PERIODIC

MAINTENANCE
H8-12XM-6, H10XMS-6 (H190-280HD2,
H230HDS2) [K007];H13-16XM-6,
H10-12XM-12EC (H300-360HD2, H360HD2-EC) [J019]

PART NO. 4059569 8000 SRM 1593

 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................... 1
Serial Number Data......................................................................................................................................... 1
Truck Handling Procedures.................................................................................................................................. 2
Moving and Towing a Lift Truck..................................................................................................................... 2
Precautions.....................................................................................................................................................2
Moving the Truck...........................................................................................................................................2
Putting a Lift Truck on Blocks........................................................................................................................ 3
Raising the Drive Tires..................................................................................................................................3
Raising the Steering Tires.............................................................................................................................3
Cleaning a Lift Truck....................................................................................................................................... 4
Safety Procedures Before Starting Maintenance.................................................................................................5
Making Checks From the Driver Seat with Engine Running........................................................................5
Fire Hazard.................................................................................................................................................... 5
Hydraulic Service Switch................................................................................................................................. 6
Transmission Calibration Switch.................................................................................................................... 6
Wait 100 Seconds Before Disconnecting Battery............................................................................................6
Periodic Maintenance Schedule............................................................................................................................ 6
Daily Inspection................................................................................................................................................8
Daily Condition Checks................................................................................................................................. 8
Daily Fluid Level Checks...............................................................................................................................9
Daily Checks from the Driver Seat with Engine Running.......................................................................... 9
Initial Inspection............................................................................................................................................ 10
First Inspection after First 100 Hours of Operation..................................................................................10
Periodic Maintenance.....................................................................................................................................11
Inspect and Adjust....................................................................................................................................... 11
Lubricate...................................................................................................................................................... 14
Change..........................................................................................................................................................15
Periodic Maintenance Schedule - ELME 580 Series Container Attachment................................................... 16
Periodic Maintenance.....................................................................................................................................16
Inspect and Adjust ...................................................................................................................................... 16
Lubricate ..................................................................................................................................................... 17
Change..........................................................................................................................................................17
Periodic Maintenance Procedures.......................................................................................................................18
Air Conditioning System................................................................................................................................18
Attachment..................................................................................................................................................... 18
Brake System Accumulator........................................................................................................................... 18
Brake Cooling Filter.......................................................................................................................................18
Cab Air Filter..................................................................................................................................................19
Cab Door Hinges.............................................................................................................................................19
Control Levers, Switches, and Pedals........................................................................................................... 19
Cooling System............................................................................................................................................... 19
Coolant Hoses...............................................................................................................................................19
Coolant Level................................................................................................................................................20
Coolant Quality............................................................................................................................................ 20
Cooling Fan.................................................................................................................................................. 20
Cooling Fan Drive Belt................................................................................................................................ 21
Cooling Fan Drive Belt Tensioner and Pulleys.......................................................................................... 21
Bearing Condition .................................................................................................................................... 21
Pulley Alignment.......................................................................................................................................21
Tensioner Condition.................................................................................................................................. 21
Crankcase Breather........................................................................................................................................22
Drive Axle and Differential............................................................................................................................23

©2019 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Check Oil level............................................................................................................................................. 23
Change Oil....................................................................................................................................................23
Drive Shaft .....................................................................................................................................................23
End Beam Slider Pads....................................................................................................................................23
Engine Air Filter............................................................................................................................................ 23
Engine Air Intake Piping and Charge Air Piping........................................................................................ 24
Engine and Transmission Mounts.................................................................................................................24
Engine Compartment..................................................................................................................................... 24
Engine Oil....................................................................................................................................................... 24
Engine Oil Level...........................................................................................................................................24
Engine Oil and Engine Oil Filter................................................................................................................ 25
Engine Valve Adjustment.............................................................................................................................. 25
Extension Beam Wear Pads...........................................................................................................................28
Fault Codes..................................................................................................................................................... 28
Forks................................................................................................................................................................28
Fork Pins, Carriage Pins, and Carriage Sliding Surfaces............................................................................29
Frame, Mast, Carriage and Attachment....................................................................................................... 29
Fuel, Oil or Coolant Leaks............................................................................................................................. 30
Fuel Filter and Water Separator Filter.........................................................................................................30
Header Hose Assembly...................................................................................................................................30
Horn, Gauges, Lights, Alarms and Control System..................................................................................... 31
Hydraulic System Oil..................................................................................................................................... 31
Hydraulic Oil Testing Procedures...............................................................................................................32
Hydraulic Oil Replacement......................................................................................................................... 32
Hydraulic Tank Breather...............................................................................................................................33
Hydraulic Tank Return Filter....................................................................................................................... 33
Inching Pedal Sensor Calibration..................................................................................................................34
Lift Chains...................................................................................................................................................... 34
Check and Lubricate Lift Chains................................................................................................................34
Adjust Lift Chains........................................................................................................................................34
Inspect Lift Chains ..................................................................................................................................... 35
Chain Elongation.......................................................................................................................................35
Lift Chain Wear and Damage...................................................................................................................36
Lift System Accumulator (Optional)............................................................................................................. 36
Load Rollers.................................................................................................................................................... 36
Carriage Load Rollers..................................................................................................................................36
Inner Mast Load Rollers..............................................................................................................................36
Mast, Carriage, and Attachment................................................................................................................... 36
Mast Pivot Pins...............................................................................................................................................37
Operator Presence System............................................................................................................................. 37
Operator Restraint System............................................................................................................................ 37
Seat Belt and Seat Rails..............................................................................................................................37
Steering Column Latch................................................................................................................................38
Parking and Service Brakes...........................................................................................................................38
Radiator Assembly..........................................................................................................................................38
Side Shift Bearing Pads (ECH)......................................................................................................................39
Steering Axle Grease Fittings........................................................................................................................39
King Pins...................................................................................................................................................... 39
Tie Rod Pins................................................................................................................................................. 39
Steering System..............................................................................................................................................39
Steering Wheel Hub Bearings....................................................................................................................... 39
Remove and Disassemble............................................................................................................................ 39

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Clean and Inspect........................................................................................................................................ 39
Assemble and Install................................................................................................................................... 40
Tilt Cylinder Pivot Pins..................................................................................................................................40
Transmission.................................................................................................................................................. 40
Transmission Clutch Calibration................................................................................................................40
Transmission Oil Level................................................................................................................................41
Transmission Oil and Oil Filter.................................................................................................................. 41
Twist locks...................................................................................................................................................... 42
Inspect.......................................................................................................................................................... 42
Lubricate...................................................................................................................................................... 42
Replace..........................................................................................................................................................42
Vibration Damper...........................................................................................................................................42
Warning and Safety Labels............................................................................................................................43
Windows and Mirrors.....................................................................................................................................43
Windshield Washer Fluid Level.................................................................................................................... 43
Wheels and Tires............................................................................................................................................ 44
Wheels, Tires, and Tire Pressure................................................................................................................44
Remove Wheels from Lift Truck................................................................................................................. 45
Remove Pneumatic Tire from Wheel.......................................................................................................... 45
Install Pneumatic Tire on Wheel................................................................................................................ 49
Adding Air Pressure to Pneumatic Tires....................................................................................................51
Remove Solid Rubber Tire from Wheel.......................................................................................................52
Install Solid Rubber Tire on Wheel.............................................................................................................54
Install Wheels on Lift Truck....................................................................................................................... 55
Wheel Nuts on Drive and Steer Wheels..................................................................................................... 56
Capacities and Specifications..............................................................................................................................57
Approved Fuel and Engine Oils.....................................................................................................................57
Approved Oils, Fluids, and Grease................................................................................................................ 58
Engine Oil Viscosity....................................................................................................................................... 59
Lift Chain Lubricant Requirements.............................................................................................................. 59
Fuses and Relays............................................................................................................................................ 59
Side Console................................................................................................................................................. 60
Relays........................................................................................................................................................... 63

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 1593 General

General
maintenance shown in the Periodic Maintenance
This section contains a Periodic Maintenance Schedule. Service Manuals are available from your
Schedule and the Periodic Maintenance Procedures dealer for HYSTER lift trucks to help users who do
for K007 and J019 . their own maintenance.
The Periodic Maintenance Schedule has hour
intervals for inspection, lubrication, and component SERIAL NUMBER DATA
replacement for your lift truck. The serial number for the lift truck is on the
When in addition to the hour intervals a calendar nameplate and also on the right hand frame rail,
interval is mentioned, then the first expiring near the counterweight. The serial number
interval must be observed. indicates the design series, manufacturing plant,
and the year manufactured.
It may be necessary to apply shorter maintenance
intervals under circumstances, such as continuous
heavy rain, dusty environment and extreme
temperatures.
The Periodic Maintenance Procedures are placed in
alphabetical order. The relevant page number is
mentioned in the Maintenance Schedule and in the
Table of Contents.
Your dealer for HYSTER lift trucks has the
equipment and trained personnel to do a complete
program of inspection, lubrication, and
maintenance. A regular program of inspection,
lubrication, and maintenance will help your lift
truck perform more efficiently and extend its
Figure 1. Truck Nameplate
lifetime.
Example K007 or E 4369 G
WARNING : J019
Do not make repairs or adjustments unless you (1) (2) (3) (4)
have both authorization and training. Repairs and
adjustments made on a lift truck by people without (1) The first letter and number of the serial number
authorization and training can make a dangerous indicates the design series and the model number of
operating condition. the lift truck.
Do not operate a lift truck that needs repairs. (2) The second letter identifies the manufacturing
Report the need for repairs immediately. If repair is plant. In this example: E = Nijmegen, The
necessary, put a DO NOT OPERATE tag in the Netherlands.
operators area. Remove the key from the key
(3) The number series following the second letter
switch.
indicates the sequence of manufacture where the lift
truck was made.

CAUTION (4) The letter following the number series indicates

the year of manufacture starting with A=2003. The
Maintenance procedures have to be executed with
letter B=2004, E=2007, G=2009 and so on.
the engine OFF, unless indicated otherwise.

Some lift truck users have service personnel and

equipment to do the inspection, lubrication, and

1
Truck Handling Procedures 8000 SRM 1593

Truck Handling Procedures

MOVING AND TOWING A LIFT TRUCK

Precautions
While the lift truck is being towed the engine must
stay running in order to generate sufficient
hydraulic oil pressure. Without hydraulic pressure
the steering system and service brake system do not
operate, and the park brake will automatically
apply. The parking brake can be manually released
if no hydraulic pressure is available.

WARNING
When the parking brake is manually released, the
lift truck does not have any parking brake function.
Block the wheels to prevent the lift truck from
moving. If the wheels are not blocked, serious
personal injury and damage to components can
occur.
NOTE: If the parking brake is manually released, it
will need to be adjusted before the lift truck is
returned to service. With hydraulic pressure applied
to the parking brake, adjust play between brake
disc and park brake pads to 1.0 mm (0.04 in.).
The parking brake caliper is mounted on a support
bracket at the differential carrier assembly. To
manually release the parking brake, perform the
following steps:
1. Place blocks on both sides (front and rear) of
the drive and steering tires to prevent
movement of the lift truck.
2. Remove the plastic screw cap. See Figure 2.
3. Loosen the lock nut.
4. Turn the adjustment bolt or socket
counterclockwise until the brake disc is free.
5. Tighten the lock nut and install the plastic
screw cap hand tight.
1. PLASTIC SCREW CAP
2. ADJUSTMENT BOLT OR SOCKET
3. LOCK NUT
Figure 2. Releasing the Parking Brake
Moving the Truck
WARNING
DO NOT tow the lift truck if a load is attached.
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 hydraulic
pressure available for the steering system and
service brake system. 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.

1. The towed lift truck must have an operator.

2
8000 SRM 1593
2. Make sure transmission oil level is above
minimum. Observe a maximum towing speed of
5 km/hr and a maximum towing distance of 5
km (3 miles).
3. Use a lifting device to raise the carriage and
forks approximately 30 cm (12 in.) from the
surface. Install a chain around the mast cross
member and the carriage to prevent the
carriage and mast channels from moving.
4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or
larger capacity than the disabled lift truck.
Install an approximate half-capacity load on
the forks of the lift truck that is being used to
tow the disabled lift truck. This half-capacity
load will increase the traction of the lift truck.
Keep the load as low as possible.
5. Use a towing link made of steel that fastens to
both lift trucks. Connect the towing link to an
adequate provision, such as a towing pin or
lifting eye.
6. After towing is completed, place blocks on both
sides (front and rear) of all drive and steering
tires and re-apply the parking brake.
PUTTING A LIFT TRUCK ON BLOCKS
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
following assemblies will cause large changes in
the center of gravity: drive axle, engine,
transmission and the counterweight. When the lift
truck is put on blocks, put additional blocks in the
following positions to maintain stability:
Before removing the mast and drive axle, put
blocks under the counterweight to prevent
the lift truck from falling backward.
Before removing the counterweight, put
blocks under the mast assembly to prevent
the lift truck from falling forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid, one
piece units. Put a steel plate on top of the block.
Before putting the lift truck on blocks, check the
presence of components, hoses or wires mounted
under the frame, to prevent damage to these parts.
Truck Handling Procedures
NOTE: Some lift trucks have lifting eyes. Truck
lifting eyes can be used to raise the lift truck and
put the truck on blocks.
Raising the Drive Tires
1. Put blocks on each side (front and rear) of the
steering tires to prevent movement of the lift
truck. See Figure 3.
2. Slightly tilt the mast towards the operators
cab. Put a block with steel plates under each
outer mast channel.
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put blocks with steel plates under the drive
axle mounting. Make sure the steel plates do
not damage hoses, cables or hardware.
5. If the hydraulic system does not operate, use a
hydraulic jack under the side of the frame near
the drive axle. Make sure that the jack has a
capacity of at least half the weight of the lift
truck. See the nameplate.
Raising the Steering Tires
1. Apply the parking brake. Put blocks on both
sides (front and rear) of the drive tires to
prevent movement of the lift truck. See
Figure 3.
2. Put blocks between the steering axle and
frame. See Figure 4.
3. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at
least 2/3 of the weight of the lift truck. See the
nameplate.
4. Put the jack under the steering axle to raise the
lift truck. Put blocks under the frame to
support the lift truck.
5. Put blocks with steel plates under the LH and
RH side of the steering axle. Lower the jack
until the steering axle is supported by the
blocks.
3
Truck Handling Procedures 8000 SRM 1593

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

Figure 3. Putting Lift Truck on Blocks

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

CAUTION
Units may be washed with a non-heated pressure
washer. Steam cleaning is not recommended in
most instances, as condensation may form in
1. FRAME
2. BLOCKS BETWEEN FRAME AND AXLE electrical components causing damage or erratic
3. SUPPORT BLOCKS behavior.
4. STEERING AXLE
5. WHEEL Use the following guidelines when cleaning a
6. AXLE PIVOT POINT forklift truck:
Figure 4. Steering Axle on Blocks 1. Assure truck components have cooled down
before starting the cleaning procedure.
CLEANING A LIFT TRUCK
2. Disconnect the battery.

WARNING 3. Remove accumulated debris using a

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

4
8000 SRM 1593
5. Be sure to avoid directing the spray into
electrical panel compartment. Ensure
overspray does not come in contact with
electrical components; DO NOT spray water
directly at electrical components, wiring
connectors, or electrical enclosures. Even
sealed connectors may allow water egress
under pressure or if connector is damaged.
6. Avoid spraying in areas containing electrical
components such as:
• Floor Plates.
• Battery Compartment.
• Dash/cowl assembly.
Safety Procedures Before Starting Maintenance
WARNING
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the
operators area. Remove the key from the key
switch.
1. Put the lift truck on a level surface.
2. Lower the carriage and forks.
3. Switch the engine OFF.
4. Apply the parking brake.
5. Open the hood and check for leaks and
conditions that are not normal.
6. Clean any oil or fuel spills.
7. Verify all surfaces are free of oils, lubricants,
fuel, and organic dust or fibers (paper, wood,
cotton, wool, agricultural grass/grain, etc.).
MAKING CHECKS FROM THE DRIVER
SEAT WITH ENGINE RUNNING
WARNING
Exhaust from internal combustion engines
contains carbon monoxide and other harmful
chemicals. Carbon monoxide is a colorless,
odorless poison and can cause unconsciousness
Safety Procedures Before Starting Maintenance
• Armrests with electrical components.
7. Clean the battery compartment by using a
clean cloth to wash the battery with water. Dry
with compressed air.
8. DO NOT use a pressure washer to clean the
battery.DO NOT use hot water.
9. DO NOT use a pressure washer to clean lift
chains, sheaves, or load rollers in the mast
assembly.
10. After cleaning, immediately start and run the
lift truck to dry out components.
or death without warning. Long-term exposure to
exhaust or chemicals in the exhaust can cause
cancer, birth defects, and other reproductive harm.
Avoid exposure to engine exhaust:
• DO NOT use diesel engines indoors where
soot can accumulate.
• If engines are operated in confined spaces,
maintain adequate ventilation or vent
exhaust to the outside. DO NOT exceed
applicable air contaminant limits.
• Follow the inspection and maintenance
schedule and procedures in this manual. DO
NOT alter exhaust, ignition, or fuel systems.
Fire Hazard
The hot engine surfaces and exhaust of
internal combustion engine-powered lift
trucks can present fire hazards when
operating in areas containing flammable
gases, vapors, liquids, dusts, or fibers. Engine
and exhaust component surface temperatures
can exceed the ignition temperatures of
common solvents, fuels, oil, paper, and other
organic materials (wood, wheat, cotton, etc.).
Exhaust-emitted sparks can ignite these
materials as well. Engine and exhaust surface
temperatures increase after engine shutoff,
presenting increased fire hazard. Check the
engine compartment immediately following
the lift truck operation in areas containing
combustible dusts, fibers, or paper and
remove any foreign material.
5
Periodic Maintenance Schedule
Operate the lift truck only in areas that have
been approved for lift truck operation.
FASTEN YOUR SEAT BELT! The seat belt is
installed to help the operator stay on the
truck if the lift truck tips over.
Make sure that the area around the lift truck is
clear before starting the engine or making any
operational checks. Be careful when making the
checks. If the lift truck is stationary during a check,
apply the parking brake and put the transmission
in NEUTRAL. Make the checks carefully.
HYDRAULIC SERVICE SWITCH
The Hydraulic Service Switch allows operation of
hydraulic functions for service purposes only,
without an operator being present in the seat. Move
the switch to the spanner symbol when operation of
hydraulic functions is desired during truck
servicing. See Figure 50, Side Console for location.
DO NOT FORGET to return the switch to the
hydraulic symbol when putting the truck back into
service. If the switch is NOT returned into its
Periodic Maintenance Schedule
NOTE: Portions reproduced by permission of
Cummins Inc.
6
8000 SRM 1593
normal position, the transmission will remain
disabled.
TRANSMISSION CALIBRATION SWITCH
The Transmission Calibration Switch must be
moved down to the spanner symbol during
calibration. See Side Console for location.
DO NOT FORGET to return the switch up to the
transmission symbol when putting the truck back
into service. Hydraulic functions do not operate
when the switch is in the down position.
WAIT 100 SECONDS BEFORE
DISCONNECTING BATTERY
DO NOT operate the battery disconnect switch
until 100 seconds after key switch is in OFF
position to avoid damage to the different controllers.
Early disconnect of controllers may trigger fault
codes and prohibit a memory reset.
See Side Console for location of the Battery
Disconnect Switch.
8000 SRM 1593 Periodic Maintenance Schedule

1. LIFT CHAIN 8. TRANSMISSION OIL FILTER

2. CARRIAGE LOAD ROLLER 9. ENGINE OIL FILTER
3. MAST LOAD ROLLER 10. TIE ROD PINS AND KING PINS
4. MAST PIVOT PIN 11. STEER WHEEL HUB
5. TILT CYLINDER PIVOT PIN 12. HYDRAULIC RETURN FILTER
6. DRIVE SHAFT 13. HYDRAULIC BREATHER
7. FUEL FILTER/WATER SEPARATOR

Figure 5. Filters and Lubrication Points

REMARK: Periodic greasing of the axle pivot pin

and the chain sheave is NOT required. Greasing of
these items is only required at assembly.

7
Periodic Maintenance Schedule 8000 SRM 1593

DAILY INSPECTION
Daily Condition Checks
Table 1. Daily Condition Checks
Daily Condition Procedure Page
Checks
Warning and Safety • Check for presence and readability. See Page 43
Labels For position and replacement, see Parts Manual.
Frame, Mast, Carriage, • Make sure retaining hardware is tightened and in See Page 29
and Attachment good condition.
• Check for cracks and deformation. In particular after
any collision or when any unusual noise is heard.
Repair as required.
Forks • Check condition and fork tip alignment. See Page 28
Replace as required.
Lift Chains • Check proper lubrication. See Page 34
• Make sure both chains are slack during parking.
• Check condition of link plates and pins.
Replace chains as required. See Parts Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves. See Page 30
Replace as required. See Parts Manual.
Wheels, Tires, and Tire • Check condition and absence of damage. See Page 44
Pressure • Check pressure as specified on nameplate.
Correct or replace as required.
Wheel Nuts on Drive and • Re-torque 2 - 5 hours after replacement of a wheel, or See Page 56
Steer Wheels 8 hours after a nut could be turned at re-torqueing.
Torque to 615 to 710 N•m (454 to 524 lbf ft).
Hydraulic Tank Breather • Inspect restriction indicator. See Page 33
Replace elements as required. See Parts Manual.
Fuel, Oil or Coolant • Check for leaks. See Page 30
Leaks Repair as required.
Engine Air Intake Piping • Check for air leaks and loose connections. See Page 24
and Charge Air Piping Repair as required.
Cooling Fan Drive Belt • Check tension and condition. See Page 21
Replace as required.
Radiator Assembly • Check that radiator is clean and not obstructed. See Page 38
• Check radiator, hoses and connections for leakage.
Clean and repair as required.
Engine Compartment • Remove combustible materials. See Page 24
• Remove all foreign materials.
Windows and Mirrors • Clean windows, wipers and mirrors. See Page 43
Adjust and replace as required. See Parts Manual.

8
8000 SRM 1593 Periodic Maintenance Schedule

Daily Fluid Level Checks

Table 2. Daily Fluid Level Checks
Daily Fluid Level Procedure Page
Checks
Windshield Washer Fluid • Check level in reservoir. See Page 43
Level Add fluid as required.
Hydraulic System Oil • Check level indicator with mast fully lowered. See Page 31
• Add hydraulic oil as required through the tank return
filter and record added volume and hour meter reading.
Use JDM-J20C ISO VG46.
Coolant Level • Check level at the expansion tank. See Page 20
• Add coolant as required and record added volume and
hour meter reading.
For coolant see Approved Oils, Fluids, and Grease.
Engine Oil Level • Maintain level at two/thirds of full range on dipstick See Page 24
when cold.
See Approved Oils, Fluids, and Grease for required
specifications.

Daily Checks from the Driver Seat with

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

Table 3. Daily Checks from the Driver Seat with Engine Running
Daily Checks from the Procedure Page
Driver Seat with
Engine Running
Operator Restraint • Check condition and operation of seat belt, seat rails See Page 37
System and steering column latch.
Repair as required.
Horn, Gauges, Lights, • Visual and audible verification. See Page 31
Alarms and Control Repair as required.
System
Fault Codes • The display should be free of fault codes. The central See Page 28
warning light will be ON when a fault code is shown.
• Stop the engine when the Engine Stop Warning Light
is ON.
Report any fault code to have the fault diagnosed and
repaired.

9
Periodic Maintenance Schedule 8000 SRM 1593

Table 3. Daily Checks from the Driver Seat with Engine Running (Continued)
Daily Checks from the Procedure Page
Driver Seat with
Engine Running
Engine Air Filter • Replace Main Filter Element when warning light is See Page 23
ON, and record hour meter reading.
• Also replace the Safety Element at every third
replacement of the Main Filter Element.
See Parts Manual.
Fuel Filter and Water • Drain water/sediment when the warning light is ON. See Page 30
Separator
Coolant Level • Add coolant when warning light is ON, and record See Page 20
added volume and hour meter reading.
For details, see Approved Oils, Fluids, and Grease.
Fuel Level • Avoid low fuel level. Refuel in time. See Page 57
Control Levers, • Check operation as described in the Operating See Page 19
Switches, and Pedals Manual.
Repair as required.
Parking and Service • Check operation. Repair as required. See Page 38
Brakes
Steering System • Check operation. See Page 39
Repair as required.
Mast, Carriage, and • Check proper tracking of header hoses. See Page 36
Attachment • Check smooth operation.
Repair as required.
Transmission • Check operation. See Page 40
Repair as required.
Operator Presence • Check operation. See Page 37
System Repair as required.
Transmission Oil • Check oil level and add ZF TE-ML 03 oil as required. See Page 41

INITIAL INSPECTION
First Inspection after First 100 Hours of
Operation
Table 4. First Inspection after First 100 Hours of Operation
Initial 100 Hours Procedure Page
Inspection
Lift Chains • Lubricate and adjust lift chains. See Page 34
• Make sure chains are slack during parking.
Transmission Oil and Oil • Replace filter. See Parts Manual. See Page 41
Filter

10
8000 SRM 1593 Periodic Maintenance Schedule

PERIODIC MAINTENANCE
Inspect and Adjust
Table 5. Inspect and Adjust
Inspect and Adjust Procedure Page
Every 250 Hours
Warning and Safety • Check for presence and readability. See Page 43
Labels • For position and replacement, see Parts Manual.
Frame, Mast, Carriage • Make sure retaining hardware is tightened and in See Page 29
and Attachment good condition. Re-torque or replace as required.
• Look for deformations in the material and irregular
lines in welds. Repair as required.
Forks • Check condition and fork tip alignment. See Page 28
Replace as required. See Parts Manual.
Lift Chains • Check proper lubrication and adjustment. See Page 34
• Check condition of link plates and pins.
Replace as required. See Parts Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves. See Page 30
• Check proper tracking during operation.
Replace as required. See Parts Manual.
Wheels, Tires and Tire • Check condition and absence of damage. See Page 44
Pressure • Check pressure as specified on nameplate.
Correct or replace as required.
Wheel Nuts on Drive and • Make sure all nuts are properly torqued. See Page 56
Steer Wheels Required torque is 615 to 710 N•m (454 to 524 lbf ft).
Hydraulic Tank Breather • Inspect restriction indicator. See Page 33
Replace element when indicator is raised. See Parts
Manual.
Fuel, Oil or Coolant • Check for leaks. See Page 30
Leaks Repair as required.
Engine Air Intake Piping • Check for leaks and proper installation. See Page 24
and Charge Air Piping Repair as required.
Coolant Hoses • Inspect for cracks, cuts, and collapsing. See Page 19
Repair as required.
Cooling Fan Drive Belt • Check tension and condition. See Page 21
Repair as required.
Radiator Assembly • Check radiator, hoses and connections for leakage. See Page 38
Clean and repair as required.
Engine Compartment • Remove combustible materials. See Page 24
• Remove all foreign materials.

11
Periodic Maintenance Schedule 8000 SRM 1593

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page
Drive Axle and • Inspect magnetic plugs and oil level. See Page 23
Differential • If oil is added, check for leaks and record added
volume and hour meter reading.
• Inspect wear parts on plugs, clean plugs and reinstall.
For details, see Approved Oils, Fluids, and Grease.
Windshield Washer • Check level in reservoir and add fluid as required. See Page 43
Fluid Level For details, see Approved Oils, Fluids, and Grease.
Hydraulic System Oil • Check level indicator. See Page 31
• Add hydraulic oil as required through the hydraulic
return filter.
• If oil is added, check for leaks, and record added
volume and hour meter reading.
For details, see Approved Oils, Fluids, and Grease.
Coolant Level • Inspect level at the expansion tank. See Page 20
• If level is below “MIN” mark, inspect for leaks, repair
as required, and add coolant to the “MAX” mark.
Record added volume and hour meter reading.
For coolant see Approved Oils, Fluids, and Grease.
Engine Oil Level • Maintain level at two/thirds of full range on dipstick See Page 24
when cold.
See Approved Oils, Fluids, and Grease.
Fuel Filter and Water • Drain water until clear fuel flows from the filter. See Page 30
Separator
Operator Restraint • Check condition and operation of seat belt, seat rails See Page 37
System and steering column latch.
Repair as required.
Horn, Gauges, Lights, • Visual and audible verification. See Page 31
Alarms and Control Repair as required.
System
Fault Codes • Check fault code warning lights. The display should be See Page 28
free of fault codes.
• Diagnose and repair the cause of any fault code.
Control Levers, • Check operation as described in the Operating See Page 19
Switches, and Pedals Manual.
Repair as required.
Parking and Service • Check condition and operation. See Page 38
Brakes Repair as required.
Steering System • Check operation. See Page 39
Repair as required.
Operator Presence • Check operation. See Page 37
System Repair as required.

12
8000 SRM 1593 Periodic Maintenance Schedule

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page
Mast, Carriage, and • Check smooth operation. See Page 36
Attachment • Check tracking of header hoses.
Repair as required.
Transmission Oil Level • Check oil level and add ZF TE-ML 03 oil as required. See Page 41
If oil is added, check for leaks and record added
volume and hour meter reading.
Every 500 Hours
Cab Air Filter • Check and clean element. See Page 19
Replace filter when required. See Parts Manual.
Engine Air Filter • Verify maintenance records to establish if normal air See Page 23
filter replacement is due. Make sure Tier 3 air filter
sensor performs properly.
• If required, replace the Main Filter Element, clean the
inside of the housing and record filter replacement.
• At every third replacement of the Main Filter
Element, also replace the Safety Filter Element.
Cooling Fan • Check for cracks and damage. See Page 20
Replace fan when required. See Parts Manual.
Every 2,000 Hours
Coolant Quality • Measure and record acidity and freezing point. See Page 20
• Compare measurement with earlier records and take
appropriate action.
For coolant see Approved Oils, Fluids, and Grease.
Cooling Fan Drive Belt • Verify if the bearings for the hubs and pulleys produce See Page 21
Tensioner and Pulleys more noise during operation than normal.
• Check tension and belt condition.
Replace or repair as required. See Parts Manual.
Brake System • Make sure pre-charge pressure is 9.0 ±0.5 MPa See Page 18
Accumulator (1,305.3 ±72.5 psi).
Re-charge or replace accumulator as required.
Transmission Clutch • Perform clutch calibration at each transmission oil See Page 40
Calibration change.
Inching Pedal Sensor • Check calibration value and adjust as required. See Page 34
Calibration
Lift System Accumulator • Make sure pre-charge pressure is 9.0 ±0.5 MPa See Page 36
(Optional) (1,305.3 ±72.5 psi).
Correct if required.
Crankcase Breather • Check element. See Page 22
Element Replace when required. See Parts Manual.
Engine and • Check isolators and hardware. See Page 24
Transmission Mounts Replace as required. See Parts Manual.

13
Periodic Maintenance Schedule 8000 SRM 1593

Table 5. Inspect and Adjust (Continued)

Inspect and Adjust Procedure Page
Vibration Damper • Check for fluid loss and deformation. See Page 42
Replace as required. See Parts Manual.
Every 5,000 Hours
Engine Valve • Check valve clearance. See Page 25
Adjustment See engine identification plate for valve adjustment.

Lubricate
Table 6. Lubricate
Lubricate Procedure Page
Every 250 Hours
Lift Chains • Lubricate every 250 Hours, but at least every 3 See Page 34
Months.
• Make sure chains are slack during re-lubrication.
Use engine oil SAE 15W-40.
Mast Pivot Pins • Lubricate 2 fittings under no load condition. See Page 37
Use multipurpose grease with MoS2 additive. For
details, see Approved Oils, Fluids, and Grease.
Tilt Cylinder Pivot Pins • Lubricate 4 fittings. See Page 40
Use multipurpose grease.
Fork Pins, Carriage Pins, • Lubricate pins and surfaces. See Page 29
and Carriage Sliding Use multipurpose grease.
Surfaces
Inner Mast Load Rollers • Lubricate 4 fittings. See Page 36
Use multipurpose grease.
Carriage Load Rollers • Lubricate 4 fittings. See Page 36
Use multipurpose grease.
Every 500 Hours
Drive Shaft • Lubricate 3 fittings. See Page 23
Use multipurpose grease.
Steering Axle Grease • Lubricate 4 fittings. See Page 39
Fittings Use multipurpose grease.
Steering Axle King Pins • Lubricate 4 fittings. See Page 39
Use multipurpose grease.
Every 1,000 Hours
Cab Door Hinges • Lubricate 4 fittings. See Page 19
Use multipurpose grease.

14
8000 SRM 1593 Periodic Maintenance Schedule

Change
Table 7. Change
Change Procedure Page
Every 500 Hours
Engine Oil • Change engine oil. See Page 24
For details, see Approved Oils, Fluids, and Grease.
Engine Oil Filter • Replace filter. See Page 25
See Parts Manual.
Fuel Filter and Water • Replace filter. See Page 30
Separator See Parts Manual.
Every 1,500 Hours
Drive Axle and • Change oil. See Page 23
Differential For details, see Approved Oils, Fluids, and Grease.
Every 2,000 Hours
Brake Cooling Filter • Replace filter. See Page 18
See Parts Manual.
Crankcase Breather • Inspect and replace crank case breather element as See Page 22
Element required.
See Parts Manual.
Transmission Oil • Change transmission oil. See Page 41
For details, see Approved Oils, Fluids, and Grease.
Transmission Oil Filter • Replace filter. See Page 41
See Parts Manual.
Every 3,000 Hours
Hydraulic System Oil • Take oil sample and follow instructions from the See Page 31
laboratory report.
For details, see Approved Oils, Fluids, and Grease
when replacing oil.
Hydraulic Tank Return • Replace filter at each hydraulic oil change. See Page 33
Filter See Parts Manual.
Every 5,000 Hours
Steering Wheel Hub • Replace multipurpose grease and re-adjust bearing See Page 39
Bearings preload.
Air Conditioning System • Contact certified AC specialist for replacing dryer, See Page 18
lubricant and refrigerant.
For Dryer, see Parts Manual.
For Lubricant, see Compressor Nameplate.
For Refrigerant use 1300 ±50 grams (2.87 ±0.11 lb) of
R134a.

15
Periodic Maintenance Schedule - ELME 580 Series Container Attachment 8000 SRM 1593

Periodic Maintenance Schedule - ELME 580 Series Container

Attachment

1. TWIST LOCK 4. SIDE SHIFT WEAR PAD

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

Figure 6. Container Attachment Maintenance Points

PERIODIC MAINTENANCE
Inspect and Adjust
Table 8. Inspect and Adjust
Inspect and Adjust Procedures Page
Daily
Attachment • Check for damage, cracks and distortion. See Page 18
• Check spreader control system and spreader
operation.
• Check for hydraulic leaks.
Repair as required.
Every 250 Hours
Attachment • Check for damage, cracks and distortion. See Page 18
• Check spreader control system and spreader
operation.
• Check for hydraulic leaks.
Repair as required.

16
8000 SRM 1593 Periodic Maintenance Schedule - ELME 580 Series Container Attachment

Table 8. Inspect and Adjust (Continued)

Inspect and Adjust Procedures Page
Twist Locks • Monitor wear and check for possible damage. See Page 42
Repair as required.

Lubricate
Lubricate
Every 500 Hours
Twist Locks
Extension Beam Wear Pads
End Beam Slider Pads
Side Shift Bearing Pads
Carriage Load Rollers
Table 9. Lubricate
Procedures Page
• Lubricate 2 or 4 fittings. See Page 42
Use multipurpose grease.
For details, see Approved
Oils, Fluids, and Grease.
• Replace wear pads if See Page 28
thickness is 18 mm (0.7 in)
or less.
• Check torqueing of retention
hardware.
• Lubricate tracks at wear
pads for extension beams.
Use multipurpose grease.
• Monitor maximum play and See Page 23
retention.
Replace as required.
• Apply lubricant to fittings at See Page 39
two central greasing points.
Use multipurpose grease.
• Lubricate fitting at each See Page 36
carriage roller.
Use multipurpose grease.

Change
Table 10. Change
Change Procedures Page
Every 5,000 hours
Twist Locks • Replace twist locks. See Page 42
See Parts Manual.

17
Periodic Maintenance Procedures
Periodic Maintenance Procedures
AIR CONDITIONING SYSTEM
CAUTION
Contact certified AC trained technician
extracting and refilling refrigerant.
Every 5,000 Hours or 36 Months
Have a new dryer installed and refill with new
lubricant and refrigerant.
For Dryer, see Parts Manual.
For Lubricant, see Compressor Nameplate.
For Refrigerant, use
1300 ± 50 grams (2.87 ± 0.11 lb) of R134a.
ATTACHMENT
Daily and Every 250 Hours
Make sure that retaining hardware is tightened and
in good condition.
Check the controls and the attachment functions for
correct operation as described in the Operating
Manual. See the symbols at each of the controls.
Every 250 Hours
Check the attachment for damage, cracks and
distortion. Look for deformations in the material
and irregular lines in welds. Repair as required.
Check for hydraulic leaks. Make sure wear pad
retainers are tightened to 63 N•m (46.4 lbf ft).
BRAKE SYSTEM ACCUMULATOR
Every 2,000 Hours
Check the precharge pressure of the Brake System
Accumulator.
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Lower the mast completely.
4. Tilt the mast completely forward.
5. Switch the engine OFF.
6. Place blocks in front of and behind the tires to
prevent movement of the lift truck.
18
8000 SRM 1593
7. Raise (side tilt) the cab to the fully open
position to gain access to the main control
valve.
8. Remove the cap from check port M ACC on the
for main control valve.
9. Connect a 0 to 30 MPa (0 to 4,351 psi)
hydraulic pressure gauge at port M ACC.
10. Lower the cab until it is in the fully lowered
and latched position.
11. Apply the brake pedal and observe the gauge
reading. Repeat this procedure until the brake
pedal pressure nears the accumulator pressure.
A sudden sharp pressure drop will be observed.
The gauge reading immediately before the
sharp pressure drop represents the precharge
pressure of the accumulator.
12. Refill the accumulator with nitrogen gas at
approximately 20°C (68°F) to the required
precharge pressure of 9.00 MPa (1,305.34 psi).
13. After refilling the accumulator, raise (side tilt)
the cab to the fully open position to gain access
to the main control valve.
14. Remove the pressure gauge from port M ACC.
15. Install the cap on check port M ACC on the
main control valve.
BRAKE COOLING FILTER
Every 2,000 Hours
Remove and replace the filter element.
1. Lower the mast.
2. Switch the engine OFF.
3. Apply the parking brake.
4. Use a wrench to loosen the bowl that holds the
filter cartridge. See Figure 7.
5. Remove and replace the filter cartridge and
reinstall the bowl. Torque to
20 N•m (14.8 lbf ft).
8000 SRM 1593 Periodic Maintenance Procedures

1. CAB AIR FILTER

2. LOCK

Figure 8. Cab Air Filter

20 N•m (14.8 lbf ft) CAB DOOR HINGES

Every 1,000 Hours
1. FILTER BOWL
2. FILTER ADAPTER There are four grease fittings on the cab door
hinges, two on each hinge. Lubricate the cab door
Figure 7. Brake Cooling Filter hinges. See Approved Oils, Fluids, and Grease.

CAB AIR FILTER CONTROL LEVERS, SWITCHES, AND

Every 500 Hours
The cab air filter is located at the left rear corner of
the cab.
Move the locks to each other and pull the cab air
filter for inspection. Clean the element if possible.
PEDALS
Daily
Check that the control levers for the transmission,
mast, attachment, and the pedals operate as
described in the Operating Manual.

Replace the filter when necessary. COOLING SYSTEM

After the filter has been installed, push the locks
into the locked position. See Figure 8.
Coolant Hoses
Every 250 Hours
Verify if coolant hoses are collapsed when the
engine is cold. Collapsed hoses indicate a
malfunctioning radiator cap. Replace the radiator
cap as required.
Inspect the condition of the coolant hoses by looking
for cracks, leakage or other damage.
Replace damaged hoses.

19
Periodic Maintenance Procedures 8000 SRM 1593

Coolant Level

WARNING
DO NOT remove the radiator cap when the engine
is hot. When the radiator cap is removed from the
expansion tank, the pressure is released from the
system. If the system is hot, the steam and boiling
coolant can cause burns.

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

Daily and Every 250 Hours

Check coolant level in the expansion tank when 1. RADIATOR CAP
cold. Coolant level must be between the 'MIN' and 2. EXPANSION TANK
'MAX' mark on the expansion tank. 3. "MIN" MARK
4. "MAX" MARK
Add coolant when level is at or below the ‘MIN’ 5. COOLANT LEVEL SWITCH
mark.
Figure 9. Cooling System
Also add coolant when the Coolant Level Warning
Light is ON during operation of the truck.
Coolant Quality
If coolant must be added, use an OAT (Organic Acid
Every 1,000 Hours or Every 6 Months
Technology) type coolant. Add coolant until just
below the 'MAX' mark on the expansion tank. See Measure and record acidity and ethylene glycol
Figure 9. content of the coolant.
When coolant has been added, make a note of the Compare measurement with earlier records and
date and added quantity. take appropriate action.
Check the cooling system for leaks if more than Replace factory filled coolant if pH level is lower
1 liter (0.26 gal) of coolant must be added per 3,000 than 7.7.
running hours. If pH level is above 7.7, make a judgement when
actual pH level will probably reach 7.7.
See Cooling System 0700SRM1595 for coolant
replacement procedures.
Measure ethylene glycol content with a
refractometer. Maintain ethylene glycol content
between 40% and 50%. Certain freezing conditions
may require an ethylene glycol level that is higher
than 50%. Add ethylene glycol to raise ethylene
glycol content. Add distilled water to lower ethylene
glycol content.

Cooling Fan
Every 500 Hours
Check the fins for cracks and damage. Replace the
fan when required.

20
8000 SRM 1593 Periodic Maintenance Procedures

Cooling Fan Drive Belt

Daily and Every 250 Hours
Check that the key is in the OFF position and the
engine is stopped. Check the drive belt for wear and
damage. Small cracks that run across the belt are
acceptable. A drive belt with cracks that run the
length of the belt or missing pieces are not
acceptable. Check proper belt tension. See
Figure 10.

Figure 11. Cooling Fan Drive Belt

Pulley Alignment
Use a straightedge and an inclinometer to establish
misalignment between the belt and the different
pulleys. Maximum misalignment is 3 degrees. See
Figure 12.

1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE

Figure 10. Cooling Fan Drive Belt Inspection

Cooling Fan Drive Belt Tensioner and

Pulleys
Every 2,000 Hours
Verify if the bearings for the hubs and pulleys
produce more noise during operation than normal. If
there is excessive noise, check condition of the
pulley bearings, pulley alignment, and functioning
of the belt tensioner.
Figure 12. Pulley Alignment
Bearing Condition
Tensioner Condition
Remove the belt and rotate each hub and pulley to
verify smooth rotation and absence of play. See 1. Check that neither the top nor bottom
Figure 11. tensioner arm stop is touching the cast boss on
the tensioner body. If either of the stops is
Verify whether the alternator bearings are the
touching a cast boss, the drive belt must be
source for the noise.
replaced. Make sure that the correct belt part
Replace components or bearings as necessary. number is being used if either condition exists.
Reinstall the fan belt. See Figure 13.

21
Periodic Maintenance Procedures
Figure 13. Cooling Fan Belt Tensioner Arm Stops
with Drive Belt
2. Remove the drive belt from the tensioner.
Verify that the bottom tensioner arm stop is in
contact with the bottom tensioner arm stop
boss on the tensioner body. If these two are not
touching, the tensioner must be replaced. See
Figure 14.
Figure 14. Cooling Fan Belt Tensioner Arm Stops
without Drive Belt
3. Check the tensioner pulley and body for cracks.
If any cracks are noticed, the tensioner must be
replaced. See Figure 15.
22
8000 SRM 1593
Figure 15. Tensioner Pulley Inspection
4. Check the tensioner for dirt build up. If this
condition exists, the tensioner must be removed
and steam cleaned.
5. Inspect the tensioner for evidence of the
pivoting tensioner arm contacting the
stationary circular base. If there is evidence of
these two areas touching, the pivot tube
bushing has failed and the tensioner must be
replaced. See Figure 16.
Figure 16. Tensioner Inspection
CRANKCASE BREATHER
Every 2,500 Hours
Remove the crankcase breather element for
inspection and replace as required. Check the
breather ventilation tube and crankcase breather
tube for deposits and clean as necessary to ascertain
sufficient ventilation capacity.
8000 SRM 1593 Periodic Maintenance Procedures

DRIVE AXLE AND DIFFERENTIAL Check that the universal joints are tightened and
not damaged. Check the drive shaft for damage. If
Check Oil level any of the components are loose or damaged they
Every 250 Hours or 3 Months must be replaced.
Remove magnetic oil plugs in differential and END BEAM SLIDER PADS
planetary drives to check oil level and verify size of
wear particles. Every 500 Hours
• If particles are large shine chips, check for Check the end beam slider pads for excessive play.
damages on bearings and gears before Maintain a play of 1 to 2 mm (0.039 to 0.079 in.)
continuing operation. between slider pads and end beam. Re-shim or
• If particles are course, check wheel bearing replace the slider pads as required. See Figure 17.
pre-tension.
• The situation is normal if a fine powder has
been collected.
Gear oil level in differential and planetary gears
must be checked separately.
The gear oil level in the differential is correct when
the gear oil is even with the plug at the front of the
housing.
The gear oil level in the planetary gears is correct
when the "level line" on the planetary cover is
parallel to the floor and oil is even with the plug.
Add clean gear oil as required. See Approved Oils,
Fluids, and Grease.
Check for leaks if oil must be added.
Record added volume and hour meter reading.

Change Oil
Every 1,500 Hours or 6 Months
Figure 17. End Beam Slider Pads
Change the oil for differential and drive axle. To
drain the oil, remove the plugs from the planetary
covers and the plug at the bottom of the differential
ENGINE AIR FILTER
housing. Verify particle size on the magnetic plugs
and clean the magnetic plugs. Fill the drive axle
CAUTION
with the oil specified in Approved Oils, Fluids, and
If the air filter container is not cleaned during
Grease. Fill slowly to the bottom of the fill plug
maintenance or replacement of the air filter, dirt
holes. After filling, operate the lift truck to make
will gradually build up in the filter housing. This
sure the oil level is even. Check the oil level again
may cause the filter unit to function incorrectly. If
and check for leaks.
the filter element has been forced into place, the
filter housing can crack over time, allowing dirt to
DRIVE SHAFT enter into and damage the engine.
Every 2,000 Hours or 1 Year
Daily
Lubricate the three grease fittings on the drive
shaft. See Approved Oils, Fluids, and Grease. The air filter canister should not be opened until an
air filter element replacement is required, but
Two of these fittings are located on the universal inspect the inside at least once a year.
joints at each end of the drive shaft. The third
fitting is on the slip yoke at the center of the drive Replace the main filter element, when the Air Flow
shaft. Restriction Indicator Light on the instrument panel

23
Periodic Maintenance Procedures 8000 SRM 1593

is ON. Record the hour meter reading at

replacement.
Replace the safety element every third time the
main element is replaced. Clean the inside of the
housing when changing filters. See Figure 18.

Figure 19. Air Intake Piping and Charge Air Piping

ENGINE AND TRANSMISSION MOUNTS

Every 2,000 Hours or 1 Year
Inspect all rubber mounts for ageing and damage.
Look for traces, which indicate excessive relative
movement between the frame supports and the
engine and transmission brackets.

1. PRECLEANER ENGINE COMPARTMENT

2. ELECTRICAL AIR RESTRICTOR INDICATOR Daily and Every 250 Hours or 3 Months
3. AIR FILTER CANISTER
4. RETAINING CLIPS Open the hood and check for leaks and abnormal
5. SAFETY ELEMENT conditions. Clean any oil or fuel spills. Make sure all
6. MAIN ELEMENT surfaces are free of oil, lubricants, fuel, and organic
7. AIR FILTER CANISTER COVER
dust or fibers (paper, wood, cotton, wool, etc.).
Figure 18. Engine Air Filter Remove all foreign materials.

ENGINE AIR INTAKE PIPING AND ENGINE OIL

CHARGE AIR PIPING
Daily and Every 250 Hours
Inspect the intake and charge air piping for wear
points and leakage. Look for loose clamps and
punctures that can allow ingress of dirt into the
engine. See Figure 19.
Engine Oil Level
WARNING
Long-term exposure to used engine oil can cause
skin irritation or cancer. Use caution when
checking or adding oil to the engine. If oil comes
in contact with skin, wash with detergent and
water.

CAUTION
DO NOT permit dirt to enter the engine when the
oil level is checked or the filter is changed. NEVER
operate the engine without oil. The operation of
the engine without oil will damage the engine.

24
8000 SRM 1593
Daily and Every 250 Hours
Check engine oil level after the engine has stopped
for more than a minute.
Keep the oil level at two thirds of the full range on
the dipstick. See Figure 20. When adding oil, use
the correct oil as shown in Approved Oils, Fluids,
and Grease.
1. ENGINE OIL DIPSTICK
2. TRANSMISSION OIL DIPSTICK
Figure 20. Engine and Transmission Oil Dipstick
Engine Oil and Engine Oil Filter
WARNING
Long-term exposure to used engine oil can cause
skin irritation or cancer. Use caution when
checking or adding oil to the engine. If oil comes
in contact with skin, wash with detergent and
water.
CAUTION
DO NOT permit dirt to enter the engine when the
oil level is checked or the filter is changed. NEVER
operate the engine without oil. The operation of
the engine without oil will damage the engine.
Every 500 Hours
Change engine oil and replace the engine oil filter.
Periodic Maintenance Procedures
The engine oil filter is installed at the left-hand side
of the engine. See Figure 20. Replace spin-off filter
element. Fill the filter element with the oil specified
in the Approved Oils, Fluids, and Grease and apply
clean oil to the gasket of the new filter. Turn the
filter until the gasket touches oil filter housing, then
tighten ½ to ¾ turn further by hand.
Place a suitable container that can hold
19 liter (20 qt) under the engine oil pan, remove the
drain plug and drain the oil. Install the drain plug
and refill the engine with new oil as specified in
Approved Oils, Fluids, and Grease.
ENGINE VALVE ADJUSTMENT
Every 5,000 Hours
Adjust the engine valves according the values listed
on the engine serial number plate on the valve
cover. See Figure 21.
Figure 21. Serial Number Plate on Valve Cover
CAUTION
Engine coolant temperature should be lower than
60°C (140°F).
1. Remove the crankcase breather tube from the
rocker lever cover.
2. Remove the variable geometry turbocharger
actuator air supply line, if equipped.
3. Remove the capscrews that secure the rocker
lever cover.
NOTE: Rocker lever cover configurations will be
different depending on if the cover is center bolted
or perimeter bolted. The rocker lever cover can also
be taller if the engine is equipped with engine
brakes.
4. Remove the rocker lever cover and gasket. See
Figure 22.
25
Periodic Maintenance Procedures 8000 SRM 1593

6. Using a barring tool, rotate the crankshaft to

align the top dead center marks on the gear
cover and the fuel pump gear. See Figure 24.

1. CAPSCREWS
2. ROCKER LEVER COVER

Figure 22. Rocker Lever Cover Removal

5. Remove the plastic fuel pump drive cover

located on the front of the engine. See 1. BARRING TOOL
Figure 23. 2. TOP DEAD CENTER MARK

Figure 24. Barring Tool and Top Dead Center Mark

NOTE: Lash checks are performed as part of a

troubleshooting procedure, and resetting is not
required during lash checks as long as the lash
measurements are within the above limits.

7. With the engine in this position, lash can be

checked on the following rocker arms: 1l, 1E, 2l,
3E, 4l, and 5E. See Table 11.

1. PLASTIC FUEL PUMP DRIVE COVER

Figure 23. Plastic Fuel Pump Drive CoverRemoval/

Installation

Table 11. Valve Adjust Limits

Valve Adjust Limits
Intake "MIN" 0.152 mm (0.006 in.) "MAX" 0.559 mm (0.022 in.)
Exhaust "MIN" 0.381 mm (0.015 in.) "MAX" 0.813 mm (0.032 in.)

8. Measure lash by inserting a feeler gauge and adjust the lash to the nominal specification
between the crosshead and the rocker lever ball as indicated on the engine identification plate.
insert and socket while lifting up on the end of See Figure 25.
the rocker arm. If the lash measurement is out
of specification, loosen the locknut while
holding the adjusting screw with a screwdriver

26
8000 SRM 1593
1. WRENCH ON LOCKING NUT
2. FEELER GAUGE
3. SCREWDRIVER
Figure 25. Locking Nut and Feeler Gauge
NOTE: Lash resets are only required at the interval
specified in the Maintenance Schedule, when lash is
measured and found out of specification, or when
engine repairs cause removal of the rocker arms
and/or loosening of the adjusting screws.
9. While holding the adjusting screw in place with
a screwdriver to prevent losing the proper
adjustment, torque the locknut to
24 N•m (18 lbf ft) to set the adjustment, then
measure the lash again with the feeler gauge.
Repeat Step 4 through Step 14 until the proper
lash adjustment is acquired.
10. Using a barring tool, rotate the crankshaft 360
degrees and repeat Step 4 through Step 9 for
rocker arms 2E, 3l, 4E, 5l, 6l, and 6E. Reset the
lash, if out of specification.
11. Place the gasket on the cylinder head. Be sure
the gasket is properly aligned around the
cylinder head capscrews. See Figure 26.
Periodic Maintenance Procedures
1. CAPSCREW
2. ROCKER LEVER COVER
3. ROCKER LEVER COVER GASKET
Figure 26. Rocker Lever Cover Installation
12. Install the rocker lever cover and capscrews.
13. Torque the capscrews to 12 N•m (106 lbf ft).
14. Install the press-in gasket. See Figure 27.
• Press the molded gasket into the corners of
the rocker lever cover.
• Press the gasket around the cap screw
mounting holes.
• Press the remaining gasket into the rocker
lever cover.
1. ROCKER LEVER COVER GASKET
2. ROCKER LEVER COVER
Figure 27. Rocker Lever Cover Gasket Installation
15. Install the rocker lever cover and cap screws.
Torque cap screws to 12 N•m (106 lbf in).
27
Periodic Maintenance Procedures 8000 SRM 1593

16. Install the crankcase breather tube onto the show a fault code instead of engine running hours,
rocker lever cover. and the central warning lights will be ON.
If a fault appears, report the fault immediately. DO
17. Install the variable geometry turbocharger
NOT operate the lift truck until the fault is
actuator air supply line, if equipped.
corrected. When all faults have been cleared or
18. Install the plastic fuel pump drive cover. See repaired, the hourmeter/fault code display will show
Figure 23. engine running hours again.
See Cummins Engine Fault Code Guide
EXTENSION BEAM WEAR PADS 0600SRM1101 for engine fault codes.
Every 500 Hours or 6 Months See Transmission Operations and Diagnostics
1300SRM1455 for ZF transmission fault codes.
1. Inspect the bearing pads for wear. See
See Hydraulic Control System 2200SRM1481 for
Figure 28.
hydraulic system fault codes.

FORKS

WARNING
DO NOT try to correct the alignment of the fork
tips by bending the forks or adding shims. Never
repair damaged forks by heating or welding. Forks
are made of special steel using special
procedures. If either fork is damaged, replace the
forks as a set.

NOTE: Also perform below checks immediately

after any collision of the truck, load or attachment.
Daily and Every 250 Hours
Replace the forks as a set if any of the below
Figure 28. Extension Beam Bearing Pads requirements is not met.
2. Replace the bearing pads if thickness is 1. Check that the fork angle is less than 93°.
18 mm (0.709 in.) or less. When replacing
bearing pads, simultaneously replace all pads 2. Check that the fork tips are aligned within 3%
that are fitted in the same plane. (All lower of fork length.
pads, all upper pads or all side pads). Using
bearing pads with a different thickness will 3. Check for absence of cracks at fork pin
twist and damage the extension beam connection.
weldment.
4. Check for absence of cracks at fork heel. See
3. Check torqueing of the hardware that retain Figure 29.
the bearing pad brackets. The required torque
Replace any damaged or broken part that is
is 63 N•m (46 lbf ft).
used to keep forks locked in position.
4. Grease the tracks for the bearing pads.
Every 250 Hours
FAULT CODES Make sure the bottom of the fork is at least 90% of
the original thickness.
Daily and Every 250 Hours
If either fork is worn, replace the forks as a set.
If the engine, transmission or hydraulic controller
detects a fault, the hourmeter/fault code display will

28
8000 SRM 1593 Periodic Maintenance Procedures

Fork Tip Alignment

Length of Forks 3% Dimension
1,220 mm (48 in.) 37 mm (1.5 in.)
1,830 mm (72 in.) 55 mm (2.2 in.)
2,440 mm (96 in.) 74 mm (3.0 in.)

1. TIP ALIGNMENT
2. CRACKS
3. SQUARE
4. WOOD BLOCK
5. MUST BE AT LEAST 90% OF DIMENSION X
6. FORK WEAR
7. 93° MAXIMUM ANGLE
8. FORK PIN DAMAGE

Figure 29. Check the Forks

FORK PINS, CARRIAGE PINS, AND FRAME, MAST, CARRIAGE AND

CARRIAGE SLIDING SURFACES
Every 250 Hours
Replace a fork pin, or a side shift apron pin, if found
bent or damaged. See 2-Stage Mast 4000SRM1647.
Lubricate the fork pin area with grease where the
forks and fork guides travel. For side shift carriages,
lubricate the fitting on the apron brackets.
Reposition forks and carriage to make sure the
entire area of travel is lubricated. See Approved
Oils, Fluids, and Grease.
ATTACHMENT
WARNING
Lower the lift mechanism completely. Never allow
any person under a raised carriage. DO NOT put
any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
Daily
1. Make sure all retaining hardware for carriage,
mast pivots end tilt cylinder rod ends is
tightened and in good condition.

29
Periodic Maintenance Procedures
2. Check welds for cracks immediately when any
unusual noise is heard during lifting or
maneuvering of a load. An immediate check
must be made also after any collision of the
truck, load or attachment.
NOTE: Early detection and repair of cracks will
prevent major structural failures and will limit the
associated cost of repairs. Applications involving
poor ground conditions, floating or offset loads,
overloading, or other circumstances that influence
structural integrity, will require more frequent
servicing and inspection. At your request, your
Hyster dealer will advise you of the appropriate
service intervals based on an application survey.
Every 250 Hours
Look for deformations in the material and
irregular lines in welds.
Remove dirt and grease from the surrounding
surface and check for cracked paint and any
rust showing up through the paint.
If abnormalities are detected, notify qualified
maintenance personnel for further evaluation.
FUEL, OIL OR COOLANT LEAKS
WARNING
All fuels are very flammable and can burn or cause
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel
system. If there is a leak in the fuel system, extra
care must be used during the repair. DO NOT
operate the lift truck until the leak is repaired. Fuel
leaks MUST be repaired IMMEDIATELY.
Daily and Every 250 Hours
Make a visual check for leaks in the engine
compartment and under the lift truck. Start
checking the underside of reservoirs, filters,
radiators, hydraulic valves and radiators. All hoses
and hose connections should be dry on the outside.
Check the condition of radiator and heater hoses.
Soft or cracked hoses need to be replaced before a
leak occurs.
Be aware of internal leaks. Although no outside
leakage is visible, it is possible that fluids from one
system (coolant, brake oil) leak into a different
system (engine sump, planetary gear). Always make
a note of the volumes being topped up.
30
8000 SRM 1593
FUEL FILTER AND WATER SEPARATOR
FILTER
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
Daily
Drain water from the fuel/water separator when the
warning light on the instrument panel is ON during
operation. The fuel/water separator is located at the
left-hand side of the truck.
1. Open the drain valve by turning the valve
counter clockwise until draining occurs.
2. Drain water into a cup until clean fuel flows
from the valve.
3. Close the valve.
Every 250 Hours or 3 Months
Drain water from the fuel/water separator.
Every 500 Hours or 6 Months
Replace the fuel/water separator and the final fuel
filter.
• Close the fuel shutoff valve on the fuel tank.
• Remove the final fuel filter, which is located
at the right-hand side of the engine, near the
transmission dipstick and fill-tube. Fill the
new filter element with clean diesel fuel and
install.
• Remove the electrical connector from the fuel/
water separator and remove the filter.
• Install the new fuel/water separator and
reconnect the connector.
• Open the fuel shutoff valve.
• Rotate the handpump at the filter head until
it springs open.
• Operate the handpump at the filter head until
fuel escapes from the de-aeration plug.
• Push and rotate the handpump to lock the
hand pump.
HEADER HOSE ASSEMBLY
Daily and Every 500 Hours
1. Check if hoses are aged, kinked, crushed or
twisted.
8000 SRM 1593 Periodic Maintenance Procedures

2. Check the hose covers for cuts, cracks, or without hydraulic oil in the hydraulic system. The
exposed reinforcement. operation of the hydraulic pumps without
hydraulic oil will cause damage to the pumps.
3. Check proper hose tension.
Only use the hydraulic oil specified in Approved
4. Check hoses and fittings for hydraulic leaks. Oils, Fluids, and Grease.
Additives in the hydraulic system oil may damage
5. Check the clamps and sheaves for defective or the hydraulic system. Before using additives,
broken parts. contact your local Hyster dealer.

6. Check proper tracking during operation. Daily and Every 250 Hours
Adjust, or replace components as required. For Check hydraulic oil level at the level indicator when
procedures see 2-Stage Mast 4000SRM1647. the carriage is lowered and the engine stopped. See
Figure 30.
HORN, GAUGES, LIGHTS, ALARMS AND Hydraulic oil level is correct when it is in the green
CONTROL SYSTEM area.
Daily If hydraulic oil level is in the yellow area, there is a
Turn the key to the ON position. Verify that all risk that during operation hydraulic oil will leak
warning lights and indicator lights will light up. from the hydraulic tank breather cap.
After two seconds all warning lights will be OFF, • If hydraulic oil level is in the red area, add
except for the Wait to Start Light , Central Warning clean hydraulic oil through the fill plug at the
Lights, Brake System Low Pressure Warning Light, return filter and check the hydraulic system
and the Parking Brake Warning Light. Start the for leaks. Record added volume and hour
engine after the Wait to Start Light is OFF. meter reading.
With the engine running at idle, check the gauges
and indicator lights for correct operation. See the
Controls, Instruments, Indicators, and Switches
section in the Operating Manual.
Have any failed light gauge, horn or alarm repaired
immediately.
Check for presence of fault codes on the display and
rectify as required.
For location of fuses and relays, see Fuses and
Relays and Side Console.

HYDRAULIC SYSTEM OIL

WARNING
At operating temperature, hydraulic oil is hot. DO
NOT permit oil to contact the skin and cause a
burn.

1. HYDRAULIC TANK
CAUTION 2. HYDRAULIC OIL LEVEL GAUGE
3. HYDRAULIC SYSTEM OIL FILTER
DO NOT permit dirt to enter the hydraulic system 4. HYDRAULIC OIL FILL/SOCKET-HEAD SCREW
when the hydraulic oil level is checked or the filter 5. HYDRAULIC TANK BREATHER WITH
is changed. Never operate the hydraulic pumps INDICATOR

Figure 30. Hydraulic System

31
Periodic Maintenance Procedures
Hydraulic Oil Testing Procedures
Every 3,000 Hours
When oil life is 3,000 Hours, but when it has not yet
reached 6,000 hours, oil can be tested if it complies
with the requirements for extended usage.
1. Take an oil sample at port Mp, which is located
on the main valve. Alternative sampling
methods (extraction pump) are not
recommended.
2. Send the sample to a specified laboratory for
investigation.
3. Oil can be used for another 1000 hours if it
passes following tests:
• Particle count according ISO 4406, the result
may not exceed 21/17/14
• Kinematic Viscosity 40°C (104°F) per ASTM
D445
• (Total) Acid Number (TAN) per ASTM D664
Oil has to be replaced if it fails the test or if
there are no possibilities to test the oil.
Replace the hydraulic tank return filter when
replacing hydraulic oil.
Hydraulic Oil Replacement
WARNING
At operating temperature, the hydraulic oil is hot.
DO NOT permit the hydraulic oil to contact the skin
and cause a burn.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
CAUTION
DO NOT permit dirt to enter the hydraulic system
when the hydraulic oil is checked or the filters are
changed or lift truck damage may occur.
CAUTION
Additives in the hydraulic system oil may damage
the hydraulic system. Before using additives,
contact your local Hyster dealer.
32
8000 SRM 1593
Every 3,000 Hours or according oil test report.
Replace hydraulic oil.
1. Put the lift truck on a level surface.
2. Put the mast in a vertical position and lower
the carriage completely.
3. Shut the engine OFF.
4. Apply the parking brake.
5. Put a container with a capacity of
approximately 605 liter (160 gal) under the
hydraulic tank.
6. Remove the drain plug to drain the hydraulic
oil.
7. Replace the hydraulic tank return filter.
8. When the hydraulic oil is drained, install the
drain plug.
9. Fill the hydraulic tank with clean hydraulic oil
as specified in Approved Oils, Fluids, and
Grease.
10. Loosen the supply hose connections at the
hydraulic pumps to bleed the air from the
hoses.
Once the air is removed and hydraulic oil is present
at the supply hose and hydraulic pump connections,
tighten the supply hose connections.
CAUTION
Never start the engine when the hydraulic pumps
are not filled with hydraulic oil. Make sure that the
hydraulic pumps are filled with oil by
disconnecting the drain hoses and filling the pump
chambers through the drain port on each hydraulic
pump. Failure to comply can result in serious
damage and loss of durability to the hydraulic
pump(s).
11. Disconnect the drain hoses and fitting from the
hydraulic pumps and fill the pump chambers
with clean hydraulic oil through the drain port
on each hydraulic pump. See Figure 31.
8000 SRM 1593
1. DRAIN HOSE
2. FITTING
3. DRAIN PORT
Figure 31. Hydraulic Pump Fill
12. Connect the drain hoses to the hydraulic
pumps.
13. Start the engine while operating the lift
function. Keep engine speed at idle.
14. Lift the mast until it has almost reached its
end of stroke.
15. Lower the mast and keep the engine at idle for
about one minute.
16. Return to Step 14 if the pump has produced a
sound that relates to cavitation.
17. Raise engine speed to high idle (1,000 – 1,200
rpm) and lift the mast until it has almost
reached its end of stroke.
18. Lower the mast and keep the engine at idle for
about one minute.
19. Return to Step 17 if the pump has produced a
sound that relates to cavitation.
Periodic Maintenance Procedures
20. Operate each hydraulic function in both
directions twice, at high engine speed (1,600 –
1,900 rpm). Release the function when it has
reached its end of stroke.
21. Switch the engine OFF, check oil level and
check for leaks.
HYDRAULIC TANK BREATHER
CAUTION
DO NOT remove the complete hydraulic oil
breather cap assembly to avoid dirt from entering
the hydraulic system.
Daily and Every 250 Hours
1. Check if the yellow indicator on the hydraulic
oil breather cap is raised. See Figure 30.
2. If the indicator is fully raised or almost fully
raised, replace the filter element in the
hydraulic oil breather.
3. Before replacing the element, push the yellow
indicator down to release pressure from the
hydraulic oil breather cap.
4. Remove the hydraulic oil breather cap and
clean the inside of the breather cap.
5. Install a new filter element and replace the
hydraulic oil breather cap.
6. Push the yellow indicator down.
HYDRAULIC TANK RETURN FILTER
Every 3,000 Hours or at hydraulic oil
replacement.
Replace the hydraulic tank return filter when
replacing hydraulic oil.
Measure filter back pressure if excessive back
pressure is suspected.
To measure filter back pressure, heat hydraulic oil
temperature to at least 60°C (140°F). Connect a
pressure gauge at check port MRF. Run the engine
at full throttle while lowering the mast at maximum
lowering speed. Replace the tank return filter if the
measured value is 250 kPa (36 psi) or higher.
Replace the hydraulic return filter by removing the
4 bolts and the filter head from the hydraulic tank.
33
Periodic Maintenance Procedures
Remove the spring and the filter.
Install a new filter, the spring and the filter head.
Tighten the four bolts to 20 N•m (14.7 lbf ft).
INCHING PEDAL SENSOR CALIBRATION
Every 2,000 Hours
Calibrate the inching pedal sensor to compensate
for normal wear.
Normal wear may cause that the signal from the
sensor to the transmission controller moves outside
of the acceptable range. This causes the controller to
shift the transmission into neutral and to show fault
code t0211 on the display.
See Transmission Operations and Diagnostics
1300SRM1455 for calibration procedure.
LIFT CHAINS
Check and Lubricate Lift Chains
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. DO NOT put any
part of your body in or through the lift mechanism
unless all parts of the mast are completely lowered
and the engine is STOPPED.
Before making any repairs, use chains to secure
the mast weldments and carriage into position so
that they cannot move. Make sure the moving
parts are attached to a part that does not move.
DO NOT repair a worn lift chain. Replace both lift
chains when one or both lift chains are worn.
WARNING
Adjustment or repair of the lift chains must be
done by authorized personnel.
Daily
Check that the oil film on the outside of the lift
chains is intact and that the oil at the links is still
free flowing. Make sure both chains are slack during
parking.
If oil is not sufficiently present, or if lift chains
produce noises under operation, there is an
increased risk for chain failure. Call a mechanic to
have the lift chains inspected and re-lubricated.
34
8000 SRM 1593
When the oil film is still intact, check absence of
following conditions:
1 Broken, damaged or missing chain link
plates.
2 Damaged, turned or protruding link pins.
Have both lift chains replaced if any of the above
conditions is observed.
Check the chain anchors and chain pins for cracks
and damage. Replace if cracked or damaged.
First 100 Hour inspection and Every 250
Hours
Lubricate both lift chains:
1 Slacken the chains. This may require setting
the forks or attachment on a support such as
a wooden block or container.
2 Clean the chains as necessary to allow
penetration of oil into the chain links. Remove
debris, grease and thick oil.
3 Make sure that any trapped water or
condensation is removed.
4 Apply engine oil onto the chains. Do not use
grease.
5 Allow sufficient time for the oil to penetrate
before the chains are put under tension again.
6 Wipe excess oil.
Adjust Lift Chains
First 100 Hour inspection and Every 250
Hours
Adjust the lift chains as necessary to align the
carriage with the inner mast and correct the fork
height.
1 Put mast in a vertical position and lower
carriage completely.
Side shift the carriage until it is at the center
2
line of the mast.
3 Move both forks into maximum extended
position.
4 Loosen chain anchor lock nut and bend
fingers of the securing plate to release large
nut.
5 Turn large nuts on both chain anchors. Make
sure that both forks have at least 1 cm (0.40
in.) clearance with ground.
8000 SRM 1593 Periodic Maintenance Procedures

6 Align the vertical carriage bar with the inner If a chain scale is not available, measure the length
mast channel by tightening the large nut of of 20 links of chain. Measure from the center of a
the anchor chain that is in lowest position. pin to the center of another pin which is 20 pitches
Make sure that the vertical carriage bar runs away. See Figure 32.
parallel with the inner mast channel. Apply
an accuracy of 0.5 mm per 50 cm (0.025 in.
per 2 feet).
7 Adjust fork height by turning both chain
anchor nuts with the same angle until the
required ground clearance has been obtained.
Make sure that the ground clearance of both
forks is between
10 and 20 mm (0.4 and 0.8 in.).
8 After adjustments are completed, bend
fingers of securing plates around large nut
and tighten lock nut.
A. CHAIN PITCH
Inspect Lift Chains Figure 32. Lift Chain Pitch

Compare the length with the chart in Figure 33.

WARNING Replace the chain if the length of 20 links of the
Lower the lift mechanism completely. Never allow worn section is longer than the wear limit. For
anyone under a raised carriage. DO NOT put any replacement procedures see 2-Stage Mast
part of your body in or through the lift mechanism 4000SRM1647 .
unless all parts of the mast are completely lowered
and the engine is STOPPED.
Before making any repairs, use chains to secure
the mast weldments and carriage into position so
that they cannot move. Make sure the moving
parts are attached to a part that does not move.
DO NOT repair a worn lift chain. Replace both lift
chains when one or both lift chains are worn.

Every 250 Hours

Depending on the application, the chains will have
to be removed from the truck periodically for
cleaning, inspection and re-lubrication. Cleaning
must allow thorough visual inspection and result in
the removal of wear particles and used oil at the pin
contact area.

Chain Elongation
Inspect and replace both lift chains if any chain has
elongated 3% or more. 1. CHAIN WEAR SCALE
NOTE: The instructions for measuring chain
elongation are also shown on the Figure 33.

Pitch Total Length of 20 Links Wear Limit - Maximum Length

(Pitches) of New Chain of 20 Links
38.10 mm (1.50 in.) 762 mm (30 in.) 785 mm (30.9 in.)

35
Periodic Maintenance Procedures 8000 SRM 1593

Pitch Total Length of 20 Links Wear Limit - Maximum Length

(Pitches) of New Chain of 20 Links
44.45 mm (1.75 in.) 889 mm (35 in.) 916 mm (36.1 in.)

Figure 33. Measuring Chain Elongation LIFT SYSTEM ACCUMULATOR

Lift Chain Wear and Damage
Every 250 Hours
Inspect and replace if any of the following conditions
occur, see Figure 34:
1 Wear of any plate exceeds 5% of the original
dimension. See Figure 34.
2 Wear of any pin exceeds 5% of the original
dimension.
3 Broken, damaged or missing chain link
plates.
4 Damaged, turned or protruding link pins.
5 Stiff articulation between chain links.
6 Presence of lubricant, which is brown colored
by rust.
For replacement procedures see 2-Stage Mast
4000SRM1647 .
(OPTIONAL)
Every 2,000 Hours
Connect a nitrogen filling device and refill the
accumulator with nitrogen gas at approximately
20°C (68°F) to the required precharge pressure of
9.00 ±0.5 MPa (1305 ±72 psi). For the correct
nitrogen gas refilling procedure, refer to Hydraulic
System 1900SRM1934 .
LOAD ROLLERS
Carriage Load Rollers
Every 250 Hours
Add grease through the grease nipple until grease
escapes from the sides of the load roller. See
Approved Oils, Fluids, and Grease.
Inner Mast Load Rollers
Every 250 Hours
Raise the inner mast until the holes in the sides of
the outer mast provide access to the lube fittings of
the rollers. Add grease through the grease fitting
until grease escapes from the sides of the load roller.
See Approved Oils, Fluids, and Grease.

MAST, CARRIAGE, AND ATTACHMENT

Daily and Every 250 Hours

1 Slowly raise and lower the mast several times

without a load. Raise the mast to its full
extension height at least once. The mast
components must raise and lower smoothly in
the correct sequence.
2 Check proper tracking of header hoses.
3 Check for excessive play of rollers and bearing
blocks.
1. MOVED PIN 4 The inner weldment and the carriage must
2. RUST lower completely.
3. LOOSE LEAVE 5 Check for leaks of hydraulic components.
4. PIN WEAR (MAX 5%)
5. CRACK 6 Raise the mast 1 m (3 ft) with a capacity load.
6. HOLE WEAR The inner weldment and the carriage must
7. EDGE WEAR (MAX 5%) raise smoothly. Lower the mast. All moving
components must lower smoothly.
Figure 34. Lift Chain Check

36
8000 SRM 1593
7 Lower the load to approximately 0.3 m (1 ft)
from the floor. Tilt the mast forward and
backward. The mast must tilt smoothly and
all tilt cylinders must stop evenly.
8 Check that the controls for the attachment
operate the functions of the attachment
correctly as described in the Operating
Manual. See the symbols by each of the
controls.
9 Perform Leak Checks for lift cylinders and tilt
cylinders if excessive creep is suspected.
Repair and adjust as required. For procedures, see
2-Stage Mast 4000SRM1647.
MAST PIVOT PINS
Every 250 Hours
Lubricate the fittings for the mast pivot pins, under
no load conditions. For proper lubrication, the mast
should be lifted. Place blocks under the mast and
tilt the mast forward until the drive tires start
lifting off of the ground. The carriage and the mast
must stay in the lowered position during this
procedure. See Approved Oils, Fluids, and Grease.
OPERATOR PRESENCE SYSTEM
Daily and Every 250 Hours
NOTE: Check correct operation of the Operator
Presence System.
1 Run the engine and verify normal operation of
transmission and hydraulic functions.
2 Raise yourself from the seat for more than 2.5
sec.
3 Verify that hydraulic lift, lower and tilt
functions do not operate as long as you are
raised from the seat.
4 Verify that the transmission has been
disengaged.
5 Verify that hydraulic lift, lower and tilt
functions operate again after you have re-
seated.
6 Verify that the transmission can be re-
engaged.
To re-engage the transmission the operator must
either:
Periodic Maintenance Procedures
• Depress the inching brake pedal more than
75%.
• Move the gear selector into the NEUTRAL
position and then move the gear selector into
travel mode.
• Make a direction change using the
MONOTROL® pedal.
If the Operator Presence System does not work, first
check if the Hydraulic Service Switch is in the
correct position. The Hydraulic Service Switch is
located behind the fuse panel.
The Hydraulic Service Switch must be moved to the
hydraulic symbol for normal truck operation.
The Hydraulic Service Switch must be moved to the
spanner symbol for servicing, to allow operation of
hydraulic functions without an operator being
present in the seat. See Side Console.
OPERATOR RESTRAINT SYSTEM
The seat belt, seat, seat mounting and steering
column are all part of the operator restraint system.
Each item must be checked to make sure it is
attached securely, functions correctly, and is in good
condition.
Seat Belt and Seat Rails
Daily and Every 250 Hours
Make sure the seat belt is in good condition and the
end of the seat belt fastens correctly in the latch.
Make sure the seat belt pulls and retracts from the
retractor assembly smoothly. Pull the seat belt with
a sudden jerk to verify that the retractor assembly
will lock the seat belt.
Replace the seat belt assembly when it is worn or
damaged, or when the retractor does not function
correctly. See Figure 35.
Make sure the seat rails lock securely in position,
but move freely when unlocked. Make sure the seat
rails attach securely to the seat suspension. The
seat suspension must be securely bolted to the cab
floor. Repair as required.
37
Periodic Maintenance Procedures 8000 SRM 1593

A. AIR SEAT B. MECHANICAL SEAT

1. SEAT BELT AND SEAT BELT RETRACTOR 5. AIR SEAT WEIGHT ADJUSTMENT
2. ARM REST ADJUSTMENT 6. FORWARD/BACKWARD SEAT MOVEMENT
3. BACK REST ADJUSTMENT 7. MECHANICAL SEAT HEIGHT ADJUSTMENT
4. AIR SEAT HEIGHT ADJUSTMENT

Figure 35. Safety Belt and Seat Rails

Steering Column Latch
Daily and Every 250 Hours
Make sure the latch for the steering column
operates correctly. The latch must NOT allow the
column to move unless the latch is released. Repair
as required.
PARKING AND SERVICE BRAKES
CAUTION
Always apply the parking brake when the truck is
parked. A parking brake that is not applied will
drain the batteries.
Daily and Every 250 Hours
Check the operation of the parking brake.
The parking brake must apply when the knob for
the parking brake is pulled, and must release when
the knob is pushed.
The park brake must be able to hold the truck with
a capacity load on a 15% grade (a slope that raises
1.5 m every 10 m (1.5 ft every 10 ft)). Repair the
parking brake if it fails these requirements.
Check the operation of the service brakes.
The service brake must apply when pushing the
brake pedal and/or the inching pedal.
The service brake must be able to hold the truck
with a capacity load on a 20% grade when applying
108 N•m (24.28 lbf ft) to the brake pedal. A 20%
grade is a slope that raises 1 m every 5 m (1 ft every
5 ft).
Repair the service brake if it fails these
requirements.
RADIATOR ASSEMBLY
CAUTION
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

38
8000 SRM 1593
Daily and Every 250 Hours
1 Clean the radiator with compressed air or
water as required. Be careful not to bend the
radiator fins.
2 Inspect the radiator sections and hose
connections for leakage. Repair as required.
SIDE SHIFT BEARING PADS (ECH)
Every 500 Hours
Check upper and lower bearing pads. Replace
bearing pads if thickness is 18 mm (0.709 in.) or
less.
Make sure that retaining hardware is torqued to
63 N•m (46 lbf ft).
STEERING AXLE GREASE FITTINGS
King Pins
Every 500 Hours
There are two grease fittings at each kingpin of the
steering axle. See Figure 36.
1. KINGPIN GREASE FITTING
Figure 36. Kingpin and Tie Rod Grease Fittings
Tie Rod Pins
Every 500 Hours
Lubricate the tie rods at both ends of the steering
axle. Each tie rod has two grease fittings. See
Figure 36.
Periodic Maintenance Procedures
STEERING SYSTEM
Daily
NOTE: The lift truck has hydraulic power steering.
Steering is not possible when the engine is not
running due to hydraulic pressure not being
supplied to the steering system.
Check operation of the steering system.
Make sure the steering system operates smoothly
and steering control is good. Check for leaks.
Repair as required.
STEERING WHEEL HUB BEARINGS
Every 5,000 Hours
Remove and disassemble the steering wheel hub
bearings to replace the lubricant and adjust wheel
bearing pre-torque.
Remove and Disassemble
1. Remove the wheel. See Remove Wheels from
Lift Truck.
2. Remove grease cap from hub.
3. Remove cotter pin, castle nut and washer from
spindle.
NOTE: The hub assembly for this truck model
weighs about 58 to 63 kg (128 to 139 lb). Use a
lifting device when removing the hub assembly.
4. Remove outer bearing cone and hub from
spindle and put on a flat clean surface.
5. Remove seal and inner bearing cone from hub.
Clean and Inspect
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
1. Clean all parts with solvent. Make sure
bearings are clean and dry.
2. Inspect the bearings, bearing cups and seal.
Replace as required. Use appropriate pushers
when replacing cups with a press.
39
Periodic Maintenance Procedures 8000 SRM 1593

3. Inspect spindle and hub for cracks and damage. hub. Tighten nuts to
Ensure spindle and hub do not have any rough 615 to 710 N•m (454 to 524 lbf ft). See
or sharp areas that would prevent the bearings Figure 47.
from being correctly installed. If required,
smoothen any rough or sharp areas before TILT CYLINDER PIVOT PINS
installing the bearings.
Every 250 Hours
4. Inspect the contact surface between spindle The tilt cylinder pivot pins have four grease fittings,
and seal. Smoothen as required. two fittings per tilt cylinder. The grease fittings are
located at the end of each pivot pin. Apply grease
Assemble and Install until it escapes from the bushings. See Approved
Oils, Fluids, and Grease and Figure 37.
1. Apply grease and install inner bearing cone
and seal on hub. See Approved Oils, Fluids, and
Grease. Install the seal in the hub until it
almost touches the face of the inner bearing
cone.

2. Fill the cavity inside the hub with grease.

NOTE: The hub assembly for this truck model

weighs about 58 to 63 kg (128 to 139 lb). Use a
lifting device when installing the hub assembly on
the spindle.
3. Use a lifting device to position the hub on the
spindle.

4. Install the outer bearing cone, washer and

castle nut.

5. Install washer and castle nut. Tighten castle

nut to 203 N•m (150 lbf ft) while rotating
wheel hub in both directions to properly seat
the bearings. Loosen castle until wheel hub
1. TILT PIVOT PIN
turns freely with no end play. 2. GREASE FITTING
3. ROD END
6. Tighten castle nut to 34 N•m (25 lbf ft). 4. TILT CYLINDER ASSEMBLY
5. BUSHING
7. Align the castle nut with the cotter pin hole at
first alignment position at or above Figure 37. Tilt Cylinder Pivot Pin
34 N•m (25 lbf ft) and install and lock the
cotter pin. TRANSMISSION
Daily and every 250 Hours
8. Completely fill hub cap with grease and install
cap in hub. Inspect for leaks and check the condition of all hoses
and external components of the transmission. Make
9. Install wheel on hub. Be careful not to damage sure the transmission is shifting smoothly. If a
threads on studs. problem is present, report the problem immediately.
Do not operate the lift truck until the problem is
10. Start with wheel nut at the top and tighten
corrected.
nuts to 65 to 130 N•m (48 to 96 lbf ft) in
sequence shown. Make sure there is no dirt
between wheel and hub. The wheel must fit
Transmission Clutch Calibration
over the pilot surface and be tight against the Every 2,000 Hours

40
8000 SRM 1593
After each transmission oil change the transmission
must be recalibrated to compensate for the
difference in oil viscosity between used oil and new
transmission oil.
For calibration procedure, see Transmission
Operations and Diagnostics 1300SRM1455.
During calibration the Transmission Calibration
Switch must be moved down to the spanner symbol.
See Side Console for location.
Make sure the switch is returned up to the
transmission symbol when putting the truck back
into service. No hydraulic pressure is available if
the switch is in the down position.
Transmission Oil Level
WARNING
At operating temperature, the transmission oil is
hot. DO NOT permit the hot oil to touch the skin
and cause severe burns. Let transmission cool
before performing any maintenance.
WARNING
DO NOT permit dirt to enter the transmission when
the oil level is checked or the filter is changed. Dirt
can cause damage to transmission components.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
Daily and every 250 Hours
Check transmission oil level with the engine
running at idle and the park brake applied.
Keep oil level at the "FULL" mark on the dipstick.
Add transmission oil as required. See Approved
Oils, Fluids, and Grease.
Check for leaks if oil must be added and record
added volume and hour meter reading.
Periodic Maintenance Procedures
Transmission Oil and Oil Filter
WARNING
At operating temperature, the transmission oil is
hot. DO NOT permit the hot oil to touch the skin
and cause severe burns. Let transmission cool
before performing any maintenance.
WARNING
DO NOT permit dirt to enter the transmission when
the oil level is checked or the filter is changed. Dirt
can cause damage to transmission components.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
Initial 100 Hours and Every 2,000 Hours
1. Put a suitable container under the
transmission.
2. Remove and clean the drain plug.
3. Reinstall the drain plug when all oil has
drained. Torque the plug to 45 N•m (35 lbf ft).
4. Remove and discard the old filter.
5. Apply clean transmission oil to the gasket of
the new filter.
6. Install the new filter and tighten by hand.
7. Refill transmission to FULL mark. See
Approved Oils, Fluids, and Grease.
CAUTION
When restarting the engine, DO NOT exceed
engine low idle speed during the first 5 seconds.
After filter change the initial low oil pressure may
damage the transmission.
NOTE: Check for leaks during operation.
8. Start the engine and allow the lift truck to
reach normal operating temperature, recheck
the transmission oil level with the engine
running. If necessary, add more oil to fill the
transmission to the correct level.
41
Periodic Maintenance Procedures
9. Recalibrate the transmission. For procedure
see Transmission Operations and
Diagnostics 1300SRM1455.
TWIST LOCKS
Every 250 Hours
Inspect and lubricate the two twist Locks.
Inspect
Inspect the twist locks for wear and damage.
Replace the twist lock if the top area has worn
6 mm (0.24 in.) or more, and if the remaining
thickness of the twist lock head is 25 mm (1.00 in.)
or less. See Figure 38.
Figure 38. Twist Lock Wear Check
Lubricate
Every 250 Hours
Each twist lock has two grease fittings. Lubricate
the grease fittings and sleeves using MoS2 grease.
42
8000 SRM 1593
1. NIPPLE FOR SLEEVE
2. NIPPLE FOR TWIST LOCK
Figure 39. Twist Lock Lubrication
Replace
Every 5,000 Hours
Replace twist locks.
For procedures see Extendable Container
Attachment (Elme) 5000SRM1399.
VIBRATION DAMPER
CAUTION
The silicone fluid in the vibration damper will
become solid after extended service, which makes
the vibration damper inoperative. An inoperative
vibration damper can cause major engine or
driveline failures. Replace the damper at overhaul.
Every 2,000 Hours
Inspect the vibration damper and replace it when
evidence is found of fluid loss, dents, cracks, raised
surfaces, eccentricity, and shake. See Figure 40.
8000 SRM 1593
Figure 40. Vibration Damper Damage Identification
To establish maximum deformation, measure and
record the thickness of the vibration damper at four
places. Replace the vibration damper if its thickness
has increased, or varies by more than
6.35 mm (0.25 in.). See Figure 41.
Figure 41. Vibration Damper Measure Points
WARNING AND SAFETY LABELS
WARNING
Safety labels are installed on the lift truck to give
information about operation and possible hazards.
It is important that all safety labels are installed on
the lift truck and can be read.
Daily and Every 250 Hours
Check that all safety labels are installed at the
correct location on the lift truck and can be read.
See the Parts Manual for part numbers and
correct location.
If new labels must be installed, use the following
procedure:
Periodic Maintenance Procedures
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of the old paint with a cleaning
solvent.
2. Partially remove the paper from the back of the
label. Do not touch the adhesive surface.
3. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface and remove the rest of the paper at the
back. Make sure that all air is removed from
under the label and the corners and edges are
tight.
WINDOWS AND MIRRORS
Daily
Make sure the windows of the cab are clean, and the
window wipers operate correctly.
Have the mirrors correctly adjusted.
Replace components as required.
WINDSHIELD WASHER FLUID LEVEL
Daily and Every 250 Hours
The reservoir is located at the left rear corner of the
operator's cab. Check the level in the reservoir
through the three holes in the operator's cab. Add
fluid as necessary through the fill opening outside
the operator's cab.
43
Periodic Maintenance Procedures 8000 SRM 1593

WHEELS AND TIRES

Wheels, Tires, and Tire Pressure

WARNING
The type of tire and tire pressure are shown on the
nameplate. Make sure the nameplate is correct for
the type of tires on the lift truck.
Wheels and tires must be changed and repaired by
trained personnel only.
Always wear safety glasses.
Always use a tire inflator with a clip-on chuck
when deflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in length.
During deflation or when adjusting the tire 1. ACCURATE IN-LINE PRESSURE GAUGE
pressure, the technician must not stand in-line
with the axis of the wheel. See Figure 42. Figure 42. Adjusting and Deflating Position
If the air pressure is less than 80% of the correct
air pressure, the tire must be removed before air is
added. Follow the procedures described in the
section: Remove Wheels from Lift Truck and the
section: Adding Air Pressure to the Tires.
Adjusting tire pressure is allowed only if residual
air pressure exceeds 80% of the pressure as
indicated on the nameplate.
If the tire is removed from the truck and flat on the
ground, the technician should not have any body
part within the diameter of the tire when adjusting
the tire pressure. See Figure 43.
Wheels can explode and cause injury or death if
the above procedures are not followed.
1. HOSE LONG ENOUGH FOR USER TO STAND
Air pressure in pneumatic tires can cause tire and OUTSIDE POTENTIAL TRAJECTORY OF
wheel parts to explode. The explosion of wheel EXPLOSION
parts can cause serious injury or death. Remove
all of the air from the tires before the tires are Figure 43. Adjusting Tire Pressure Position
removed from the lift truck.
Daily and Every 250 Hours
Keep the tires at the correct air pressure as
specified on the lift truck name plate. Using a tire
pressure gauge, check the tire pressure when the
tires are at ambient temperature. If it is necessary
to add air to a tire that is warm, check one of the
other tires on the same axle and add air to the tire
that has lowest pressure so that the air pressures
are equal. The air pressure of warm tires must
always be equal to or greater than the specification
for air pressure for cold tires.

44
8000 SRM 1593
Check the tires for damage. See Figure 44. Inspect
the tread and remove any objects that will cause
damage. Remove any wire, straps, or other material
wrapped around the axle. Check for loose or missing
hardware. Check for bent or damaged rims. Inspect
wheel components for deformation, corrosion and
fractures.
1. CHECK TIRE PRESSURE
2. CHECK FOR DAMAGE
Figure 44. Tire Check
Remove Wheels from Lift Truck
CAUTION
Lift truck wheels are very heavy, use caution when
removing wheels or personal injury may occur.
Remove Pneumatic Tire from Wheel
NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 45.
Periodic Maintenance Procedures
1. Raise the lift truck as described in Putting a
Lift Truck on Blocks.
2. Attach a tire inflator as described above. Note
tire pressure. After air is drained from tire,
check the tire pressure to ensure there is no
residual pressure. Remove chuck. Remove the
tire stem valve core. Push a wire through the
valve stem to make sure that the stem does not
have a blockage causing a flow restriction. For
dual tires, remove air pressure from both tires
using the described procedure before loosening
the wheel nuts.
WARNING
Lift truck wheels are heavy and can cause
personal injury.
3. Remove the wheel nuts and remove the wheel
from the lift truck. Be careful NOT to damage
the studs when removing the wheels.
4. Use a tire jack to remove the wheel assembly.
45
Periodic Maintenance Procedures 8000 SRM 1593

1. SIDE FLANGE
2. WHEEL RIM FOR SOLID TIRE
3. FLANGE SEAT
4. WHEEL RIM FOR PNEUMATIC TIRE
5. LOCK RING

Figure 45. Types of Wheels

WARNING
Completely remove the air pressure from the tire
before it is removed from the lift truck. If dual
wheels are installed, remove the air from both
tires. Air pressure in the tires can cause the tire
and rim to explode causing serious injury or
death.

WARNING
Keep tire tools in firm contact with the wheel
parts. If the tool slips, it can move with enough
force to cause serious injury. See Figure 45.

STEP 1.
For tubeless tires, remove the air valve by
rotating it 60 degrees until the valve releases
from the valve slot.

46
8000 SRM 1593 Periodic Maintenance Procedures

STEP 2.
Loosen the tire bead from the side ring and/or
lock ring.

STEP 3.
Put the tire tool into the slot between the side
ring and/or lock ring and the wheel rim.
Remove the side ring and/or lock ring.

STEP 4.
Turn the tire over. Separate the tire from the
wheel rim.

STEP 5.
For tires with an inner tube, push the air valve
through the rim opening into the tire.

47
Periodic Maintenance Procedures 8000 SRM 1593

STEP 6.
Remove the wheel rim from the tire. Remove
the inner tube and flap.

48
8000 SRM 1593 Periodic Maintenance Procedures

Install Pneumatic Tire on Wheel

WARNING
Wheels can explode and cause injury or death if
the following procedures are not followed:
• Clean and inspect all parts of the wheel
before installing the tire.
• Inspect all wheel components for
deformation, corrosion and fractures.
• Look for fractures at the contact area
between tire and wheel parts in particular.
• Unacceptable deformation includes
progressed wear, buckling, twisting or
presence of dents.
• Discard all wheel components showing any
of the above defects, and replace by new
ones.
• DO NOT use any damaged or repaired wheel
parts.
• Make sure that all parts of the wheel are the
correct parts for that wheel assembly.
• DO NOT mix parts between different types
or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different
manufacturers on any one lift truck.
• Check with your dealer whether a specific
tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel.
Use a rubber, lead, plastic, or brass hammer
to put parts together. Make sure that the
lock ring is in the correct position. The ends
of the lock ring must not touch. The
clearance at the ends of the lock ring will be
approximately 4 to 14 mm (0.15 to 0.55 in.)
after it is installed. If the clearance is wrong,
the wrong part has been used.

WARNING
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury.

CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.

49
Periodic Maintenance Procedures 8000 SRM 1593

NOTE: There are two types of wheels used on this

series of lift trucks. If pneumatic shaped solid
rubber tires are installed, the four-piece wheel
assemblies must be used. If pneumatic tires are
installed, the three-piece wheel assemblies must be
used. See Figure 45.
STEP 1.
Clean and inspect all parts of the wheel. If the
wheel has rust or corrosion, remove loose rust
and corrosion and paint the parts.

WARNING
Do not lubricate the tire bead with antifreeze or
petroleum based liquid. Vapors from these liquids
can cause an explosion during inflation or use

STEP 2.
Apply a rubber lubricant or a soap solution to
the tire bead and tube.

STEP 3.
Make sure that the wheel is the correct size for
the tire. Lubricate the part of the wheel that is
in contact with the bead and flap.

STEP 4.
For tire with inner tube, install the inner tube
and the tire flap in the tire. For tubeless tires,
install the bead seal in the tire.

STEP 5.
For tires with inner tube, align the valve slot in
the rim with the air valve and install the wheel
rim in the tire. Guide the air valve through the
valve slot in the rim. For tubeless tires, align
the valve slot hole in the rim with the valve
bead hole in the valve bead, and install the
wheel rim in the tire.

50
8000 SRM 1593 Periodic Maintenance Procedures

STEP 6.
Turn over the rim and tire. Put a block under
the rim so that the rim is
8 to 10 cm (3.15 to 3.94 in.) above the floor.
Install the side ring and the lock ring. When
correctly installed, there will be a
4 to 14 mm (0.15 to 0.55 in.) clearance between
the ends of the side ring and the lock ring.

WARNING
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury.

STEP 7.
For tubeless tires insert the air valve into the
bead seal and rotate the valve 60 degrees until
the air valve locks into the valve slot.

Adding Air Pressure to Pneumatic Tires

WARNING
Add air pressure to the tires only in a safety cage.
Inflating or adjusting tire pressure outside of a
cage is allowed only if residual air pressure
exceeds 80% of the pressure as indicated on the
nameplate.
Inspect the safety cage for damage before use.
Always use a tire inflator with a clip-on chuck
when inflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in length.
During inflation the technician must stand away
from the safety cage. See Figure 46.
Do not use a hammer to try and correct the
position of the side flange or lock ring when the
tire has air pressure greater than 20 kPa (3 psi).
1. QUICK-RELEASE COUPLING

Figure 46. Adding Air Pressure to the Tire Position

WARNING
Wheels can explode and cause injury or death if 1. Put the tire in a safety cage. See Figure 46.
the above procedures are not followed.
2. Add 20 kPa (3 psi) of air pressure to the tire.

51
Periodic Maintenance Procedures 8000 SRM 1593

3. Check that all wheel parts are correctly
installed. Hit the side ring and/or lock ring
lightly to make sure that it is in the seat.
4. If installation is correct, add air pressure to the
tire. The correct pressure is shown on the
Nameplate.
valve core to make sure all of the air pressure
has been removed and make adjustments. The
clearance at the ends of the lock ring will be
4 to 14 mm (0.15 to 0.55 in.) when the tire has
the correct air pressure.

5. Check that all wheel parts are correctly

installed. If installation is not correct, remove
all of the air pressure from the tire. Remove the

Remove Solid Rubber Tire from Wheel

WARNING
Completely remove the air pressure from the tire
before it is removed from the lift truck. If dual
wheels are installed, remove the air from both
tires. Air pressure in the tires can cause the tire
and rim to explode causing serious injury or
death.
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury. See Figure 45.
Always use a cage when removing the solid
rubber tire from the rim or personal injury may
occur.

NOTE: There are two types of wheels used on this

series of lift trucks. If pneumatic shaped solid
rubber tires are installed, the four-piece wheel
assemblies must be used. If pneumatic tires are
installed, the three-piece wheel assemblies must be
used. See Figure 45.
STEP 1.
Put the wheel rim on the bed of the press. Put
the cage in position on the tire. Use the press to
push the tire away from the side ring.

STEP 2.
Put the tire tool into the slot between the side
ring and/or lock ring and the wheel rim.
Remove the side ring, lock ring, and wedge
band.

52
8000 SRM 1593 Periodic Maintenance Procedures

STEP 3.
Turn the tire over. Put a support under the
wheel rim. Make sure the wheel rim is at least
150 to 200 mm (6 to 8 in.) from the bed of the
press.

STEP 4.
Put the cage in position on the tire. Use the
press to push the tire from the wheel rim.

53
Periodic Maintenance Procedures 8000 SRM 1593

Install Solid Rubber Tire on Wheel

WARNING
Wheels can explode and cause injury or death if
the following procedures are not followed:
• Clean and inspect all parts of the wheel
before installing the tire.
• Inspect all wheel components for
deformation, corrosion and fractures.
• Look for fractures at the contact area
between tire and wheel parts in particular.
• Unacceptable deformation includes
progressed wear, buckling, twisting or
presence of dents.
• Discard all wheel components showing any
of the above defects, and replace by new
ones.
• DO NOT use any damaged or repaired wheel
parts.
• Make sure that all parts of the wheel are the
correct parts for that wheel assembly.
• DO NOT mix parts between different types
or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different
manufacturers on any one lift truck.
• Check with your dealer whether a specific
tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel. Use a
rubber, lead, plastic, or brass hammer to put parts
together. Make sure that the lock ring is in the
correct position. The ends of the lock ring must
not touch. The clearance at the ends of the lock
ring will be approximately
4 to 14 mm (0.15 to 0.55 in.) after it is installed. If
the clearance is wrong, the wrong part has been
used.

CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.

NOTE: There are two types of wheels used on this

series of lift trucks. If pneumatic shaped solid
rubber tires are installed, the four-piece wheel
assemblies must be used. If pneumatic tires are
installed, the three-piece wheel assemblies must be
used. See Figure 45.
STEP 1.

54
8000 SRM 1593 Periodic Maintenance Procedures

Lubricate the wheel rim and the inner surface

of the tire with tire lubricant or soap.

STEP 2.
Put the wheel rim on the bed of the press. Put
the tire over the wheel rim. Put the cage in
position on the tire. Use the press to install the
tire on the wheel rim.

STEP 3.
Remove the cage and put the wedge band, the
side ring, and the lock ring in position on the
wheel assembly. Install the cage on the tire.
Use the press to push the tire onto the wheel
rim so that the wedge band and side ring can be
installed.

STEP 4.
While the cage is holding the tire on the wheel
rim, install the lock ring. Use a tire tool to
make sure the lock ring is in the correct
position. Slowly release the press and verify
that the clearance at the ends of the lock ring
will be 4 to 14 mm (0.15 to 0.55 in.) when the
cage almost loses contact with the tire.

Install Wheels on Lift Truck

Align and Install the wheel(s) and tire(s) on the
hub. Tighten the nuts according to Wheel Nuts on
Drive and Steer Wheels.

55
Periodic Maintenance Procedures 8000 SRM 1593

Wheel Nuts on Drive and Steer Wheels

CAUTION
Check all wheel nuts after 2 to 5 hours of operation, when new lift trucks begin operation, and on all lift
trucks when the wheels have been removed and installed. Tighten the nuts as shown in Figure 47. When
the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 250 Hours.

Daily and Every 250 Hours

Start with the wheel nut at the top and tighten the nuts to 68 to 136 N•m (50 to 100 lbf ft) in the sequence
shown in Figure 47. Check to make sure that the wheel(s) is tight against the hub, then tighten the nuts to
615 to 710 N•m (454 to 524 lbf ft).

Figure 47. Wheel Nut Tightening Sequence

56
8000 SRM 1593 Capacities and Specifications

Capacities and Specifications

APPROVED FUEL AND ENGINE OILS

Engine WWFC Diesel Sulfur Content ASTM D975 Emission Engine Oil
Emission Fuel Legislation
Legislation
Tier 4i Stage Category 4 <10 mg/kg S15 <15 mg/kg ACEA E9 - API
IIIB Engines CJ-4
Tier 3 Stage IIIA Category 4 <10 mg/kg S15 <15 mg/kg ACEA E7, or E9
Engines - API CI-4, or
CJ-4
Category 2 <500 mg/kg S500 <500 mg/kg ACEA E7 API
CI-4
Non-Compliance Category 1 <5000 mg/kg S5000 <5000 mg/kg ACEA E7 API
CI-4 (see Notes)
NOTE:
• Diesel Category 1 is not allowed in countries with Tier 3 or more stringent emission legislation.
• When using Diesel Category 1, the factory-filled CJ-4 engine oil must be replaced at initial 250 hours
by API CI-4 specification oil.
• When using Diesel Category 1, engine oil specification API CI-4 must be used to allow 500-hour oil
change intervals.
• Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content does not
exceed 5 percent of total volume.

57
Capacities and Specifications 8000 SRM 1593

APPROVED OILS, FLUIDS, AND GREASE

Fluid Specification Truck/Engine Type Quantity

Oils
Air Conditioner – See Compressor
PAG
Compressor Oil Nameplate
Chain Oil 15W-40 Engine oil – As required
Differential Oil MIL-L-2105D, API-GL-5, – 21 liter (5.5 gal)
SAE 80W-90
ACEA E7 API CI-4 QSB 6.7 Tier 3 16 liter (17 qt)
Engine Oil: ACEA E9 API CJ-4 QSB 6.7 Tier 4 14 liter (15 qt)
ACEA E9 API CJ-4 QSB 4.5 Tier 4 10.5 liter (11 qt)
H8-12XM-6 / 160 liter (42.2 gal)
John Deere JDM-J20C H190-280HD2
Hydraulic System Oil
ISO VG46 H13-16XM-6 /
H300-360HD2
H8-12XM-6 / 2.8 liter (2.9 qt)
MIL-L-2105D, API-GL-5, H190-280HD2
Planetary Gear Oil
SAE 80W-90 H13-16XM-6 /
2.4 liter (2.5 qt)
H300-360HD2
Transmission Oil ZF TE-ML 03 – 20 liter (5.28 gal)
Fuel
H8-9XM-6 / H190-280 128 liter (33.8 gal)
HD2
See Approved Fuel and H10-12XM-6 /
Fuel
Engine Oils H280-280HD2
H13-16XM-6 /
H300-360HD2
Fluids
Air Conditioner – 1300 +/- 50 grams (45.8
R134a
Refrigerant +/- 1.8 oz)
3174102 - Shell Rotella Tier 3 Stage IIIA 25.5 liter (26.9 qt)
ELC, 3116456 – Eurol
Coolant Coolant XL-NM, Or
equivalent OAT type Tier 4i Stage IIIB
coolant
Windshield Washer Fluid Clean water with – 5 liter (5.3 qt)
detergent and anti-freeze
as required.
Grease
EP2/3
Multipurpose Grease – –
EP2/3 with 2–4% MoS2

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8000 SRM 1593 Capacities and Specifications

ENGINE OIL VISCOSITY

Ambient Temperature Temperature Range Oil Viscosity

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

LIFT CHAIN LUBRICANT REQUIREMENTS

Chain lubricant must be a mineral or synthetic
engine oil. Oil viscosity must match ambient
temperature, so that oil remains viscous and can
penetrate to the contact area between link pin and
intermediate links.

• Use SAE 20W to 30W oil in ambient

temperatures of −30 to 5°C (−22 to 41°F).
• Use SAE 15W-40 oil in ambient temperatures
of -10 to 35°C (14 to 95°C).
• Use SAE 40 oil in ambient temperatures of 5
to 45°C (41 to 113°F).
• Use SAE 50 oil in ambient temperatures
above 45°C (113°F).

FUSES AND RELAYS

1. GRID HEATER RELAY
Before replacing a failed fuse or relay, first repair 2. 125A FUSE GRID HEATER
the defect that caused the fuse or relay to fail. The 3. 100A FUSE ALTERNATOR
optional battery disconnect switch is located in the 4. STARTER RELAY
battery box. Main electrical supply fuses are located
Figure 48. Main Fuses and Relays (Tier 3
in the engine compartment. See Figure 48 for Tier
III truck series. See Figure 49 for Tier IV truck
series. Fuses for the various functions are on the
fuse panels, which are located behind the fuse panel
cover to the right of the side console. The relays are
located to the left of the fuse panel. See Figure 50
and Figure 51.

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Capacities and Specifications 8000 SRM 1593

Legend for Figure 49.

1. 125A FUSE ALTERNATOR

2. 125A FUSE GRID HEATER
3. GRID HEATER RELAY

Figure 49. Main Fuses and Relays (Tier 4)

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8000 SRM 1593 Capacities and Specifications

Side Console

1. FUSE PANEL 1 (TABLE 12) 7. RELAYS (FIGURE 51)

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

Figure 50. Side Console

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Capacities and Specifications 8000 SRM 1593

Table 12. Fuse Locator

Fuse Panel 1 Fuse Panel 2
10A TIER 3 ENGINE START 30A FLOOD LIGHTS
30A TIER 4 ENGINE START 5A STROBE LIGHT B+
5A ECM IGNITION 10A BRAKE LIGHTS
30A ECM SUPPLY 10A FRONT DRIVE LIGHTS
7.5A TRANSMISSION 5A INTERIOR LIGHTS
7.5A TRANSMISSION B+ 15A MAST/ATTACHMENT
LIGHTS
30A HYDRAULIC 10A DIRECTION
CONTROLLER INDICATORS
15A ATTACHMENT 10A SIDE/TAIL LIGHTS
CONTROLS
5A PARKING BRAKE 10A REAR DRIVE LIGHTS
SOLENOID
10A INSTRUMENTATION 10A REVERSE LIGHTS/
5A OPS SWITCH ALARM/ STROBE

Fuse Panel 3 Fuse Panel 4

10A FRONT SCREEN WASH/ 10A POWER SOCKET 12V
WIPE
10A ROOF WASH/ WIPE 10A RADIO/CB/ INTERCOM
10A REAR WASH/ WIPE 10A 12V CONVERTER
ACCESSORIES
10A HORN 10A HAZARD LIGHTS
20A CAB TILT POWER 10A AIR DRYER
ASSIST
– OPEN 3A 12V RELAY
5A SEAT SUSPENSION – OPEN
COMPRESSOR
20A HEATER/AC/ – OPEN
VENTILATION FAN
15A AC FAN 1 15A POWER SOCKET 24VDC
15A AC FAN 2 – OPEN

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8000 SRM 1593 Capacities and Specifications

Relays

1. FLOOD LIGHTS
2. MAIN LIGHTS
3. START INHIBIT
4. NEUTRAL
5. HYDRAULIC CONTROLLER
6. REVERSE
7. MAIN POWER
8. AC FAN 3
9. IGNITION
10. AC FAN 2
11. AC FAN 1
12. FLASHER UNIT (OPTIONAL)
13. STARTER ENABLE (TIER IV ONLY)
14. TWIST LOCKS
15. 12V RELAY
16. OVERRIDE
17. HORN
18. SEAT SWITCH

Figure 51. Relays

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 TECHNICAL PUBLICATIONS

8000 SRM 1593 7/19 (11/16)(3/15)(11/13)(7/12)