Manutenção Periodica - 360

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MANUTENÇÃO
PERIÓDICA
H8-12XM-6, H10XMS-6 H190-280HD2 , H230HDS2 [
( )
L007]; H13-16XM-6, H6-7XM-12EC (H210-250-48HD ,
2
H300-360HD , H360HD -EC) [K019]
2 2
Região Linguagem
NÓS pt
es
fr
de
isto
Reino Unido pt
es
fr
de
isto
PARTE NO. 4133481 8000 SRM 1939
https://www.hypassonline.com/lib/service/US/EN/html/8000SRM1939.html 1/86
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PRECAUÇÕES DE
SEGURANÇA MANUTENÇÃO E
REPAROS
• Os Manuais de Serviço são atualizados regularmente, mas podem não refletir alterações recentes no
projeto do produto. Informações de serviço técnico atualizadas podem estar disponíveis em seu
®
revendedor autorizado Hyster local . Os Manuais de Serviço fornecem diretrizes gerais para
manutenção e serviço e devem ser usados por técnicos treinados e experientes. A falha em manter
adequadamente o equipamento ou não seguir as instruções contidas no Manual de Serviço pode
resultar em danos aos produtos, ferimentos pessoais, danos materiais ou morte.
• Ao levantar peças ou conjuntos, certifique-se de que todas as eslingas, correntes ou cabos estejam
presos corretamente e que a carga que está sendo levantada esteja equilibrada. Certifique-se de que o
guindaste, cabos e correntes tenham capacidade para suportar o peso da carga.
• Não levante peças pesadas manualmente, use um mecanismo de elevação.
• Use óculos de segurança.
• DESCONECTE O CONECTOR DA BATERIA antes de fazer qualquer manutenção ou reparo em
empilhadeiras elétricas. Desconecte o cabo de aterramento da bateria em empilhadeiras de combustão
interna.
• Sempre use os blocos corretos para evitar que a unidade role ou caia. Veja COMO COLOCAR O

EMPILHADOR EM BLOCOS no Manual de Operação ou na seção Manutenção Periódica .
• Mantenha a unidade limpa e a área de trabalho limpa e organizada.
• Use as ferramentas corretas para o trabalho.
• Mantenha as ferramentas limpas e em boas condições.
• Sempre use peças HYSTER APPROVED ao fazer reparos. As peças de reposição devem atender ou

exceder as especificações do fabricante do equipamento original.
• Certifique-se de que todas as porcas, parafusos, anéis elásticos e outros dispositivos de fixação foram
removidos antes de usar força para remover as peças.
• Sempre prenda uma etiqueta NÃO OPERAR nos controles da unidade ao fazer reparos ou se a

unidade precisar de reparos.
• Certifique-se de seguir as notas de ADVERTÊNCIA e CUIDADO nas instruções.
• Gasolina, Gás Líquido de Petróleo (GLP), Gás Natural Comprimido (GNC) e óleo diesel são
inflamáveis. Certifique-se de seguir as precauções de segurança necessárias ao manusear esses
combustíveis e ao trabalhar nesses sistemas de combustível.
• As baterias geram gás inflamável quando estão sendo carregadas. Mantenha fogo e faíscas longe da

área. Certifique-se de que a área esteja bem ventilada.
NOTA: Os seguintes símbolos e palavras indicam informações de
segurança neste manual:
AVISO
Indica uma situação perigosa que, se não for evitada, pode resultar
em morte ou ferimentos graves.
CUIDADO
Indica uma situação perigosa que, se não for evitada, pode resultar
em ferimentos leves ou moderados e danos materiais.
Na empilhadeira, o símbolo de AVISO e a palavra estão em fundo
laranja. O símbolo de CUIDADO e a palavra estão em fundo
amarelo.
© 2021
HYSTER COMPANY
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ÍNDICE
Em geral
Dados do número de série
Procedimentos de manuseio de caminhões
Movendo e rebocando uma empilhadeira
Precauções
Movendo o caminhão
Colocando uma empilhadeira em blocos
Elevando os pneus de acionamento
Elevando os pneus de direção
Limpando uma empilhadeira
Procedimentos de segurança antes de iniciar a manutenção
Fazendo verificações no banco do motorista com o motor funcionando
Risco de incêndio
Interruptor de serviço hidráulico
Interruptor de calibração da transmissão
Aguarde 100 segundos antes de desconectar a bateria
Cronograma de Manutenção Periódica
Inspeção diária
Verificações diárias de condição
Verificações diárias de nível de fluido
Verificações diárias do banco do motorista com o motor funcionando
Inspeção inicial
Primeira inspeção após as primeiras 100 horas de operação
Manutenção periódica
Inspecione e ajuste
Lubrificar
Mudar
Cronograma de Manutenção Periódica - Anexo de Contêiner da Série ELME 580
Manutenção periódica
Inspecione e ajuste
Lubrificar
Mudar
Procedimentos de manutenção periódica
Sistema de ar condicionado
Acessório
Filtro de resfriamento de freio
Acumulador do sistema de freio
Filtro de ar da cabine
Dobradiças da porta da cabine
Alavancas de controle, interruptores e pedais
Sistema de refrigeração
Mangueiras de refrigerante
Nível do líquido refrigerante
Qualidade do refrigerante
Ventoinha
Correia do Ventilador de Resfriamento
Tensionador e polias da correia do ventilador de resfriamento
Condição do Rolamento
Alinhamento da polia
Condição do tensor
Elemento de respiro do cárter (somente nível 4F/estágio IV)
Sistema de Fluido de Escape Diesel (DEF)
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ÍNDICE
Filtro da Bomba DEF

Tampa de enchimento do tanque DEF
Filtro de sucção do tanque DEF
Eixo de acionamento e diferencial
Verifique o nível de óleo
Trocar óleo
Eixo de acionamento
Almofadas deslizantes do feixe final
Filtro de ar do motor
Tubulação de admissão de ar do motor e tubulação de ar de carga
Suportes de motor e transmissão
Compartimento do motor
Óleo de motor
Nível de óleo do motor
Óleo do motor e filtro de óleo do motor
Ajuste da válvula do motor
Almofadas de desgaste do feixe de extensão
Códigos de falha
Garfos
Pinos de garfo, pinos de carro e superfícies deslizantes de carro
Estrutura, Mastro, Carro e Acessório
Vazamentos de combustível, óleo, DEF ou refrigerante
Separador de Combustível/Água e Filtro Final de Combustível
Respiro do tanque de combustível
Conjunto de Mangueira de Cabeçalho
Buzina, medidores, luzes, alarmes e sistema de controle
Óleo do Sistema Hidráulico
Procedimentos de teste de óleo hidráulico
Substituição de óleo hidráulico
Respiro do tanque hidráulico
Filtro de retorno do tanque hidráulico
Calibração do Sensor do Pedal de Avanço
Correntes de elevação
Verifique e lubrifique as correntes de elevação
Ajuste as correntes de elevação
Inspecione as correntes de elevação
Alongamento da Cadeia
Desgaste e Danos da Corrente de Elevação
Acumulador do Sistema de Elevação (Opcional)
Rolos de carga
Rolos de Carga de Transporte
Rolos de carga do mastro interno
Mastro, carro e acessório
Pinos de articulação do mastro
Sistema de Presença do Operador
Sistema de retenção do operador
Cinto de segurança e trilhos de segurança
Trava da coluna de direção
Freios de estacionamento e serviço
Conjunto do radiador
Almofadas de rolamento de deslocamento lateral (ECH)
Sinais do Sistema de Controle do Espalhador
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ÍNDICE
Graxas do eixo de direção

Alfinetes de Rei
Pinos do Tirante
Sistema de direção
Rolamentos do cubo do volante
Remover e desmontar
Limpar e inspecionar
Montar e instalar
Pinos de Pivô do Cilindro de Inclinação
Transmissão
Calibração da embreagem da transmissão
Nível de óleo da transmissão
Óleo da transmissão e filtro de óleo
Fechaduras de torção
Inspecionar
Lubrificar
Substituir
Amortecedor de vibração (viscoso)
Etiquetas de Aviso e Segurança
Janelas e espelhos
Nível de fluido do lavador do para-brisa
Rodas e Pneus
Rodas, Pneus e Pressão dos Pneus
Remova as rodas da empilhadeira
Remova o pneu pneumático da roda
Install Pneumatic Tire on Wheel
Adding Air Pressure to Pneumatic Tires
Remove Solid Rubber Tire from Wheel
Install Solid Rubber Tire on Wheel
Install Wheels on Lift Truck
Wheel Nuts on Drive and Steer Wheels
Capacities and Specifications
Approved Fuel and Engine Oils
Approved Oils, Fluids, and Grease
Engine Oil Viscosity
Lift Chain Lubricant Requirements
Fuses and Relays
Main Electrical Supply
Relays
General
This section contains a Periodic Maintenance Schedule and the Periodic Maintenance Procedures for L007
and K019 .
The Periodic Maintenance Schedule has hour
intervals for inspection, lubrication, and component
replacement for your lift truck.
When in addition to the hour intervals a calendar interval is mentioned,
then the first expiring interval must
be observed.
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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 lifetime.

WARNING
Do not make repairs or adjustments unless you have both authorization and training.
Repairs and adjustments made on a lift truck by people without authorization and training
can make a dangerous operating condition.
Do not operate a lift truck that needs repairs. Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE tag in the operators area. Remove the key from
the key switch.

CAUTION
Maintenance procedures have to be executed with the engine OFF, unless indicated
otherwise.
Some lift truck users have service personnel and equipment to do the inspection, lubrication, and maintenance
shown in the Periodic Maintenance Schedule. Service Manuals are available from your dealer for HYSTER
lift trucks to help users who do their own maintenance.
SERIAL NUMBER DATA
The serial number for the lift truck is on the nameplate and also on the right hand frame rail, near the
counterweight. The serial number indicates the design series, manufacturing plant, and the year
manufactured.
Figure 1. Truck Nameplate
Example: L007 or K019 E 4369 N

(1) (2) (3) (4)
(1) The first letter and number of the serial number indicates the design series and the model number of the
lift truck.
(2) The second letter identifies the manufacturing plant. In this example: E = Nijmegen, The Netherlands.
(3) The number series following the second letter indicates the sequence of manufacture where the lift truck
was made.
(4) The letter following the number series indicates the year of manufacture starting with A=2003. The letter
B=2004, N = 2015, and so on.
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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: Ifthe 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. TAMPA DE PARAFUSO DE PLÁSTICO

2. PARAFUSO OU SOQUETE DE AJUSTE
3. PORCA DE TRAVAMENTO
Figura 2. Soltar o freio de estacionamento
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Movendo o caminhão

AVISO
NÃO reboque a empilhadeira se houver uma carga anexada.
Tenha cuidado extra ao mover uma empilhadeira se qualquer uma das seguintes condições
existir:
• Os freios não funcionam corretamente.
• A direção não funciona corretamente.
• Os pneus estão danificados.
• As condições de tração são ruins.
• A empilhadeira deve ser rebocada em um declive.
Se o motor não funcionar, não há pressão hidráulica disponível para o sistema de direção e
sistema de freio de serviço. Isso pode dificultar o controle da empilhadeira. A má tração
pode fazer com que a empilhadeira ou o veículo de reboque deslizem. Inclinações íngremes
aumentarão o esforço de frenagem necessário.
NUNCA levante e mova uma empilhadeira desativada, a menos que a empilhadeira
desativada DEVE ser movida e não possa ser rebocada.
1. A empilhadeira rebocada deve ter um operador.
2. Certifique-se de que o nível de óleo da transmissão esteja acima do mínimo. Observe uma velocidade

máxima de reboque de 5 km/h e uma distância máxima de reboque de 5 km (3 milhas).
3. Use um dispositivo de elevação para levantar o carro e os garfos a aproximadamente 30 cm (12 pol.)
da superfície. Instale uma corrente ao redor da travessa do mastro e do carro para evitar que o carro e
os canais do mastro se movam.
4. Se outra empilhadeira for usada para rebocar a empilhadeira desativada, essa empilhadeira deve ter
uma capacidade igual ou maior que a empilhadeira desativada. Instale uma carga aproximada de meia
capacidade nos garfos da empilhadeira que está sendo usada para rebocar a empilhadeira desativada.
Essa carga de meia capacidade aumentará a tração da empilhadeira. Mantenha a carga o mais baixa
possível.
5. Use um elo de reboque feito de aço que se prende a ambas as empilhadeiras. Conecte o elo de reboque

a um dispositivo adequado, como um pino de reboque ou olhal de içamento.
6. Após a conclusão do reboque, coloque calços em ambos os lados (dianteiro e traseiro) de todos os

pneus de tração e direção e aplique novamente o freio de estacionamento.
COLOCANDO UMA EMPILHADEIRA EM BLOCOS

AVISO
A empilhadeira deve ser colocada em blocos para alguns tipos de manutenção e reparo. A
remoção dos seguintes conjuntos causará grandes alterações no centro de gravidade: eixo
motriz, motor, transmissão e contrapeso. Quando a empilhadeira for colocada em blocos,
coloque blocos adicionais nas seguintes posições para manter a estabilidade:
Antes de remover o mastro e o eixo motriz, coloque calços sob o contrapeso para evitar que

a empilhadeira caia para trás.
Antes de remover o contrapeso, coloque blocos sob o mastro para evitar que a empilhadeira

caia para frente.
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A superfície deve ser sólida, plana e nivelada quando a empilhadeira é colocada em blocos.
Certifique-se de que todos os blocos usados para apoiar a empilhadeira sejam sólidos,
unidades de uma peça. Coloque uma placa de aço em cima do bloco.
Antes de colocar a empilhadeira em blocos, verifique a presença de componentes,
mangueiras ou fios montados sob a estrutura, para evitar danos a essas peças.
NOTA: Algumasempilhadeiras possuem olhais de içamento. Os olhais de elevação do caminhão
podem ser usados para levantar a empilhadeira e colocá-la em blocos.
Elevando os pneus de acionamento
1. Coloque blocos em cada lado (dianteiro e traseiro) dos pneus de direção para evitar o movimento da

empilhadeira. Consulte a Figura 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.
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1. STEER AXLE / STEER TIRES 2. DRIVE AXLE / DRIVE TIRES
Figure 3. Putting Lift Truck on Blocks
1. FRAME
2. BLOCKS BETWEEN FRAME AND AXLE
3. SUPPORT BLOCKS
4. STEERING AXLE
5. WHEEL
6. AXLE PIVOT POINT
Figure 4. Steering Axle on Blocks

CLEANING A LIFT TRUCK

WARNING
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.

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 electrical components
causing
damage or erratic behavior.
Use the following guidelines when cleaning a forklift truck:
1. Assure truck components have cooled down before starting the cleaning procedure.
2. Disconnect the battery.
3. Remove accumulated debris using a compressed

air line and nozzle.
4. Lightly spray a noncorrosive cleaning agent onto

the areas to be cleaned. This will help loosen
grime,
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so close contact direct spraying will not be

necessary.
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.
• 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.
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 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:
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• 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.
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 Main Electrical Supply 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 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
Main Electrical Supply 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 DEF system and to the different controllers.
Early disconnect will prohibit the DEF system to finish the purge cycle, possibly resulting in crystallization of
the DEF injection nozzle and damage caused by freezing.
Early disconnect of controllers may trigger fault codes and prohibit a memory reset.
See Main Electrical Supply for location of the Battery Disconnect Switch.
Periodic Maintenance Schedule

NOTA: Partes reproduzidas com permissão da Cummins Inc.
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1. PINOS DE GARFO 11. DEF BOMBA E FILTRO DE SUCÇÃO

2. CORRENTE DE ELEVAÇÃO 12. FILTRO DE ÓLEO DO MOTOR
3. ROLO DE CARGA DE TRANSPORTE 13. PINOS DA HASTE E PINOS REI
4. ROLO DE CARGA DO MASTRO 14. CUBO DA RODA DE DIREÇÃO
5. PINO DO MASTRO 15. FILTRO DE COMBUSTÍVEL
6. PINO PIVÔ DO CILINDRO DE INCLINAÇÃO 16. RESPIRO DO CÁRTER
7. EIXO DE TRANSMISSÃO 17. FILTRO DE RETORNO HIDRÁULICO
8. RESPIRO DO TANQUE DE COMBUSTÍVEL 18. RESPIRO DO TANQUE HIDRÁULICO
9. SEPARADOR DE ÁGUA 19. FILTRO DE REFRIGERAÇÃO DO FREIO
10. FILTRO DE ÓLEO DE TRANSMISSÃO
Figura 5. Filtros e Pontos de Lubrificação
OBSERVAÇÃO: NÃO é necessário engraxar periodicamente o pino de articulação do eixo e a roldana da

corrente . A lubrificação desses itens é necessária apenas na montagem.
INSPEÇÃO DIÁRIA
Verificações diárias de condição
Tabela 1. Verificações Diárias de Condição
Verificações diárias de Procedimento Página

condição
Etiquetas de Aviso e Segurança • Verifique a presença e legibilidade.
Para posição e substituição, consulte o Manual de Peças .
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condição
Estrutura, Mastro, Carro e •
Acessório Certifique-se de que as ferragens de retenção estejam
apertadas e em boas condições.
• Verifique se há rachaduras e deformações. Em particular
após qualquer colisão ou quando algum ruído incomum é
ouvido.
Repare conforme necessário.
Garfos • Verifique a condição e o alinhamento da ponta do garfo.
Substitua conforme necessário.
Correntes de elevação • Verifique a lubrificação adequada.
• Certifique-se de que ambas as correntes estejam frouxas
durante o estacionamento.
• Verifique a condição das placas de ligação e pinos.
Substitua as correntes conforme necessário. Consulte o
Manual de Peças .
Conjunto de Mangueira de • Verifique o estado das mangueiras, braçadeiras e polias.
Cabeçalho
Substitua conforme necessário. Consulte o Manual de
Peças .
Rodas, Pneus e Pressão dos • Verifique o estado e a ausência de danos.
Pneus
• Verifique a pressão conforme especificado na placa de
identificação.
Corrija ou substitua conforme necessário.
Porcas de roda nas rodas de •
tração e direção Retorque 2 - 5 horas após a substituição de uma roda, ou
8 horas após uma porca ter sido girada no reaperto.
Torque de 615 a 710 N•m (454 a 524 lbf ft) .
Respiro do tanque hidráulico • Inspecione o indicador de restrição.
Substitua os elementos conforme necessário. Consulte o

Manual de Peças .
Vazamentos de combustível, • Verifique se há vazamentos.
óleo, DEF ou refrigerante
Tubulação de admissão de ar do • Verifique se há vazamentos de ar e conexões soltas.
motor e tubulação de ar de carga
Correia do Ventilador de • Verifique a tensão e condição.
Resfriamento
Conjunto do radiador • Verifique se o radiador está limpo e desobstruído.
• Verifique o radiador, as mangueiras e as conexões quanto
a vazamentos.
Limpe e repare conforme necessário.
Compartimento do motor • Remova materiais combustíveis.
• Remova todos os materiais estranhos.
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condição
Janelas e espelhos • Clean windows, wipers and mirrors.
Adjust and replace as required. See Parts Manual.
Daily Fluid Level Checks
Table 2. Daily Fluid Level Checks
Daily Fluid Level Procedure Page

Checks
Windshield Washer • Check level in reservoir.
Fluid Level
Add fluid as required.
Hydraulic System • Check level indicator with mast fully lowered.
Oil
• 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.
• 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 when cold.
See Approved Fuel and Engine Oils for required specifications.
Daily Checks from the Driver Seat with Engine Running

NOTE: Firstread 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 Driver Procedure Page

Seat with Engine Running
Operator Restraint System •
Check condition and operation of seat belt, seat rails and
steering column latch.
Repair as required.
Horn, Gauges, Lights, Alarms and • Visual and audible verification.
Control System
Repair as required.
Fault Codes •
The display should be free of fault codes. The central
warning light will be ON when a fault code is shown.
• Stop the engine when the Engine Stop Warning Light is
ON.
Report any fault code to have the fault diagnosed and
repaired.
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Table 3. Daily Checks from the Driver Seat with Engine Running
Daily Checks from the Driver Procedure Page
Seat with Engine Running
Engine Air Filter •
Replace Main Filter Element when warning light is ON,
and record hour meter reading. •
• Also replace the Safety Element at every third replacement

of the Main Filter Element.
See Parts Manual.
Fuel/Water Separator and Final • Drain water/sediment when the warning light is ON.
Fuel Filter
Coolant Level •
Add coolant when warning light is ON, and record added
volume and hour meter reading.
For details, see Approved Oils, Fluids, and Grease.
Fuel Level • Avoid low fuel level. Refuel in time.
Diesel Exhaust Fluid (DEF) • Avoid low DEF level. Refuel in time.
Control Levers, Switches, and • Check operation as described in the Operating Manual.
Pedals
Repair as required.
Parking and Service Brakes • Check operation. Repair as required.
Steering System • Check operation.
Repair as required.
Mast, Carriage, and Attachment • Check proper tracking of header hoses.
• Check smooth operation.
Repair as required.
Signals from the Spreader Control • Check operation.
System (ECH)
Repair as required.
Transmission • Check operation.
Repair as required.
Operator Presence System • Check operation.
Repair as required.
Transmission Oil • Check oil level and add ZF TE-ML 03 oil as required.
INITIAL INSPECTION
First Inspection after First 100 Hours of Operation

Table 4. First Inspection after First 100 Hours of Operation
Initial 100 Hours Inspection Procedure Page

Lift Chains • Lubricate and adjust lift chains.
• Make sure chains are slack during parking.
Transmission Oil Filter • Replace filter. See Parts Manual.
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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.
Labels
• For position and replacement, see Parts Manual.
Frame, Mast, Carriage, •
and Attachment Make sure retaining hardware is tightened and in 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.
Replace as required. See Parts Manual.
Lift Chains • Check proper lubrication and adjustment.
• Check condition of link plates and pins.
Header Hose Assembly • Check condition of hoses, clamps and sheaves.
• Check proper tracking during operation.
Wheel, Tires, and Tire • Check condition and absence of damage.
Pressure
• Check pressure as specified on nameplate.
Correct or replace as required.
Wheel Nuts on Drive • Make sure all nuts are properly torqued.
and Steer Wheels
Required torque is 615 to 710 N•m (454 to 524 lbf ft).
Hydraulic Tank • Inspect restriction indicator.
Breather
Replace element when indicator is raised. See Parts Manual.
Fuel, Oil, DEF, or • Check for leaks.
Coolant
Repair as required.
Engine Air Intake • Check for leaks and proper installation.
Piping and Charge Air
Repair as required.
Piping
Coolant Hoses • Inspect for cracks, cuts, and collapsing.
Repair as required.
Cooling Fan Belt • Check tension and condition.
Repair as required.
Radiator Assembly • Check radiator, hoses and connections for leakage.
Clean and repair as required.
Engine Compartment • Remove combustible materials.
• Remove all foreign materials.
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DEF Tank Fill Cap • Check cap sealing and membrane breathing capabilities.
• Rinse off DEF crystals as necessary.
Drive Axle and • Inspect magnetic plugs and oil level.
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.
Windshield Washer • Check level in reservoir and add fluid as required.
Fluid Level
Hydraulic System Oil • Check level indicator.
• 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.
Coolant Level • Inspect level at the expansion tank.
• 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.
Engine Oil Level • Maintain level at two/thirds of full range on dipstick when cold.
See Approved Fuel and Engine Oils.
Fuel/Water Separator • Drain water until clear fuel flows from the filter.
and Final Fuel Filter
Operator Restraint •
System Check condition and operation of seat belt, seat rails and steering
column latch.
Repair as required.
Horn, Gauges, Lights, • Visual and audible verification.
Alarms and Control
Repair as required.
System
Fault Codes •
Check fault code warning lights. The display should be free of fault
codes.
• Diagnose and repair the cause of any fault code.
Control Levers, • Check operation as described in the Operating Manual.
Switches, and Pedals
Repair as required.
Parking and Service • Check condition and operation.
Brakes
Repair as required.
Steering System • Check operation.
Repair as required.
Operator Presence • Check operation.
System
Repair as required.
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Mast, Carriage, and • Check smooth operation.
Attachment
• Check tracking of header hoses.
Repair as required.
Signals from the • Check operation.
Spreader Control
Repair as required.
System (ECH)
Transmission Oil • Check oil level and add ZF TE-ML 03 oil as required.
If oil is added, check for leaks and record added volume and hour
meter reading.
Every 500 Hours
Cab Air Filter • Check and clean element.
Replace filter when required. See Parts Manual.
Engine Air Filter • Verify maintenance records to establish if normal air filter
replacement is due. Make sure Tier 3 air filter sensor performs
properly.
• If required, replace the Main Filter Element, clean the inside of the
housing and record filter replacement.
• At every third replacement of the Main Filter Element, also replace
the Safety Filter Element.
Cooling Fan • Check for cracks and damage.
Replace fan when required. See Parts Manual.
Every 2,000 Hours
Coolant Quality • Measure and record acidity and freezing point.
• Compare measurement with earlier records and take appropriate
action.
Cooling Fan Belt • Verify if the bearings for the hubs and pulleys produce more noise
Tensioner and Pulleys
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 (1305.3 ±72.5 psi).
Accumulator
Re-charge or replace accumulator as required.
Transmission Clutch • Perform clutch calibration at each transmission oil change.
Calibration
Inching Pedal Sensor • Check calibration value and adjust as required.
Calibration
Lift System • Make sure pre-charge pressure is 9 ±0.5 MPa (1300 ±38 psi).
Accumulator (Optional)
Correct if required.
Crankcase Breather • Check element.
Element
Replace when required. See Parts Manual.
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Engine and • Check isolators and hardware.
Transmission Mounts
Vibration Damper • Check for fluid loss and deformation.
Every 5,000 Hours
Engine Valve • Check valve clearance.
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 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.
Use multipurpose grease with MoS2 additive. For details,

see Approved Oils, Fluids, and Grease.
Tilt Cylinder Pivot Pins • Lubricate 4 fittings.
Use multipurpose grease.
Fork Pins, Carriage Pins, and • Lubricate pins and surfaces.
Carriage Sliding Surfaces
Inner Mast Load Rollers • Lubricate 4 fittings.
Carriage Load Rollers • Lubricate 4 fittings.
Every 500 Hours
Drive Shaft • Lubricate 3 fittings.
Steering Axle Tie Rod Pins • Lubricate 4 fittings.
Steering Axle King Pins • Lubricate 4 fittings.
Every 1,000 Hours
Cab Door Hinges • Lubricate 4 fittings.
Change
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Table 7. Change
Change Procedure Page

Every 500 Hours
Engine Oil • Change engine oil.
For details, see Approved Fuel and Engine Oils.
Engine Oil Filter • Replace filter.
See Parts Manual.
Fuel/Water Separator • Replace filter.
See Parts Manual.
Final Fuel Filter • Replace filter.
See Parts Manual.
Every 1,500 Hours
Drive Axle and • Change oil.
Differential
Every 2,000 Hours
Crankcase Breather • Inspect and replace crank case breather element as required.
Element
See Parts Manual.
Transmission Oil • Change transmission oil.
Transmission Oil Filter • Replace filter.
See Parts Manual.
Brake Cooling Filter • Replace filter.
See Parts Manual.
Every 3,000 Hours
Hydraulic System Oil • Take oil sample and follow instructions from the laboratory report.
For details, see Approved Oils, Fluids, and Grease when replacing
oil.
Hydraulic Tank Return • Replace filter at each hydraulic oil change.
Filter
See Parts Manual.
Every 5,000 Hours
Fuel Tank Breather • Replace filter.
See Parts Manual.
DEF Pump Filter • Replace filter.
See Parts Manual.
DEF Tank Suction Filter • Replace filter.
See Parts Manual.
Steering Wheel Hub • Replace multipurpose grease and re-adjust bearing preload.
Bearings
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Table 7. Change
Change Procedure Page
Air Conditioning System •
Contact certified AC specialist for replacing dryer, lubricant and
refrigerant.
For Dryer, see Parts Manual.
For Lubricant, see Compressor Nameplate.
For Refrigerant use 1300 ±50 grams (2.87 ±0.11 lb) of R134a.
Periodic Maintenance Schedule - ELME 580 Series Container

Attachment
1. TWIST LOCK 4. ALMOFADA DE DESGASTE LATERAL

2. SLIDER PAD 5. ROLOS DE TRANSPORTE
3. EXTENSION BEAM WEAR PAD
Figura 6. Pontos de Manutenção do Anexo de Contêiner

MANUTENÇÃO PERIÓDICA
Inspecione e ajuste
Tabela 8. Inspecione e Ajuste
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Tabela 8. Inspecione e Ajuste

Inspecione e Procedimentos Página
ajuste
Diário
Acessório • Verifique se há danos, rachaduras e distorções.
• Verifique o sistema de controle do espalhador e a operação do

espalhador.
• Verifique se há vazamentos hidráulicos.
A cada 250 horas
Acessório • Verifique se há danos, rachaduras e distorções.
• Verifique o sistema de controle do espalhador e a operação do

espalhador.
• Verifique se há vazamentos hidráulicos.
Travas de torção • Monitore o desgaste e verifique possíveis danos.
Lubrificar
Tabela 9. Lubrifique
Lubrificar Procedimentos Página

A cada 500 horas
Travas de torção • Lubrifique 2 ou 4 conexões.
Use graxa multiuso. Para obter detalhes, consulte Óleos,

fluidos e graxas aprovados .
Almofadas de desgaste do feixe • Substitua os coxins se a espessura for de 18 mm (0,7 pol)
de extensão
ou menos.
• Verifique o torque do hardware de retenção.
• Lubrifique as esteiras nos coxins das vigas de extensão.
Use graxa multiuso.
Almofadas deslizantes do feixe • • Monitore o máximo de jogo e retenção.
final
Pastilhas de Desgaste de • Aplique lubrificante nas conexões em dois pontos
Deslocamento Lateral
centrais de lubrificação.
Use graxa multiuso.
Rolos de Carga de Transporte • Lubrifique o encaixe em cada rolete do carro.
Use graxa multiuso.
Mudar
Tabela 10. Mudança
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Tabela 10. Mudança

Mudar Procedimentos Página
A cada 5.000 horas
Travas de torção • Substitua as travas de torção.
Consulte o Manual de Peças .
Procedimentos de manutenção periódica

SISTEMA DE AR CONDICIONADO

CUIDADO
Entre em contato com um técnico treinado em AC certificado para extrair e reabastecer
refrigerante.
A cada 5.000 horas ou 36 meses
Instale um novo secador e reabasteça com lubrificante e refrigerante novos.
Para Secador, consulte o Manual de Peças .
Para lubrificante, consulte a placa de identificação do compressor.
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 COOLING FILTER

Every 2,000 Hours
Remove and replace the filter element.
1. Lower the mast.
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 (177.02 lbf in).
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1. FILTER BOWL
2. FILTER ADAPTOR
Figure 7. Brake Cooling Filter
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.
3. Lower the mast completely.
4. Tilt the mast completely forward.
6. Shut down the engine.
7. Place blocks in front of and behind the tires to prevent movement of the lift truck.
8. Raise (side tilt) the cab to the fully open position to gain access to the main control valve.
9. Remove the cap from check port M ACC on the main control valve.
10. Connect a 0 to 30 MPa (0 to 4,351 psi) hydraulic pressure gauge at port M ACC.
11. Lower the cab until it is in the fully lowered and latched position.
12. Apply the brake pedal and observe the gauge reading. Repeat this procedure until the brake pedal
pressure nears the accumulator pressure. A sudden sharp pressure drop will be observed. The gauge

reading immediately before the sharp pressure drop represents the precharge pressure of the
accumulator.
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13. 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).
14. After refilling the accumulator, raise (side tilt) the cab to the fully open position to gain access to the

main control valve.
15. Remove the pressure gauge from port M ACC.
16. Install the cap on check port M ACC on the main control valve.
CAB AIR FILTER

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.
Replace the filter when necessary.
After the filter has been installed, push the locks into the locked position. See Figure 8.
1. CAB AIR FILTER

2. LOCK
Figure 8. Cab Air Filter
CAB DOOR HINGES

Every 1,000 Hours
There are four grease fittings on the cab door hinges, two on each hinge. Lubricate the cab door hinges. See
Approved Oils, Fluids, and Grease.
CONTROL LEVERS, SWITCHES, AND PEDALS

Daily
Check that the control levers for the transmission, mast, attachment, and the pedals operate as described in the
Operating Manual.
COOLING SYSTEM
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.
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Inspect the condition of the coolant hoses by looking for cracks, leakage or other damage.
Replace damaged hoses.
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.
Check coolant level in the expansion tank when cold. Coolant level must be between the 'MIN' and 'MAX'
mark on the expansion tank.
Add coolant when level is at or below the ‘MIN’ mark.
Also add coolant when the Coolant Level Warning Light is ON during operation of the truck.
If coolant must be added, use an OAT (Organic Acid Technology) type coolant. Add coolant until just below
the 'MAX' mark on the expansion tank. See Figure 9.
When coolant has been added, make a note of the date and added quantity.
Check the cooling system for leaks if more than 1 liter (0.26 gal) of coolant must be added per 3,000 running
hours.
1. RADIATOR CAP
2. EXPANSION TANK
3. "MIN" MARK
4. "MAX" MARK
5. COOLANT LEVEL SWITCH
Figure 9. Cooling System

Coolant Quality
Every 2,000 Hours
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Measure and record acidity and ethylene glycol content of the coolant.
Compare measurement with earlier records and take appropriate action.
Replace factory filled coolant if pH level is lower than 7.7.
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.
Cooling Fan Belt

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.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figura 10. Inspeção da Correia de Transmissão
Tensionador e polias da correia do ventilador de resfriamento

A cada 2.000 horas
Verifique se os rolamentos dos cubos e polias produzem mais ruído durante a operação do que o normal. Se
houver ruído excessivo, verifique o estado dos rolamentos da polia, alinhamento da polia e funcionamento do
tensor da correia.
Condição do Rolamento
Remova a correia e gire cada cubo e polia para verificar a rotação suave e a ausência de folga. Consulte a
Figura 11 .
Verifique se os rolamentos do alternador são a fonte do ruído.
Substitua componentes ou rolamentos conforme necessário.
Reinstale a correia do ventilador.
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Figura 11. Correia de acionamento
Alinhamento da polia
Use uma régua e um inclinômetro para estabelecer o desalinhamento entre a correia e as diferentes polias. O
desalinhamento máximo é de 3 graus. Consulte a Figura 12 .
Figura 12. Alinhamento da polia

Condição do tensor
1. Verifique se nem o batente superior nem inferior do braço do tensor está tocando a saliência fundida
no corpo do tensor. Se qualquer um dos batentes estiver tocando uma saliência fundida, a correia de

transmissão deve ser substituída. Certifique-se de que o número de peça correto da correia esteja
sendo usado se houver qualquer uma das condições. Consulte a Figura 13 .
Figura 13. Paradas do braço tensor da correia do ventilador de resfriamento com correia de
acionamento
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2. Remova a correia de transmissão do tensor. Verifique se o batente do braço do tensor inferior está em
contato com o ressalto do batente do braço do tensor inferior no corpo do tensor. Se estes dois não
estiverem se tocando, o tensor deve ser substituído. Consulte a Figura 14 .
Figura 14. Paradas do braço tensor da correia do ventilador de resfriamento sem correia de
acionamento
3. Check the tensioner pulley and body for cracks. If any cracks are noticed, the tensioner must be

replaced. See Figure 15.
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.
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Figure 16. Tensioner Inspection
CRANKCASE BREATHER ELEMENT (TIER 4F/STAGE IV ONLY)

Every 2,000 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. See Figure 17.
1. CRANKCASE VENTILATION HOSE

2. CRANKCASE BREATHER
3. OIL DRAIN TUBE
4. CRANKCASE BREATHER TUBE
Figure 17. Crankcase Breather
DIESEL EXHAUST FLUID (DEF) SYSTEM

DEF Pump Filter
Every 5,000 Hours
Replace the DEF Pump Filter and filter insert using the filter removal tool. See Figure 18.
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1. DEF PUMP
2. FILTER SCREW CAP
Figure 18. DEF Pump
1. Remove the cover using a wrench.
2. Use the filter tool to pull the filter from the pump. See Figure 19.
1. DEF PUMP
2. FILTER
3. FILTER REMOVAL TOOL
Figure 19. DEF Pump Filter Remove
3. Insira o elemento filtrante no elemento filtrante. Consulte a Figura 20 .
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1. INSERÇÃO DE FILTRO
2. ELEMENTO DE FILTRO
Figura 20. Conjunto de Filtro da Bomba DEF
4. Instale o filtro na bomba DEF, instale a tampa de rosca e aperte manualmente.
Tampa de enchimento do tanque DEF

A cada 250 horas
Verifique a vedação da tampa de enchimento do tanque DEF e as capacidades de respiração da membrana. Se
necessário, limpe a tampa de enchimento embebendo-a em água e enxágue os cristais de DEF. Consulte a
Figura 21 .
1. TAMPA DE ENCHIMENTO DO TANQUE DE DEF
Figura 21. Tampa de enchimento do tanque DEF
Filtro de sucção do tanque DEF

A cada 5.000 horas
Substitua o filtro de sucção do tanque DEF.
1. Remova a unidade do tanque DEF do tanque DEF. Consulte a Figura 22 .
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Figura 22. Unidade de Tanque DEF
2. Remova o parafuso de retenção do filtro. Consulte a Figura 23 .
1. DEF FILTRO DE SUCÇÃO

2. PARAFUSO DE RETENÇÃO
Figura 23. Parafuso do filtro de sucção DEF
3. Retire o filtro do tubo de sucção. Consulte a Figura 24 .
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1. FIN DO TUBO DE AQUECEDOR

2. TUBO DE SUCÇÃO DEF
3. ALOJAMENTO DO PARAFUSO DE RETENÇÃO
4. ALOJAMENTO DO TUBO DE SUCÇÃO DEF
5. DEF FILTRO DE SUCÇÃO
Figura 24. Filtro de Sucção DEF
4. Posicione o novo filtro no alojamento do tubo de sucção na parte inferior do tubo de sucção e

pressione o filtro contra o fundo da aleta do tubo aquecedor.
5. Instale a unidade do tanque DEF no tanque DEF.
EIXO DE ACIONAMENTO E DIFERENCIAL
Verifique o nível de óleo

A cada 250 horas
Remova os bujões magnéticos de óleo nos acionamentos diferenciais e planetários para verificar o nível de
óleo e o tamanho das partículas de desgaste.
• Se as partículas forem grandes lascas de brilho, verifique se há danos nos rolamentos e engrenagens

antes de continuar a operação.
• Se as partículas estiverem em curso, verifique a pré-tensão do rolamento da roda.
• A situação é normal se um pó fino foi coletado.
O nível de óleo das engrenagens do diferencial e planetário deve ser verificado separadamente.
O nível do óleo da engrenagem no diferencial está correto quando o óleo da engrenagem está nivelado com o
bujão na frente da carcaça.
O nível do óleo das engrenagens planetárias está correto quando a "linha de nível" na tampa do planetário
estiver paralela ao piso e o óleo estiver nivelado com o bujão.
Adicione óleo de engrenagem limpo conforme necessário. Consulte Óleos, Fluidos e Graxas Aprovados .
Verifique se há vazamentos se for necessário adicionar óleo.
Registre o volume adicionado e a leitura do horímetro.
A cada 500 horas
Lubrifique as três graxeiras no eixo de acionamento. Consulte Óleos, Fluidos e Graxas Aprovados .
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Duas dessas conexões estão localizadas nas juntas universais em cada extremidade do eixo de acionamento.
O terceiro encaixe está no garfo deslizante no centro do eixo de acionamento.
Verifique se as juntas universais estão apertadas e não danificadas. Verifique o eixo de acionamento quanto a
danos. Se algum dos componentes estiver solto ou danificado, deve ser substituído.
Trocar óleo
A cada 1.500 horas
Troque o óleo do diferencial e do eixo motor. Para drenar o óleo, remova os bujões das tampas planetárias e o
bujão na parte inferior da carcaça do diferencial. Verifique o tamanho das partículas nos plugues magnéticos e
limpe os plugues magnéticos. Encha o eixo motor com o óleo especificado em Óleos, fluidos e graxa
aprovados . Encha lentamente até o fundo dos orifícios do bujão de enchimento. Após o enchimento, opere a
empilhadeira para garantir que o nível de óleo esteja nivelado. Verifique o nível do óleo novamente e
verifique se há vazamentos.
EIXO DE ACIONAMENTO
A cada 500 horas
Lubrifique as três graxeiras no eixo de acionamento. Consulte Óleos, Fluidos e Graxas Aprovados .
Duas dessas conexões estão localizadas nas juntas universais em cada extremidade do eixo de acionamento.
O terceiro encaixe está no garfo deslizante no centro do eixo de acionamento.
Verifique se as juntas universais estão apertadas e não danificadas. Verifique o eixo de acionamento quanto a
danos. Se algum dos componentes estiver solto ou danificado, deve ser substituído.
ALMOFADAS DESLIZANTES DO FEIXE FINAL
A cada 500 horas
Verifique os pads deslizantes da viga final quanto a folga excessiva. Mantenha uma folga de 1 a 2 mm
(0,039 a 0,079 pol.) entre os blocos deslizantes e a viga final. Recalque ou substitua os coxins deslizantes
conforme necessário. Consulte a Figura 25 .
1. SUPORTE
2. ALMOFADA DESLIZANTE
Figura 25. Almofadas deslizantes da viga final

FILTRO DE AR DO MOTOR

CUIDADO
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Se o recipiente do filtro de ar não for limpo durante a manutenção ou substituição do filtro

de ar, a sujeira se acumulará gradualmente no compartimento do filtro. Isso pode fazer com
que a unidade de filtro funcione incorretamente. Se o elemento filtrante for forçado no lugar,
a carcaça do filtro pode rachar com o tempo, permitindo que a sujeira entre e danifique o
motor.
Diário
Substitua o elemento filtrante principal quando a luz indicadora de restrição do fluxo de ar no painel de
instrumentos estiver acesa . Registre a leitura do horímetro na substituição.
Substitua o elemento de segurança a cada três vezes que o elemento principal for substituído. Limpe o interior
da carcaça ao trocar os filtros.
A cada 500 horas ou pelo menos a cada 12 meses
Verifique os registros de manutenção para estabelecer se a substituição normal do filtro de ar é necessária.
Certifique-se de que o sensor do filtro de ar Tier 3/Estágio IIIA funcione corretamente.
Se necessário, substitua o elemento filtrante, limpe o interior da carcaça e registre a substituição do filtro.
Consulte o Manual de Peças .
A cada terceira substituição do elemento principal, substitua também o elemento filtrante de segurança.
Para motores Tier 3/Estágio IIIA, teste o funcionamento da luz de advertência do filtro de ar, se houver
suspeita de mau funcionamento. O interruptor de vácuo deve ligar em um vácuo de 6,3 kPa (0,91 psi) .
A carcaça do filtro de ar não deve ser aberta até que seja necessária a substituição do elemento do filtro de ar
ou uma inspeção. Consulte a Figura 26 .
1. PRÉ PURIFICADOR
2. GRAMPO DE RETENÇÃO
3. TAMPA DO ALOJAMENTO DO FILTRO DE AR
4. ALOJAMENTO DO FILTRO DE AR
5. REMETENTE DE RESTRIÇÃO AÉREA
Figura 26. Filtro de ar do motor (Tier 4F/Estágio IV mostrado)

TUBULAÇÃO DE ADMISSÃO DE AR DO MOTOR E TUBULAÇÃO DE AR DE CARGA
Diariamente e a cada 250 horas
Inspecione a tubulação de admissão e ar de admissão quanto a pontos de desgaste e vazamentos. Procure por
grampos soltos e furos que possam permitir a entrada de sujeira no motor. Consulte a Figura 27 .
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Figura 27. Tubulação de entrada de ar e tubulação de ar de carga
SUPORTES DE MOTOR E TRANSMISSÃO

A cada 2.000 horas
Inspecione todas as montagens de borracha quanto a envelhecimento e danos. Procure por traços, que
indiquem movimento relativo excessivo entre os suportes do chassi e os suportes do motor e da transmissão.
Verifique se os parafusos de montagem estão apertados a 165 N•m (122 lbf pés) . Substitua qualquer peça
danificada. Consulte a Figura 28 e a Figura 29 .
1. SUPORTE DE MONTAGEM
2. SUPORTE DE BORRACHA
3. ARRUELA GRANDE
4. NOZ
5. PARAFUSO DE TAMPA
6. SUPORTE DA ESTRUTURA
Figura 28. Montagens do Motor
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1. SUPORTE DE MONTAGEM
2. MÁQUINA DE LAVAR
5. NOZ
6. NOZ
7. PARAFUSO
9. NÚCLEO DE METAL
10. SUPORTE DE BORRACHA
11. SUPORTE
Figura 29. Montagens de Transmissão
COMPARTIMENTO DO MOTOR
Abra o capô e verifique se há vazamentos e condições anormais. Limpe qualquer derramamento de óleo ou
combustível. Certifique-se de que todas as superfícies estejam livres de óleo, lubrificantes, combustível e
poeira ou fibras orgânicas (papel, madeira, algodão, lã, etc.).
Remova todos os materiais estranhos.
ÓLEO DE MOTOR
Nível de óleo do motor

AVISO
A exposição prolongada ao óleo de motor usado pode causar irritação na pele ou câncer.
Tenha cuidado ao verificar ou adicionar óleo ao motor. Se o óleo entrar em contato com a
pele, lave com detergente e água.

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CUIDADO
NÃO permita a entrada de sujeira no motor quando o nível do óleo for verificado ou o filtro
for trocado. NUNCA opere o motor sem óleo. O funcionamento do motor sem óleo danificará
o motor.
Verifique o nível de óleo do motor após o motor ter parado por mais de um minuto.
Mantenha o nível de óleo em dois terços da faixa total na vareta. Consulte a Figura 30 . Ao adicionar óleo,
use o óleo correto conforme mostrado em Óleos, fluidos e graxas aprovados .
1. FILTRO DE ÓLEO DO MOTOR

2. VARA DO ÓLEO DO MOTOR
Figura 30. Filtro de óleo do motor e vareta
Óleo do motor e filtro de óleo do motor

AVISO
A exposição prolongada ao óleo de motor usado pode causar irritação na pele ou câncer.
Tenha cuidado ao verificar ou adicionar óleo ao motor. Se o óleo entrar em contato com a
pele, lave com detergente e água.

CUIDADO
NÃO permita a entrada de sujeira no motor quando o nível do óleo for verificado ou o filtro
for trocado. NUNCA opere o motor sem óleo. O funcionamento do motor sem óleo danificará
o motor.
A cada 500 horas
Troque o óleo do motor e substitua o filtro de óleo do motor.
O filtro de óleo do motor está instalado no lado esquerdo do motor. Consulte a Figura 30 . Substitua o
elemento do filtro spin-off. Encha o elemento do filtro com o óleo especificado nos Óleos de motor e
combustível aprovados e aplique óleo limpo na junta do novo filtro. Gire o filtro até que a gaxeta toque o
alojamento do filtro de óleo e, em seguida, aperte ½ a 3/4 de volta com a mão.
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Coloque um recipiente adequado que possa conter 19 litros (20 qt) sob o cárter de óleo do motor, remova o
bujão de drenagem e drene o óleo. Instale o bujão de drenagem e reabasteça o motor com óleo novo conforme
especificado em Óleos, fluidos e graxa aprovados .
AJUSTE DA VÁLVULA DO MOTOR

A cada 5.000 horas
Ajuste as válvulas do motor de acordo com os valores listados na placa do número de série do motor na
tampa das válvulas. Consulte a Figura 31 .
Figura 31. Placa de número de série na tampa da válvula

CUIDADO
A temperatura do líquido de arrefecimento do motor deve ser inferior a 60 °C (140 °F) .
1. Remova as porcas de montagem e os isoladores que prendem a tampa da alavanca oscilante.
2. Remova o conector do sensor de pressão de exaustão. Consulte a Figura 32 .
3. Remova a tampa do balancim e a gaxeta embaixo do tubo de conexão EGR.
1. PORCA DE MONTAGEM E ISOLADOR

2. TUBO DE CONEXÃO EGR
3. SENSOR DE PRESSÃO DE ESCAPE
Figura 32. Remoção da tampa da alavanca do balancim
4. Use uma ferramenta de barramento para girar o virabrequim para alinhar as marcas superiores do
ponto morto na tampa da engrenagem e na engrenagem da bomba de combustível. Consulte a Figura
33 .
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1. FERRAMENTA DE LIMITAÇÃO
Figura 33. Ferramenta de Barramento
5. Com o motor nesta posição, a folga pode ser verificada nos seguintes balancins: 1l, 1E, 2l, 3E, 4l e 5E.

Consulte a Tabela 11 .
Tabela 11. Limites de Ajuste da Válvula
Limites de ajuste de válvula

Ingestão "MIN" 0,152 mm (0,006 pol.) "MAX" 0,559 mm (0,022 pol.)
Escape "MIN" 0,381 mm (0,015 pol.) "MAX" 0,813 mm (0,032 pol.)
6. Meça a folga inserindo um calibrador entre a cruzeta e a esfera e o soquete do balancim enquanto
levanta a extremidade do balancim. Se a medição da folga estiver fora da especificação, solte a

contraporca enquanto segura o parafuso de ajuste com uma chave de fenda e ajuste a folga para a
especificação nominal conforme indicado na placa de identificação do motor. Consulte a Figura 31 .
1. CHAVE NA PORCA DE TRAVAMENTO

2. MEDIDOR DO FELADOR
3. CHAVE DE FENDA
Figura 34. Porca de travamento e calibrador de folga
NOTA: Reinicializações
de folga são necessárias apenas no intervalo especificado no
Cronograma de Manutenção, quando a folga é medida e encontrada fora da especificação, ou
quando os reparos do motor causam a remoção dos balancins e/ou afrouxamento dos parafusos
de ajuste.
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7. Enquanto segura o parafuso de ajuste no lugar com uma chave de fenda para evitar perder o ajuste
adequado, aperte a contraporca a 24 N•m (18 lbf ft) para ajustar o ajuste e, em seguida, meça a folga

novamente com o calibrador de folga. Repita do Passo 4 ao Passo 9 até que o ajuste apropriado dos
cílios seja adquirido.
8. Usando uma ferramenta de barramento, gire o virabrequim 360 graus e repita da Etapa 4 até a Etapa 7

para os balancins 2E, 3l, 4E, 5l, 6l e 6E. Redefina o chicote, se estiver fora da especificação.
9. Instale a junta de pressão. Consulte a Figura 35 .

• Pressione a junta moldada nos cantos da tampa do balancim.
• Pressione a junta em torno dos orifícios de montagem dos parafusos.
• Pressione a junta restante na tampa do balancim.
1. JUNTA DA TAMPA DA ALAVANCA DO ROCKER

2. TAMPA DA ALAVANCA DO ROCKER
Figura 35. Instalação da junta da tampa da alavanca do balancim
10. Instale a tampa do balancim e os parafusos de fixação. Aperte os parafusos com torque de 12 N•m

(106 lbf in) .
11. Instale o tubo de respiro do cárter na tampa do balancim.
12. Instale a linha de suprimento de ar do atuador do turbocompressor de geometria variável, se equipado.
ALMOFADAS DE DESGASTE DO FEIXE DE EXTENSÃO

A cada 500 horas
1. Inspecione os coxins quanto a desgaste. Consulte a Figura 36 .
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1. ALMOFADA DE DESGASTE
2. CALÇO DA ALMOFADA DE DESGASTE
5. SUPORTE DA ALMOFADA DE DESGASTE
6. FEIXE DE EXTENSÃO
Figura 36. Pastilhas de desgaste da viga de extensão
2. Substitua os coxins se a espessura for de 18 mm (0,709 pol.) ou menos. Ao substituir as pastilhas de
desgaste, substitua simultaneamente todas as pastilhas instaladas no mesmo plano. (Todos os pads

inferiores, todos os pads superiores ou todos os pads laterais). O uso de coxins com uma espessura
diferente irá torcer e danificar a soldagem da viga de extensão.
3. Verifique o torque das ferragens que retêm os suportes dos coxins. O torque necessário é de 63 N•m

(46 lbf ft) .
4. Lubrifique os trilhos dos coxins.
CÓDIGOS DE FALHA
Se o motor, a transmissão ou o controlador hidráulico detectar uma falha, o visor do horímetro/código de
falha mostrará um código de falha em vez das horas de funcionamento do motor e as luzes de advertência
centrais acenderão .
Se aparecer uma falha, comunique a falha imediatamente. NÃO opere a empilhadeira até que a falha seja
corrigida. Quando todas as falhas tiverem sido eliminadas ou reparadas, o visor do horímetro/código de falha
mostrará novamente as horas de funcionamento do motor.
Consulte o Guia de código de falha do motor Cummins 0600SRM1101 para obter os códigos de falha do
motor.
Consulte Operações e diagnósticos da transmissão 1300SRM1455 para obter os códigos de falha da
transmissão ZF.
Consulte o Sistema de Controle Hidráulico 2200SRM1935 para os códigos de falha do sistema hidráulico.
GARFOS

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AVISO
NÃO tente corrigir o alinhamento das pontas dos garfos dobrando os garfos ou adicionando
calços. Nunca repare garfos danificados por aquecimento ou soldagem. Os garfos são
feitos de aço especial usando procedimentos especiais. Se um dos garfos estiver
danificado, substitua os garfos como um conjunto.
NOTA: Realize também as verificações abaixo imediatamente após qualquer colisão do
caminhão, carga ou acessório.
Substitua os garfos como um conjunto se algum dos requisitos abaixo não for atendido.
1. Verifique se o ângulo do garfo é inferior a 93°.
2. Verifique se as pontas do garfo estão alinhadas dentro de 3% do comprimento do garfo.
3. Verifique a ausência de rachaduras na conexão do pino do garfo.
4. Verifique a ausência de rachaduras no calcanhar do garfo. Consulte a Figura 37 .

Substitua qualquer peça danificada ou quebrada que seja usada para manter os garfos travados na

posição.
A cada 250 horas

Certifique-se de que a parte inferior do garfo tenha pelo menos 90% da espessura original.
Se um dos garfos estiver gasto, substitua os garfos como um conjunto.
Alinhamento da ponta do garfo

Comprimento dos garfos 3% Dimensão
1.220 mm (48 pol.) 37 mm (1,5 pol.)
1.830 mm (72 pol.) 55 mm (2,2 pol.)
2.440 mm (96 pol.) 74 mm (3,0 pol.)
1. DIMENSÃO ORIGINAL
2. ALINHAMENTO DAS PONTAS DENTRO DE 3%
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3. SEM RACHADURAS
4. DEVE SER PELO MENOS 90% DA DIMENSÃO ORIGINAL
5. DESGASTE DOS GARFOS MÁX. 10%
6. ÂNGULO MÁXIMO DE 93°
Figura 37. Verifique os garfos

PINOS DE GARFO, PINOS DE CARRO E SUPERFÍCIES DESLIZANTES DE CARRO
A cada 250 horas
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.
FRAME, MAST, CARRIAGE AND ATTACHMENT

WARNING
Lower the lift mechanism completely. Never allow any person under a raised carriage. DO
NOT put any part of your body in or through the lift mechanism unless all parts of the mast
are completely lowered and the engine is STOPPED.
1. Make sure all retaining hardware for carriage, mast pivots end tilt cylinder rod ends is tightened and in

good condition.
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, DEF, 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.
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
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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.
FUEL/WATER SEPARATOR AND FINAL FUEL FILTER

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
Daily
Drain water from the fuel/water separator when the warning light on the instrument panel is ON during
operation. The fuel/water separator is located at the left-hand side of the truck. See Figure 38.
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

Drain water from the fuel/water separator.
Every 500 Hours
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. See Figure 39. 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.
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1. FUEL/WATER SEPARATOR
2. HANDPUMP
3. DRAIN VALVE
4. ELECTRICAL CONNECTOR
5. SHUTOFF VALVE
Figure 38. Fuel/Water Separator
1. FINAL FUEL FILTER
Figure 39. Final Fuel Filter

FUEL TANK BREATHER
Every 5,000 Hours
Use a spanner to remove and replace the breather. See Figure 40.
1. FUEL TANK BREATHER

2. FUEL TANK FILL CAP
3. FUEL TANK
Figure 40. Fuel Tank Breather

HEADER HOSE ASSEMBLY
1.
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Check if hoses are aged, kinked, crushed or twisted.
2. Check the hose covers for cuts, cracks, or exposed reinforcement.
3. Check proper hose tension.
4. Check hoses and fittings for hydraulic leaks.
5. Check the clamps and sheaves for defective or broken parts.
6. Check proper tracking during operation.

Adjust, or replace components as required. For procedures see 2-Stage Mast 4000SRM1647.
HORN, GAUGES, LIGHTS, ALARMS AND CONTROL SYSTEM

Turn the key to the ON position. Verify that all warning lights and indicator lights will light up. After
two
seconds all warning lights will be OFF, except for the Wait to Start Light , Central Warning
Lights, Brake
System Low Pressure Warning Light, and the Parking Brake Warning Light. Start
the engine after the Wait to
Start Light is OFF.
With the engine running at idle, check the gauges and indicator lights for correct operation. See the
Controls,
Instruments, Indicators, and Switches section in the Operating Manual.
Have any failed light gauge, horn or alarm repaired immediately.
Check for presence of fault codes on the display and rectify as required.
For location of fuses and relays, see Table 13 and Figure 66.
HYDRAULIC SYSTEM OIL

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

CAUTION
DO NOT permit dirt to enter the hydraulic system when the hydraulic oil level is checked or
the filter is changed. Never operate the hydraulic pumps without hydraulic oil in the
hydraulic system. The operation of the hydraulic pumps without hydraulic oil will cause
damage to the pumps.
Only use the hydraulic oil specified in Approved Oils, Fluids, and Grease.
Additives in the hydraulic system oil may damage the hydraulic system. Before using
additives, contact your local Hyster dealer.
Check hydraulic oil level at the level indicator when the carriage is lowered and the engine stopped. See
Figure 41.
Hydraulic oil level is correct when it is in the green area.
If hydraulic oil level is in the yellow area, there is a risk that during operation hydraulic oil will leak from the
hydraulic tank breather cap.
• If hydraulic oil level is in the red area, add clean hydraulic oil through the fill plug at the return filter

and check the hydraulic system for leaks. Record added volume and hour meter reading.
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1. LEVEL INDICATOR
2. HYDRAULIC TANK
3. BATTERY BOX
4. RIGHT-HAND PANEL
5. HYDRAULIC TANK BREATHER
6. HYDRAULIC FILL PLUG
Figure 41. Hydraulic System
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
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At operating temperature, the hydraulic oil is hot. DO NOT permit the hydraulic oil to contact
the skin and cause a burn.

CAUTION

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.
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.
5. Put a container with a capacity of approximately 200 liter (52.8 gal) under the hydraulic tank.
6. Remove the drain plug to drain the hydraulic oil.
7. Replace the hydraulic tank return filter.
8. When the hydraulic oil is drained, install the drain plug.
9. Fill the hydraulic tank with clean hydraulic oil 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 42.
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1. SUPPLY HOSES
2. DRAIN PORT
Figure 42. 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.
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.
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1. Check if the yellow indicator on the hydraulic oil breather cap is raised. See Figure 41.
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.
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.
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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.
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.
2 Side shift the carriage until it is at the center 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. See

Figure 43.
5 Turn large nuts on both chain anchors. Make sure that both forks have at least 1 cm (0.40 in.)
clearance with ground.
6 Align the vertical carriage bar with the inner mast channel by tightening the large nut of the anchor
chain that is in lowest position. Make sure that the vertical carriage bar runs parallel with the inner
mast channel. Apply an accuracy of 0.5 mm per 50 cm (0.025 in. per 2 feet). See Figure 44.
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.
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1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. NUT
9. WASHER
10. CAP SCREW
Figure 43. Chain Anchor on Carriage
A. MEASURING POINT
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B. MEASURING POINT B
1. CARRIAGE
2. INNER MAST
3. OUTER MAST
Figure 44. Lift Chain Adjustment
Inspect 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.
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.
NOTE: The instructions for measuring chain elongation are also shown on the Figure 46.
If a chain scale is not available, measure the length of 20 links of chain. Measure from the center of a pin to
the center of another pin which is 20 pitches away. See Figure 45.
A. CHAIN PITCH
Figure 45. Lift Chain Pitch
Compare the length with the chart in Figure 46. Replace the chain if the length of 20 links of the worn section
is longer than the wear limit. For replacement procedures see 2-Stage Mast 4000SRM1647 .
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1. CHAIN WEAR SCALE
Pitch Total Length of 20 Links (Pitches) of Wear Limit - Maximum Length

New Chain of 20 Links
31.75 mm (1.25 in.)38.10 mm 635 mm (25 in.)762 mm (30 in.) 654 mm (27.75 in.)785 mm
(1.50 in.) (30.9 in.)
44.45 mm (1.75 in.) 889 mm (35 in.) 916 mm (36.1 in.)
Figure 46. Measuring Chain Elongation

Lift Chain Wear and Damage
Every 250 Hours
Inspect and replace if any of the following conditions occur, see Figure 47:
1 Wear of any plate exceeds 5% of the original dimension. See Figure 47.
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 .
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1. MOVED PIN
2. RUST
3. LOOSE LEAVE
4. PIN WEAR (MAX 5%)
5. CRACK
6. HOLE WEAR
7. EDGE WEAR (MAX 5%)
Figure 47. Lift Chain Check
LIFT SYSTEM ACCUMULATOR (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 MPa (0.75 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 and Figure 48.
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 and Figure 48.
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1. MAST LOAD ROLLER GREASE POINT

2. CARRIAGE LOAD ROLLER GREASE NIPPLE
Figure 48. Load Roller Lubrication
MAST, CARRIAGE, AND ATTACHMENT

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.
4 The inner weldment and the carriage must lower completely.
5 Check for leaks of hydraulic components.
6 Raise the mast 1 m (3 ft) with a capacity load. The inner weldment and the carriage must raise

smoothly. Lower the mast. All moving components must lower smoothly.
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

NOTE: Check correct operation of the Operator Presence System.
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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:
• 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 Figure 64.
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
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 49.
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.
1. SEAT BELT RETRACTOR

2. SEAT BELT LATCH
3. SEAT RAIL
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Figure 49. Safety Belt and Seat Rails
Steering Column Latch

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.
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.
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).
SIGNALS FROM THE SPREADER CONTROL SYSTEM

Check that the control lights on the spreader and on the TWIST module work correctly for the positions:
seated, locked and unlocked. Repair the spreader if any of the control lights is blinking or does not work
correctly.
STEERING AXLE GREASE FITTINGS
King Pins
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Every 500 Hours

There are two grease fittings at each kingpin of the steering axle. See Figure 50.
1. KINGPIN GREASE FITTING

2. TIE ROD GREASE FITTING
Figure 50. 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 50.
STEERING SYSTEM
Daily and every 250 Hours
NOTE: Thelift 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 Wheels and Tires, Remove Wheels from Lift Truck.
2. Remove grease cap from hub. See Figure 51.
3. Remove cotter pin, castle nut and washer from spindle.
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NOTE: The
hub assembly for this truck model weighs about 60 kg (135 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.
1. STEERING AXLE
2. SPINDLE
3. SEAL
4. OUTER BEARING CONE
5. HUB
6. INNER BEARING CONE
7. WASHER
8. COTTER PIN
9. CASTLE NUT
10. GREASE CAP
Figure 51. Steering Wheel Hub Bearings
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.
3. Inspect spindle and hub for cracks and damage. Ensure spindle and hub do not have any rough or
sharp areas that would prevent the bearings from being correctly installed. If required, smoothen any
rough or sharp areas before installing the bearings.
4. Inspect the contact surface between spindle and seal. Smoothen as required.
Assemble and Install

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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: Thehub assembly for this truck model weighs about 60 kg (132 lb). Use a lifting device
when installing the hub assembly on the spindle.
3. Use a lifting device to position the hub on the spindle.
4. Install the outer bearing cone, washer and 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 turns freely with no end
play.
6. Tighten castle nut to 34 N•m (25 lbf ft).
7. Align the castle nut with the cotter pin hole at first alignment position at or above 34 N•m (25 lbf ft)

and install and lock the cotter pin.
8. Completely fill hub cap with grease and install cap in hub.
9. Install wheel on hub. Be careful not to damage threads on studs.
10. Start with wheel nut at the top and tighten 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 over the pilot surface and be
tight against the hub. Tighten nuts to 615 to 710 N•m (454 to 524 lbf ft). See Figure 63.
TILT CYLINDER PIVOT PINS

Every 250 Hours
The tilt cylinder pivot pins have four grease fittings, two fittings per tilt cylinder. The grease fittings are
located at the end of each pivot pin. Apply grease until it escapes from the bushings. See Approved Oils,
Fluids, and Grease and Figure 52.
1. GREASE FITTING
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2. TILT PIVOT PIN
Figure 52. Tilt Cylinder Pivot Pin

TRANSMISSION
Inspect for leaks and check the condition of all hoses and external components of the transmission. Make sure
the transmission is shifting smoothly. If a problem is present, report the problem immediately.
Do not operate the lift truck until the problem is corrected.
Transmission Clutch Calibration
Every 2,000 Hours
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
Figure 65 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
Check transmission oil level with the engine running at idle and the park brake applied.
For the location of the dipstick and fill tube, see Figure 53. 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.
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
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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
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. For the location of the dipstick and fill tube, see Figure 53.
1. TRANSMISSION OIL FILTER

2. DIPSTICK AND FILL TUBE
Figure 53. Transmission Oil Filter and Dipstick
9. Recalibrate the transmission. For procedure see Transmission Operations and Diagnostics

1300SRM1455.
TWIST LOCKS
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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 54.
A. TWIST LOCK WEAR TOP AREA B. TWIST LOCK HEAD THICKNESS
Figure 54. Twist Lock Wear Check

Lubricate
Every 250 Hours
Each twist lock has two grease fittings. Lubricate the grease fittings and sleeves using EP2/3 grease.
1. NIPPLE FOR SLEEVE

2. NIPPLE FOR TWIST LOCK
Figure 55. Twist Lock Lubrication
Replace
Every 5,000 Hours
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Replace twist locks.

For procedures see Extendable Container Attachment (Elme) 5000SRM1221.
VIBRATION DAMPER (VISCOUS)

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 56.
Figure 56. 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 57.
A. THICKNESS
Figure 57. Vibration Damper Measure Points
WARNING AND SAFETY LABELS

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

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
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.
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 pressure, the technician must not stand
in-line with the axis of the wheel. See Figure 58.
If the air pressure is less than 80% of the correct air pressure, the tire must be removed
before air 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.
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If the tire is removed from the truck and flat on the ground, the technician should not have
any body part within the diameter of the tire when adjusting the tire pressure. See Figure 59.
Wheels can explode and cause injury or death if the above procedures are not followed.
Air pressure in pneumatic tires can cause tire and wheel parts to explode. The explosion of
wheel parts can cause serious injury or death. Remove all of the air from the tires before the
tires are removed from the lift truck.
1. ACCURATE IN-LINE PRESSURE GAUGE
Figure 58. Adjusting and Deflating Position
1. HOSE LONG ENOUGH FOR USER TO STAND OUTSIDE POTENTIAL TRAJECTORY OF EXPLOSION
Figure 59. Adjusting Tire Pressure Position

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.
Check the tires for damage. See Figure 60. 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.
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1. CHECK TIRE PRESSURE

2. CHECK FOR DAMAGE
Figure 60. Tire Check
Remove Wheels from Lift Truck

CAUTION
Lift truck wheels are very heavy, use caution when removing wheels or personal injury may
occur.
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.
Remove Pneumatic Tire from Wheel

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid
rubber tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are
installed, the three-piece wheel assemblies must be used. See Figure 61.
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1. SIDE FLANGE
2. WHEEL RIM FOR SOLID TIRE
3. FLANGE SEAT
4. WHEEL RIM FOR PNEUMATIC TIRE
5. LOCK RING
Figure 61. Types of Wheels

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

WARNING
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with
enough force to cause serious injury. See Figure 61.
STEP 1.
For tubeless tires, remove the air valve by rotating it 60 degrees until the valve releases

from the valve slot

STEP 2.
Loosen the tire bead from the side ring

and/or lock ring.

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

ring.

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

the wheel rim.

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

STEP 6.
Remove the wheel rim from the tire.

Remove the inner tube and flap.
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
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ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different

manufacturers on any one lift truck.
• Check with your dealer whether a specific tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to
put parts together. Make sure that the lock ring is in the correct position. The ends of the
lock ring must not touch. The clearance at the ends of the lock ring will be approximately
4 to 14 mm (0.15 to 0.55 in.) after it is installed. If the clearance is wrong, the wrong part
has been used.

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

CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped
solid rubber tires are installed, the four-piece wheel assemblies must be used. If pneumatic
tires are installed, the three-piece wheel assemblies must be used. See Figure 61.
STEP 1.
Clean and inspect all parts of the wheel. If the wheel has rust or corrosion, remove loose

rust and corrosion and paint the parts.

WARNING
Do not lubricate the tire bead with antifreeze or petroleum based liquid. Vapors from
these liquids can cause an explosion during inflation or use
STEP 2.
Apply a rubber lubricant or a soap solution to the tire bead and tube.

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.
14/04/2022 18:57 Documento

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

For tubeless tires, align the valve slot hole
in the rim with the valve bead hole in the
valve bead, and install the wheel rim in
the tire.

STEP 6.
Turn over the rim and tire. Put a block
under the rim so that the rim is 8 to
10 cm (3.15 to 3.94 in.) above the floor.
Install the side ring and the lock ring.

When correctly installed, there will be a 4
to 14 mm (0.15 to 0.55 in.) clearance
between the ends of the side ring and the
lock ring.

WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough
force to cause serious injury.
STEP 7.
For tubeless tires insert the air valve into the bead seal and rotate the valve 60 degrees until

the air valve locks into the valve slot.
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 62.
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).

WARNING
Wheels can explode and cause injury or death if the above procedures are not followed.
14/04/2022 18:57 Documento
1. QUICK-RELEASE COUPLING
Figure 62. Adding Air Pressure to the Tire Position
1. Put the tire in a safety cage. See Figure 62.
2. Add 20 kPa (3 psi) of air pressure to the tire.
3. Check that all wheel parts are correctly 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.
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 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.
Remove Solid Rubber Tire from Wheel

WARNING
Completely remove the air pressure from the
tire before it is removed from the lift truck. If
dual wheels are installed, remove the air from
both tires. Air pressure in the tires can cause
the tire and rim to explode causing serious
injury or death.
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury. See Figure 61.
Always use a cage when removing the solid
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
14/04/2022 18:57 Documento
p
assemblies must be used. If pneumatic tires are
installed, the three-piece wheel assemblies must
be used. See Figure 61.
STEP 1.
Put the wheel rim on the bed of the press.
Put the cage in position on the tire. Use

the press to push the tire away from the
side ring.

STEP 2.
Put the tire tool into the slot between the
side ring and/or lock ring and the wheel

rim. Remove the side ring, lock ring, and
wedge band.

STEP 3.
Turn the tire over. Put a support under the
wheel rim. Make sure the wheel rim is at

least 150 to 200 mm (6 to 8 in.) from the
bed of the press.

STEP 4.
Put the cage in position on the tire. Use
the press to push the tire from the wheel
rim.
Install Solid Rubber Tire on Wheel

WARNING
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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 61.
STEP 1.
Lubricate the wheel rim and the inner
surface of the tire with tire lubricant or
soap.

STEP 2.
14/04/2022 18:57 Documento

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.
Wheel Nuts on Drive and Steer Wheels

CAUTION
Check all wheel nuts after 2 to 5 hours of operation, when new lift trucks begin operation,
and on all lift trucks when the wheels have been removed and installed. Tighten the nuts as
shown in Figure 63. When the nuts stay tight for 8 hours, the interval for checking the torque
can be extended to 250 Hours.
Start with the wheel nut at the top and tighten the nuts to 68 to 136 N•m (50 to 100 lbf ft) in the sequence
shown in Figure 63. Check to make sure that the wheel(s) is tight against the hub, then tighten the nuts to 615
14/04/2022 18:57 Documento
to 710 N•m (454 to 524 lbf ft).
Figure 63. Wheel Nut Tightening Sequence
Capacities and Specifications

APPROVED FUEL AND ENGINE OILS
Engine Emission WWFC Sulfur ASTM Emission Engine Oil

Legislation Diesel Fuel Content D975 Legislation
Tier 4F/Stage IV Category 4 <10 mg/kg S15 <15 mg/kg ACEA E9 - API CJ-4
Engines
Tier 3/Stage IIIA Category 4 <10 mg/kg S15 <15 mg/kg ACEA E7, or E9 - API CI-
Engines 4, or CJ-4
Category 2 <500 S500 <500 mg/kg ACEA E7 API CI-4
mg/kg
Non-Compliance Category 1 <5000 S5000 <5000 mg/kg ACEA E7 API CI-4 (see
mg/kg Notes)
NOTE:
• Diesel Category 1 is not allowed in countries with Tier 3/Stage IIIA or more stringent

emission legislation.
• When using Diesel Category 1, the factory-filled CJ-4 engine oil must be replaced at

initial 250 hours by API CI-4 specification oil.
• When using Diesel Category 1, engine oil specification API CI-4 must be used to allow
500-hour oil change intervals.
• Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content
does not exceed 5 percent of total volume.
APPROVED OILS, FLUIDS, AND GREASE
Fluid Truck/Engine Quantity

Specification
Type
Oils
Air Conditioner – See Compressor
PAG
Compressor Oil Nameplate
14/04/2022 18:57 Documento
Fluid Truck/Engine Quantity

Specification
Type
Chain Oil 15W-40 Engine oil – As required
Differential Oil MIL-L-2105D,
API-GL-5,
SAE 80W-90 – 21 liter (5.5 gal)
QSB 6.7 Tier 16 liter (17 qt)
ACEA E7 API CI-4
3/Stage IIIA
ACEA E9 API CJ-4 QSB 6.7 Tier 14 liter (15 qt)
Engine Oil:
4F/Stage IV
ACEA E9 API CJ-4 QSB 4.5 Tier 10.5 liter (11 qt)
4F/Stage IV
H8-12XM-6 / 151 liter
Hydraulic H170-280HD2 (39.9 gal)
John Deere JDM-J20C ISO VG46
System Oil H13-16XM-6 / 172 liter
H300-360HD2 (45.4 gal)
H8-12XM-6 / 4.4 liter (4.7 qt)
Planetary Gear H170-280HD2
MIL-L-2105D, API-GL-5, SAE 80W-90
Oil H13-16XM-6 /
5.0 liter (5.3 qt)
H300-360HD2
Transmission – 20 liter (5.28 gal)
ZF TE-ML 03
Oil
Fuel
H8-9XM-6 / 108 liter
H190-210 HD2 (28.5 gal)
H10-12XM-6 / 140 liter (37 gal)
Fuel See Approved Fuel and Engine Oils
H210-280HD2
H13-16XM-6 / 158 liter
H300-360HD2 (41.7 gal)
Fluids
Air Conditioner – 1300 +/- 50 grams
R134a
Refrigerant (45.8 +/- 1.8 oz)
Tier 3/Stage 25.5 liter (26.9 qt)
3174102 - Shell Rotella ELC, 3116456 – Eurol IIIA
Coolant
Coolant XL-NM, Or equivalent OAT type coolant Tier 4F/Stage 22 liter (23 qt)
IV
Diesel Exhaust – 18.9 liter (5 gal)
AUS 32, ISO 22241-1
Fluid (DEF)
Windshield Clean water with detergent and anti-freeze as – 5 liter (5.3 qt)
Washer Fluid required.
Grease
Multipurpose EP2/3
– –
Grease EP2/3 with 2–4% MoS2
ENGINE OIL VISCOSITY
Ambient Temperature Temperature Range Oil Viscosity

All Season -15°C (5°F) and above 15W-40
Winter Conditions -20°C (-4°F) to 20°C (68°F) 10W-30
14/04/2022 18:57 Documento
Ambient Temperature Temperature Range Oil Viscosity

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°F).
• 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

If an electrical component does not function properly,
also check the main electrical supply, relays
and fuses.
• Components for main electrical supply are
shown in Figure 64.
• Fuses and relays are shown in Table 13 and Figure 66.
Before replacing a failed fuse or relay, first repair
the defect that caused the fuse or relay to fail. Have
any
failed component replaced.
Figure 64. Main Electrical Supply
Table 12. Legend for Main Electrical Supply
14/04/2022 18:57 Documento
Table 12. Legend for Main Electrical Supply

1. BATTERY DISCONNECT SWITCH
2. BATTERY DISCONNECT SWITCH LOCK
3. BATTERY
4. POWERBOARD
Name Value Description
5. F1 125A ALTERNATOR
6. R1 — RELAY GRID HEATER
7. F2 125A CAB SUPPLY
*8. F4 15A DEF HOSE HEATING
9. F3 150A GRID HEATER
10. F5 10A SPARE
*11. F6 10A DEF UNIT
12. F7 7.5A SPARE
13. F8 10A SPARE
14. F11 15A SPARE
*15. R4 — RELAY DEF HOSE 3
*16. R5 — RELAY DEF MODULE HEATER
*17. R3 — RELAY DEF HOSE CPS 141
*18. R2 — RELAY DEF HOSE CPS 140
19. F10 30A ENGINE ECM SUPPLY
20. F9 30A CAB TILT
* Tier 4F / Stage IV only.
Main Electrical Supply
14/04/2022 18:57 Documento
1. FUSE PANEL 1 (TABLE 13) 7. RELAYS (FIGURE 66)

2. FUSE PANEL 2 (TABLE 13) 8. TRANSMISSION CONTROLLER
3. FUSE PANEL 3 (TABLE 13) 9. HYDRAULIC CONTROLLER
4. FUSE PANEL 4 (TABLE 13) 10. IFAK CONNECTOR
5. HYDRAULIC SERVICE SWITCH 11. 24 VOLT SERVICE CONNECTOR
6. TRANSMISSION CALIBRATION SWITCH 12. ECO-ELO HIP SWITCH
Figure 65. Main Electrical Supply
Table 13. Fuse Locator
14/04/2022 18:57 Documento
Table 13. Fuse Locator
Fuse Panel 1 Fuse Panel 2

30A ENGINE
START 30A FLOOD
LIGHTS
5A ECM IGN 5A STROBE LIGHT
B+
5A BRAKE PRESSURE
WARNING 10A BRAKE
LIGHTS
7.5A TRANSMISSION 15A FRONT DRIVE
LIGHTS
7.5A TRANSMISSION
B+ 5A INTERIOR
LIGHTS
30A HYDRAULIC
CONTROLLER 15A MAST/ATTACHMENT
LIGHTS
15A ATTACHMENT
CONTROLS 10A DIRECTION INDICATORS
5A PARK BRAKE
SOLENOID 10A SIDE/TAIL
LIGHTS
10A INSTRUMENTATION 10A REAR DRIVE
LIGHTS
5A ALTERNATOR
ON 10A REVERSE
LIGHTS/
ALARM/
STROBE
Painel de Painel de
Fusíveis 3 Fusíveis 4
10A LAVAGEM/LIMPAGEM DA TELA 10A TOMADA DE ALIMENTAÇÃO
FRONTAL 12V
10A LAVAGEM/ LIMPEZA DE 10A RÁDIO/CB/ INTERCOM
TELHADO
10A LAVAGEM/ LIMPEZA TRASEIRA 10A ACESSÓRIOS DO
CONVERSOR DE 12V
10A CHIFRE 10A LUZES DE PERIGO
5A IGNIÇÃO DE ENERGIA 25A VELOCIDADE B+
VELOCIDADE
10A LUBRIFICAÇÃO AUTOMÁTICA 3A RELÉ 12V
(OPT)
15A COMPRESSOR DE SUSPENSÃO 3A SISTEMA DE OPS
DO ASSENTO
25A AQUECEDOR/AC/VENTILADOR 10A SENSOR EAS
30A Ventilador do Condensador AC 15A TOMADA DE ALIMENTAÇÃO
24V B +
5A Campainha de aviso do freio de 5A TOMADA DE ALIMENTAÇÃO
estacionamento 24V IGN
Relés
14/04/2022 18:57 Documento
1. ALIMENTAÇÃO PRINCIPAL
2. LUZES
3. CHIFRE
4. OPS
5. INICIAR ATIVAR
6. IGN
7. CONTROLADOR HIDRÁULICO
8. TRAVA DE TORÇÃO
9. INICIAR INIBIR
10. NEUTRO
11. RELÉ 12V
12. SOBREPOR
13. CA 3
14. LUZES DE RÉ E ALARME
15. UNIDADE DE PISCADOR
16. CA 1
17. CA 2
Figura 66. Relés

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PARTE NO. 4133481 8000 SRM 1939

Filtro da Bomba DEF

Graxas do eixo de direção

Figure 1. Truck Nameplate

Example: L007 or K019 E 4369 N

Truck Handling Procedures

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

3. Loosen the lock nut.

1. TAMPA DE PARAFUSO DE PLÁSTICO

Figura 2. Soltar o freio de estacionamento

COLOCANDO UMA EMPILHADEIRA EM BLOCOS

Raising the Steering Tires

1. Apply the parking brake. Put blocks on both

2. Put blocks between the steering axle and

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

4. Put the jack under the steering axle to

5. Put blocks with steel plates under the LH and

Figure 3. Putting Lift Truck on Blocks

Figure 4. Steering Axle on Blocks

2. Disconnect the battery.

3. Remove accumulated debris using a compressed

4. Lightly spray a noncorrosive cleaning agent onto

so close contact direct spraying will not be

5. Be sure to avoid directing the spray into electrical

6. Avoid spraying in areas containing electrical

7. Clean the battery compartment by using a clean

8. DO NOT use a pressure washer to clean the battery.DO NOT use

10. After cleaning, immediately start and run the lift

Safety Procedures Before Starting Maintenance

2. Lower the carriage and forks.

3. Switch the engine OFF.

4. Apply the parking brake.

6. Clean any oil or fuel spills.

MAKING CHECKS FROM THE DRIVER SEAT WITH ENGINE RUNNING

• DO NOT use diesel engines indoors where soot can accumulate.

HYDRAULIC SERVICE SWITCH

TRANSMISSION CALIBRATION SWITCH

WAIT 100 SECONDS BEFORE DISCONNECTING BATTERY

Periodic Maintenance Schedule

1. PINOS DE GARFO 11. DEF BOMBA E FILTRO DE SUCÇÃO

Figura 5. Filtros e Pontos de Lubrificação

OBSERVAÇÃO: NÃO é necessário engraxar periodicamente o pino de articulação do eixo e a roldana da

Verificações diárias de condição

Tabela 1. Verificações Diárias de Condição

Verificações diárias de Procedimento Página

Tabela 1. Verificações Diárias de Condição

Tabela 1. Verificações Diárias de Condição

Daily Fluid Level Checks

Table 2. Daily Fluid Level Checks

Daily Fluid Level Procedure Page

Daily Checks from the Driver Seat with Engine Running

Daily Checks from the Driver Procedure Page

First Inspection after First 100 Hours of Operation

Initial 100 Hours Inspection Procedure Page

Inspect and Adjust

Table 5. Inspect and Adjust

Inspect and Adjust Procedure Page

Table 5. Inspect and Adjust

Table 5. Inspect and Adjust

Table 5. Inspect and Adjust

Lubricate Procedure Page

Use multipurpose grease with MoS2 additive. For details,

Change Procedure Page