install .....................................................................................................................

Forks, Mast, and Lift Chains, Inspect .....................................................................................................

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

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

Air Intake Piping and Charge Air Piping ................................................................................................

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

Pre-Cleaner for Air Filter .........................................................................................................................

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

Hydraulic Tank Breather..........................................................................................................................

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

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

Hydraulic High Pressure Oil Filter..........................................................................................................

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

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

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

How to Add Fuel to Lift Truck ......................................................................................................................

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

Gauges, Lights, Horn, Fuses, and Relays ................................................................................................

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

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

Engine Air Filter .......................................................................................................................................

Engine Oil Pressure ..................................................................................................................................

Electrical System.......................................................................................................................................

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

Service Brakes ...........................................................................................................................................

Parking Brake ...........................................................................................................................................

Control Levers and Pedals........................................................................................................................

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

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

First Inspection After First 100 Hours of Operation .......................................................................................

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

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

©2007 HYSTER COMPANY

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Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued) Lift Chains .....................................................................................................................................................

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

Air Conditioning ............................................................................................................................................

Steer Wheel Hubs ..........................................................................................................................................

Maintenance Procedures Every 250 Hours Or Monthly..................................................................................

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

Twist Locks (F117 Only)................................................................................................................................

Gantry Carriage and Container Attachments (F117 Only).........................................................................

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

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

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

Hydraulic Return Line Oil Filter..................................................................................................................

Air Conditioning ............................................................................................................................................

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

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

Steering Axle Kingpins .................................................................................................................................

Steering Axle Tie Rods ..................................................................................................................................

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

Steering Axle Pivots ......................................................................................................................................

Mast and Carriage Load Rollers...................................................................................................................

Mast Pivots, Sliding Surfaces .......................................................................................................................

Sideshift Carriage..........................................................................................................................................

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

Fuel Filter ......................................................................................................................................................

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

Oil Filter for Oil-Cooled Brakes (Brake Filter)............................................................................................

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

Change .......................................................................................................................................................

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

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

Service Brake System....................................................................................................................................

Brake System Accumulator ..........................................................................................................................

Hub Bearings, Steer Wheels .........................................................................................................................

General Lubrication ......................................................................................................................................

Maintenance Procedures Every 1500 Hours or 1 Year ....................................................................................

Engine ............................................................................................................................................................

Water Pump ...................................................................................................................................................

Turbocharger..................................................................................................................................................

Engine Mounting Bolts .................................................................................................................................

Air Leaks, Air Intake and Exhaust ..............................................................................................................

Valve and Injector Adjustments....................................................................................................................

General.......................................................................................................................................................

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

Injector Adjustment ..............................................................................................................................

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

Maintenance Procedures Every 2000 Hours or 1 Year ....................................................................................

Parking Brake Assembly...............................................................................................................................

Clean ..........................................................................................................................................................

Inspect........................................................................................................................................................

Maintenance Procedures Every 3000 Hours or 18 Months .............................................................................

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

ii

30 30 30 30 31 31 31 31 31 31 31 32 32 32 32 32 33 33 33 33 33 33 34 34 34 34 34 34 35 35 35 35 35 35 35 35 35 36 36 37 38 38 39 39 40 42 42 42 42 44 44

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS (Continued) Maintenance Procedures Every 5000 Hours ....................................................................................................

Container Attachment (F117) .......................................................................................................................

Maintenance Procedures Every 6000 Hours or 2 Years...................................................................................

Vibration Damper ..........................................................................................................................................

Fan Drive Idler Pulley...................................................................................................................................

Fan Hub .........................................................................................................................................................

Turbocharger..................................................................................................................................................

Cooling System Fluid ....................................................................................................................................

Maintenance Procedures Every 10,000 Hours or 5 Years................................................................................

High Pressure Hydraulic Oil Filter ..............................................................................................................

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

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

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

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

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

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

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

Remove Tire From Five-Piece Wheel .......................................................................................................

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

Install Tire on Five-Piece Wheel ..............................................................................................................

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

Install Wheels on Lift Truck .........................................................................................................................

44 44 44 44 45 46 46 46 47 47 48 49 49 49 50 50 50 51 52 53 54 55

This section is for the following models: H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]; H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]

iii

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1237

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 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.

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 give more efficient performance and operate for a longer period of time.

WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments made on a lift truck by people without authorization and training can make a dangerous operating condition.

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 operators area. Remove the key from the key switch.

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

Example:

F117

E

4369

A

(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.

(2) The second letter identifies the manufacturing plant.

Examples: D

= Danville, IL U.S.A.

E

= Nijmegen, The Netherlands

(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=2003. The letter B=2004 and so on.

HOW TO MOVE DISABLED LIFT TRUCK The service brake system requires hydraulic pressure to operate. The park brake will automatically apply when hydraulic pressure drops. If there is no hydraulic pressure to release the parking brake, the parking brake caliper must be manually released.

Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. The parking brake caliper is installed at the back of the differential housing. To manually release the parking brake, remove cotter pin from bolt in caliper. Tighten nut to compress spring that applies brake.

NOTE: If there is no hydraulic pressure to release the parking brake, the parking brake caliper must be manually released. Put blocks on both sides, front and rear, 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 caution when moving a lift truck if any of the following conditions exist: • 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 assist available for the steering and service brakes. This can make the control of the lift truck difficult. Poor traction can cause the disabled lift truck or towing vehicle to slide.

Steep grades will increase the required brake effort.

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.

8000 SRM 1237 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 How to Raise Drive Tires 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: drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: 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 when the lift truck is put on blocks. Verify that any blocks used to support the lift truck are solid, one piece units. Put a steel plate on top of the block.

NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the lift truck so that blocks can be installed.

NOTE: The lifting eyes of the counterweight are for lifting of the counterweight only. Never use the lifting eyes or the counterweight to lift the truck.

2. Tow the lift truck slowly.

3. Using a lift truck or a lifting device that can be attached to the mast (I.E. come-a-long), raise the carriage and forks approximately 30 cm (12 in.) from surface. Install a chain around the mast crossmember and the carriage, to prevent 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 increase the traction of the lift truck. Keep the load as low as possible.

2

1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. See Figure 1 and Figure 2.

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 drive axle. Verify that the jack has a capacity of at least half the weight of the lift truck. See the nameplate.

8000 SRM 1237

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 and Figure 2.

1. STEER AXLE/STEER TIRES

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

Verify that the jack has a capacity of at least 2/3 of the weight of the lift truck. See 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. DRIVE AXLE/DRIVE TIRES

Figure 1. Put Lift Truck on Blocks (F117)

1. STEER AXLE/STEER TIRES

2. DRIVE AXLE/DRIVE TIRES

Figure 2. Put Lift Truck on Blocks (A917)

3

Maintenance Schedule

8000 SRM 1237

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

Figure 3. Maintenance Points (F117) (Sheet 1 of 2)

Figure 3. Maintenance Points (F117) (Sheet 2 of 2)

4

8000 SRM 1237

Maintenance Schedule

Figure 4. Maintenance Points (A917) (Sheet 1 of 2)

Figure 4. Maintenance Points (A917) (Sheet 2 of 2)

5

Maintenance Schedule

8000 SRM 1237 Table 1. Condition Check

Item No.

Item

Procedure

Safety Labels

Replace if necessary. See Parts Manual.

Seat Rails and Safety Belt

Check condition and operation.

Wheels and Tire Pressure

Check condition of wheels and tire pressure.

See Nameplate. Check for missing wheel nuts.

35

Forks

Check condition.

12

Lift Chains, Mast, and Carriage

Check condition and operation. Check lubrication. Engine oil.

Mast Header Hose Assembly

Adjust, repair, or replace hoses and/or components as necessary. See the section Mast 4000 SRM 1160 for hose repair.

16

23

14 17, 2

Mast Header Hoses

Check hoses and fittings for hydraulic leaks.

Check for proper tracking during operation.

Hose Cover

Check for cuts, cracks, or exposed reinforcement.

Clamps/Sheaves

Check for defective or broken clamping devices or sheaves.

Drive Belts

Check condition. See Parts Manual.

Crankcase Breather Tube

Check for sludge and ice.

Air Intake Piping and Charge Air Piping

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

Cooling Fan

Check for damage.

Air Precleaner

Check. Clean or replace if necessary. See Parts Manual.

Fuel, Oil, and Coolant Leaks

Check for leaks.

Seat and Steering Column Latches

Check condition and operation.

Hydraulic Tank Breather

Check indicator and clean/replace if necessary.

Radiator Section for Engine Coolant, Charge Air Cooler, Hydraulic Oil, and Transmission Hose and Tube Connections.

Check fins and clean if necessary.

Coolant Hoses

Inspect for cracks, cuts, and collapsing.

Frames

Check condition.

See Figure 3 and Figure 4 for Item Nos.

6

8000 SRM 1237

Maintenance Schedule Table 2. Daily Inspections

Item No. 21, 33

Fluid Level Check

Item Engine Oil Dipstick

Procedure 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 15

Hydraulic System Oil

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

Check gauge with mast fully lowered. Add if needed. John Deere JDM J20C 17

Coolant Level

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.

19

Battery Electrolyte

Add if needed. Distilled water.

30

Fuel Filter/Water Separator

Drain water.

Windshield Washer Fluid

Check level and add fluid as necessary.

See Figure 3 and Figure 4 for Item Nos.

7

Maintenance Schedule

8000 SRM 1237

Table 3. Daily Inspections Item No.

31

Checks With the Engine Running

Item

Procedure or Specification

Engine Fault Codes

Check fault code warning lights.

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

Visual or audible verification of operation and condition.

Transmission Oil

Add if needed. 62 liter (16 gal) Dexron® NOTE: When oil is added, perform additional check with transmission hot.

29

20

9

Transmission

Check operation.

Engine Oil Pressure

Check instrument panel engine oil pressure gauge.

Electrical System

Check alternator warning light.

Fuel

Add if required. Diesel No. 2.

Steering System

Check operation.

Service Brake

Check brake system operation.

Parking Brake

Check operation.

Control Levers, Switches, and Pedals

Check operation as described in the Operating Manual.

See Figure 3 and Figure 4 for Item Nos.

8

8000 SRM 1237

Maintenance Schedule Table 4. First Inspection After First 100 Hours of Operation

Item No. 1

Item

Procedure

Quantity 1

Specification

Engine Oil Filter

Change

Drive Axle and Differential

Change. Clean magnetic plugs.

65 liter (17.2 gal)

12

Lift Chains

Check condition and lubricate.

2

Engine oil

7

Transmission Oil Filter

Change

2

See Parts Manual.

32

Return Line Oil Filter

Check hydraulic oil pressure at check port M RF (full throttle, maximum lowering speed at minimum oil temperature 60 C (140 F). If measured value is higher than 250 kPa (36 psi), change filters.

2

See Parts Manual.

8

Brake Return Line Filter

Change

1

See Parts Manual

Hydraulic Oil High Pressure Filter

Change

1

See Parts Manual

Air Conditioning

Inspect AC\Dryer inspection glass.

If bubbles are present, contact certified AC trained technician if filling is necessary.

Oil in Steer Wheel Hubs

Change

Steer Wheel Hub Bearings

Check torque.

10, 11

34

See Parts Manual.

SAE80W-90 or SAE85W-140.

API GL-5

See Parts Manual.

As required.

2

MIL-L-2105 SAE90 See the section Steering Axle 1600 SRM 1114 for procedures.

See Figure 3 and Figure 4 for Item Nos.

9

Maintenance Schedule

8000 SRM 1237

Table 5. Periodic Maintenance Schedule Item No.

12

Item

Inspect and Adjust

Interval

Procedure

Steer Wheel Hubs

250 hr/1 mo

Check level.

Lift Chains

500 hr/3 mo

Check condition and adjustment.

Mast Header Hose Assembly

500 hr/3 mo

Check if hoses are kinked, crushed, flattened, twisted, hard, or charred.

Check for hose slippage and proper hose tension.

Adjust, repair, or replace as necessary. See the section Mast 4000 SRM 1160 for hose repair.

27, 18

Wheel Nuts

Check torque.

Drive Wheels

500 hr/3 mo

405 to 440 N•m (299 to 325 lbf ft)

Steer Wheels

500 hr/3 mo

271 to 339 N•m (200 to 250 lbf ft)

Return Line Oil Filter

500 hr/3 mo

Check hydraulic oil pressure at check port M RF (full throttle, maximum lowering speed at minimum oil temperature 60 C (140 F). If measured value is higher than 250 kPa (36 psi), change filters. Check and repair electric wires.

Air Conditioning

500 hr/3 mo

Inspect AC\Dryer inspection glass. If bubbles are present, contact certified AC trained technician if filling is necessary.

Forks

500 hr/3 mo

Check condition.

Drive Axle/Differential Oil

500 hr/3 mo

Check level. SAE80W-90 or SAE85W-140. API GL-5

Service Brake System

1000 hr/6 mo

Check system. See the section Service Brake 1800 SRM 1038.

25

Brake System Accumulator

1000 hr/6 mo

Check. See the section Accumulator 1800 SRM 1036 for leakage pressure settings.

9

Parking Brake Pads

1000 hr/6 mo

Check. See the section Parking Brake 1800 SRM 1117.

Water Pump

1500 hr/1 yr

Inspect for leakage.

32

35 10, 11

See Figure 3 and Figure 4 for Item Nos.

10

8000 SRM 1237

Maintenance Schedule

Table 5. Periodic Maintenance Schedule Item No.

26

Item

Inspect and Adjust (Continued)

Interval

Procedure

Turbocharger

1500 hr/1 yr

Tighten mounting hardware and V-band clamp.

Engine Mounting

1500 hr/1 yr

Inspect the rubber mounts and hardware torque.

Air Leaks, Air Intake and Exhaust

1500 hr/1 yr

Inspect mounting hardware and check for leaks.

Engine

1500 hr/1 yr

Steam clean.

Valve Adjustment

1500 hr/1 yr

Check with coolant temperature below 60 C (140 F)

Inlet (Cold)

0.36 mm (0.014 in.)

Exhaust (Cold)

0.68 mm (0.027 in.)

Optional Mast Dampening Accumulator

2000 hr/1 yr

Check. See the section Accumulator 1800 SRM 1036.

Automatic Clutch Calibration

2000 hr/1 yr

Check calibration. See the section Transmission, (TE27 and TE32) 1300 SRM 1220.

Vibration Damper

6000 hr/2 yr

Inspect vibration damper.

Fan Drive Idler Pulley

6000 hr/2 yr

Inspect drive idler pulley.

Fan Hub

6000 hr/2 yr

Inspect for proper functioning.

Turbocharger

6000 hr/2 yr

Inspect for damage.

See Figure 3 and Figure 4 for Item Nos.

11

Maintenance Schedule

8000 SRM 1237 Table 6. Periodic Maintenance Schedule

Item No.

Item

Interval

Quantity

Lubricate Specification

5

Tie Rod End Steering

250 hr/1 mo

4 fittings

Multipurpose grease with 2-4% molybdenum disulfide.

6

King Pins

250 hr/1 mo

4 fittings

Multipurpose grease with 2-4% molybdenum disulfide. Lubricate under no load conditions.

28

Mast Pivots

250 hr/1 mo

2

Multipurpose grease with 2-4% molybdenum disulfide.

13

Drive Shaft

250 hr/1 mo

2 fittings

Multipurpose grease with 2-4% molybdenum disulfide.

4

Steering Axle Pivot

250 hr/1 mo

2 fittings

Multipurpose grease with 2-4% molybdenum disulfide. Lubricate under no load conditions.

36

Mast and Carriage Load Rollers

250 hr/1 mo

8 fittings

Multipurpose grease with 2-4% molybdenum disulfide.

12

Chain Sheaves

250 hr/1 mo

2 fittings

Multipurpose grease with 2-4% molybdenum disulfide.

37

Fork Guides

500 hr/3 mo

2

Control Pedals and Linkages

1000 hr/6 mo

Lubricate as necessary. Engine oil.

Operator Compartment Doors, Side Compartment Doors

1000 hr/6 mo

Multipurpose grease with 2-4% molybdenum disulfide.

Multipurpose grease with 2-4% molybdenum disulfide. Lubricate under no load conditions.

See Figure 3 and Figure 4 for Item Nos.

12

8000 SRM 1237

Maintenance Schedule Table 7. Periodic Maintenance Schedule

Item No. 1, 21

Item

Interval

Engine Oil and Filter

500 hr/3 mo

Change

Quantity 34 liter (9 gal)

Specification SAE 10W-30 68 F)

28 to 20 C ( 18 to

SAE 15W-40

18 C (0 F) and up.

API CH-4/SJ. 30

Fuel Filter

500 hr/6 mo

1

See Parts Manual.

Engine Coolant Filter

500 hr/6 mo

1

See Parts Manual.

Transmission Oil Filter

500 hr/6 mo

2

See Parts Manual.

Cab Air Filter

500 hr/6 mo

1

Clean or replace. See Parts Manual.

31

Transmission Oil

500 hr/6 mo

3

Steer Wheel Hubs

14

Hydraulic Tank Breather Filters

7

62 liter (16 gal)

SAE 10W, API CC or CC/SE. Dexron®

1000 hr/6 mo

4 liter (4 qt) each side.

SAE80W-90 or SAE85W-140.

API GL-5

1000 hr/6 mo

2

Replace filter elements. See Parts Manual.

NOTE: Replace filters when restriction indicator is in the red zone.

24

Intake Air Filter

1000 hr/6 mo

1

Replace when restriction indicator warning light is ON. See Parts Manual.

8

Brake Return Line Filter

2000 hr/1 yr

1

Replace when restriction indicator warning light is ON. See Parts Manual.

10, 11 2

Drive Axle/Differential Oil

2000 hr/1 yr

64.8 liter (17 gal)

Cooling System Fluid

2000 hr/1 yr

40 liter (10.6 gal)

SAE80W-90 or SAE85W-140.

API GL-5

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

50% water with 50% ethylene glycol.

15

Hydraulic Return Line Oil Filter

3000 hr/18 mo

2

See Parts Manual.

See Figure 3 and Figure 4 for Item Nos.

13