Periodic Manteinance

PERIODIC MAINTENANCE YARDMASTER
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H [A227, B227]
PART NO. 1470238
8000 SRM 780
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance YardMaster
Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... Serial Number Data ...................................................................................................................................... How to Move Disabled YardMaster .............................................................................................................. How to Tow YardMaster............................................................................................................................ How to Put YardMaster on Blocks................................................................................................................ How to Raise Drive Tires .......................................................................................................................... How to Raise Steering Tires.......................................................................................................................... Maintenance Schedule....................................................................................................................................... Daily Inspections ........................................................................................................................................... First Inspection After First 100 Hours of Operation................................................................................... Periodic Maintenance Schedule .................................................................................................................... Boom Maintenance ........................................................................................................................................ Spreader Maintenance .................................................................................................................................. PPM Spreader Maintenance ......................................................................................................................... Maintenance Procedures Every 8 Hours or Daily............................................................................................ How to Make Checks With Engine Stopped................................................................................................. Tires and Wheels ....................................................................................................................................... Safety Labels ............................................................................................................................................. Fuel, Oil, or Coolant Leaks Check............................................................................................................ Drive Belts ................................................................................................................................................. Battery ....................................................................................................................................................... Engine Oil .................................................................................................................................................. Drain Water From Fuel Filter .................................................................................................................. Hydraulic System ...................................................................................................................................... Brake System Oil ...................................................................................................................................... Cooling System .......................................................................................................................................... Boom and Spreader ................................................................................................................................... Hook, Winch, and Boom (HR45H) ............................................................................................................ How to Make Checks With Engine Running................................................................................................ Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays.............................................................. Air Filter .................................................................................................................................................... Air Conditioning ........................................................................................................................................ Control Levers and Pedals........................................................................................................................ Electrical System....................................................................................................................................... Transmission Oil ....................................................................................................................................... Steering System ........................................................................................................................................ Service Brakes ........................................................................................................................................... Parking Brake ........................................................................................................................................... Engine Oil .................................................................................................................................................. Cooling System .......................................................................................................................................... Hydraulic System ...................................................................................................................................... Boom and Spreader Operation ................................................................................................................. Maintenance Procedures Every 50 Hours or Weekly....................................................................................... Boom............................................................................................................................................................... PPM Spreader................................................................................................................................................ Rotator and Extension Transmissions ..................................................................................................... Rotator Motor ............................................................................................................................................ Rotator Assembly ...................................................................................................................................... Twist Locks ................................................................................................................................................ Wear Pads (Extension Beam) ................................................................................................................... Sideshift Cylinders .................................................................................................................................... 1 1 1 2 2 2 2 3 3 5 5 7 8 10 12 12 12 12 13 13 13 14 14 14 15 15 15 15 15 15 18 18 18 18 18 19 19 19 19 19 19 19 20 20 20 20 20 20 21 21 21
2005 HYSTER COMPANY
Table of Contents
TABLE OF CONTENTS (Continued)

Maintenance Procedures Every 250 Hours or 6 Weeks ................................................................................... Engine Oil and Filter..................................................................................................................................... Fuel Filter/Water Separator.......................................................................................................................... Drive Belts ..................................................................................................................................................... Steering Axle.................................................................................................................................................. Battery ........................................................................................................................................................... Wheel Nuts..................................................................................................................................................... Winch Oil Level.............................................................................................................................................. Steering Axle Tie Rods and King Pins.......................................................................................................... Drive Shaft Joints.......................................................................................................................................... General Lubrication ...................................................................................................................................... ELME Spreader ............................................................................................................................................. Rotator and Extension Transmission....................................................................................................... Rotator Assembly ...................................................................................................................................... Twist Locks ................................................................................................................................................ Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. Air Filter ........................................................................................................................................................ Hydraulic Oil Filters ..................................................................................................................................... Transmission Oil Filter ................................................................................................................................. Differential and Wheel End Housings Oil.................................................................................................... Hydraulic Tank Breather .............................................................................................................................. Boom Horizontal Wear Pads ......................................................................................................................... Boom Side Wear Pads.................................................................................................................................... Sideshift Cylinder .......................................................................................................................................... Stop Cylinders (ELME Option)..................................................................................................................... ELME Sideshift Wear Pads .......................................................................................................................... Wear Pads (Extension Beams) ...................................................................................................................... Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... Coolant Filter................................................................................................................................................. Hydraulic Accumulators................................................................................................................................ Brake Accumulator ................................................................................................................................... Transmission Oil............................................................................................................................................ Disc Brake ...................................................................................................................................................... Inspect........................................................................................................................................................ Brake System Oil and Filter ......................................................................................................................... Air Filter Primary Element .......................................................................................................................... Hydraulic Tank Breather .............................................................................................................................. PPM Spreader................................................................................................................................................ Extension Beam Horizontal Pads............................................................................................................. Extension Beam Side Wear Pads ............................................................................................................. Ring Gear Fixation Bolts .......................................................................................................................... ELME Spreader ............................................................................................................................................. Wear Pads (Extension Cylinder) .............................................................................................................. Winch Oil........................................................................................................................................................ Pedals, Levers, Hinges, and Seat Rails (General Lubrication)................................................................... Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... Engine Valve Adjustment.............................................................................................................................. Hydraulic Relief Pressures ........................................................................................................................... Counterweight Fixation ................................................................................................................................ Load Sensing System .................................................................................................................................... Door and Window Seals................................................................................................................................. 21 21 21 21 21 21 21 21 22 22 22 22 22 22 22 23 23 23 23 23 23 23 23 24 24 24 24 25 25 25 25 25 25 26 26 26 26 26 26 26 26 27 27 27 27 27 27 27 27 27 27
ii
Table of Contents
TABLE OF CONTENTS (Continued)

Drive Axle and Differential Oil..................................................................................................................... Hydraulic Oil ................................................................................................................................................. Change Hydraulic Oil ............................................................................................................................... Steer Wheel Hub Bearing Cavity ................................................................................................................. Brake System Oil and Filter ......................................................................................................................... Rotor and Extension Transmission Fixation Bolts ...................................................................................... Rotator and Extension Transmission Oil ..................................................................................................... Maintenance Procedures Every 6000 Hours or 2 Years................................................................................... Engine Coolant .............................................................................................................................................. Vibration Damper .......................................................................................................................................... Twist Locks .................................................................................................................................................... Maintenance Procedures Every 8000 Hours .................................................................................................... PPM Spreader................................................................................................................................................ Wheel and Tire Replacement ............................................................................................................................ Wheels, Remove ............................................................................................................................................. Remove Tire From Wheel.............................................................................................................................. Install Tire on Wheel ..................................................................................................................................... Install Wheel in Tire...................................................................................................................................... Add Air to Tires ............................................................................................................................................. Wheels, Install ............................................................................................................................................... General Maintenance ........................................................................................................................................ Spreader ......................................................................................................................................................... Twist Locks ................................................................................................................................................ Rotator Assembly ...................................................................................................................................... How to Store YardMaster .............................................................................................................................. Short-Term Storage ................................................................................................................................... Long-Term Storage .................................................................................................................................... How to Move YardMaster On Transport ...................................................................................................... Loading ...................................................................................................................................................... Unloading .................................................................................................................................................. Preparation for Use ....................................................................................................................................... Preparation After Transport..................................................................................................................... Preparation After Storage ........................................................................................................................ This section is for the following models: HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H [A227, B227] 27 27 27 28 28 28 28 28 28 28 28 29 29 29 29 30 31 31 32 33 33 33 33 33 33 33 34 34 34 35 35 35 35
iii
"THE QUALITY KEEPERS" HYSTER APPROVED PARTS
8000 SRM 780
General
General
This section contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your YardMaster. The recommendation for the time intervals are for 8 hours of operation per day. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: If the YardMaster is used more than 8 hours per day If the YardMaster must work in dirty operating conditions Your dealer for Hyster YardMasters 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 YardMaster give more efficient performance and operate for a longer period of time.
SERIAL NUMBER DATA

The serial number for the Yardmaster is located on the nameplate in the cabin. The serial number indicates the design series, manufacturing plant, and the year manufactured. Example: A227 (1) E (2) 1509 (3) U (4)
WARNING
Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments made on a YardMaster by people without authorization and training can make a dangerous operating condition. Do not operate a YardMaster that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operators area. Remove the key from the key switch. Some users have service personnel and equipment to do the inspection, lubrication, and maintenance shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster YardMasters to help users who do their own maintenance.
1. The first letter and number of the serial number indicates the design series and the model number of the Yardmaster. 2. The second letter identifies the manufacturing plant. Example: E=Nijmegen, the Netherlands. 3. The number series indicates the sequence of manufacture where the vehicle was made. 4. The letter indicates the year of manufacture starting with A=2003. The letter X=2000, Y=2001, Z=2002, L=2013, M=2014, and N=2015. (The letters I, O, and Q are not used.)
HOW TO MOVE DISABLED YARDMASTER WARNING

Manual release of the parking brake caliper will result in loss of brakes. NOTE: The service brake system requires hydraulic pressure to operate. The park brake will automatically apply when hydraulic pressure drops. If there is no hydraulic pressure to release parking brake, parking brake caliper must be manually released. Put blocks on both sides (front and back) of drive tires to prevent movement of YardMaster. The caliper is installed at the back of the differential housing. To manually release parking brake, remove cotter pin from bolt in caliper. Tighten nut to compress spring that applies brake.
General
8000 SRM 780 2. Fully lower and retract boom. 3. Use a hydraulic jack under the side of the drive axle to raise tire from ground. Use a block under jack as necessary. Make sure that jack and block have a capacity of at least 36,000 kg (40 ton). 4. Put additional blocks under drive axle as support.
How to Tow YardMaster WARNING

Do not tow a YardMaster if a load is attached. Use extra caution when moving a YardMaster if any of the following conditions exist: Brakes do not operate correctly. Steering does not operate correctly. Tires are damaged. Traction conditions are bad. If the engine cannot run, there is no power assist available for the steering and service brakes. This can make the control of the YardMaster difficult. Poor traction can cause the disabled YardMaster or towing vehicle to slide. Manual release of the parking brake caliper will result in loss of brakes. 1. The towed YardMaster must have an operator. 2. Tow YardMaster slowly. 3. Tow YardMaster from lifting points of counterweight attached to frame. 4. If another YardMaster is used to tow disabled YardMaster, that YardMaster must have an equal or larger capacity than disabled YardMaster.
HOW TO RAISE STEERING TIRES

1. Apply parking brake. Put blocks on both sides (front and back) of drive tires to prevent movement of YardMaster. See Figure 1. 2. Fully lower and retract boom. 3. Use a hydraulic jack under the side of the steering axle to raise tire from ground. Use a block under jack as necessary. Make sure jack and block have a capacity of at least 36,000 kg (40 ton). 4. Put additional blocks under steering axle as a support.
HOW TO PUT YARDMASTER ON BLOCKS How to Raise Drive Tires WARNING

The YardMaster must be put on blocks for some types of maintenance and repair. The surface must be solid, even, and level when the YardMaster is put on blocks. Make sure any blocks used to support the YardMaster are solid, one-piece units. Do not use component lifting points on the boom or frame to lift the YardMaster. 1. STEERING TIRES 1. Apply parking brake. Put blocks on both sides (front and back) of steering tires to prevent movement of YardMaster. See Figure 1. 2. DRIVE TIRES Figure 1. Put YardMaster on Blocks
8000 SRM 780
Maintenance Schedule
DAILY INSPECTIONS
Figure 2. Maintenance and Lubrication Points Table 1. Condition Check Item No. Item Boom, Rotator, and Spreader Fuel, Oil, or Coolant Leaks 1 10 Tires and Tire Pressure Drive Belts Engine Compartment 21 Radiators for Engine Coolant, Turbo Air, Hydraulic, and Transmission Oil Safety Labels Seat Belts and Seat Rails See Figure 2 for Item Nos. Procedure Inspect for damage, cracks and distortion. Check frame, boom, and spreader. See nameplate. Check tension. Remove combustible materials. Clean as necessary. See Parts Manual. Check operation.
Maintenance Schedule Table 2. Fluid Level Check Item No. 12 13 Item Hydraulic System Oil Brake System Oil (Until A227J 01587, B227J 01501, 01503, and 01504) Brake System Oil (Starting with A227J 01588, B227J 01502, and 01505) Fuel Coolant Battery Electrolyte Engine Oil Water Separator Windshield Washer Fluid See Figure 2 for Item Nos. J20C or equivalent SAE 10W, API CC, or CC/SE with 3 to 6% lubrisol Procedure
8000 SRM 780
13
Donax TD SAE 10W
7 22 4 28 8
Diesel No. 2 (520 liter) 50% Ethylene glycol, 50% water Distilled water See Maintenance Procedures Every 8 Hours or Daily and Engine Oil. Drain water. Add as necessary.
Table 3. Checks With Engine Running Item No. Item Air Conditioning Horn, Gauges, Lights, Alarms, Mirrors, and Control System Control Levers and Pedals Boom, Rotator, Spreader, Signal From Spreader, and Control System Steering System Service Brakes and Parking Brake Transmission 5 29 24 Transmission Oil Level Air Filter Hydraulic Oil Filter Procedure Operate at least once every 15 days for 10 minutes. Check operation.
Check operation. Check operation.
Check operation. Check operation. Check operation. Add if necessary, J20C or equivalent. Clean or replace elements when indicator light is ON. Clean or replace when indicator light is ON.
See Figure 2 for Item Nos.
8000 SRM 780
FIRST INSPECTION AFTER FIRST 100 HOURS OF OPERATION

Table 4. Initial 100-Hour Inspection Item No. 31 27 6 24 25 26 11 Item Drive Axle, Differential Oil Engine Oil Filter Transmission Oil Filter Hydraulic System Oil Filter Brake System Oil Filter Coolant Filter Hydraulic Oil Return Screen Procedure Change Change Change Clean Change Change Clean Quantity 66 liter (69.7 qt) 1 1 1 1 1 1 Procedure or Specification SAE 80W-90 See Parts Manual See Parts Manual See Parts Manual See Parts Manual See Parts Manual
PERIODIC MAINTENANCE SCHEDULE

Table 5. Inspect and Adjust Item No. 3 10 31 12 20 30 9 9 19 14 Wheel Nuts Drive Belts Drive Axle and Differential Oil Hydraulic Tank Breather Accumulator Parking Brake Engine Valve Adjustment Inlet (cold) Exhaust (cold) Hydraulic Relief Pressures Counterweight Fasteners Load Sensing System 11 10 Hydraulic Oil Return Screen Vibration Damper Item Interval 250 hr/1 mo 250 hr/1 mo 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo 1000 hr/6 mo 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr 4000 hr/2 yr 0.36 mm (0.014 in.) 0.68 mm (0.027 in.) Check and adjust if necessary. Check torque. 900 Nm (665 lbf ft) Check calibration, see publication 1495851. Clean or replace. Inspect for wear. Procedure Check torque. 380 Nm (280 lbf ft) Check tension. Check level. SAE 80W-90 Clean or replace if necessary. See Accumulator 1800 SRM 1036 Check wear.
Maintenance Schedule Table 6. Lubricate Item No. 23 18 17 Drive Shaft Steering Axle Pivot Pin Tie Rods King Pins Pedals, Levers, Seat Rails, and Hinges Doors, Window Seals, and Door Lock See Figure 2 for Item Nos. Item Interval 250 hr/1 mo 250 hr/1 mo 250 hr/1 mo 1000 hr/6 mo 2000 hr/1 yr Quantity 6 Fittings 2 Fittings 4 Fittings As necessary As necessary
8000 SRM 780
Specification Multipurpose grease Multipurpose grease Multipurpose grease Engine oil Silicon spray
Table 7. Change Item No. 28 Engine Oil Item Interval 250 hr/1 mo Quantity 38 liter (40.2 qt) Procedure or Specification See Maintenance Procedures Every 8 Hours or Daily, Engine Oil. See Parts Manual See Parts Manual See Parts Manual See Parts Manual J20C or equivalent SAE 10W, API CC, or CC/SE Donax TD SAE 10W
27 8 6 24 5 13
Engine Oil Filter Fuel Filter Transmission Oil Filter Hydraulic System Filter Transmission Brake System Oil (Until A227J 01587, B227J 01501, 01503, and 01504) Brake System Oil (Starting with A227J 01588, B227J 01502, and 01505) Brake System Oil Filter Air Filter, Central Element Hydraulic Tank Breather Coolant Filter Hydraulic System Oil Drive Axle/Differential Oil Steer Wheel Hub Bearing Cavity
250 hr/1 mo 250 hr/1 mo 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo 1000 hr/6 mo
1 1 2 1 41 liter (43.3 qt) 50 liter (52.8 qt)
13
1000 hr/6 mo
50 liter (52.8 qt)
25 29 12 26 12 31 15
1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 2000 hr/1 yr 2000 hr/1 yr 2000 hr/1 yr
1 1 1 1 1100 liter (290.6 gal) 66 liter (69.7 qt) As required
See Parts Manual See Parts Manual See Parts Manual See Parts Manual J20C or equivalent SAE 80W-90 Multipurpose grease
8000 SRM 780
Table 7. Change (Continued) Item No. 29 22 Procedure or Specification See Parts Manual 50% ethylene glycol, 50% water Flush and replace.
Item Air Filter, Primary Element Cooling System
Interval 2000 hr/1 yr 6000 hr/2 yr
Quantity 1 56 liter (59.2 qt)
BOOM MAINTENANCE
Figure 3. Maintenance and Lubrication Points for Boom Table 8. Inspect and Adjust Item No. 1 2 5 Boom Wear Pads Boom Side Wear Pads Hydraulic Accumulator Item Interval 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo Procedure Check wear, play, and fixation. Check wear, play, and fixation. See Accumulator 1800 SRM 1036.
Maintenance Schedule Table 9. Lubricate Item No. 3 4 6 7 1,2 Item Telescoping Cylinder Keys Boom Pivot Bearings Rotator Pivot Bearing Dampening Cylinders Boom Wear Pads Interval 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk Quantity 2 4 Fittings 1 Fitting 4 Fittings 10 Fittings
8000 SRM 780
Specification Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease
SPREADER MAINTENANCE
Figure 4. Spreader Maintenance and Lubrication Points for ELME 817 Table 10. Initial 100-Hour Inspection Item No. 1 2 Item Rotator Brake Oil Rotator Transmission Oil Rotator Assembly 3 4 Rotator Bearing Rotator Gear Lubricate Lubricate 4 Fittings Multipurpose grease Apply exposed gear lube through 2 access holes. Procedure Change Change Quantity Specification SAE 80W-90 API GL5 SAE 80W-90 API GL5
8000 SRM 780 Table 11. Inspect and Adjust Item No. 5 7 8 10 Twist Locks Sideshift Slider Pads Extension Beams Wear Pads Extension Cylinder Wear Pads Item Interval 500 hr/3 mo 500 hr/3 mo 500 hr/3 mo 1000 hr/6 mo
Procedure Check condition. Check condition of the 4 pads. Check condition of the 24 pads. Check condition of the 4 pads.
Table 12. Lubricate Item No. Item Rotator Assembly 3 4 5 6 9 Bearing Gear Twist Locks Sideshift Cylinder Stop Cylinders 250 hr/1 mo 250 hr/1 mo 250 hr/1 mo 500 hr/3 mo 500 hr/3 mo 4 Fittings 4 Fittings 2 Fittings 4 Fittings Multipurpose grease Apply exposed gear lube through 2 access holes. Multipurpose grease Multipurpose grease Multipurpose grease Interval Quantity Specification
Table 13. Change Item No. 1 2 5 Item Rotator Brake Oil Rotator Transmission Oil Twist Locks Interval 2000 hr/1 yr 2000 hr/1 yr 5000 hr Quantity 2.6 liter (2.7 qt) 2.8 liter (3.0 qt) 4 Specification SAE 80W-90 API GL5 SAE 80W-90 API GL5 See Parts Manual
8000 SRM 780
PPM SPREADER MAINTENANCE
Figure 5. Maintenance and Lubrication Points for PPM Spreader Table 14. Initial 100-Hour Inspection Item No. 5 3 Item Rotator Transmission Oil Rotator Fixation Bolts Procedure Change Check torque Quantity 2 @ 2.6 liter (2.75 qt) 64 bolts M20 Specification SAE 80W-90 API GL5 500 Nm (368 lbf ft)
Table 15. Inspect and Adjust Item No. 8 5 4 1 8 3 5 Twist Locks Rotator Transmission Oil Extension Transmission Oil Extension Beams Horizontal Pads Extension Beams Side Wear Pads Rotator Gear Fixation Bolts Rotator Transmission Fixation Spreader Control System See Figure 5 for Item Nos. Item Interval 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 1000 hr/6 mo 1000 hr/6 mo 1000 hr/6 mo 2000 hr/1 yr 2000 hr/1 yr Procedure Check wear and condition. Check level. Check level. Check progress of wear and fixation. Check condition, shimming, and fixation. Torque to 500 Nm (368 lbf ft) Torque 20 Bolts to 210 Nm (155 lbf ft) Check condition, adjustment, and fixation.
10
8000 SRM 780 Table 16. Lubricate Item No. 3 3 3 8 9 7 1 Item Rotating Ring Gear Assembly Rotator Gear Bearing Rotator Gear Teeth Twist Locks Seated Pin Sideshift Cylinder Extension Beams Horizontal Pads 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 50 hr/1 wk 4 Fittings As required 4 Fittings 4 Fittings 2 Fittings 12 Fittings Interval Quantity
Specification
Multipurpose grease Exposed gear lube Multipurpose grease Multipurpose grease Multipurpose grease Multipurpose grease
Table 17. Change Item No. 4 5 8 3 3 Item Extension Transmission Oil Rotator Transmission Oil Twist Locks Rotator Ring Gear Rotator Gear Fixation Bolts Interval 1000 hr/6 mo 1000 hr/6 mo 6000 hr 8000 hr 8000 hr Quantity 2.6 liter (2.7 qt) 5.2 liter (5.5 qt) 4 1 64 bolts, M20 Specification SAE 80W-90 SAE 80W-90 API GL5 See Parts Manual See Parts Manual See Parts Manual
11
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 780

HOW TO MAKE CHECKS WITH ENGINE STOPPED WARNING
Do not operate a YardMaster 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. Put YardMaster on level surface. Fully lower and retract boom, stop engine, and apply parking brake. Do all checks outside of engine compartment first. Open hood and check for abnormal leaks and conditions. Clean any oil or fuel spills. Make sure dirt and other materials are removed from engine compartment.
1. CHECK TIRE PRESSURE 2. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM TREAD) Figure 6. Check Tires Check tires for damage. Inspect tread and remove any objects that will cause damage. Check for bent or damaged rims. Check for loose or missing parts. Remove any wire, straps, or other material wrapped around axle.
Tires and Wheels WARNING

Remove all of the air from the tires before the tires are removed from the YardMaster. Air pressure in tires can cause tire and wheel parts to explode. The explosion of wheel parts can cause serious injury or death. If the air pressure is less than 80% of the correct air pressure, the tire must be removed before air is added. Put the tire in a safety cage when adding air pressure to the tire. Follow the procedures described in Add Air to Tires. When air is added to the tires, use a remote air chuck. The person adding air must stand away and to the side and not in front of the tire. Keep tires at correct air pressure. See Figure 6. See Nameplate. Check air pressure with a gauge when tires are cold. If it is necessary to add air to a tire that is warm, check one of the other tires on the same axle and add air to the tire that has low pressure so air pressures are equal. The air pressure of the warm tires must always be equal to or greater than the specification for air pressure for cold tires.
CAUTION
Check all wheel nuts after 2 to 5 hours of operation: when new YardMasters begin operation and on all YardMasters when the wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 250 hours. Make sure wheel nuts are tight. Tighten wheel nuts as shown in Figure 25. The correct torque value is shown in the Maintenance Schedule.
Safety Labels WARNING

Safety labels are installed on the YardMaster to give information about operation and possible hazards. It is important that all safety labels are installed on the YardMaster and can be read.
12
8000 SRM 780 Check that all safety labels are installed in correct locations on YardMaster. See the Parts Manual for the correct locations of the safety labels. If new labels must be installed, use the following procedures:
Maintenance Procedures Every 8 Hours or Daily acceptable. A drive belt with cracks that run the length of the belt or a belt with missing pieces is not acceptable. Check drive belt for correct tension.
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 surface is dry and has no oil or grease. Do not use solvent on new paint. Clean surface of old paint with cleaning solvent. 2. Remove paper from back of label. Do not touch adhesive surface. 3. Carefully hold label in correct position above surface. The label cannot be moved after it touches the surface. Put label on the surface. Make sure all air is removed from under label and corners and edges are tight.
1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 7. Drive Belt
Battery
A check of the battery electrolyte level is normally required only every 250 hours of operation. Heavy duty or high temperature operations will require more frequent checks. It is not necessary to check the electrolyte level on a maintenance-free battery. A low electrolyte level can cause the discharge indicator light to come on or cause battery damage during YardMaster operation.
Fuel, Oil, or Coolant Leaks Check 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 YardMaster until a leak is repaired. Make a visual check for leaks on and under YardMaster. If possible, find and repair leak at the source. Leaks can indicate a need for repair of damaged or worn components. Check fuel system for leaks and condition of parts. When fuel is added to YardMaster, see How To Add Fuel to YardMaster procedures in Operating Manual. Also check condition of radiator or heater hoses. Replace soft or cracked hoses.
WARNING
The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the eyes must be flushed with water immediately. Wear eye protection. Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flame away from the battery area. Do not make sparks from the battery connections. Disconnect the battery ground cable when doing maintenance. Keep battery and cable terminals clean. Check electrolyte level (unless maintenance-free battery). Keep electrolyte level above separators and plates. Use distilled water. Do not fill battery more than to bottom of internal filler neck.
Drive Belts
Make sure key is in OFF position and engine is stopped. Check drive belt for wear and damage. See Figure 7. Small cracks that run across belt are
13
Maintenance Procedures Every 8 Hours or Daily If the battery becomes discharged and requires a booster battery to start engine, follow these procedures carefully when connecting jumper cables: 1. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal. 2. Always connect jumper cable that is the ground cable last.
8000 SRM 780
CAUTION
Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. Verify that all of the cylinder are retracted. The hydraulic oil level gauge is on the outside of the hydraulic tank. See Figure 8. Keep the oil level between the two marks on the tube for the maximum oil level. Remove the hydraulic breather to add hydraulic oil to the reservoir. Check the hydraulic system for leaks and damaged or loose components.
CAUTION
Disposal of batteries must meet local environmental regulations. 3. Always connect jumper cables to discharged battery before connecting them to booster battery.
Engine Oil
Check oil level in engine daily. After engine has stopped, wait one minute before checking oil level. Keep oil at correct level as indicated on dipstick. Use correct oil as indicated below:
API CE/SF or SAE 10W-30 SAE 15W-40 SAE 20W-40
CE/SG 25 to 25 C ( 13 to 77 F) 15 to 35 C (5 to 95 F) 5 to 45 C (23 to 113 F)
Drain Water From Fuel Filter CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Open drain valve on bottom of fuel filter. Drain some fuel (and any water) into a container until clean fuel flows from filter. Close drain valve. 1. SHUTOFF VALVE 2. FUEL FILL CAP 3. HYDRAULIC OIL FILL CAP 4. MINIMUM OIL LEVEL 5. MAXIMUM OIL LEVEL 6. BRAKE FLUID RESERVOIR
Hydraulic System WARNING

At operating temperature the hydraulic oil is HOT. Do not permit the hot oil to touch the skin and cause a burn.
Figure 8. Hydraulic Tank
14
8000 SRM 780
Brake System Oil WARNING

At operating temperature the brake system oil is HOT. Do not permit the hot oil to touch the skin and cause a burn. The oil level is visible at side of tank. Keep oil level in tank at correct level. See Figure 9.
WARNING
DO NOT let anyone use their hands to guide the cable on the winch drum. The moving cable can cause serious injury. 3. Inspect cable for wear or damage. Check for cuts, sharp bends, corrosion, or other damage to cable.
HOW TO MAKE CHECKS 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: 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. Make sure the area around YardMaster is clear before starting engine or making any checks of the operation. Be careful when making checks. If YardMaster is stationary during a check, apply parking brake and put transmission in NEUTRAL. Make checks carefully.
1. LEVEL INDICATOR
2. FILL CAP
Figure 9. Brake Fluid Reservoir
Cooling System WARNING

DO NOT remove the radiator cap when the engine is hot. When the cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. Check coolant level at the expansion tank on the LH running board. If coolant is added, use correct mixture of 50% water and 50% ethylene glycol. Check radiator fins. Clean radiator with compressed air or water as needed.
Boom and Spreader

1. Inspect boom sections for cracks and wear. 2. Inspect spreader sections for cracks and wear. 3. Tighten any nuts or bolts that are loose. Replace any damaged or broken parts.
Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays

Check operation of horn. Push on START switch and turn key switch to ON position. Check all gauges and indicator lights for correct operation. Start engine. Check gauges and indicator lights for correct operation as described in the Operating Manual. If any indicator lights or gauges do not operate correctly, turn key switch OFF and check thermal switches. Push on switch to reset circuit. The panel for the circuit breakers is located under the seat. See Figure 10 and Figure 11.
Hook, Winch, and Boom (HR45H)

1. Inspect boom sections for cracks and wear. 2. Inspect winch for damage or loose bolts.
15
8000 SRM 780
NOTE: NUMBERS ON THE FUSE PANEL CORRESPOND WITH THE NUMBERS LISTED BELOW. CIRCUIT BREAKERS F1 - ENGINE STOP (10 AMP) F2 - WINDSHIELD WIPER (20 AMP) F3 - WORKING LIGHT, CHASSIS (20 AMP) F4 - BOOM WORKING LIGHT (20 AMP) F5 - BEACON LIGHT (20 AMP) F6 - GEAR SELECTOR (15 AMP) F7 - HAZARD WARNING LIGHT (10 AMP) F8 - SPREADER/PIGGY BACK CONTROLS (15 AMP) F9 - SAFETY DEVICES AND FLOW SELECTIONS (15 AMP) F10 - PARKING LIGHTS (15 AMP) F11 - SPREADER/PIGGY BACK CONTROLS (10 AMP) F12 - HEADLIGHTS AND HORN (20 AMP) F13 - STARTER RELAY (10 AMP) F14 - NOT USED F15 - DASHBOARD LIGHTS (5 AMP) F16 - AIR CONDITIONER (35 AMP) F17 - NOT USED F18 - NOT USED
Figure 10. Circuit Breaker Panel Until Serial Number 01566
16
8000 SRM 780
NOTE: NUMBERS ON THE FUSE PANEL CORRESPOND WITH THE NUMBERS LISTED BELOW. F1 - BATTERY OFF SWITCH, 10A F2 - PARK BRAKE, 5A F3 - LH AND RH DOME LIGHT, 5A F4 - FRONT, REAR, AND ROOF WINDSHIELD WIPERS, 15A F5 - WINDSHIELD WASHER, ALARM, CONTROL LIGHTS, AND SENDERS, 5A F6 - CABIN, SPREADER, AND FRAME WORKING LIGHTS, 20A F7 - BRAKE LIGHTS, TURN SIGNAL INDICATOR LIGHTS, 15A F8 - CABIN, BOOM WORKING LIGHTS, 20A F9 - ROTATING BEACON, 20A F10 - REVERSE LIGHT, 5A F11 - AIR CONDITIONING, 15A F12 - SPREADER SIGNALS, SPREADER SENSORS, 15A F13 - SPREADER LEVELING, DERRICKING UP/DOWN, HYDRAULIC OIL COOLING, 15A F14 - CONDENSER, 15A F15 - TRANSMISSION, 20A F16 - DIRECTION INDICATOR LIGHTS, 15A F17 - SPREADER FUNCTIONS, 10A F18 - FRONT STABILIZERS, OPTIONAL, 5A F19 - SLIDING CAB, 10A F20 - DAMPENING NEUTRALIZATION, 10A F21 - SPREADER ROTATION, SIDESHIFT SPREADER, 10A F22 - CAB CONTROLLER SUPPLY, 10A F23 - ENGINE STOP, 5A F24 - HEADLIGHTS, HORN, 20A F25 - NOT USED F26 - NOT USED F27 - DIODE F28 - DIODE F29 - AIR CONDITIONING PROTECTION FUSES, 3A F30 - NOT USED F31 - NOT USED F32 - NOT USED F33 - NOT USED F34 - NOT USED F35 - NOT USED F36 - NOT USED F37 - NOT USED F38 - NOT USED F39 - BATTERY SHUTOFF, ENGINE START, 10A F40 - WARNING LIGHTS, 10A F41 - PARKING LIGHTS, 10A F42 - REVOLUTION COUNTER, HOURMETER, 5A F43 - CAR RADIO CONVERTER 24V/12V, 10A F44 - ELECTRONIC ENGINE CONTROLLER, 10A F45 - ELECTRONIC ENGINE CONTROLLER, 10A F46 - NOT USED F47 - NOT USED F48 - NOT USED F49 - NOT USED F50 - NOT USED F51 - NOT USED F52 - NOT USED F53 - NOT USED F54 - NOT USED F55 - NOT USED F56 - NOT USED F57 - NOT USED F58 - NOT USED
Figure 11. Circuit Breaker Panel Starting With Serial Number 01566
17
Maintenance Procedures Every 8 Hours or Daily In the battery box there is an additional fuse panel. See Figure 12. This panel protects the indicated circuits shown below: PF100 (100 amp fuse) provides protection to all functions behind the battery shutoff. PF80 (80 amp fuse) provides protection to the starter motor behind the battery shutoff. PF50 (50 amp fuse) provides general protection for the direct battery supplies.
8000 SRM 780
1. SECONDARY ELEMENT 2. RESTRICTION SENDER 3. PRIMARY ELEMENT Figure 13. Air Filter Assembly
Control Levers and Pedals

Check that controls for transmission, boom, and spreader operate as described in the Operating Manual. Check that pedals operate correctly as described in the Operating Manual.
Electrical System
Check voltmeter and discharge indicator light during operation. The discharge indicator light can come on during operation if the drive belt does not have the correct tension. Also check condition of battery.
Figure 12. General Fuse Panel
Air Filter
Check indicator light for air filter during operation. Also, check restriction indicator with engine running at full speed. When the light comes on, filters are dirty. Clean or install a new air filter element(s) as necessary. See Figure 13. Replace secondary element every third time primary element is cleaned. Use compressed air to clean filter elements. Air pressure must be less than 2 bar (30 psi). Apply air from inside to outside of the filter element. Inspect filter elements. Put a bright light inside filter elements and look for holes or other damage. If a filter element is damaged, install a new filter element. Use a cloth with solvent to clean inside of canister before filter elements are installed.
Transmission Oil
Check gauges and indicator lights for transmission during operation. There are indicator lights for the oil pressure and oil temperature of the transmission. The light for the oil pressure is on when the oil pressure is too low for correct operation. The light for the oil temperature is on when the temperature is too high for correct operation. Make a visual check of transmission and check transmission oil level. See Figure 14. Apply parking brake. Put blocks on both sides (front and back) of drive tires to prevent movement of vehicle. Check oil level in transmission when engine is running at idle speed and transmission oil is at operating temperature. Put direction control lever in NEUTRAL position. Open lower petcock on righthand side of transmission. If oil does not drain from port, close petcock. Open upper petcock. Add correct oil as shown in the Maintenance Schedule at filler tube until oil drains from upper petcock. Close upper petcock.
Air Conditioning
It is recommended to operate the system at least once per 15 days for 10 minutes consecutively.
18
8000 SRM 780
Engine Oil CAUTION

Do not continue to operate the vehicle when the light is on during operation. Check the indicator light during operation. The indicator light is located on the instrument panel. The light for the indicator is on when the engine oil pressure is too low for correct operation. Stop engine and check oil level.
Cooling System
1. OIL FILLER TUBE 2. OIL FILL PETCOCK 3. OIL LEVEL PETCOCK
CAUTION
Do not continue to operate vehicle when light is on during operation. For trucks before serial number 01566, check coolant temperature gauge and indicator light during operation. Do not operate vehicle when temperature is above 100 C (212 F). The red light is on when the coolant temperature is to low. Starting serial number 01567 and up, check the engine default code when the engine warning light is ON
Figure 14. Transmission Oil Level Check
Steering System WARNING

The YardMaster has hydraulic power steering. The steering can be difficult when the engine is not running. Make sure steering system operates smoothly and gives good steering control.
Hydraulic System
Check hydraulic oil filter light during operation. The light is on when filters are dirty.
Service Brakes
Check operation of service brakes. Push on brake pedal. The service brakes must be applied before the brake pedal reaches the floor plate. The pedal must apply equally to each of both the drive wheel assemblies. The service brakes must not pull the YardMaster to either side of the direction of travel when they are applied.
Boom and Spreader Operation WARNING

Lower and retract boom completely. Never allow any person under a raised boom or spreader. Do not put any part of your body in or through the lift mechanism unless all parts of the boom and spreader are completely lowered and the engine is STOPPED. Do not try to find hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by the pressure.
Parking Brake
Check operation of parking brake. The parking brake, when in good condition and operating correctly will hold a YardMaster with a capacity load on a 15% grade. A 15% grade is a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft).
19
Maintenance Procedures Every 50 Hours or Weekly Do the following checks and inspections: 1. Check for leaks in hydraulic system. Check condition of hydraulic hoses and tubes. 2. Slowly raise and lower boom several times without a load. Extend and retract boom at least once. The boom must raise and lower smoothly.
8000 SRM 780 3. Check that controls for boom and spreader operate the functions correctly. See symbols by each of the controls. 4. On HR45H units, check that controls for boom and winch operate the functions correctly. See symbols by each of the controls.
Maintenance Procedures Every 50 Hours or Weekly

NOTE: Do these procedures in addition to the 8-hour checks. fitting. Some rotator transmissions have separated oil fill and drain ports for the brake transmissions.
BOOM
Lubricate the fittings at the wear pads. For wear pads without grease fittings, lubricate the wear pad tracks with a brush and multipurpose grease. Lubricate the fittings at the boom pivots, the dampening cylinders, and at the rotator pivot bearing with multipurpose grease. Use a brush to lubricate the keys of the telescoping cylinder. Lubrication of the boom pivots is necessary to allow removal of the boom when required. See Figure 15.
Rotator Motor
Check oil level at motor assemblies. The oil level is correct when oil is visible in fill/check port (3, Figure 16).
1. 2. 3. 4.
FILL/CHECK PORT (ROTATOR BRAKE) DRAIN PORT (ROTATOR BRAKE) FILL/CHECK PORT (ROTATOR MOTOR) DRAIN PORT (ROTATOR MOTOR) Figure 16. Rotator Motor
1. LINKS AND JOINTS 2. CYLINDERS AND PINS
3. SLIDE PADS 4. HYDRAULIC LINES
Rotator Assembly
Lubricate rotator gears through access holes (Figure 17) in stop blocks. Be sure to use a lubricant for exposed gears. Rotate the gear completely in each direction and apply the grease to both sides of the teeth. Lubricate rotator assembly at grease fittings. There are four fittings for the rotator bearing. Rotate the ring four times, until all fittings have received one pump action of the grease gun.
Figure 15. Boom
PPM SPREADER Rotator and Extension Transmissions

Check the oil level in the transmission and the extension motor at the checkport. See Figure 16. The oil level is correct when the oil level is visible in the
20
8000 SRM 780
Maintenance Procedures Every 250 Hours or 6 Weeks
Twist Locks
Check the wear and the condition of the twist locks. Lubricate the fittings at the twist locks and seated pin.
Wear Pads (Extension Beam)

Apply grease through the grease fittings of the horizontal wear pads. Extend the beams and apply grease with a brush to the tracks of the side wear pads. 1. ACCESS HOLE 2. GREASE FITTINGS
Sideshift Cylinders
Lubricate the grease fittings at the end of the sideshift cylinder with multipurpose grease.
Figure 17. Rotator Gears

NOTE: Do these procedures in addition to the 8-hour and 50-hour checks.
DRIVE BELTS
Check the tension of the drive belts for the engine and air conditioning.
ENGINE OIL AND FILTER CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Change oil and filter for the engine after the first 100 hours on a new YardMaster. After the first 100 hours, change oil and filter every 250 hours. Change oil filter and engine oil at the same time. Use correct oil according to the Maintenance Schedule. Fill filter with oil before installing it on engine. After changing filter and oil, start engine and check area around filter for leaks. Check oil level at dipstick that is on the left-hand side of the engine.
STEERING AXLE
Use multipurpose grease to lubricate the four grease fittings at the king pins, the grease fittings at the tie rods, and the fittings at the two pins of the central pivot.
BATTERY
See procedures under Maintenance Procedures Every 8 Hours or Daily.
WHEEL NUTS
Check torque of the wheel nuts in the sequence shown in Figure 25. The correct torque value is in the Maintenance Schedule.
FUEL FILTER/WATER SEPARATOR

The fuel filter/water separator is installed on the right side of the engine. When replacing the spin on filter element, fill the new filter with clean fuel. Install the filter and tighten it by hand. Start the engine and check for leaks.
WINCH OIL LEVEL

Check oil level in winch reduction unit at the fill/ check port (Figure 18).
21
8000 SRM 780
ELME SPREADER Rotator and Extension Transmission

Check the oil level in the transmission of the rotator and the extension motor at the checkport. See Figure 16. The oil level is correct when the oil level is visible in the fitting. Some rotator transmissions have separated oil fill and drain parts for the brake and the transmission.
Rotator Assembly
Lubricate the rotator gears through the access holes in the stop blocks. See Figure 17. Be sure to use a lubricant for exposed gears. Rotate the gear completely in each direction and apply the grease to both sides of the teeth. Lubricate the rotator assembly at the grease fittings. There are four fittings for the rotator bearing. Rotate the ring four times, a quarter of a turn each time, until all fittings have received one pump action of the grease gun.
1. DRAIN PLUG
2. FILL/CHECK PORT
Figure 18. Winch Reduction Unit
STEERING AXLE TIE RODS AND KING PINS

Lubricate grease fittings on steering tie rods with multipurpose grease.
DRIVE SHAFT JOINTS

Lubricate grease fittings on drive shafts.
Twist Locks
Check the wear and condition of the twist locks. Lubricate the fittings at the twist locks and seated pins.
GENERAL LUBRICATION
Lubricate any linkages, rod ends, levers, cab rails, hinges, and seat rails with engine oil.
22
8000 SRM 780
Maintenance Procedures Every 500 Hours or 3 Months

NOTE: Do these procedures in addition to the 250hour checks.
BOOM HORIZONTAL WEAR PADS

Measure the remaining thickness of the horizontal wear pads and replace if the thickness is 21 mm (0.83 in.) or less. Position new wear pads with the "V" of the grooves pointing toward the rear of the boom. Retract the boom. Verify that the bottom of the inner boom rests in the outer boom. Measure the play between the outer boom and the rear and front upper wear pads. Reshim wear pad play to 0 to 1 mm (0 to 0.04 in.), if play exceeds 3 mm (0.12 in.). Place shims under the upper rear pads to reshim at the rear side. Place shims under the lower front wear pads to reshim at the front side. Use medium Loctite on the bolts. Torque the bolts of the wear pads to 130 Nm (96 lbf ft), and the bolts of the pad stops to 200 Nm (148 lbf ft).
AIR FILTER
Replace the central air filter element every 500 hours. See Figure 13. See Maintenance Procedures Every 8 Hours or Daily for more information.
HYDRAULIC OIL FILTERS CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. When replacing the spin-on filter elements, fill new filters with clean oil. Install filters and tighten them by hand. Start engine and check for leaks.
TRANSMISSION OIL FILTER CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Change oil filters for the transmission after the first 100 hours on new YardMasters. After the first 100 hours, change filter every 500 hours. Remove and install a new oil filter for the transmission. Fill transmission as necessary.
BOOM SIDE WEAR PADS

Measure the play between the outer boom and the side wear pads. Reshim the wear pad play to 1 mm (0.04 in.), if the play exceeds 1.5 mm (0.06 in.). Replace the side wear pads when the wear mark has reached; this is when the remaining thickness is 50 mm (1.97 in.) or less. Apply medium Loctite to the fixation bolts of the pad support and torque the bolts to 200 Nm (148 lbf ft). Before adjusting the play, the inner boom has to be centered by means of adjustment bolts of the side wear pads. To center the rear of the inner boom, the clearance between the LH side clamp plate and the cylinder bracket must be made equal to the clearance of the RH side clamp plate and cylinder bracket. See Figure 19.
DIFFERENTIAL AND WHEEL END HOUSINGS OIL

The oil level in the differential is correct when the oil is even with the plug in the front of the housing. The oil level in each wheel end housing is correct when the oil is even with the plug in the hub cover. Make sure the raised line on the cover is horizontal and the plug is toward the bottom. Add correct oil as specified in the Maintenance Schedule.
HYDRAULIC TANK BREATHER

Inspect the filter of the hydraulic tank breather. Clean or replace the filter as needed.
23
8000 SRM 780
NOTE: J REPRESENTS THE CLEARANCE BETWEEN THE CLAMP PLATE AND THE CYLINDER BRACKET. 1. CLAMP PLATE 2. CYLINDER BRACKET Figure 19. Centering the Rear of the Inner Boom Tighten the two clamp plates while verifying that are parallel with the cylinder, with clearance on each side between 3 mm (0.12 in.) and 6.5 mm (0.26 in.). To center the front of the inner boom, the lower portion of the inner boom must be centered in the outer boom. See Figure 20. To shim the side wear pads, loosen the adjustment bolt and insert a 1 mm (0.04 in.) shim between the outer boom and the side wear pad. Retighten the bolt to establish contact with the adjustment shim. Do not move the inner boom in the outer boom. Remove the shim and secure the position of the bolt by tightening the nut. Adjust the clearance for the upper side wear pads without moving the inner boom.
1. INNER BOOM 2. OUTER BOOM 3. DISTANCE BETWEEN INNER AND OUTER BOOM 4. LOWER WEAR PADS Figure 20. Centering the Front of the Inner Boom
SIDESHIFT CYLINDER
Lubricate two grease fittings at the end of each sideshift cylinder with multipurpose grease. See Figure 4.
STOP CYLINDERS (ELME OPTION)

Lubricate the fittings at each stop cylinder.
ELME SIDESHIFT WEAR PADS

Lubricate two tracks on each side of the spreader for the slider pads. See Figure 4. Use a brush with multipurpose grease. Inspect pads during lubrication. The wear pads must be replaced before metalto-metal contact occurs.
WEAR PADS (EXTENSION BEAMS)

Lubricate tracks for the wear pads at the ends of the beams. See Figure 4. There are twelve wear pads at each end of the spreader. Use a brush with multipurpose grease. Inspect pads during lubrication. The wear pads must be replaced before metal-to-metal contact occurs.
24
8000 SRM 780

NOTE: Do these procedures in addition to the 500hour checks. Install radiator cap and open shutoff valve. Start engine. Check area around filter for leaks.
COOLANT FILTER WARNING

DO NOT remove cap from radiator when engine is hot. When the cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.
HYDRAULIC ACCUMULATORS Brake Accumulator

1. Press the brake pedal 15 times to decompress the hydraulic side of the accumulator. 2. Slightly open the controller bleed screw and attach an inflator controller to read the inflation pressure. The pressure in the bottle should be 50 bar at 20 C (68 F). 3. To reduce pressure, open the bleed screw until the required level is obtained.
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. Remove radiator cap and close shutoff valve at filter. See Figure 21. Clean area around filter head. Remove and discard coolant filter. Apply clean engine oil to gasket of new filter. Install new filter and turn filter until gasket touches, then tighten it 1/2 to 3/4 turn.
WARNING
Always use nitrogen only. Do NOT use air, which contains oxygen. Compressed oxygen may cause an explosion. 4. To increase the pressure, attach a nitrogen bottle with a pressure regulator and inflate until 50 bar has been reached. 5. After initial inflation, wait at least 30 seconds to allow the pressure to stabilize. Check and correct the pressure if necessary. 6. Close all valves and remove the connected bottle and inflator controller. 7. Verify that the controller bleed screw is completely closed.
TRANSMISSION OIL CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Change oil in transmission and clean strainer. When filling transmission, start by putting in 19 liter (20 qt) of correct oil. Start engine and let it run for at least 5 minutes. Apply brakes and shift range selector lever through all ranges. Fill transmission to full mark. The dipstick is on right-hand side of engine. Check oil level with engine at idle speed.
1. SHUTOFF VALVE
2. COOLANT FILTER
Figure 21. Coolant Filter
CAUTION
Do not start engine with the coolant shutoff valve in the closed (OFF) position. The engine can be damaged when running with the valve closed.
DISC BRAKE
There is a disc brake assembly installed on the differential housing that is used for the parking brake. Inspect disc brake assembly every 1000 hours.
25
8000 SRM 780
WARNING
Brake linings can contain dangerous fibers. Breathing the dust from brake linings is a cancer or lung disease hazard. Do not create dust! Do not clean brake parts with compressed air or by brushing. Use vacuum equipment approved for dangerous fibers or follow the cleaning procedure in this section. Do not sand, grind, chisel, hammer, or change linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. Cleaning Procedures: 1. Do not release dust from brake linings into air when checking brakes. 2. Use a solvent to wet the lining dust on the parts of the brake. If a solvent spray is used, do not create dust with spray. 3. When lining dust is wet, clean parts. Put any cloth or towels in plastic bag or airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.
AIR FILTER PRIMARY ELEMENT

Replace the primary air filter element every 1000 hours. Clean the inside of the canister. See Figure 13.
HYDRAULIC TANK BREATHER

Replace the hydraulic tank breather.
PPM SPREADER Extension Beam Horizontal Pads

Measure remaining thickness of the horizontal wear pads. Replace if the thickness is 16 mm (0.63 in.) or less. Use medium Loctite when retorquing the fixation bolts at 100 Nm (74 lbf ft). Check the torque of all pads and pad holders.
Extension Beam Side Wear Pads

Measure the remaining thickness of the side wear pads. Replace if the thickness if 16 mm (0.63 in.) or less. Use medium Loctite when retorquing the fixation bolts at 100 Nm (74 lbf ft). Check the torque of all pads and pad holders.
Ring Gear Fixation Bolts

Verify that all 68 fixation bolts are at least torqued to 420 Nm (310 lbf ft). Replace a bolt if it has moved while applying a torque of 420 Nm (310 lbf ft) or less. If more than 20 percent of the bolts had to be replaced, then all ring gear fixation bolts have to be replaced. Torque the bolts to 500 Nm (369 lbf ft) in a sequence as indicated in Figure 22.
Inspect
Inspect brake lining and parts of brake assembly for wear or damage. If brake linings are worn or damaged, they must be replaced. Brake linings must be replaced in complete sets. Inspect brake rotor for wear or damage. Check caliper for leaks.
BRAKE SYSTEM OIL AND FILTER CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Replace oil filter and change oil for the brake system at the same time. Use oil specified in the Maintenance Schedule. Figure 22. Rotator Ring Torque Sequence
26
8000 SRM 780
Maintenance Procedures Every 2000 Hours or Yearly Change oil in the winch reduction unit. See Figure 18. Unwind cable to get access to ports on drum. Rotate drum until drain port is toward bottom. Remove plug to drain oil. When filling unit, check level at fill/check port.
ELME SPREADER Wear Pads (Extension Cylinder)

Lubricate tracks for wear pads at the end of the extension cylinders. See Figure 4. Use a brush with multipurpose grease to lubricate the tracks. Inspect pads during lubrication. The wear pads must be replaced before metal to metal contact occurs.
PEDALS, LEVERS, HINGES, AND SEAT RAILS (GENERAL LUBRICATION)

Lubricate any linkages, rod ends, levers, cab rails, hinges, and seat rails with engine oil.
WINCH OIL CAUTION

Disposal of lubricants and fluids must meet local environmental regulations.
Maintenance Procedures Every 2000 Hours or Yearly

NOTE: Do these procedures in addition to the 1000hour checks. Change the oil in the drive axle and the differential. To drain the oil, remove plugs from the wheel end housings and the plug at the bottom of the differential housing. Fill drive axle with oil specified in the Maintenance Schedule. After filling, operate the YardMaster to verify the oil level is even. Check oil level again and check for leaks.
ENGINE VALVE ADJUSTMENT

The dealer for Cummins engines maintains and adjusts the engine. Contact the dealer to make any valve adjustments.
HYDRAULIC RELIEF PRESSURES

See the section Hydraulic System YardMaster 1900 SRM 783. For the boom settings, see the section Boom YardMaster 4500 SRM 787. For the spreader settings, see the section Extendable Container Attachment, PPM 5000 SRM 1063.
HYDRAULIC OIL CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Change oil filters for hydraulic system at the first 50 hours of operation on new YardMasters.
COUNTERWEIGHT FIXATION
Verify the torque at 900 Nm (665 lbf ft).
Change Hydraulic Oil WARNING

At operating temperature, the hydraulic oil is HOT. Do not permit the oil to touch the skin and cause a burn. 1. Put YardMaster on a level surface and retract and lower boom completely. Put a container under hydraulic tank. Remove drain plug to drain the oil.
LOAD SENSING SYSTEM

Check for proper operation and settings. See Publication 1495851 (Load Limiter).
DOOR AND WINDOW SEALS

Apply silicon spray before the winter season.
DRIVE AXLE AND DIFFERENTIAL OIL CAUTION

Disposal of lubricants and fluids must meet local environmental regulations.
27
Maintenance Procedures Every 6000 Hours or 2 Years
8000 SRM 780
CAUTION
Do not permit dirt to enter the hydraulic system when the oil is checked or the filters are changed. 2. When the hydraulic oil has drained, install drain plug. Fill hydraulic tank with correct oil. Operate system and check for leaks.
ROTOR AND EXTENSION TRANSMISSION FIXATION BOLTS

Position the blue colored tooth of the rotator ring gear in line with one of the rotator transmissions. Dental play should be between 0.1 and 0.3 mm (0.004 and 0.012 in.). Rotate the eccentric ring 5 degrees for a movement of 0.1 mm (0.004 in.). Repeat for the second rotator transmission. Retorque the fixation bolts of the rotator and extension transmissions to 210 Nm (155 lbf ft).
STEER WHEEL HUB BEARING CAVITY

Clean and replace the grease in the wheel bearing cavities. Remove the steer wheel as described in the Operators Manual. Remove and clean the bearing cones in solvent. Verify all of the solvent is out of the bearing cones and completely fill the bearing cones with multipurpose grease. Install the bearing cone as described in the section Steering System YardMaster 1600 SRM 786. Install steer wheel as described in the Operators Manual.
ROTATOR AND EXTENSION TRANSMISSION OIL CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Change the oil for the transmissions. Note that the rotator transmissions can have separated housings with two filler and two drain plugs or one filler and one drain plug. The oil level is correct when oil is visible in the fittings. See Figure 16.
BRAKE SYSTEM OIL AND FILTER CAUTION

Disposal of lubricants and fluids must meet local environmental regulations. Replace oil filter and change oil for the brake system at the same time. Use oil specified in the Maintenance Schedule.
Maintenance Procedures Every 6000 Hours or 2 Years

ENGINE COOLANT CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 1. Change coolant in cooling system. Put YardMaster on a level surface. Stop engine. 3. Close the drain valve. Fill cooling system with correct coolant (50% water and 50% ethylene glycol). 4. Install radiator cap. Start engine. Check for leaks and add additional coolant as necessary.
VIBRATION DAMPER
Verify that the position of the damper has not moved. Replace the damper if the marker line has moved.
WARNING
If the coolant is hot, do not permit coolant to touch the skin and cause a burn. 2. Open the drain valve. Allow the coolant to drain into a container that will hold approximately 40 liter (42 qt). Remove the radiator cap. Flush the cooling system. Check hoses and fittings as needed.
TWIST LOCKS
Replace the twist locks. See the section Extendable Container Attachment (Elme) 5000 SRM 776.
28
8000 SRM 780
Wheel and Tire Replacement
Maintenance Procedures Every 8000 Hours

PPM SPREADER
Replace the rotator ring gear and its fixation bolts. Torque the bolts in a cross pattern to 500 Nm (368 lbf ft). See Figure 22.

WHEELS, REMOVE 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 YardMaster. air from both tires. Air pressure in the tires can cause the tire and wheel parts to explode, causing serious injury or death. 1. Raise YardMaster as described in How to Put YardMaster on Blocks, in this section. 2. Remove air from tire. Remove valve core to make sure all air pressure is out of tire. Push a wire through valve stem to make sure stem does not have a restriction. See Figure 23. When dual tires are installed, remove air pressure from both tires. 3. Remove wheel nuts and rim clamps. Remove wheel from YardMaster. Tires and wheels are heavy.
WARNING
Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. Completely remove the air pressure from the tire before it is removed from the YardMaster. If dual wheels are installed, remove the
A. STEER WHEEL 1. SIDE FLANGE 2. WHEEL RIM 3. FLANGE SEAT
B. DRIVE WHEELS 4. VALVE STEM 5. LOCK RING 6. SEAL RING Figure 23. Wheel Arrangements 7. RIM CLAMP 8. HUB 9. SPACER
29
8000 SRM 780
REMOVE TIRE FROM WHEEL WARNING

Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the tires can cause the tire and wheel parts to explode, causing serious injury or death. Keep tire tools in firm contact with wheels parts. If the tool slips, it can move with enough force to cause serious injury. STEP 1. Loosen tire from side flange. Remove lock ring.
STEP 2. Push flange seat downward and remove seal ring.
STEP 3. Remove side flange and flange seat.
STEP 4. Loosen tire from other side of wheel rim. Remove side flange and seal ring as necessary. Remove rim from tire.
30
8000 SRM 780
Wheel and Tire Replacement in the correct position. The ends of the lock ring must not touch. 1. Clean and inspect all parts of wheel. If wheel has rust or corrosion, remove loose rust and corrosion and paint the parts.
INSTALL TIRE ON WHEEL WARNING

Damage to the tire and wheel assembly and injury or death can occur if you do not do the following procedures: Clean and inspect all parts of the wheel before installing the tire. 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 YardMaster. 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
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. 2. Apply rubber lubricant or soap solution to tire bead and tube. 3. Make sure that rim is correct size for tire. Lubricate the part of the wheel that contacts the bead. 4. Install wheel in tire as shown in Install Wheel in Tire.
INSTALL WHEEL IN TIRE

STEP 1. Put rim on blocks. Install side flange. Make sure side flange is engaged with rim.
STEP 2. Install valve stem in rim. Install tire on rim.
31
Wheel and Tire Replacement STEP 3. Install flange seat and seal ring.
8000 SRM 780
STEP 4. Install side flange.
STEP 5. Install lock ring. Make sure all parts are correctly aligned. When correctly installed, there will be a 13 to 25 mm (0.5 to 1.0 in.) clearance between ends of side ring and/or lock ring. Add air pressure to tire as described in Add Air to Tires.
ADD AIR TO TIRES WARNING

Add air pressure to the tires only in a safety cage. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem. Make sure there is enough air hose to permit the operator stand away from the safety cage when air pressure is added to the tire.
5. Check that all wheel parts are correctly installed. If installation is not correct, remove all air pressure from tire. Remove valve core to make sure all air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be 13 to 25 mm (0.5 to 1.0 in.) when tire has the correct air pressure.
WARNING
Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). 1. Put tire in safety cage. See Figure 24. 2. Add 20 kPa (3 psi) air pressure to tire. 3. Check that all wheel parts are correctly installed. Hit lock ring to make sure it is in the seat. 4. If installation is correct, add correct air pressure to tire. (See Nameplate.) Figure 24. Add Air to Tires
32
8000 SRM 780
General Maintenance to 295 Nm (218 lbf ft) and finally to 375 Nm (277 lbf ft).
WHEELS, INSTALL CAUTION

Check all wheel nuts after 2 to 5 hours of operation when new YardMasters begin operation and on all YardMasters when the drive wheels have been removed and installed. Tighten nuts as shown in Figure 25. When the nuts stay tight for 8 hours the interval for checking the torque can be extended to 250 hours. Align and install wheel on hub. Install clamps or flange on studs. Install six nuts and washers (one at every fourth position) and tighten while rotating wheel. See Figure 25. Make sure wheel is in correct position, then tighten nuts in a cross pattern to 195 Nm (144 lbf ft). Install remaining nuts and then tighten them in a cross pattern to 195 Nm (144 lbf ft). Tighten nuts in a cross pattern
Figure 25. Tighten Wheel Nuts
General Maintenance
SPREADER Twist Locks
Inspect twist locks for wear whenever twist locks are lubricated. Inspect heads of twist locks as shown in Figure 26. When the wear is more than 10 mm (0.4 in.), replace twist lock. It is recommended that twist locks are replaced after a maximum of 5000 hours of use. M24, grade 10.9 = 740 Nm (545 lbf ft) M12, grade 10.9 = 90 Nm (66 lbf ft) Check torque for mounting bolts for rotator motors. The correct torque for M12 bolts is 90 Nm (66 lbf ft).
HOW TO STORE YARDMASTER

The following storage procedures are for conditions and temperatures above 0 C (32 F). Adjust these procedures for local conditions and any changes in conditions during storage. The preparations necessary for storage are also determined from the following conditions: Short-term storage is from 1 to 6 months. Longterm storage is over 6 months. Storage Location. A YardMaster stored indoors will not require as much external protection as a YardMaster stored outdoors.
Short-Term Storage
Figure 26. Twist Locks Do the following steps to prepare the YardMaster for storage from 1 to 6 months: 1. Check lubricant and fluid levels. Completely fill fuel tank. Make sure coolant mixture will protect cooling system and engine to lowest temperature expected during storage. Make sure all caps and dipsticks are installed correctly.
Rotator Assembly
Inspect rotator assembly for loose mounting bolts whenever parts are lubricated. Check torque at least twice a year. The correct torques for bolts for rotator ring gear are:
33
General Maintenance 2. Fully lower and retract boom. Apply thin coat of engine oil to cylinder rods. 3. Check that all switches and accessories are in the OFF position. 4. If the YardMaster must be left on an incline, put blocks on down hill side of wheels so YardMaster cannot move - do not use parking brake. 5. Disconnect battery cables from batteries. Apply a protective coat to cable connectors and battery terminals to prevent corrosion. 6. Check tire pressure. Make sure tires have correct pressure (see Nameplate). 7. Clean engine compartment to prevent corrosion. 8. If YardMaster is not stored in a shelter, put a cover over YardMaster to prevent damage from weather. In wet conditions, a cover will not prevent corrosion to a YardMaster that is in longterm storage outside of a dry storage area.
8000 SRM 780 when traveling in the forward direction with steering wheel turned to move the YardMaster away from the edge of the dock, the rear will swing toward the edge. This can cause the YardMaster to fall off the dock.
WARNING
IF THE YardMaster FALLS OFF THE DOCK, DO NOT JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR FEET, AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT. Before YardMaster is moved on a transport, check the selected route to make sure there is enough clearance for YardMaster as loaded on the transport vehicle. Bridges, overpasses, power lines, and natural barriers can prevent clearance. Removal of the boom and/or spreader can be necessary. If a trailer is the method of transportation, use blocks in front and back of trailer tires to prevent movement of trailer when YardMaster is loaded and unloaded. If a loading ramp is used, make sure the ramp is the correct design and capacity. Lift YardMaster only at designated lifting points.
Long-Term Storage
Do the following steps to prepare the YardMaster for storage for 6 months or longer: 1. Complete all short-term storage procedures. 2. Wrap or cover all exterior lights, radiator grill, and air vents with a moisture barrier cover. Use tape to hold covers in position. 3. Remove batteries from YardMaster. Store batteries in an approved space. Be sure to follow local regulations. Batteries that are stored for long periods can become damaged. A recommendation is that batteries be used in service if possible. 4. Spray exterior surfaces and frame with preservative coating.
Loading
If boom and/or spreader must be removed for transport of the YardMaster, see the Service Manual for removal procedures. The operator must never leave YardMaster in a condition so that it can cause damage and injury. When YardMaster is loaded on the transport, do the following operations: 1. Apply parking brake. 2. Fully lower and retract boom. 3. Put direction control lever for transmission in NEUTRAL. 4. Turn key switch to OFF to stop engine. Check that all switches and accessories are turned off. 5. Put blocks in front and back of YardMaster tires to prevent YardMaster from moving. Make sure blocks are attached to load surface.
HOW TO MOVE YARDMASTER ON TRANSPORT WARNING

Stay a safe distance from the edge of docks, ramps, platforms, and other similar working surfaces. Watch the tail swing. Remember
34
8000 SRM 780 6. Unload YardMaster.
General Maintenance
WARNING
The straps or chains used to fasten the YardMaster to the transport must be directly connected to the YardMaster frame or to a component (drive axle) that is solidly attached to the frame. Do not fasten a strap or chain to the boom or spreader to hold the YardMaster on the transport.
PREPARATION FOR USE

After being transported or stored, YardMaster must be prepared for use for proper operation. All problems must be corrected before use of YardMaster. See the Service Manual for procedures.
Preparation After Transport

1. Complete unloading procedures. 2. Inspect YardMaster for damage and missing components. 3. Follow the steps in the section, How to Make Checks With Engine Stopped.
CAUTION
Make sure that any straps or chains used to fasten the YardMaster to the transport do not contact any tubes, hoses, hydraulic cylinders, or other parts of the truck that are easily damaged. If YardMaster is transported in severe weather or any other condition that can damage YardMaster, cover YardMaster. Make sure protective cover is designed for the application and is securely fastened.
Preparation After Storage

1. Remove all tape, covers, and preservation materials. 2. Check YardMaster for damage and missing components. Repair damage and/or replace missing components. NOTE: If YardMaster has been stored longer than one year, all lubricants and fluids must be drained and replaced. See the section for the fluid specifications. 3. Clean battery cables and terminals. Check battery voltage. If voltage is not correct, charge battery. Connect battery cables to battery. 4. Do the procedures in the section Maintenance Procedures Every 8 Hours or Daily.
Unloading
If components normally attached to YardMaster were removed for transport, see the Service Manual for installation procedures. 1. If used, remove any protective cover. 2. Make sure parking brake is applied. 3. Disconnect straps or chains. 4. Remove wheel blocks. 5. Check that all switches and accessories are turned off.
35
NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
36
TECHNICAL PUBLICATIONS
8000 SRM 780 6/05 (11/03)(4/03)(2/03)(1/00) Printed in U.S.A.

Periodic Manteinance

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Periodic Manteinance

Загружено:

Авторское право:

Доступные форматы

PERIODIC MAINTENANCE YARDMASTER

PART NO. 1470238

8000 SRM 780

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

Periodic Maintenance YardMaster

2005 HYSTER COMPANY

Periodic Maintenance YardMaster

TABLE OF CONTENTS (Continued)

Periodic Maintenance YardMaster

TABLE OF CONTENTS (Continued)

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 780

SERIAL NUMBER DATA

HOW TO MOVE DISABLED YARDMASTER WARNING

How to Tow YardMaster WARNING

HOW TO RAISE STEERING TIRES

HOW TO PUT YARDMASTER ON BLOCKS How to Raise Drive Tires WARNING

8000 SRM 780

8000 SRM 780

Donax TD SAE 10W

Check operation. Check operation.

See Figure 2 for Item Nos.

8000 SRM 780

FIRST INSPECTION AFTER FIRST 100 HOURS OF OPERATION

See Figure 2 for Item Nos.

PERIODIC MAINTENANCE SCHEDULE

See Figure 2 for Item Nos.

8000 SRM 780

1 1 2 1 41 liter (43.3 qt) 50 liter (52.8 qt)

50 liter (52.8 qt)

1 1 1 1 1100 liter (290.6 gal) 66 liter (69.7 qt) As required

See Figure 2 for Item Nos.

8000 SRM 780

Item Air Filter, Primary Element Cooling System

Interval 2000 hr/1 yr 6000 hr/2 yr

Quantity 1 56 liter (59.2 qt)

See Figure 2 for Item Nos.

See Figure 3 for Item Nos.

8000 SRM 780

See Figure 3 for Item Nos.

See Figure 4 for Item Nos.

See Figure 4 for Item Nos.

See Figure 4 for Item Nos.

See Figure 4 for Item Nos.

8000 SRM 780

PPM SPREADER MAINTENANCE

See Figure 5 for Item Nos.

See Figure 5 for Item Nos.

See Figure 5 for Item Nos.

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 780

Maintenance Procedures Every 8 Hours or Daily

Tires and Wheels WARNING

Safety Labels WARNING

Fuel, Oil, or Coolant Leaks Check WARNING

8000 SRM 780

API CE/SF or SAE 10W-30 SAE 15W-40 SAE 20W-40

CE/SG 25 to 25 C ( 13 to 77 F) 15 to 35 C (5 to 95 F) 5 to 45 C (23 to 113 F)

Drain Water From Fuel Filter CAUTION

Hydraulic System WARNING

Figure 8. Hydraulic Tank

8000 SRM 780

Maintenance Procedures Every 8 Hours or Daily