H170-360HD MANTENIMIENTO

PERIODICMAINTENANCE

H8.00-12.00XM (H170-280HD) [G007];H13.00-16.00XM (H300-360HD) [F019];

H10.00-12.00XM-12EC (H360HD-EC) [F019]

PART NO. 1556602 8000 SRM 1099

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains 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 repairon electric lift trucks. Disconnect the battery ground cable on internal combustion lifttrucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUTTHE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-nance 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 partsmust meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed beforeusing 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 fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1How to Move Disabled Lift Truck ................................................................................................................. 1

How to Tow Lift Truck............................................................................................................................... 1How to Put Lift Truck on Blocks................................................................................................................... 2

How to Raise Drive Tires .......................................................................................................................... 2How to Raise Steering Tires ..................................................................................................................... 2

Maintenance Schedule....................................................................................................................................... 4Empty Container Attachment Maintenance................................................................................................ 10

Maintenance Procedures Every 8 Hours or Daily............................................................................................ 12How to Make Checks With Engine Stopped................................................................................................. 12

Hydraulic System Oil ................................................................................................................................ 12Engine Oil .................................................................................................................................................. 12Cooling System .......................................................................................................................................... 13Fuel System ............................................................................................................................................... 14Water Separator/Fuel Filter ..................................................................................................................... 14Fuel, Oil, or Coolant Leaks, Check........................................................................................................... 14Cab Hydraulic System .............................................................................................................................. 14Drive Belts ................................................................................................................................................. 15Battery ....................................................................................................................................................... 15Air Filters .................................................................................................................................................. 15Forks .......................................................................................................................................................... 15

Adjust..................................................................................................................................................... 15Remove .................................................................................................................................................. 15Install..................................................................................................................................................... 15

Forks, Mast, and Lift Chains, Inspect ..................................................................................................... 16Tires and Wheels ....................................................................................................................................... 17Operator Restraint System....................................................................................................................... 17Steering Column Latch ............................................................................................................................. 18Safety Labels ............................................................................................................................................. 18

How to Make Checks With Engine Running................................................................................................ 19Fault Codes................................................................................................................................................ 19

Access..................................................................................................................................................... 19Exit ........................................................................................................................................................ 19Clear ...................................................................................................................................................... 19

Gauges, Lights, Horn and Fuses .............................................................................................................. 19Control Levers and Pedals........................................................................................................................ 21Transmission Oil ....................................................................................................................................... 21Lift System Operation............................................................................................................................... 22Brakes ........................................................................................................................................................ 22Steering System ........................................................................................................................................ 22Attachments .............................................................................................................................................. 22

Maintenance Procedures Every 250 Hours or Every 2 Months ...................................................................... 22Empty Container Handler ............................................................................................................................ 22

Maintenance Procedures Every 500 Hours or Every 3 Months ...................................................................... 23Lift Chains ..................................................................................................................................................... 23

Lubrication ................................................................................................................................................ 23Adjust......................................................................................................................................................... 23

Drive Shaft ..................................................................................................................................................... 23Steering Axle.................................................................................................................................................. 24Wheel Nuts..................................................................................................................................................... 24Shafts for Brake Actuators ........................................................................................................................... 24

2004 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)Drive Axle and Differential........................................................................................................................... 24Hydraulic Tank Breather .............................................................................................................................. 24Air Filter, Engine, and Air Compressor ....................................................................................................... 24Cabin Air Filter, Heater ................................................................................................................................ 24Engine Oil and Filter..................................................................................................................................... 24Drive Belts ..................................................................................................................................................... 25

Perkins....................................................................................................................................................... 25Cummins.................................................................................................................................................... 25

Mast................................................................................................................................................................ 26Bearing Rollers (Three-Stage Only) ......................................................................................................... 27

Lubrication ............................................................................................................................................ 27Clearance............................................................................................................................................... 27

General Lubrication ...................................................................................................................................... 27Fork Wear and Damage Check ..................................................................................................................... 27Lift Chains Wear Check ................................................................................................................................ 28

Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 28Transmission Oil and Filter, Change............................................................................................................ 28Fuel Filter ...................................................................................................................................................... 29

Perkins....................................................................................................................................................... 29Remove .................................................................................................................................................. 29Install..................................................................................................................................................... 29

Cummins.................................................................................................................................................... 29Remove .................................................................................................................................................. 29Install..................................................................................................................................................... 30

Fuel System Air Removal (Perkins) ......................................................................................................... 30Fuel System Air Removal (Cummins)...................................................................................................... 30Fuel Injection Pump Without Vent Tube.................................................................................................. 30

Fuel Injection Pump Timing (Perkins Only)................................................................................................ 31Valve Adjustment .......................................................................................................................................... 31

Perkins....................................................................................................................................................... 31Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 32

Rubber Vibration Damper............................................................................................................................. 32Hydraulic System .......................................................................................................................................... 32

Hydraulic Oil Filter, Change .................................................................................................................... 32Hydraulic Oil, Change .............................................................................................................................. 33Hydraulic Pilot Valve Filter, Change ....................................................................................................... 33

Transmission Calibration.............................................................................................................................. 33Differential and Drive Axle........................................................................................................................... 33Wheel Bearings.............................................................................................................................................. 34

Steer Wheels .............................................................................................................................................. 34Drive Wheels ............................................................................................................................................. 34

Service Brakes ............................................................................................................................................... 34Cleaning Procedures (Dry Brake Axle) .................................................................................................... 34

Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 35Valve Adjustment .......................................................................................................................................... 35

Cummins.................................................................................................................................................... 35Safety Procedures When Working Near Mast.................................................................................................. 36Fuel Injectors Check .......................................................................................................................................... 37

Perkins ........................................................................................................................................................... 37Lift and Tilt System Leak Check ...................................................................................................................... 38

Lift System..................................................................................................................................................... 38

ii

Periodic Maintenance Table of Contents

TABLE OF CONTENTS (Continued)Tilt System..................................................................................................................................................... 38

Welding Repairs ................................................................................................................................................. 39Wheel and Tire Replacement ............................................................................................................................ 40

Remove Wheels From Lift Truck .................................................................................................................. 40Pneumatic Tires............................................................................................................................................. 40

Remove Tire From Wheel ......................................................................................................................... 40Remove Tire From Three- and Four-Piece Wheel ............................................................................... 41

Install Tire on Wheel................................................................................................................................. 42Install Three- or Four-Piece Wheel in Tire.......................................................................................... 42

Add Air to Tires ............................................................................................................................................. 43Solid Rubber Tires ......................................................................................................................................... 44

Remove Tire From Wheel ......................................................................................................................... 44Install Tire on Wheel................................................................................................................................. 46

Wheels, Install ............................................................................................................................................... 48

This section is for the following models:

H8.00-12.00XM (H170-280HD) [G007];H13.00-16.00XM (H300-360HD) [F019];

H10.00-12.00XM-12EC (H360HD-EC) [F019]

iii

"THEQUALITYKEEPERS"

HYSTERAPPROVEDPARTS

8000 SRM 1099 General

GeneralWARNING

Do not make repairs or adjustments unless youhave both authorization and training. Repairsand adjustments that are not correct can makea dangerous operating condition.

WARNINGDo not operate a lift truck that needs repairs.Report the need for repairs immediately. If re-pair is necessary, put a DO NOT OPERATE tagin the operators area. Remove the key fromthe key switch.

WARNINGDisposal of lubricants and fluids must meet lo-cal environmental regulations.

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

The Maintenance Schedule has time intervals for in-spection, lubrication, and maintenance of your lifttruck. The recommended time intervals are basedupon 8 hours of operation per day. Shorten the rec-ommended time intervals in the Maintenance Sched-ule 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 con-

ditions.

Your dealer for Hyster lift trucks has the equipmentand trained service personnel to do a complete pro-gram of inspection, lubrication, and maintenance. Aregular program of inspection, lubrication, and main-tenance will help your lift truck give more efficientperformance and operate for a longer period of time.

Some users have service personnel and equipmentto do the inspection, lubrication, and maintenanceshown in the Maintenance Schedule. Service Man-uals are available from your dealer for Hyster lifttrucks to help users who do their own maintenance.

HOW TO MOVE DISABLED LIFT TRUCK

WARNINGUse caution when towing a lift truck if there isa 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 steep grade.

If the engine cannot run, there is no poweravailable for the hydraulic steering systemand the service brakes. This condition canmake the lift truck difficult to steer and stop.Poor traction can cause the disabled lift truckor towing vehicle to slide. A slope will alsomake the lift truck more difficult to stop.

Never lift and move a disabled lift truck unlessthe disabled lift truck MUST be moved andcannot be towed. A lift truck used to movea disabled lift truck MUST have a capacityrating equal to or greater than the weight ofthe disabled lift truck. The capacity of the lifttruck used to move a disabled lift truck musthave a load center equal to half the width ofthe disabled lift truck. See the capacity plateof the disabled lift truck for the approximatetotal weight. The forks must extend the fullwidth of the disabled lift truck. Put the weightcenter of the disabled lift truck on the loadcenter of the forks. Be careful not to damagethe underside of the lift truck.

NOTE: For lift trucks equipped with air brakes, ifthere is no air pressure in the brake system, the park-ing brake must be manually released. To manuallyrelease the parking brake, use the release bolt ateach air chamber to compress the spring that appliesthe brake. Tighten the release bolt (or nut) until thebrake is released.

H8.00-12.00XM (H170-280HD) models: The re-lease bolt, washer, and nut are in a receptacle on theside of the air chamber. Make sure the release boltis engaged in the piston before the nut is tightened.

H13.00-16.00XM (H300-360HD) models: The re-lease bolt is permanently installed in the piston ofthe park brake.

How to Tow Lift Truck1. The towed lift truck must have an operator.

2. Tow the lift truck slowly.

3. Raise the carriage and forks approximately30 cm (12 in.) from the surface. Install a chainto prevent the carriage and mast channels frommoving.

1

General 8000 SRM 1099

4. If another lift truck is used to tow the disabled lifttruck, that lift truck must have a weight equalto or greater than the weight of the disabled lifttruck. Install approximately 1/2 capacity load onthe forks of the lift truck that is being used to towthe disabled lift truck. This 1/2 capacity load willincrease the traction of the lift truck. Travel withthe load as low as possible.

5. Use a towing link made of steel that attaches tothe tow pins in the counterweights of both lifttrucks.

HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires

WARNINGThe lift truck must be put on blocks for sometypes of maintenance and repair. The removalof the following assemblies will cause largechanges in the center of gravity: mast, driveaxle, engine and transmission, and the coun-terweight. When the lift truck is put on blocks,put additional blocks in the following posi-tions to maintain stability:1. Before removing the mast and drive axle,

put blocks under the counterweight so thatthe lift truck cannot fall backward.

2. Before removing the counterweight, putblocks under the mast assembly so that thelift truck cannot fall forward.

The surface must be solid, even, and level whenthe lift truck is put on blocks. Make sure thatany blocks used to support the lift truck aresolid, one-piece units. Put a steel plate on topof the block.

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

1. Put blocks on each side (front and back) of thesteering tires to prevent movement of the lifttruck. See Figure 1.

2. Put the mast in a vertical position. Put a blockunder each outer mast channel and place steelplates between the blocks and the mast.

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

4. Put additional blocks with steel plates underthe frame behind the drive tires. Make sure theblocks are under the frame and not under thehydraulic or fuel tanks.

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

How to Raise Steering Tires

WARNINGThe lift truck must be put on blocks for sometypes of maintenance and repair. The removalof the following assemblies will cause largechanges in the center of gravity: mast, driveaxle, engine and transmission, and the coun-terweight. When the lift truck is put on blocks,put additional blocks in the following posi-tions to maintain stability:1. Before removing the mast and drive axle,

put blocks under the counterweight so thatthe lift truck cannot fall backward.

2. Before removing the counterweight, putblocks under the mast assembly so that thelift truck cannot fall forward.

The surface must be solid, even, and level whenthe lift truck is put on blocks. Make sure thatany blocks used to support the lift truck aresolid, one-piece units. Put a steel plate on topof the block.

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

1. Put the mast in the vertical position.

2. Apply the parking brake. Put blocks on bothsides (front and back) of the drive tires to preventmovement of the lift truck. Put blocks betweenthe steering axle and the frame. See Figure 1and Figure 2.

2

8000 SRM 1099 General

WARNINGDo not put the jack under the counterweight toraise the lift truck.

3. Use a hydraulic jack to raise the steering tires.Put the jack under the steering axle or frame toraise the lift truck. Make sure that the jack has

a capacity of at least 2/3 of the total weight of thelift truck as shown on the capacity plate.

4. Put blocks with steel plates under both sides ofthe steering axle to support lift truck. Make surethe blocks are under the frame and not under thehydraulic or fuel tanks.

1. STEERING TIRES 2. DRIVE TIRES

Figure 1. Put Lift Truck on Blocks

Figure 2. Steering Axle Blocks

Legend for Figure 2

1. FRAME2. TIRE3. STEERING AXLE4. BLOCKS BETWEEN FRAME AND AXLE5. SUPPORT BLOCKS6. STEERING AXLE PIVOT POINT

3

Maintenance Schedule 8000 SRM 1099

Maintenance Schedule

Figure 3. Maintenance Points - Perkins Engine

Figure 4. Maintenance Points - Cummins Engine

4

8000 SRM 1099 Maintenance Schedule

Table 1. Daily Inspections Condition Check

Item No. Item Procedure

Fuel, Oil, Coolant Leaks Check for leaks.

Engine Compartment Remove combustible materials.

Frame Check condition.

Safety Labels See Parts Manual for replacement.

Seat Belt and Seat Rails Check condition and operation.

16 Air Compressor Air Filter Check, clean, or change if necessary. SeeParts Manual.

7 Drive Belts Check condition.

11 Radiator Section for Engine Coolant, CAC,and Hydraulic Oil

Check and clean if necessary. Check hosesand tube connections for leakage.

14 Tires and Tire Pressure Check condition and pressure. See nameplate.

22 Mast, Carriage, and Attachment Check condition.

20 Forks Check condition.

23 Lift Chains Check condition.

See Figure 3 and Figure 4 for Item Nos.

Table 2. Daily Inspections Fluid Level Check

ItemNo.

Item Procedure

Add if needed. 10W HCE 4 (with air brakes).1 Hydraulic System Oil

J20C HCE 102 (with wet brakes).

SAE 10W 30 28 C ( 18 F) to 20 C (68 F).SAE 15W 40 18 C (0 F) and up.SAE 5W 30 20 C (68 F) and below.

5 Engine Oil Dipstick

CG 4

17 Fuel Level Diesel No. 2, 128 liter (34 gal).

8 Coolant Level Add if needed. 50% ethylene glycol, 50% water.

27 Battery Electrolyte Add distilled water if needed.

3 Fuel Filter/Water Separator Drain water.

12 Windshield Washer Fluid Add as necessary.


5


Table 3. Daily Inspections Checks With the Engine Running

ItemNo.

Item Procedure or Specification

Horns, Gauges, Lights, Alarms, Mirrors, andControl System

Visual or audible verification.

Control Levers, Switches, and Pedals Check operation as described in OperatorManual.

Steering System Check operation.

16 Air Filter Clean, or if needed, replace element whenwarning light is ON.

Transmission Check operation.

Add if needed.

Hyster Part No. 336831


4

Transmission Oil Dipstick/Fill


3 Fuel Filter Clean or replace element when warning light isON. See Operator Manual.

Service Brakes Check operation.24

Parking Brake Check operation.


Table 4. First Inspection After First 100 Hours of Operation

ItemNo.

Item Procedure Quantity Specification

Engine Oil Filter

Perkins Change 2 See Parts Manual.

6

Cummins Change 1 See Parts Manual.

23 Lift Chains Lubricate withengine oil.

2

21 Drive Axle and Differential Clean magneticplug.

1

18 Transmission Oil Filter Change 1 See Parts Manual.

2 Hydraulic System Oil Filter Change 1 See Parts Manual.

19 Hydraulic Pilot Valve OilFilter

Change 1 See Parts Manual.


6


Table 5. Periodic Maintenance Schedule Inspect and Adjust

ItemNo.

Item Interval Procedure

29 Hydraulic Tank Breather 500 hr/3 mo Inspect restriction indicator. Replace elementand clean breather housing if indicator will reachservice level indication before the next service visit.

Cabin Air Filter 500 hr/3 mo Clean or replace if necessary. See Parts Manual.

NOTE: Very dirty conditions will require a dailyclean and check.

Engine Speeds

Perkins

Idle Speed 500 hr/3 mo 750 rpm 10 rpm

High Idle Speed 500 hr/3 mo 2415 rpm 10 rpm

Cummins

Idle Speed 500 hr/3 mo 800 rpm 10 rpm

High Idle Speed 500 hr/3 mo 2750 rpm 10 rpm

7 Drive Belts 500 hr/3 mo Check tension.

20 Forks 500 hr/3 mo Check condition.

23 Lift Chains 500 hr/3 mo Check condition and adjustment.

Drive Axle Differential 500 hr/3 mo Check level and clean plug.21

Planetary Gear 500 hr/3 mo Check level.

Wheel Nuts Check torque.

Drive Wheels 500 hr/3 mo 640 Nm (472 lbf ft) to 680 Nm (502 lbf ft)

9

Steer Wheels 500 hr/3 mo 640 Nm (472 lbf ft) to 680 Nm (502 lbf ft)

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

Perkins

Inlet (cold) 1000 hr/6 mo 0.20 mm (0.008 in.)

Exhaust (cold) 1000 hr/6 mo 0.45 mm (0.018 in.)

25 Accumulator 1000 hr/6 mo See the section Wet Brake System 1800 SRM 951.

26 Wet Brake System 1000 hr/6 mo See the section Wet Brake System 1800 SRM 951.

Parking and ServiceBrakes (Dry Brakes Only)

2000 hr/1 yr Check condition.24

Vibration DamperInspection (CumminsOnly)

2000 hr/1 yr Check index lines.

Transmission Calibration 2000 hr/1 yr See Transmission 1300 SRM 1082


7


Table 5. Periodic Maintenance Schedule Inspect and Adjust (Continued)

ItemNo.


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

Cummins

Inlet (cold) 4000 hr/2 yr 0.25 mm (0.010 in.)

Exhaust (cold) 4000 hr/2 yr 0.51 mm (0.021 in.)


Table 6. Periodic Maintenance Schedule Lubricate

ItemNo.

Item Interval Quantity Specification

Tie Rods 500 hr/3 mo 4 fittings Multipurpose grease with 2 to 4%molybdenum disulfide

King Pins 500 hr/3 mo 4 fittings Multipurpose grease with 2 to 4%molybdenum disulfide

23 Lift Chains 500 hr/3 mo 2 Engine oil

28 Drive Shaft 500 hr/3 mo 3 fittings Multipurpose grease with 2 to 4%molybdenum disulfide

Pedals, Levers, Seat Rails,and Hinges

1000 hr/6 mo Lubricate as necessary. Use engineoil.

Steering Axle Pivot 1000 hr/6 mo 2 fittings Multipurpose grease with 2 to 4%molybdenum disulfide


8


Table 7. Periodic Maintenance Schedule Change

ItemNo.


SAE 10W 30 28 C ( 18 F) to20 C (68 F)SAE 15W 40 18 C (0 F) and upSAE 5W 30 20 C (68 F) andbelow

Engine Oil

API CG-4

Perkins 500 hr/3 mo 16.2 liter (17 qt),with filters

15

Cummins 500 hr/3 mo 16.3 liter(17.2 qt), withfilter

Engine Oil Filter

Perkins 500 hr/ 3 mo 2 See Parts Manual

6

Cummins 500 hr/ 3 mo 1 See Parts Manual

4 Transmission Oil 1000 hr/6 mo 16.5 liter(17.5 qt)

HCE-32 DEXRON III

3 Fuel Filter 1000 hr/6 mo 1 See Parts Manual.

26 Air Brake Filter 1000 hr/6 mo 1 See Parts Manual.

18 Transmission Oil Filter 1000 hr/6 mo 1 See Parts Manual.

30 Optional Air DryerCartridges

2000 hr/1 yr 2 See Parts Manual.

10W HCE 4 (with air brakes)1 Hydraulic System 2000 hr/1 yr 139 liter (37 gal)

J20C HCE 102 (with wet brakes)

8 Cooling System 2000 hr/1 yr 25.5 liter (27 qt) 50% ethylene glycol, 50% water

2 Hydraulic System OilFilter

2000 hr/1 yr 1 See Parts Manual.

13 Steer Wheels HubBearings

2000 hr/1 yr As required Multipurpose grease with 2 to 4%molybdenum disulfide

19 Hydraulic Pilot Oil Filter 2000 hr/1 yr 1 See Parts Manual.

10 Charge Air Cooler 2000 hr/1 yr 1 Drain deposit.

Drive Axle/Differential Oil 2000 hr/1 yr 19 liter (20 qt) SAE 80W 90 or 85W-140

Planetary Gear Oil 2000 hr/1 yr 2.5 liter (2.6 qt) SAE 80W 90 or 85W-140


9


EMPTY CONTAINER ATTACHMENT MAINTENANCE

Figure 5. Empty Container Attachment Maintenance Points

Table 8. Empty Container Attachment Maintenance Inspect and Adjust

ItemNo.


1 Wear Pads for Main Beamsand Extended Beams

250 hr/1 mo Check for wear of the 12 nylon pads and replace beforemetal to metal contact between carriage and frameoccurs.

3 Upper Sideshift SliderPads


Twistlock HousingsModels 553 and 558

250 hr/1 mo Check for wear and possible damage of the twistlockand the nose of the twistlock housing. Replace ifdamaged.

Lifting HooksModel 555

250 hr/1 mo Check the hooks for wear and cracking. If any sign ofeither defect is suspected, the hooks should either bereplaced or nondestructive crack tested.

4

Twistlock Assemblies 250 hr/1 mo Check for wear and possible damage of the twistlockand twistlock sleeve. Replace if in doubt.

See Figure 5 for Item Nos.

10


Table 8. Empty Container Attachment Maintenance Inspect and Adjust (Continued)

ItemNo.


5 Lower Sideshift SliderPads

250 hr/1 mo Check for wear of the nylon pads and replace beforemetal to metal contact between carriage and frameoccurs.

6 End Beam Slider Pads 250 hr/1 mo Check for wear of the nylon pads and replace beforemetal to metal contact between end beam andextension beam occurs.

2 Extension CylinderSupport Wear Pads



Table 9. Empty Container Attachment Maintenance Lubricate

ItemNo.


1 Wear Pads for MainBeams and ExtendedBeams

250 hr/1 mo 12 pads Multipurpose grease

4 Twistlock Assemblies 250 hr/1 mo 4 fittings Multipurpose grease


11

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1099

Maintenance Procedures Every 8 Hours or DailyHOW TO MAKE CHECKS WITH ENGINESTOPPED

WARNINGDo not operate a lift truck that needs repairs.Report the need for repairs immediately. If re-pair is necessary, put a DO NOT OPERATE tagin the operators area. Remove the key fromthe key switch.

Put the lift truck on a level surface. Lower the car-riage and forks, stop the engine, and apply the park-ing brake. Open the hood and check for leaks andconditions that are not normal. Clean any oil or fuelspills. Make sure all surfaces are free of oils, lubri-cants, fuel, and organic dust or fibers (paper, wood,cotton, wool, agricultural grass/grain, etc.).

Hydraulic System Oil

WARNINGAt operating temperature, the hydraulic oil isHOT. Do not permit the hot oil to contact theskin and cause a burn.

CAUTIONBefore removing the hydraulic filter head,thoroughly clean the surrounding area. Donot permit dirt to enter the hydraulic system.

When adding hydraulic oil to the hydraulic sys-tem, ascertain that the oil is clean and withoutcontaminants.

Use Hyster approved filters only.

Never operate the hydraulic pump without oilin the hydraulic system. The operation of thehydraulic pump without oil will damage thepump.

Check the hydraulic oil level when the oil is at oper-ating temperature, the carriage is lowered, and theengine is stopped. See Figure 6. Add hydraulic oilonly as needed. If more hydraulic oil is added thanthe FULL level, the hydraulic oil will leak from thebreather during operation.

To add hydraulic oil, remove the socket head plugand add hydraulic oil through the opening with thereturn filter installed. When adding large volumesof oil, use a pump with a filter assembly. The filterassembly should filter to at least 3 micron. To insertthe filler hose of the pump with the filter assemblyinto the hydraulic tank, the hydraulic return filtermust be removed.

Check the hydraulic system for leaks and damagedor loose components.

1. HYDRAULIC OIL FILL2. HYDRAULIC OIL FILTER3. BATTERY4. OIL LEVEL5. SEALED FUSES

Figure 6. Maintenance Points

Engine Oil

WARNINGLong-term exposure to used engine oil cancause skin irritation or cancer. Wash withdetergent and water.

After the engine has stopped, wait 1 minute beforechecking the oil level. Keep the oil at the correct levelas indicated on the dipstick. Use the correct oil asshown in the Maintenance Schedule. See Figure 7and Figure 8.

12

8000 SRM 1099 Maintenance Procedures Every 8 Hours or Daily

1. ENGINE OIL DIPSTICK2. ENGINE OIL FILL3. ENGINE OIL FILTERS4. FUEL/WATER FILTER5. FUEL FILTER6. ENGINE OIL DRAIN PLUG

Figure 7. Perkins Engine Maintenance

Cooling System

WARNINGDO NOT remove the radiator cap when the en-gine is hot. When the pressure cap is removedfrom the radiator, the pressure is released fromthe system. If the system is hot, the steam andboiling coolant can cause burns.

Check the coolant level at the auxiliary coolant reser-voir. Verify the coolant level is between the FULLand the ADD mark on the auxiliary coolant reservoir.The coolant will expand as it is heated and the levelin the auxiliary coolant reservoir will increase. Addcoolant to the auxiliary coolant reservoir only, do notremove the radiator cap. Fill no higher than full coldlevel. See Figure 9.

1. ENGINE OIL DIPSTICK2. ENGINE OIL FILL3. FUEL FILTER/WATER SEPARATOR4. OIL FILTER5. ENGINE OIL DRAIN PLUG

Figure 8. Cummins Engine Maintenance

1. AUXILIARY COOLANT RESERVOIR2. RADIATOR3. FULL HOT4. FULL COLD5. ADD COLD

Figure 9. Auxiliary Coolant Reservoir

13


If coolant is added, use the correct mixture of waterand ethylene glycol. See the Maintenance Schedule.

Check the radiator fins. Clean the radiator with com-pressed air or water as needed. Be careful not to bendthe radiator fins.

Check the condition of the radiator hoses and heaterhoses.

Fuel System

WARNINGAll fuels are very flammable and can burn orcause an explosion. Do not use an open flameto check the fuel level or to check for leaks inthe fuel system. If there is a leak in the fuel sys-tem, extra care must be used during the repair.Do not operate the lift truck until a leak is re-paired.

Check the fuel system for leaks and the condition ofparts. When adding fuel to the lift truck, refer toHow To Add Fuel To Lift Truck procedures in theOperator Manual.

Water Separator/Fuel FilterNOTE: For Cummins engines, the fuel filter/waterseparator is combined. See Figure 8.

Drain the water from the fuel filter as follows:

1. Open valve on the bottom of the filter canister.Drain some fuel (and any water) into a cup untilclean fuel flows from the filter. See Figure 7.

2. Close the valve.

Fuel, Oil, or Coolant Leaks, Check

WARNINGAll fuels are very flammable and can burn orcause an explosion. Do not use an open flameto check the fuel level or to check for leaks inthe fuel system. If there is a leak in the fuel sys-tem, extra care must be used during the repair.Do not operate the lift truck until a leak is re-paired.

Make a visual check for leaks on and under the lifttruck. If possible, find and repair the leak at the

source. Leaks often indicate a need for repair of dam-aged or worn components.

Check the fuel system for leaks and the condition ofparts. Also check the condition of the radiator andheater hoses that are not leaking. Soft or crackedhoses need to be replaced before a leak occurs.

Cab Hydraulic SystemThe hydraulic system for the cab tilt device has aseparate reservoir.

If the cab does not tilt completely, the oil level maybe low and require filling.

Lock the cab in the half open position. Place thepump mechanism in the full down position, and re-move the filler plug from the hand pump reservoir.See Figure 10. Add 0.2 liter (0.4 pt) of hydraulic oilto the hand pump reservoir. Install the plug in thehand pump reservoir.

1. PUMPMECHANISM

2. FILLER PLUG

3. HAND PUMPRESERVOIR

Figure 10. Cab Tilt Device

14


CAUTIONPlace oil absorbing material around the open-ing of the hand pump reservoir before lower-ing the cab. This will prevent any accidentalspillage of hydraulic oil when the cab is low-ered.

Lower the cab to the fully lowered position.

Drive BeltsCheck the drive belts for wear or damage.

Battery

WARNINGThe acid in the electrolyte can cause injury.If the electrolyte is spilled, use water to flushthe area. Use a solution of sodium bicarbonate(baking soda) to make the acid neutral. Acidin the eyes must be flushed with water imme-diately.

Wear eye protection. Batteries generate ex-plosive fumes. Keep the vents in the capsclean. Keep sparks or open flame away fromthe battery area. Do not make sparks from thebattery connections. Disconnect the batteryground cable when doing maintenance.

WARNINGDisposal of batteries must meet local environ-mental regulations.

Keep the batteries and cable terminals clean. Checkthe electrolyte level (unless maintenance-free). Keepthe electrolyte level above the separators and plates.Use distilled water. Do not fill the battery past thebottom of the internal filler neck. See Figure 6.

If the batteries become discharged and require aboost from another charged battery, follow theseprocedures carefully:

NOTE: Use only battery chargers approved by thebattery manufacturer or dealer.

1. Always connect the jumper cables to the dis-charged battery before connecting them to thebooster battery.

2. Always connect the positive jumper cable to thepositive terminal of the discharged battery and

the negative jumper cable to the negative termi-nal.

3. Always connect the jumper cable that is theground cable last.

Air FiltersNOTE: If the indicator light is on, the air filter andthe air compressor filter must be replaced.

There are air filters for the engine and the air com-pressor. Clean the inside of the canister when chang-ing filters.

ForksThe identification of a fork is determined by how itis connected to the carriage. These lift trucks havepin forks. Pin forks are fastened to the carriage withlarge fork pins.

AdjustA lock pin for each fork fits into the top carriage barand a slot in the fork. These lock pins hold the forkin position. Adjust the forks as far apart as possiblefor maximum support of the load. Verify the lock pinis engaged in the carriage bar and the fork. The forkmust be locked into position after the adjustment ismade.

Remove

WARNINGDo not try to remove a fork without a lifting de-vice. The forks can weigh up to 370 kg (816 lb)each.

Put the lift truck on a level surface and lower theforks. Tilt the mast so that the forks have stability.Remove the retainers for the fork pins and push thepins from the carriage. Move the lift truck away fromthe forks.

Install

1. Put the forks approximately 1 m (3.28 ft) in frontof the carriage.

2. Slowly move the lift truck toward the forks untilthe fork pins can be installed. Install the forkpins, fork guides, and the retainers.

15


Forks, Mast, and Lift Chains, Inspect

WARNINGNever work under a raised carriage, forks,or mast channel. Lower the carriage or useblocks and chains on the mast weldments andcarriage so they cannot move. Verify the mov-ing parts are attached to a part that does notmove.

Do not try to correct the alignment of the forktips by bending the forks or adding shims. Re-place damaged forks.

Never repair damaged forks by heating orwelding. Forks are made of special steel usingspecial procedures. Replace damaged forks.

1. Inspect welds on mast and carriage for cracks.Verify that the nuts and bolts are tight.

2. Inspect channels for wear in areas where rollerstravel. Inspect rollers for wear or damage.

3. Inspect forks for cracks and wear. Check that thefork tips are aligned within 3% of fork length.Check that bottom of the fork is not worn. SeeFigure 11.

4. Replace any damaged or broken parts that areused to keep forks locked in position.

5. For proper lubrication, verify that the chains con-tain slack. This may require that the forks or at-tachment rest on an elevated support such as awooden block or container. Use SAE 30 oil to lu-bricate the lift chains.

6. If lift truck is equipped with a sideshift carriageor attachment, inspect parts for cracks and wear.Verify parts that fasten sideshift carriage or at-tachment to carriage are in good condition.

7. Inspect lift chains for cracks or broken links andpins. See Figure 12.

8. Inspect chain anchors and pins for cracks anddamage.

9. Verify the lift chains are adjusted so that theyhave equal tension. Adjustment or repair ofthe lift chains must be done by authorizedpersonnel.

Fork Tip Alignment

Length of Forks 3% Dimension

1220 mm (48 in.)1830 mm (72 in.)2440 mm (96 in.)

37 mm (1.5 in.)55 mm (2.2 in.)74 mm (3.0 in.)

1. TIP ALIGNMENT(MUST BE WITHIN3% OF FORKLENGTH)

2. CRACKS

3. FORK PINDAMAGE

4. MUST BE 90% OFDIMENSION X

5. FORK WEAR

Figure 11. Check the Forks

1. WORK PIN2. CRACKS3. EDGE WEAR4. HOLE WEAR

5. LOOSE LEAVES6. DAMAGED PIN7. RUST

Figure 12. Lift Chains Check

16


Tires and Wheels

WARNINGAir pressure in tires can cause tire and wheelparts to explode. The explosion of wheel partscan cause serious injury or death.

Remove all air from the tires before the tiresare removed from the lift truck.

If the air pressure is less than 80% of the cor-rect air pressure, the tire must be removed be-fore air is added. Put the tire in a safety cagewhen adding air pressure to the tire. Followthe procedures described in Add Air to Tires.

When air is added to the tires, use a remote airchuck. The person adding air must stand awayand to the side and not in front of the tire.

Keep the tires at the correct air pressure. (See name-plate.) Check air pressure with a gauge when tiresare cold. If it is necessary to add air to a tire that iswarm, check one of the other tires on the same axleand add air to tire that has low pressure so that airpressures are equal. The air pressure of the warmtires must always be equal to or greater than thespecification for air pressure for cold tires. See Fig-ure 13.

1. CHECK FOR DAMAGE (REMOVE NAILS,GLASS, AND OTHER OBJECTS FROM TREAD)

2. MAKE SMOOTH EDGES3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)

Figure 13. Tires Check

Check tires for damage. Inspect tread and removeany objects that will cause damage. Check for bent

or damaged rims. Check for loose or missing parts.Remove any wire, straps, or other material wrappedaround axle.

CAUTIONCheck all wheel nuts after 2 to 5 hours of op-eration, when new lift trucks begin operationand on all lift trucks when the wheels havebeen removed and installed. Tighten the nutsin a cross pattern to the correct torque valueshown in the Maintenance Schedule table.When the nuts stay tight for 8 hours, the inter-val for checking the torque can be extended to150 hours.

NOTE: Whenever a wheel is removed, it will be nec-essary to lubricate the wheel nuts and studs. SeeWheels, Install. Put two drops of engine oil or otherlubricant between the flange and body of the wheelnut. Also, put two drops of oil on the threads of thestuds.

Verify the wheel nuts are tight. Tighten the wheelnuts in a cross pattern as shown in Wheels, Installto the correct torque value shown in the MaintenanceSchedule.

Replace solid tires when the wear line at the sideof the tire has reached the tread surface. Extendedusage beyond the wear limit affects the stability ofthe lift truck.

Operator Restraint SystemThe seat belt, seat, and mounting are all part ofthe operator restraint system. Each item must bechecked to verify it is attached securely, functionscorrectly, and is in good condition. The seat beltmust latch securely. Verify that the seat belt extendsand retracts smoothly and is not damaged or torn.See Figure 14.

Verify the seat rails are not loose. The seat rails mustlock securely in position, but move freely when un-locked. Seat rails must be securely attached to themounting surface.

17


A. AIR SEAT B. MECHANICAL SEAT

1. SEAT BELT2. SEAT RAIL

3. SEAT BELT RETRACTOR

Figure 14. Check the Seat

Steering Column LatchMake sure the latch for the steering column operatescorrectly. The latch must NOT allow the column tomove unless the latch is released.

Safety Labels

WARNINGSafety labels are installed on the lift truck togive information about operation and possiblehazards. It is important that all safety labelsare installed on the lift truck and can be read.

Check that all safety labels are installed in the cor-rect locations on the lift truck. See the Parts Man-ual or the section Frame 100 SRM 927 for the cor-rect location of the safety labels.

If new labels must be installed, use the following pro-cedure:

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the recom-mendations of the manufacturer.

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

2. Remove the paper from the back of the label. Donot touch the adhesive surface.

3. Carefully hold the label in the correct positionabove the surface. The label cannot be movedafter it touches the surface. Put the label on thesurface. Make sure that all air is removed fromunder the label and the corners and edges aretight.

18


HOW TO MAKE CHECKS WITH ENGINERUNNING

WARNINGExhaust from internal combustion enginescontains carbon monoxide and other harmfulchemicals. Carbon monoxide is a colorless,odorless poison and can cause unconscious-ness or death without warning. Long-termexposure to exhaust or chemicals in the ex-haust can cause cancer, birth defects, andother reproductive harm. Avoid exposure toengine exhaust: Do not use diesel engines indoors where soot

can accumulate. If engines are operated in confined spaces,

maintain adequate ventilation or vent ex-haust to the outside. Do not exceed applica-ble air contaminant limits.

Follow the inspection and maintenanceschedule and procedures in this manual. Donot alter exhaust, ignition, or fuel systems.

FASTEN YOUR SEAT BELT! The seat belt is in-stalled to help the operator stay on the truck ifthe lift truck tips over. IT CAN ONLY HELP IFIT IS FASTENED.

Verify that the area around the lift truck is clearbefore starting the engine or making any operationalchecks. Be careful when making the checks. If thelift truck is stationary during a check, apply theparking brake and put the transmission in NEU-TRAL (N). Proceed carefully.

Fault CodesAccess

NOTE: For descriptions of error codes, see the sectionPerkins Tier 2 Diesel Engine Electronic Trou-bleshooting Guide, 1100 (VK) 600 SRM 1072,Cummins Diesel Engine Fault Code Guide 600SRM 1101, and Transmission 1300 SRM 1082.

The display keeps records of the fault codes. To gainaccess to the fault codes, proceed as follows: Apply parking brake Turn ON ignition but do not start lift truck Turn ignition OFF and ON 3 times, switch 1 time

per second. After the first OFF and ON cycle, thedisplay will show a 1. After the second OFF andON cycle, the display will show a 2, and after thethird OFF and ON cycle, the display will show a 3.

The display is now in fault log mode. When faultshave been recorded, the display shows a letter and 4numbers for each fault code. For engine fault codesthe letter is E. For transmission fault codes the letteris T. The numbers represent the following: Engine fault code Hour meter reading at last occurrence Hour meter reading at first occurrence Number or occurrences of current fault

The faults will be shown in the opposite sequence ofoccurrence: The most recent fault first and the firstfault last. When all fault codes logged have beenshown, the display will continue to show all loggedfault codes until the user exits the system.

Display fault code E_COM is shown when the follow-ing occurs: The engine controller does not reply to the engine

identification request or request for fault codes. The engine controller stops sending one of the reg-

ular messages, e.g. engine RPM or engine coolanttemperature.

Exit

To exit the fault log mode, turn the ignition OFFand ON and leave ignition ON for more than 2 sec-onds. The cluster will also exit to normal mode whenthe parking brake is released or when the engine isstarted.

Clear

To clear the fault codes logged in the display, proceedas follows: Access into the fault log mode. See Access. Repeat the same procedure to start up the fault log.

When completed, the display will show CLEAR.

Gauges, Lights, Horn and FusesStart the engine. Check that the gauges and lightsfor correct operation as described in the OperatingManual. Check the operation of the horn.

The fuse and relay panels are located inside the in-strument console on the RIGHT SIDE of the opera-tors seat. To access the fuse and relay panels, re-move four knurled knobs and the cover.

The sealed fuse box is located on the right-hand sideof the battery box.

19


NOTE: Not all trucks may be equipped with thesame fuses and/or relays. For example, trucks notequipped with the cold start feature will not havethe cold start fuses or relays.

The fuse and relay positions and titles are as shownin Figure 15, Figure 16, Figure 17, Figure 18, andFigure 19.

1. ECM, 10 AMP2. FUEL PUMP, 3 AMP3. FUEL PUMP SUPPLY, 30 AMP

Figure 15. Sealed Fuses, Perkins

1. FUEL PUMP, 3 AMP2. ECM, 3 X 7.5 AMP

Figure 16. Sealed Fuses, Cummins

1. KNURLED KNOBS2. COVER

Figure 17. Fuse Panel Location

Figure 18. Fuse Panel

20


Legend for Figure 18

FUSE PANEL 1 HYDRAULIC CONTROLS, 15A TRANSMISSION, 10A ATTACHMENT CONTROLS, 15A OPEN TRANSMISSION B+, 7.5A PARK BRAKE, 10A TRANSMISSION B+, 7.5A FRONT WINDOW WASHER/WIPER, 10A ROOF WINDOW WASHER/WIPER, 10A REAR WINDOW WASHER/WIPER, 10AFUSE PANEL 2 FRONT INNER FLOOD LIGHTS, 10A FRONT OUTER FLOOD LIGHTS, 10A REAR DRIVE LIGHTS, 10A BEACON/STROBE, 10A STOPLIGHTS, 10A MAST LIGHTS, 10A HAZARD LIGHTS, 10A DIRECTION INDICATORS, 10A SIDE/TAIL LIGHTS, 10A FRONT DRIVE LIGHTS, 10AFUSE PANEL 3 ENGINE START, 5A AIR CONDITIONING, 15A INSTRUMENTATION, 10A CAB TILT POWER ASSIST, 20A HORN, 10A INTERIOR LIGHTS, 5A SEAT SUSPENSION COMPRESSOR, 15A HEATER/AC VENTILATION FAN, 20A OIL COOLER/AIR DRYER, 10A REVERSE LIGHTS/ALARM, 5AFUSE PANEL 4 CONSOLE ACCESSORY SOCKET, 10A RADIO/CB/INTERCOM, 3A CONVERTER, 10A OPEN OPEN OPEN ECM/ACC PEDAL (CUMMINS), 5A OPEN OPEN OPEN

Figure 19. Relays (Located Left of the FusePanel)

NOTE: Start aid (Perkins only), Pressure signal (EConly), and Flasher (Optional).

Control Levers and PedalsCheck that the control levers for the transmission,mast, and attachment operate as described in theOperator Manual.

Transmission OilApply the parking brake. Check the oil level in thepowershift transmission when the engine is runningat idle speed and, if equipped, the direction controllever is in the N (NEUTRAL) position. Use the cor-rect oil as shown in the Maintenance Schedule. Keepthe oil level at the FULL mark on the dipstick.

21

Maintenance Procedures Every 250 Hours or Every 2 Months 8000 SRM 1099

Lift System Operation

WARNINGLower the lift mechanism completely. Neverallow any person under a raised carriage. Donot put any part of your body in or throughthe lift mechanism unless all parts of the mastare completely lowered and the engine isSTOPPED.

Before making any repairs, use blocks andchains on the mast weldments and carriage sothey cannot move. Verify the moving parts areattached to a part that does not move.

Do not try to locate hydraulic leaks by puttinghands on pressurized hydraulic components.Hydraulic oil can be injected into the body bythe pressure.

Do the following checks and inspections:

1. Check for leaks in hydraulic system. Check con-dition of hydraulic hoses and tubes.

NOTE: Some parts of the mast move at differentspeeds during raising and lowering.

2. Slowly raise and lower mast several times with-out a load. Raise mast to its full extension heightat least once. The mast components must raiseand lower smoothly in correct sequence.

3. The inner weldment and carriage must lowercompletely.

4. Raise mast 1 m (3 ft) with a capacity load. Theinner weldment and the carriage must raisesmoothly. Lower the mast. All moving compo-nents must lower smoothly.

5. Lower load to approximately 0.3 m (1 ft) fromthe floor. Tilt mast forward and backward. Mast

must tilt smoothly and both tilt cylinders muststop evenly.

6. Check that controls operate the functions of theattachment correctly. (See the symbols next toeach of the controls.) Verify all hydraulic linesare connected correctly and do not leak.

BrakesCheck that the service and parking brakes operatecorrectly. The service brakes must apply when thebrake pedal is depressed. The parking brake mustapply or release with the knob movement describedin the Operator Manual. On lift trucks with aMONOTROL pedal, applying the parking brakeputs the transmission in NEUTRAL.

NOTE: Full application of the inching/brake pedalapplies the service brakes and disengages the trans-mission.

Steering System

WARNINGThe lift truck has hydraulic power steering.The steering can be difficult if the engine isnot running.

Verify the steering system operates smoothly andgives good steering control.

AttachmentsCheck that the controls for the attachment operatethe functions of the attachment correctly. See theOperator Manual. Use the symbols next to eachof the controls for identification. Verify all of the hy-draulic lines are connected correctly and do not leak.

Maintenance Procedures Every 250 Hours or Every 2 MonthsEMPTY CONTAINER HANDLERSee Empty Container Handling Attachment 5000 SRM 969.

22

8000 SRM 1099 Maintenance Procedures Every 500 Hours or Every 3 Months

Maintenance Procedures Every 500 Hours or Every 3 MonthsNOTE: Do the 8-hour and 250-hour checks beforebeginning these procedures.

LIFT CHAINS

Lubrication

WARNINGDo not repair a worn or damaged lift chain. Re-place a worn or damaged lift chain with a newchain. If a pair of lift chains is used in the mast,both lift chains must be replaced.

Lubricate the lift chains with SAE 30 engine oil. Thebest procedure is to remove the chains from the lifttruck and soak them in oil.

AdjustNOTE: When the chain adjustments are complete,make sure that the threads on the nuts of the chainanchors are completely engaged. Make sure that allof the adjustment is not removed from the chain an-chors. The chain anchors must be able to move intheir sockets.

When the lift chains are correctly adjusted: The tension will be the same on each chain of the

chain set. Check tension by pushing on both chainsat the same time.

The chain length will be correct. The chains must travel freely through the complete

cycle.

1. Put a load equal to 80 to 90% of the capacity loadon the forks. Lower the forks as much as possi-ble. Tilt the mast fully backward.

2. Check the amount that the bottom carriage rollerextends below the inner channel of the mast. SeeFigure 20. The carriage roller must not extendmore than 34 mm (1.3 in.) below the inner chan-nel. If the adjustment is not correct, adjust the

chain anchors. Make sure each anchor is ad-justed the same amount.

3. Remove the load from the forks. Check the clear-ance of the carriage when the mast is fully ex-tended. The carriage must not touch the topcrossmember of the inner weldment. The chainsare too tight if the carriage touches the cross-member. Put the mast in a vertical position andlower the carriage completely. If the forks do notjust touch the surface, the chains are too tight.If the chains are too tight, adjust the chain an-chors. Make sure each anchor is adjusted thesame amount.

DRIVE SHAFTLubricate the three fittings on the transmission driveshaft with multipurpose grease.

1. TILT MAST FULLY BACKWARD2. CARRIAGE ROLLER3. FORK4. CARRIAGE ROLLER MUST NOT EXTEND MORE

THAN 34 mm (1.3 in.) BELOW MAST CHANNELFigure 20. Lift Chain Adjustments

23


STEERING AXLERaise the steering axle as shown in How to RaiseSteering Tires in this SRM.

Lubricate the grease fittings on the tie rods and thelower spindle bearings with multipurpose grease.See Figure 21.

1. TIE ROD2. LOWER SPINDLE BEARING

Figure 21. Steering Axle

WHEEL NUTSCheck the torque of the wheel nuts. Tighten the nutsto 640 to 680 Nm (470 to 500 lbf ft) in the sequenceshown in Wheels, Install.

SHAFTS FOR BRAKE ACTUATORSLubricate the grease fitting on the shafts for thebrake actuator arms.

DRIVE AXLE AND DIFFERENTIALThe drive axle and differential use the same oil sup-ply. The oil level in the drive axle is correct when theoil is even with the plug in the planetary cover. Besure to check both planetary covers and the differen-tial when checking the oil level. Make sure the levelline on the planetary cover is parallel to the floor.

The oil level in the differential is correct when theoil is even with the plug in the front of the housing.Add the correct oil as specified in the MaintenanceSchedule.

HYDRAULIC TANK BREATHERThe hydraulic tank breather is located behind theright hand cover. Remove cover or raise cab. See thesection Operators Cab 100 SRM 1100.

Inspect restriction indicator. Replace element andclean breather housing if indicator will reach servicelevel indication before the next service visit. Thisdepends on the speed of contamination. In case ofdoubt, replace element if the indicator has reachedthe 50% level or more.

AIR FILTER, ENGINE, AND AIRCOMPRESSORReplace the air filter.

CABIN AIR FILTER, HEATERRemove the four screws and the air intake cover atthe left rear of the vehicle and clean or replace theair filter.

ENGINE OIL AND FILTER

WARNINGLong-term exposure to used engine oil cancause skin irritation or cancer. Wash withdetergent and water.

CAUTIONNever run the engine without oil.

NOTE: Change the oil filter for the engine after thefirst 100 hours on new lift trucks.

Change the filter at the same time engine oil ischanged. Use the correct oil according to the speci-fications. Install a new filter. Apply clean oil to thegasket of the new filter. Turn the filter until thegasket touches, then tighten 1/2 to 3/4 turn withyour hand.

CAUTIONTo prevent possible engine damage if the en-gine starts before sufficient oil pressure isreached, turn the ignition key to the stop po-sition.

Turn the ignition key to the start position and crankthe engine until either the oil pressure warning lightextinguishes or oil pressure is registered on the oilpressure gauge.

24


Operate the engine and check for leaks. Shut downthe engine and let the engine cool. Check the engineoil level and add oil as needed.

DRIVE BELTS

PerkinsCheck the drive belts for wear and damage. When apair of drive belts is used, they must be replaced asa pair. When a pair of drive belts is used, adjust thetension for the tightest belt.

A gauge is available that will indicate the tensionin the drive belt. Fit the gauge at the center of thelongest length of the drive belt and measure the ten-sion. See Figure 22. The correct tension is approxi-mately 355 N (80 lbf).

Figure 22. Gauge to Check Drive Belt Tension

The tension can also be checked by pushing on thedrive belt as shown in Figure 23. With moderatethumb pressure, 45 N (10 lbf), the correct deflectionof the belt is 10 mm (3/8 in.). Loosen the pivot fasten-ers and the adjustment link fasteners for the alterna-tor. Move the alternator to change the tension. Whenthe correct tension is established, tighten the pivotfasteners and the adjustment link fasteners. Verifythe belt tension is correct.

NOTE: If a new belt is installed, the belt tensionmust be checked again after the first 20 hours of op-eration.

Loosen the capscrew on the alternator mount to ad-just the tension of the drive belts.

1. PIVOT FASTENER 2. ADJUSTMENTLINK

Figure 23. Check and Adjust Drive Belt Tension

CumminsNOTE: Adjustment of the drive belt is automatic.

With the engine turned off, check that the top andbottom tensioner arm stops are not touching the bosson the tensioner body. If either of the stops is touch-ing, the drive belt must be replaced. Check to verifythe correct belt is being used if either condition ex-ists.

Check the tensioner pulley and body for cracks. Ifany cracks are detected, the tensioner must be re-placed.

Check the tensioner for dirt build up. If dirt build upis detected, remove the tensioner and clean.

NOTE: A worn tensioner that has play or a belt thatwalks off the pulley can indicate pulley misalign-ment.

Inspect the tensioner to verify the pivoting tensionerarm is not in contact with the stationary circularbase. If the pivoting tensioner is in contact with thestationary circular base, the tensioner must be re-placed.

25


MAST

WARNINGLower the lift mechanism completely. Neverallow anyone under a raised carriage. Do notput any part of your body in or through thelift mechanism unless all parts of the mastare completely lowered and the engine isSTOPPED.

Before making any repairs, use blocks andchains on the mast weldments and carriage sothat they cannot move. Make sure the movingparts are attached to a part that does not move.

To lower the mast, there must be 24-volt systempower available to energize the solenoids that oper-ate the control valve. Turn the ignition key to theON position and operate the mast lowering lever orjoystick to lower the mast.

If for any reason 24 volts are not available, the cabmust be tilted and the manual valve on the front ofthe control valve must be turned to allow the mast tobe lowered manually. See Figure 24.

1. MANUAL VALVE 2. CONTROL VALVE

Figure 24. Manual Lowering Valve

1. Lubricate the sliding surfaces for the bearingblocks along the full length of the channels as

shown in Figure 25. Apply lubricant only to theindicated surfaces.

1. LOAD ROLLER2. BEARING BLOCK3. LUBRICATE BEARING BLOCK SURFACES4. LUBRICATE STRIP BEARINGS5. OUTER WELDMENT6. INNER WELDMENT7. CARRIAGE

Figure 25. Lubricate Mast

NOTE: Before lubricating the mast pivot points, liftthe drive tires; see the section How to Raise DriveTires.

NOTE: The mast pivot pins are lubricated from thetop and MUST be lubricated under no-load condi-tions.

2. Lubricate the pivot pins for the mast at thegrease fittings on the pivot pins. Use multipur-pose grease.

3. Lubricate the pivot pins for the tilt cylinders.There is a grease fitting on each pivot pin. Usemultipurpose grease.

4. If a sideshift carriage is installed, lubricate thefittings and the sliding surfaces with multipur-pose grease.

26


Bearing Rollers (Three-Stage Only)Lubrication

NOTE: Standard lubrication frequency is 500 hours,but frequency may have to be increased when work-ing in dusty, corrosive surroundings, and/or hightemperatures.

1. Remove plug from lubrication duct, lubricate,and replace plug. See Figure 26.

1. MAIN ROLLER2. SIDE ROLLER3. CAP4. PIVOT5. SEAL6. ROLLERS

7. ROLLERS8. SEAL9. STUB SHAFT10. LUBRICATION

DUCT

Figure 26. Bearing Roller

Clearance

When the clearance value has become 2 mm (.08 in.),it is advisable to remove the roller. As wear willmainly occur on the mast profile, it is advisable to re-place the standard roller with the oversized version.See Figure 27.

Figure 27. Roller Clearance

GENERAL LUBRICATIONInspect all hinges, pins, linkages, cables, pedals, andlevers for wear and damage. Lubricate these partsas necessary with engine oil.

FORK WEAR AND DAMAGE CHECK

WARNINGNever repair damaged forks. Do not heat, weld,or bend the forks. Forks are made of specialsteel using special methods. Replace damagedforks.

1. Check the heel and attachment points of theforks with a penetrant or magnetic particle in-spection. See Figure 11.

2. Measure the thickness of the forks at a verticalsection where there is no wear. This is dimensionX. Now measure the thickness at the heel of thefork. If the thickness is not more than 90 percentof dimension X, replace the fork.

27

Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1099

LIFT CHAINS WEAR CHECKIf a section of chain is 3 percent longer than a similarsection of new chain, the chain is worn and must bereplaced. Measure the chain for wear where it movesover the sheaves. If a chain scale is available, checkthe lift chains as shown in Figure 28. If a chain scaleis not available, measure 20 links of chain. Measurefrom the center of a pin to the center of another pin 20pitches away. Compare the length with the chart inFigure 28. Replace the chain if the length of 20 linksof the worn section is more than the WEAR LIMIT.

Figure 28. Lift Chains Check

Legend for Figure 28

NOTE: THE INSTRUCTIONS FOR MEASURINGCHAIN WEAR ARE SHOWN ON THE CHAIN WEARSCALE.

Pitch Total Lengthof 20 Links

(Pitch) of NewChain

Wear Limit- Maximum

Length of 20Links

31.8 mm(1.25 in.)38.1 mm(1.50 in.)44.5 mm(1.75 in.)

635 mm(25.0 in.)762 mm(30.0 in.)889 mm(35.0 in.)

654 mm(25.7 in.)785 mm(30.9 in.)915 mm(36.0 in.)

1. CHAIN WEAR SCALE

Maintenance Procedures Every 1000 Hours or 6 MonthsNOTE: Do the 500-hour checks before beginningthese procedures.

TRANSMISSION OIL AND FILTER,CHANGE

WARNINGThe transmission oil can be hot after operationof the lift truck.

WARNINGDisposal of lubricants and fluids must meet lo-cal environmental regulations.

NOTE: Change the oil filter for the transmission afterthe first 100 hours on new lift trucks.

Change the oil and filter for the transmission. Thedrain plugs for the transmission are at the front ofthe housing, below the drive shaft. Put a containerunder the transmission. Remove the drain plug,spring, and screen at the rear of the transmissionhousing. Clean the screen. After the oil has drained,install the screen, spring, and plug. Install thedrain plugs. Replace the filter when the oil in thetransmission is changed. Remove and discard theold filter. Apply clean oil to the gasket of the newfilter. Install the new filter and tighten it with yourhand. When starting the engine, DO NOT exceedthe idle level during the first 5 seconds. Check forleaks during operation.

28

8000 SRM 1099 Maintenance Procedures Every 1000 Hours or 6 Months

FUEL FILTER

PerkinsRemove

1. Clean the outside of the fuel filter assembly. SeeFigure 29.

2. Loosen the drain device to allow the fuel/water inthe filter to drain into a suitable container.

3. Support the container and loosen the gland ring.

4. Remove the gland ring and pull downward onthe filter assembly to remove the filter assemblyfrom the filter head.

5. Discard the oil filter.

1. CAP2. GLAND RING3. FUEL FILTER4. DRAIN DEVICE

5. SEALS6. SPLINE7. GROOVE

Figure 29. Perkins Fuel Filter

Install

1. Verify the filter head and the seals are clean andin good condition.

2. Align the spline of the new filter with the grooveof the filter head and push the new filter into thefilter head.

3. Fit and tighten the gland ring.

4. Remove the air from the fuel system.

CumminsRemove

NOTE: Use the filter drain valve to drain fuel outof the filter for approximately 5 seconds. This willeliminate fuel from running over the top of the filterupon removal.

1. Clean the outside of the fuel filter assembly. SeeFigure 30.

2. Disconnect the water-in-fuel sensor from wiringharness.

3. Rotate fuel filter counterclockwise and removefuel filter.

4. Drain the fuel filter and remove the water-in-fuelsensor from fuel filter. See Figure 31.

1. FUEL FILTER2. WATER-IN-FUEL SENSOR FROM WIRING

HARNESS

Figure 30. Cummins Fuel Filter

29

Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1099

1. WATER-IN-FUEL SENSOR

Figure 31. Cummins Water In Fuel SystemSensor

Install

1. Install the water-in-fuel sensor into the fuel fil-ter.

2. Rotate filter clockwise and install the filter.

3. Connect the water-in-fuel sensor to the wiringharness.

Fuel System Air Removal (Perkins)The engine cannot be started if there is air in the fuelsystem. The air must be removed from the fuel sys-tem if any part of the fuel system has been discon-nected. Also remove the air if there was a leak in thelow-pressure part of the fuel system while the enginewas running.

Fuel System Air Removal (Cummins)

WARNINGThe pressure in the fuel system lines can pene-trate the skin and cause serious harm.

Do not remove the air from a hot engine as thiswould cause fuel to spill onto the exhaust man-ifold creating the possibility of a fire.

NOTE: To check for air in the fuel lines, loosen thefittings at the cylinder head to allow trapped air tobleed from the line. Tighten the fittings to 38 Nm(28 lbf ft).

1. Operate the engine and vent one line at a timeuntil the engine runs smoothly.

Fuel Injection Pump Without Vent Tube1. Make sure there is fuel in the fuel tank. Refer to

the How to Add Fuel to Lift Truck procedures inthe Operating Manual.

2. Loosen the valve nut on the fuel pump. See Fig-ure 32.

NOTE: If the drive cam of the fuel lift pump is at thepoint of maximum lift, it will not be possible to op-erate the priming lever. In this situation, the crank-shaft must be rotated one revolution.

3. Operate the priming lever of the fuel lift pumpuntil fuel without air bubbles comes out of thevalve nut. Tighten the valve nut.

CAUTIONThe start aid must be held in place with anopen end wrench while loosening and tighten-ing the union nut in Step 4.

4. Loosen the start aid union nut at the cold startaid and operate the priming lever until fuel,free of air, comes from the start aid union nut.Tighten the start aid union nut at the cold startaid.

5. Loosen the fuel inlet union nut of the fuel inletpipe. Operate the priming lever until fuel, free ofair, comes from the fuel inlet union nut. Tightenthe fuel inlet union nut at the fitting.

6. Loosen the high-pressure connections at all of thefuel injectors.

CAUTIONDo not tighten the union nuts of the high-pres-sure pipes more than the recommended torque.If there is leakage from the union nut, ensurethat the pipe is correctly aligned with the at-omizer inlet. Do not tighten the atomizer unionnut more, as this can cause a restriction at theend of the pipe which can affect fuel delivery.

7. Turn the ignition key to the ON position. Op-erate the starter motor until fuel, free fromair, comes from the high-pressure connections.Tighten the high-pressure pipe connections to27.5 Nm (21 lbf ft). Turn the ignition key to theOFF position.

30

8000 SRM 1099 Maintenance Procedures Every 1000 Hours or 6 Months

8. The engine is now ready to start. If the engineruns correctly for a short period of time and thenstops or runs roughly, check for air in the fuel

system. If there is air in the fuel system, there isprobably a leak in the low-pressure system.

1. VALVE NUT2. PRIMING LEVER3. START AID UNION NUT

4. START AID5. HIGH PRESSURE CONNECTORS

Figure 32. Diesel Fuel System Air Removal

FUEL INJECTION PUMP TIMING (PERKINSONLY)See the section Perkins Tier 2 Diesel Engines,1100 (VK) 600 SRM 1068 for the procedures to checkthe injection pump timing.

VALVE ADJUSTMENT

PerkinsSee the section Perkins Tier 2 Diesel Engines,1100 (VK) 600 SRM 1068 for the procedures to ad-just the valves.

31

Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1099

Maintenance Procedures Every 2000 Hours or YearlyNOTE: Do the 1000-hour checks before beginningthese procedures.

RUBBER VIBRATION DAMPERCheck the index lines in the vibration damper huband the inertia member. If the lines are more than1.59 mm (0.062 in.) out of alignment, replace thevibration damper. See Figure 33.

1. INDEX LINES2. DAMPER HUB3. INERTIA MEMBER

Figure 33. Rubber Vibration Damper

HYDRAULIC SYSTEMNOTE: Change the oil filter for the hydraulic systemafter the first 100 hours on new lift trucks.

Hydraulic Oil Filter, ChangeNOTE: When changing the hydraulic oil filter, applya small amount of grease to the O-ring.

Remove the filter head from the hydraulic tank. Re-move and discard the filter. Install a new filter. In-stall the filter head, making sure it is tight against

the tank. Operate the system and check for leaks.See Figure 34.

1. SIGHT GLASS2. FILTER3. FILTER HEAD4. SPRING5. O-RING6. CAPSCREW7. PLUG8. BREATHER9. WASHER

10. NUT11. DRAIN PLUG12. O-RING13. HYDRAULIC TANK14. COVER15. SEAL16. WASHER17. CAPSCREW

Figure 34. Hydraulic Tank

32

8000 SRM 1099 Maintenance Procedures Every 2000 Hours or Yearly

Hydraulic Oil, Change

WARNINGAt operating temperature, the hydraulic oil isHOT. Do not permit the oil to touch the skin andcause a burn.

CAUTIONDo not permit dirt to enter the hydraulic sys-tem when the oil level is checked or the filteris changed.

1. Put the lift truck on a level surface and lower thecarriage. Put a container under the hydraulictank. Remove the drain plug to drain the oil.

2. When the hydraulic oil has drained, install thedrain plug. Fill the hydraulic tank with the cor-rect oil.

3. To add hydraulic oil, remove the dipstick and addhydraulic oil through the dipstick opening withthe return filter installed. When adding largevolumes of oil, use a pump with a filter assem-bly. The filter assembly should filter to at least3 micron. To insert the filler hose of the pumpwith the filter assembly into the hydraulic tank,the hydraulic return filter must be removed.

Hydraulic Pilot Valve Filter, Change1. Remove plug. See Figure 35

2. Remove seal.

3. Remove filter and O-ring assembly.

NOTE: Always replace seal and O-ring when replac-ing the hydraulic valve filter.

4. Install new filter and O-ring assembly.

5. Install new seal.

6. Install plug.

1. PILOT VALVE BLOCK2. O-RING3. PILOT VALVE FILTER4. SEAL5. PLUG

Figure 35. Hydraulic Pilot Valve Filter

TRANSMISSION CALIBRATIONTo compensate for normal wear and to maintainsmooth shifting characteristics, the clutch packmodulation needs to be recalibrated. For clutch packmodulation and clutch filling calibration, see thesection Transmission 1300 SRM 1082.

DIFFERENTIAL AND DRIVE AXLEThe drive axle and differential use the same oil sup-ply. The oil level in the drive axle is correct when theoil is even with the plug in the planetary cover.

33

Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1099

Make sure the level line on the planetary cover is par-allel to the floor. See Figure 36. Change the oil for thedifferential and drive axle. To drain the oil, removethe plugs from the planetary covers and the plug atthe bottom of the differential housing. Operate thelift truck to make sure the oil level is even. Checkthe oil level again and check for leaks.

1. LEVEL LINE 2. DRAIN PLUG

Figure 36. Drive Axle

WHEEL BEARINGS

Steer WheelsLubricate the wheel bearings in the hubs for the steerwheels with multipurpose grease. Install the hubs asfollows:

1. Install the hub and bearings on the spindle.

2. Install the washer and the castle nut. Tightenthe castle nut to 200 Nm (150 lbf ft) while ro-tating the wheel and hub. Loosen the nut toless than 25 Nm (20 lbf ft). Tighten the nut to35 Nm (25 lbf ft). Tighten the castle nut untilthe cotter pin can be installed. Install the cotterpin and grease cap.

Drive WheelsLubricate the inner and outer wheel bearings in thehubs for the drive wheels with multipurpose grease.See the section Planetary Drive Axle, (Dry Sys-tem) 1400 SRM 945 or Dry Brake System 1800SRM 937 for the removal and installation proceduresof the drive wheels and hubs.

SERVICE BRAKES

Cleaning Procedures (Dry Brake Axle)

WARNINGBrake linings can contain dangerous fibers.Breathing the dust from these brake liningsis a cancer or lung disease hazard. Do notcreate dust! Do not clean brake parts withcompressed air or by brushing. Use vacuumequipment approved for dangerous fibers orfollow the cleaning procedure in this section.When the brake drums are removed, do notcreate dust.

Do not sand, grind, chisel, hammer, or changelinings in any way that will create dust. Anychanges to brake linings must be done in a re-stricted area with special ventilation. Protec-tive clothing and a respirator must be used.

1. Do not release brake lining dust from the brakelinings into the air when the brake drum is re-moved.

2. Use a solvent approved for cleaning of brakeparts to wet the brake lining dust. Follow theinstructions and cautions of the manufacturerfor the use of the solvent. If a solvent spray isused, do not create brake lining dust with thespray.

3. When the brake lining dust is wet, clean theparts. Put any cloth or towels in a plastic bagor an airtight container while they are still wet.Put a DANGEROUS FIBERS warning label onthe plastic bag or airtight container.

4. Any cleaning cloths that will be washed must becleaned so that fibers are not released into theair.

5. Check the brake lining and brake assembly partsfor wear or damage. See the section PlanetaryDrive Axle, (Dry System) 1400 SRM 945 orDry Brake System 1800 SRM 937 for the re-moval and installation procedures of the drivewheels and hubs. If the linings or shoes are wornor damaged, replace the brake shoes. It is recom-mended that brake shoes be replaced in completesets. Inspect the brake drums for cracks or dam-age. Replace any damaged parts.

34

8000 SRM 1099 Maintenance Procedures Every 4000 Hours or 2 Years

Maintenance Procedures Every 4000 Hours or 2 YearsVALVE ADJUSTMENT

CumminsNOTE: Check valve clearance at engine coolant tem-perature 60 C (140 F) or less.1. Remove the plastic fuel pump drive cover located

on the front of the engine. See Figure 37.

2. Rotate the crankshaft to align with the top deadcenter (TDC) marks on the gear cover and fuelpump gear.

3. Remove the rocker arm cover and gasket. SeeFigure 38.

4. Measure valve clearance of rocker arms 1I, 2I,3E, 4I, and 5E, by inserting a feeler gauge be-tween the crosshead and the rocker arm socket.If the clearance is out of specifications, loosen thelock nut and adjust nominal specifications. SeeFigure 39 and Table 10.

5. Rotate the crankshaft 360 degrees, mark on fuelpump gear rotates 180 degrees, and measurevalve cleara

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H170-360HD MANTENIMIENTO

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