AUTOMATIC GREASING

SYSTEM
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH,
RS46-41S CH, RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH
(RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S,
RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH,
RS46-41S CH, RS46-41LS CH, RS46-33IH, RS46-38L
IH, RS46-38S IH, RS46-38LS IH (RS45-27CH,
RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S
CH, RS46-41LS CH) [D222]

PART NO. 4038573 8000 SRM 1533

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Description ...............................................................................................................................................................1
Grease Pump Assembly ...................................................................................................................................... 3
Reservoir ......................................................................................................................................................... 4
Controller ........................................................................................................................................................ 4
Pump ............................................................................................................................................................... 5
5/2 Solenoid Valve ...........................................................................................................................................5
Divider Block ...................................................................................................................................................5
Pressure Switch .............................................................................................................................................. 9
Greasing Cycle .............................................................................................................................................. 11
Stage 1 Pumping ...................................................................................................................................... 11
Stage 2 Pressure Retaining ..................................................................................................................... 11
Stage 3 Pressure Decreasing ................................................................................................................... 11
Stage 4 Pause ........................................................................................................................................... 11
Display ...........................................................................................................................................................12
Description ................................................................................................................................................12
Control LED's ........................................................................................................................................... 12
3-Digit Display ..............................................................................................................................................12
Start Up .................................................................................................................................................... 12
Selected Duty Cycle ..................................................................................................................................12
Decimal Dot .............................................................................................................................................. 13
Low Grease Level ..................................................................................................................................... 13
Test Being Performed ...............................................................................................................................13
Fault Code .................................................................................................................................................13
Switch Button ............................................................................................................................................... 13
Changing the Duty Cycle ......................................................................................................................... 13
Test Cycle Selection ................................................................................................................................. 13
Activating a Single Test Cycle .................................................................................................................13
Activating Multiple Test Cycles .............................................................................................................. 14
Resetting Fault Codes .............................................................................................................................. 14
Electrical ....................................................................................................................................................... 14
Grease Line Identification .................................................................................................................................... 16
Maintenance .......................................................................................................................................................... 28
Periodic Maintenance ................................................................................................................................... 28
Grease Recommendations ............................................................................................................................ 28
Filter Replacement ....................................................................................................................................... 28
Refilling the Grease Reservoir ..................................................................................................................... 28
Test Cycles Using the Button on the Pump ................................................................................................ 29
Bleeding the Pump ....................................................................................................................................... 29
Bleeding the System .....................................................................................................................................30
Repair .....................................................................................................................................................................30
Pump Assembly .................................................................................................................................................31
Remove .......................................................................................................................................................... 31
Replace .......................................................................................................................................................... 31
Grease Reservoir ............................................................................................................................................... 32
Disassemble .................................................................................................................................................. 32
Assemble ....................................................................................................................................................... 36
Minimum-Level Switch .................................................................................................................................... 40
Checking the Level-Switch ...........................................................................................................................40
Replacing the Level-Switch ..........................................................................................................................41

©2015 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Solenoid Valve ...................................................................................................................................................41

Disassemble .................................................................................................................................................. 41
Assemble ....................................................................................................................................................... 44
Pump Unit ......................................................................................................................................................... 45
Disassemble .................................................................................................................................................. 45
Assemble ....................................................................................................................................................... 49
Electric Pump Motor .........................................................................................................................................50
Disassemble .................................................................................................................................................. 50
Assemble ....................................................................................................................................................... 52
Thread Adapter ................................................................................................................................................. 55
Remove .......................................................................................................................................................... 55
Replace .......................................................................................................................................................... 55
Troubleshooting .....................................................................................................................................................56
General Instructions and Safety Information ................................................................................................. 56
Test Procedures ............................................................................................................................................ 61
Procedure to check pressure switch (valve) and its cable. ..................................................................... 61
Procedure to check pump and 5/2-way valve. ......................................................................................... 61
Procedure when an internal system leak is suspected. ..........................................................................62
Technical Data .......................................................................................................................................................63
Pump Unit ......................................................................................................................................................... 63
Torque Specifications ............................................................................................................................................ 63

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS

CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27CH,
RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH) [D222]

ii
8000 SRM 1533
General
This SRM provides a general description of the
automatic greasing system and the replacement of
its serviceable components. The automatic greasing
system replaces the manual re-greasing
requirement of all items that have a service
interval of 500 hours or shorter. See also Periodic
Maintenance 8000SRM1492.
Description
The automated greasing system provides measured
amounts of grease at regular intervals when the
truck is in service. For technical reasons, the greas-
ing system has been divided into two separate sys-
tems, which function in an identical way.
• The frame system greases the maintenance
points for the steering axle, boom pivot and
outer boom wear pads.
• The attachment system greases the attach-
ment, attachment pivot, inner boom wear
pads and telescoping cylinder pin.
Not connected with the automated greasing system
are the cab door hinges and the drive shaft, which
still have to be greased manually at the indicated
intervals on the maintenance schedule.
Manual greasing is also required when reassem-
bling components, which enclose bigger cavities,
such as caps for mast pins. To prevent damage,
these cavities must be entirely filled with grease
before (re)connecting the automatic greasing sys-
tem.
Each of the two automated greasing systems have a
grease pump assembly, grease divider blocks and
grease lines that lead to the different greasing
General
When reassembling components that are greased
by the automatic greasing system it is important to
first fill the cavities in these components with
grease completely, before reconnecting the
automatic greasing system.
points. The grease divider blocks include for each
greasing point a metering unit that supplies a
measured amount of grease. For correct functional-
ity of the grease divider blocks, the pump supplies
grease through two separate lines, which are pres-
surized and de-pressurized in an alternating order.
These two lines are indicated with line A and line
B. See Figure 1.
The pump assemblies include a controller, which
monitors the different stages of the greasing cycle.
Each controller is also connected with a separate
display in the cab, which shows information about
operation, fault codes and test cycles. The left hand
controller is for the attachment greasing system,
the right hand controller is for the frame greasing
system. The displays and the pumps have a push
button to run test modes.
The pump includes a grease reservoir, a low level
sensor and a fitting to refill the reservoir through
pressure.
1
Description 8000 SRM 1533

1. GREASE PUMP ASSEMBLY 5. METERING UNIT

2. PRIMARY GREASE LINE "A" 6. PRESSURE SWITCH
3. PRIMARY GREASE LINE "B" 7. SECONDARY GREASE LINE
4. DIVIDER BLOCK 8. FILLER COUPLING

Figure 1. System Overview

2
8000 SRM 1533 Description

GREASE PUMP ASSEMBLY

Main components of the grease pump assembly are
shown in Figure 2.

1. FOLLOWER PLATE 11. CONTROL UNIT

2. GREASE RESERVOIR 12. TEST (PUSH BUTTON)
3. STIRRING GEAR 13. FILLER COUPLING WITH FILTER
4. CAM 14. RELIEF VALVE
5. PLUNGER 15. BLEEDING AND OVERFLOW OUTLET
6. 5/2 WAY VALVE 16. CONNECTOR
7. PRIMARY GREASE LINE "A" OUTLET 17. GUIDE ROD
8. PRIMARY GREASE LINE "B" OUTLET 18. MINIMUM LEVEL SWITCH
9. TRANSMISSION 19. BLEEDING AND OVERFLOW CHANNEL
10. ELECTRIC MOTOR

Figure 2. Grease Pump Assembly

3
Description
Reservoir
The design of the grease reservoir is aimed at
maintaining grease quality by protecting grease
against air and humidity.
For this purpose grease is directly covered by a fol-
lower plate which is pulled down on the grease
level by a spring. When refilling, grease enters from
the underside of the reservoir and grease pressure
pushes the follower plate upwards against spring
force.
Reservoir capacity is determined by the volume be-
tween highest and lowest position of the follower
plate, which measures almost 3400 cc.
The highest position is indicated by a mark on the
transparent housing that will align with the lower
seal edge of the follower plate.
The lowest position is determined by the low level
switch, which is activated by the follower plate.
About 20 working hours after the initial low level
signal, the controller will deactivate the pump and
activate the display to show a fault code.
Refilling is through an external pump that will
press grease through the filler coupling. The filler
coupling has a nipple that can receive the coupling
of a hand pump. Remove the nipple for the hand
pump when using a power driven hand pump and
connect the filler coupling directly.
The filler coupling includes a 400 micron filter to
prevent impurities from entering the system. Ex-
treme filling pressure may cause the filter to break
resulting in debris entering the greasing system.
The entire system has to be cleaned when it has ap-
peared that the filter is broken. To prevent the fil-
ter from breaking, fill pressure has to be limited to
70 bar. In addition the filter has to be replaced af-
ter every 10 reservoir refills.
To obtain sufficient fill speed, make sure that the
temperature of the added grease is at least
20°C (68°F).
While refilling, grease level can be observed
through the clear reservoir housing.
4
8000 SRM 1533
Any air that may have entered the grease reservoir
can be removed by filling the reservoir just above
the maximum level. In this position the follower
plate opens a vent hole in the guide rod that con-
nects with the bleeding outlet. The normal function
of this outlet is to allow movement of the follower
plate by admitting or releasing air above the plate.
As grease enters and leaves the pump at the bot-
tom of the reservoir, the area near the corners of
the follower plate will retain the stored grease, al-
lowing it to age. Aged grease may loose its fluidity,
making it difficult to be pumped and cause a fail-
ure. One of the resulting failures is the entrance of
air into the system, preventing sufficient grease
pressure to build up. Because the triggered fault
code will not directly link to aged grease in the res-
ervoir, it is advisable to refresh the entire contents
of the reservoir every 3 to 4 years.
Controller
The controller monitors and controls the different
stages of the greasing cycle. Relevant data are
stored in its memory, irrespective of the truck’s bat-
tery supply.
When the ignition key provides a signal, the con-
troller will start up and continue the greasing cycle
at the point where it was interrupted when the ig-
nition was switched OFF. Also functionalities for
testing, push buttons and control are available,
when the ignition switch is in the ON position.
The seat switch provides an additional signal to de-
termine actual greasing requirement.
For a complete description of the greasing cycles
and the interaction with signals, see Greasing Cy-
cle.
The controller communicates with the display
through a separate CAN-bus wire, that is separate
from the trucks CAN-bus system. For the Control-
ler Wiring Diagram, see Electrical. For the func-
tionality of the display, see Display.
8000 SRM 1533 Description

Pump

When the controller has activated the pump, an

electric motor drives a cam and a stirring gear. The
stirring gear pushes grease from the reservoir
through a perforated plate to three plungers. The
cam moves a piston in the three plungers, which
push the grease into a compression channel. A re-
lief valve leads the grease back to the reservoir in
case pressure exceeds 250 bar (3626 psi). See Fig-
ure 3.

The controller keeps the pump activated until a sig-

nal is sent by the pressure switch located at one of
the grease divider blocks, or after a certain time 1. PLUNGER
has elapsed. 2. POPPET VALVE
3. COMPRESSION CHANNEL
When the pump is not activated anymore, grease 4. 5/2 SOLENOID VALVE
5. GREASE POINTS
pressure is maintained by the poppet valves in the 6. DIVIDER BLOCK
plungers. 7. PRESSURE SWITCH
8. RELIEF VALVE
5/2 Solenoid Valve Figure 3. Pump System

The pressurized grease leaves the pump housing

through the so called 5/2 solenoid valve, which
opens either to Primary line A or to Primary line B.
Primary lines A and B are separately connected
with the divider blocks.

When the 5/2 solenoid valve is not activated,

grease will be pumped into primary line A, while
any existing pressure in line B is relieved to the
reservoir.

When the 5/2 solenoid valve is activated, grease

will be pumped into primary line B, while any ex-
isting pressure in line A is relieved to the reservoir.
See Figure 3.

The controller determines when, and for how long

the 5/2 valve is activated.

Divider Block

The divider blocks are connected with supply lines

A and B and distribute the grease over the meter-
ing units. See Figure 4.

1. PRESSURE SWITCH
2. DIVIDER BLOCK
3. METERING UNIT WITH NUMBER
4. PLUG
5. HOSE FITTING
Figure 4. Divider Block

5
Description 8000 SRM 1533

For each different greasing point there is one me-

tering unit that delivers the correct amount of
grease for that greasing point. Main items of the
metering units are shown in Figure 5.

1. SUPPLY LINE A 6. PISTON CHANNEL B

2. ADMISSION SPOOL 7. BALL VALVE
3. SUPPLY LINE B 8. GREASE LINE
4. PISTON CHANNEL A 9. HOSE FITTING
5. PISTON 10. METERING UNIT
Figure 5. Metering Unit

6
8000 SRM 1533 Description

When supply line A is pressurized (pump phase A), ment of the piston pushes all grease at the B-side
the admission spool is moved away from supply line out of the cavity, through piston channel B and fur-
A. Grease will flow through piston channel A and ther past the ball valve into the grease line. See
push the piston towards piston channel B. Move- Figure 6.

1. SUPPLY LINE A 5. PISTON

2. ADMISSION SPOOL 6. PISTON CHANNEL B
3. SUPPLY LINE B 7. BALL VALVE
4. PISTON CHANNEL A 8. GREASE LINE

Figure 6. Pump Phase A

7
Description 8000 SRM 1533

When supply line B is pressurized (pump phase B),
the admission spool is moved towards supply line
A. Grease will flow through piston channel B and
push the piston towards piston channel A. Move-
ment of the piston pushes all grease at the A-side
out of the cavity, through piston channel A and fur-
ther past the ball valve into the grease line. See
Figure 7.
The amount of grease delivered depends on the size
of the piston. A smaller piston can make a larger
stroke and will pump more grease. A larger piston
has a shorter stroke and will pump less grease. The
supply of the metering units used on this truck var-
ies between 0.05 cc per stroke (nr 1) and 2 cc per
stroke (nr 10). The metering number is stamped on
the fastening hexagon.
The speed of grease delivery depends on fluidity of
the grease and the resulting resistance in the
grease lines. Grease fluidity is determined by the
NLGI Grade and the grease temperature. See
Grease Recommendations.
Components of the metering units are not serviced
separately. Replace the entire metering unit when
malfunctioning.

1. SUPPLY LINE A 5. PISTON

2. ADMISSION SPOOL 6. PISTON CHANNEL B
3. SUPPLY LINE B 7. BALL VALVE
4. PISTON CHANNEL A 8. GREASE LINE

Figure 7. Pump Phase B

8
8000 SRM 1533 Description

Pressure Switch The construction and operation of the pressure

switch is similar to the construction of the metering
The function of the pressure switch is to provide a unit, except that the pressure switch does NOT
signal to the controller when all divider blocks are have a piston and that a switch has been fitted in-
pressurized. The pressure switch for the frame stead of the ball valve. See Figure 8.
greasing system connects at 150 bar (2176 psi), and
is located at the most distant divider block, which
is at the end of the outer boom.

The pressure switch for the attachment greasing

system switches at 175 bar (2538 psi), and is loca-
ted on the rotator, where the hoses connect with
the hoses coming from the inner boom of the truck.

1. SUPPLY LINE A 6. PISTON

2. SUPPLY LINE B 7. SPRING
3. PISTON CHANNEL A 8. CONTACT PLATE
4. ADMISSION SPOOL 9. CONTACT
5. PISTON CHANNEL B 10. SWITCH CHANNEL

Figure 8. Pressure Switch

9
Description 8000 SRM 1533

When supply line A is pressurized (pump phase A), the admission spool moves towards supply line A. Grease
will flow through piston channel A, proceed through piston channel B into the switch channel to the pressure
switch. See Figure 9.

1. SUPPLY LINE A 6. PISTON

2. SUPPLY LINE B 7. SPRING
3. PISTON CHANNEL A 8. CONTACT PLATE
4. ADMISSION SPOOL 9. CONTACT
5. PISTON CHANNEL B 10. SWITCH CHANNEL
Figure 9. Pressure Switch Pump Phase A

When supply line B is pressurized (pump phase B), the admission spool moves away from supply line A.
Grease will flow through piston channel B, proceed through piston channel A into the switch channel to the
pressure switch. See Figure 10.

1. SUPPLY LINE A 6. PISTON

2. SUPPLY LINE B 7. SPRING
3. PISTON CHANNEL A 8. CONTACT PLATE
4. ADMISSION SPOOL 9. CONTACT
5. PISTON CHANNEL B 10. SWITCH CHANNEL
Figure 10. Pressure Switch Pump Phase B

10
8000 SRM 1533
With rising pressure, the piston of the pressure
switch moves the contact plate against the electri-
cal contacts, which will provide the required signal.
When pressure has dropped, a spring returns the
contact plate, which disconnects the electrical con-
tact.
Greasing Cycle
One greasing cycle normally takes a preset time of
120 minutes. The controller allows a different time
setting to 90 minutes (heavy duty). The light duty
cycle has the same 120 minutes time setting as the
medium duty cycle. See Selected Duty Cycle.
The heavy duty setting is recommended for circum-
stances requiring a quicker grease refreshment at
the greasing points.
The greasing cycle time runs as long as both the ig-
nition switch and the seat switch provide a signal
to the controller. The controller stops the count
down to the next greasing cycle when one or both
signals are interrupted. When both signals are re-
ceived again, cycle time will continue running.
Within one greasing cycle the controller distin-
guishes four different stages, which are also reflec-
ted in the fault code listing.
Important inputs for these stages are provided by
the timer in the controller and the pressure switch
that is located in one of the divider blocks.
Stage 1 Pumping
The timer in the controller determines the start of
the pumping phase. Once the Pumping Phase has
started, also the Pressure Retaining and the Pres-
sure Decrease Phase will evolve as long as the key
switch is in the ON position. The signal from the
seat switch is irrelevant for these three phases once
started.
If the key switch is turned OFF, and later turned
ON again, the controller will continue with these
three phases at the point where it was interrupted.
The pump motor remains activated until pressure
at the pressure switch has reached
150 bar (2176 psi) in the frame system or
175 bar (2538 psi) in the spreader system. The con-
troller files the time that the pump motor was ac-
Description
tive, and files the position of the 5/2 valve during
pumping. (Not-activated = Pump phase A.) (Activa-
ted = Pump phase B).
Pumping time can vary from one minute at higher
ambient temperatures, to more than 10 minutes
under freezing conditions. Normal pumping time at
20°C (68°F) is about two minutes. The maximum
pumping time is set at 15 minutes. A fault code
shows when at 10 consecutive times the required
pressure was not reached within 15 minutes.
The controller interrupts the pumping phase for
fault conditions that trigger a code number of E25
or lower.
Pumping can also be interrupted by switching the
key switch to OFF.
Stage 2 Pressure Retaining
After the pumping phase, the pressure is retained
during a period that lasts half of the pumping time.
This allows grease from the pump to enter the cavi-
ties in the metering units and fully pressure the
pistons, and also allows grease in the secondary
grease lines to enter the greasing points.
The controller will maintain the 5/2 valve in the
same position it had during the pumping phase.
Stage 3 Pressure Decreasing
During an equally long time frame as the pressure
retaining phase, the controller will de-activate the
5/2 valve when previously activated, or activate the
5/2 valve when previously de-activated. Pressure in
the supply line decreases and allows the admission
spool in the metering unit to shift its position for a
next pumping cycle. The controller files whether
the 5/2 valve was activated or not during stage 3,
and copies this position when starting a new pump-
ing phase.
Stage 4 Pause
During the pause phase the pump and the 5/2 valve
are de-activated. The actual pause phase starts im-
mediately after the pressure decrease phase has
ended.
The pause phase ends when the greasing cycle time
has elapsed.
11
Description 8000 SRM 1533

For orientation: at 20°C (68°F), with a cycle time of
120 minutes, the duration of the pause phase is
about 115 minutes.
Display
Description
Main items on the display are the control lights,
the 3-digit display and a switch button. See Fig-
ure 11
Determine which fault is present and take appro-
priate action immediately.
The yellow LED is ON at start up and when the
grease level in the reservoir is low. The display will
show LO’ when the yellow LED is ON. Refill the
reservoir when the yellow LED is ON and the dis-
play shows LO’. The displayed message LO’ will be
replaced by fault code E15, if ten further pump cy-
cles are performed without having refilled the res-
ervoir.

The green LED is ON when the automatic greasing

system is activated. Activation requires a closed
seat switch (operator seated) and the key switch in
the ON position. For running test cycles it is suffi-
cient to just have the key switch ON.

3-Digit Display

Depending on the situation, the three digit control

light indicates different types of information.

Start Up

When ignition is switched ON, the 3-digit display

forms a rotating clock, indicating communication
with the pump control unit. After 10 seconds the
preset duty mode selection appears and the green

LED will be ON.

Selected Duty Cycle

1. SWITCH-BUTTON
2. DISPLAY
3. DECIMAL DOT During normal operation the selected duty cycle is
4. SYSTEM ACTIVATED INDICATOR GREEN LED indicated by the number of dashes. The light duty
5. LOW GREASE LEVEL INDICATOR YELLOW and medium duty cycle have the same cycle time of
LED 120 minutes, providing normal greasing output.
6. ALARM INDICATOR RED LED The heavy duty cycle has shorter greasing cycle
Figure 11. Display times of 90 minutes, providing increased greasing
output. See Switch Button for the selection of a dif-
ferent duty cycle.
Control LED's
Light Duty
There are three control LED’s. A light-sensitive cell
adjusts the brightness of these LED’s according Medium Duty
ambient light intensity.

The red LED is ON at start up and when there is a Heavy Duty

malfunction. The display will show a fault code.

12
8000 SRM 1533
Decimal Dot
During normal operation, when the seat switch is
closed, the decimal dot continually flashes at the
right hand bottom of the digits. The dot will show
up in the left, middle, respectively the right hand
digit depending on whether the pumping, pressure
retaining, respectively pressure decrease phase is
active.
The decimal dot is continuously ON when the timer
has stopped. The timer stops when power supply
from the seat switch has been interrupted at con-
nection 3. Check the wiring when the decimal dot is
continuously ON while the operator is seated. See
Electrical.
Low Grease Level
Grease level in the reservoir is low. The yellow and
green LED will be ON. Refill the reservoir at earli-
est convenience. The control unit will allow 10 fur-
ther grease cycles, which is normally sufficient for
20 hours of operation. After having refilled the res-
ervoir, the duty cycle will be shown again.
Test Being Performed
Single test cycle T1. The green LED flashes slowly
(every 2 sec.). One single greasing cycle is being
performed. When completed, normal operation will
continue by starting a pause phase.
Multiple test cycles T2. The green LED flashes
quickly (every 0.2 sec.). Greasing cycles are per-
formed continuously until the ignition switch is
turned OFF. After switching the ignition switch
ON again, normal operation will continue by start-
ing a pause phase.
Description
Fault Code
Fault codes are indicated by an E’ and a two digit
number. The red LED is ON when a fault code is
shown. Determine which fault is present and take
appropriate action immediately. For the explana-
tion of Fault Codes see Fault Code Explanation.
Take appropriate action immediately. See also the
procedure under Switch Button and Resetting
Fault Codes to erase the fault code after the repair
has been made. Fault codes will not erase automat-
ically, even when the fault condition has ceased to
exist.
Switch Button
The switch button on the display is used to activate
below functions. For instructions to activate the
same functions with the test button on the pump,
see Maintenance.
Changing the Duty Cycle
1. Turn the ignition switch to ON.
2. Push the switch button for at least 5 seconds
and release the button. The 3-digit display will
start flashing.
3. Push the switch button repeatedly until the de-
sired duty mode shows. (Light, medium or
heavy duty).
4. Leave the desired duty mode flashing for at
least 6 seconds until the duty mode is shown in
a non-flashing mode. This confirms activation
of the desired duty mode.
Test Cycle Selection
NOTE: When the system is already performing a
pumping phase, the system will not respond when
trying to select or activate a test cycle.
Activating a Single Test Cycle
1. Turn the ignition switch to ON.
2. Push the switch button for at least 5 seconds
and release the button. The 3-digit display
will start flashing.
13
Description
3. Push the switch button repeatedly until code
T1 is shown flashing.
4. Leave the display flashing for at least 6 sec-
onds until T1 is shown in a non-flashing
mode.
5. The system will now operate one greasing cy-
cle without the Pause Phase. The green LED
will be flashing slowly. Observe that the dec-
imal dot moves from one digit to the next.
Depending on ambient temperatures the time for
one test cycle is between 2 and 20 minutes. After
the test has been completed, the controller will re-
sume operation with a Pause Phase.
Activating Multiple Test Cycles
1. Turn the ignition switch to ON.
2. Push the switch button for at least 5 seconds
and release the button. The 3-digit display
will start flashing.
3. Push the switch button repeatedly until code
T2 is shown flashing.
4. Leave the display flashing for at least 6 sec-
onds until T2 is shown in a non-flashing
mode.
5. The system will now continuously operate
greasing cycles while skipping the Pause
Phase. The green LED will be flashing
quickly. Observe that the decimal dot moves
from one digit to the next.
6. To stop the Multiple Test Cycle the ignition
switch must be turned to OFF.
After the test has been completed, the controller
will resume operation with a Pause Phase.
Resetting Fault Codes
Fault codes will not automatically disappear from
the display when a fault condition no longer exists.
The system has to be reset after the appropriate re-
pair has been made.
14
8000 SRM 1533
1. Turn the ignition switch to ON.
2. Push the switch button for at least 5 seconds
and release the button.
3. The 3-digit display will show the activated
duty cycle, the red LED will go OFF, the
green LED will be ON.
Certain fault codes are activated after a particular
fault condition has occurred during 10 consecutive
pump cycles. The delay of 10 occurrences is chosen
to avoid a service call for problems that resolve
themselves. An example is insufficient pressure
build up during morning hours with temperatures
below -20°C (-4°F).
Resetting a fault code for a re-occurring problem is
processed by the controller by reducing the number
of 10 occurrences by one. After resetting the fault
code, the internal counter is set to 9 occurrences.
Once the system has completed one pump cycle
without a fault condition, the system will reset the
internal counter to zero.
The implication is that the salvation of a fault code
includes the repair of the fault, resetting the fault
code and the completion of one fault free test cycle.
Electrical
The electrical diagram for the pump assembly is
shown on Figure 12.
The fuse for the pump assembly is in the side con-
sole. See Operating Manual.
For malfunctions that are difficult to trace, a PC-
Tool program exists that allows viewing stored data
in the controller. Contact Field Service Department
to have stored data investigated.
8000 SRM 1533 Description

1. ELECTRIC MOTOR OF PUMP 7. BATTERY

2. 5/2 WAY VALVE 8. IGNITION SWITCH
3. MINIMUM LEVEL SWITCH 9. SEAT SWITCH
4. TEST (PUSH BUTTON) 10. PRESSURE SWITCH
5. CONTROLLER 11. TWIN-3 DISPLAY
6. PUMP HOUSING

Figure 12. Wiring Diagram

15
Grease Line Identification 8000 SRM 1533

Grease Line Identification

Figure 13 through Figure 24 show the location of
the different greasing points at the divider blocks
and a location overview of the divider blocks on the
truck, respectively on the Elme 817 attachment. To
find the metering unit for a particular greasing
point, look up the reference number of the greasing
point and compare with the view at the right hand
bottom corner of the figure. Plugged metering con-
nections have been marked with X’.
The word red’ (RD) or blue’ (BU) at some of the me-
tering units indicates that the connected grease
line has a red or blue color for ease of identification.
All other lines have a black color.

1. GREASE PUMP ASSEMBLY

2. STEERING AXLE AND BOOM PIVOT, SEE FIGURE 14
3. INNER BOOM REAR WEAR PADS, SEE FIGURE 15
4. OUTER BOOM FRONT WEAR PADS, SEE FIGURE 16
5. DAMPENING CYLINDERS AND BOOM EXTENSION CYLINDER, SEE FIGURE 17
6. GREASE LINE DISCONNECT AND PLUGGING
Figure 13. Truck Divider Block Locations

16
8000 SRM 1533 Grease Line Identification

1. RH KING PIN LOWER

2. RH TIE ROD CYLINDER END
3. RH TIE ROD SPINDLE END
4. LH TIE ROD CYLINDER END
5. LH TIE ROD SPINDLE END
6. LH KING PIN UPPER
7. LH KING PIN LOWER
8. RH BOOM PIVOT BEARING
9. LH BOOM PIVOT BEARING
10. BOOM EXTENSION CYLINDER BEARING
11. RH KING PIN UPPER

Figure 14. Steering Axle and Boom Pivot

17
Grease Line Identification 8000 SRM 1533

1. INNER BOOM RH UPPER WEAR PAD

2. RH INNER BOOM SIDE WEAR PAD
3. LH INNER BOOM SIDE WEAR PAD
4. INNER BOOM LH UPPER WEAR PAD

Figure 15. Inner Boom Rear Wear Pads

18
8000 SRM 1533 Grease Line Identification

1. RH LOWER SIDE WEAR PAD

2. RH INNER BOOM LOWER WEAR PAD
3. LH INNER BOOM LOWER WEAR PAD
4. LH LOWER SIDE WEAR PAD
5. LH UPPER SIDE WEAR PAD
6. RH UPPER SIDE WEAR PAD
7. PRESSURE SWITCH (PS)

Figure 16. Outer Boom Front Wear Pads

19
Grease Line Identification 8000 SRM 1533

1. RH DAMPENING CYLINDER
2. BOOM EXTENSION CYLINDER
3. LH DAMPENING CYLINDER

Figure 17. Dampening Cylinders and Boom Extension Cylinder

20
8000 SRM 1533 Grease Line Identification

1. GREASE PUMP ASSEMBLY 5. ROTATOR, SEE FIGURE 22

2. LEFT HAND MAIN FRAME, SEE FIGURE 19 6. GREASE LINE DISCONNECT AND PLUGGING
3. CARRIAGE, SEE FIGURE 20 7. RIGHT HAND MAIN FRAME, SEE FIGURE 23
4. TWIST LOCKS LEFT HAND, SEE FIGURE 21 8. TWIST LOCKS RIGHT HAND, SEE FIGURE 24

Figure 18. Attachment Divider Block Locations

21
Grease Line Identification 8000 SRM 1533

1. LOWER WEAR PAD EXTENSION BEAM, FRONT

2. STOP CYLINDER (OPTIONAL)
3. LOWER WEAR PAD EXTENSION BEAM, REAR

Figure 19. Left Hand Main Frame

22
8000 SRM 1533 Grease Line Identification

1. VERTICAL WEAR PAD RIGHT HAND FRONT

2. VERTICAL WEAR PAD RIGHT HAND REAR
3. HORIZONTAL WEAR PAD RIGHT HAND REAR
4. REAR SIDE SHIFT CYLINDER ROD END
5. VERTICAL WEAR PAD LEFT HAND REAR
6. FRONT SIDE SHIFT CYLINDER ROD END
7. VERTICAL WEAR PAD LEFT HAND FRONT
8. HORIZONTAL WEAR PAD LEFT HAND FRONT
9. HORIZONTAL WEAR PAD LEFT HAND REAR
10. HORIZONTAL WEAR PAD RIGHT HAND FRONT

Figure 20. Carriage

23
Grease Line Identification 8000 SRM 1533

1. TWIST LOCK LEFT HAND REAR

2. TWIST LOCK LEFT HAND FRONT

Figure 21. Twist Locks Left Hand

24
8000 SRM 1533 Grease Line Identification

1. ATTACHMENT PIVOT PIN RIGHT HAND

2. DAMPENING CYLINDER RIGHT HAND
3. DAMPENING CYLINDER LEFT HAND
4. ATTACHMENT PIVOT PIN LEFT HAND
5. RING GEAR TEETH
6. RING GEAR
7. RING GEAR
8. RING GEAR
9. RING GEAR

Figure 22. Rotator

25
Grease Line Identification 8000 SRM 1533

1. STOP CYLINDER (OPTIONAL)

2. LOWER WEAR PAD EXTENSION BEAM, FRONT
3. LOWER WEAR PAD EXTENSION BEAM, REAR
4. SIDE SHIFT CYLINDER REAR, CYLINDER END
5. SIDE SHIFT CYLINDER FRONT, CYLINDER END

Figure 23. Right Hand Main Frame

26
8000 SRM 1533 Grease Line Identification

1. TWIST LOCK RIGHT HAND REAR

2. TWIST LOCK RIGHT HAND FRONT

Figure 24. Twist Locks Right Hand

27
Maintenance
Maintenance
Periodic Maintenance
Perform below checks every 500 hours of operation
during normal periodic maintenance visits.
1. Check the pump for damage and or leakage.
2. Check that the grease level is above mini-
mum.
3. Check primary and secondary lines for dam-
age and leakage.
4. Check that sufficient fresh grease is present
at each individual grease point.
5. Check functionality of the control LED’s, dis-
play and push button on the display units.
6. Check that the selected duty cycle complies
with the working conditions.
Grease Recommendations
WARNING
Do not fill the automatic greasing system with
grease containing solid additives like MoS2,
PTFE, or graphite. These additives interfere with
the proper operation of its components and affect
the properties of the boom pivot bearing.
Verify the information as provided by the grease
supplier before adding grease to the reservoir.
Do not add grease that contains solid additives like
MoS2, graphite or PTFE.
Normal (non-synthetic) grease with grade NLGI 2
is suited for applications until -15°C (5°F), inciden-
tally until -20°C (-4°F). Normal grease will solidify
at temperatures below -20°C (-4°F).
Use synthetic grease with grade NLGI 1 for appli-
cations below -20°C (-4°F). Synthetic grease con-
tains synthetic oil that will NOT solidify below
-20°C (-4°F).
Never use a higher grade than NLGI 2.
Use NLGI 1 if temperatures remain below freezing
point for an extended period of time.
Both normal grease NLGI-2 and synthetic grease
NLGI 1 can be used up to 70°C (158°F).
28
8000 SRM 1533
When a different grease type is added in anticipa-
tion of different ambient temperatures, be aware
that it takes about 125 working hours before the
different grease type has reached the most distant
divider block. The most distant greasing point is
reached after 250 hours only.
Filter Replacement
The filler coupling contains a filter that needs to be
replaced every 10 times after the reservoir has been
filled. There is a risk that a clogged filter will cause
the filler coupling and or the filter to break allow-
ing particles to enter the system, requiring the re-
placement of most of the greasing system compo-
nents. Replace the filter in time.
1. Remove the dust cover and filler coupling
with a 14 mm socket spanner.
2. Clean the coupling and the O-ring and check
for damage. Replace if necessary.
3. Remove the filter with a 19 mm socket span-
ner.
4. Clean the outside of the filter and check for
any damage. Check the O-ring for damage,
replace if necessary.
5. Discard the filter when it has no damage,
and install a new filter.
6. When the filter is damaged, the entire greas-
ing system must be cleaned.
7. Reinstall the filter and the filler plug. Torque
filler plug to 15 N•m (11 lbf ft).
8. Reinstall the dust cover.
Refilling the Grease Reservoir
WARNING
Do not fill the automatic greasing system with
grease containing solid additives like MoS2,
PTFE, or graphite. These additives interfere with
the proper operation of its components and affect
the properties of the boom pivot bearing.
1. Make sure that the correct grease quality
will be added and that the NLGI grade
matches the ambient temperatures to be ex-
pected.
8000 SRM 1533
2. Clean both the grease supply coupling and
the filler coupling.
3. Make sure that the to be added grease is at
room temperature.
4. Verify pump supply pressure does not exceed
70 bar (1015 psi).
5. Prime the supply pump and verify that the
supply coupling supplies clean grease with-
out air pockets.
6. Attach the supply coupling to the filler cou-
pling.
7. Activate the supply pump until the lower
seal edge of the follower plate has lined up
with the maximum level mark on the reser-
voir.
8. Remove any air under the follower plate by
filling the reservoir just above the maximum
level mark.
9. Remove the supply coupling and refit the
dust cap on the filler coupling.
The yellow LED and the LO code on the display
will go OFF automatically when the low level
switch is no longer activated.
After a refill, it is possible that some grease escapes
from the bleeding opening at the left hand side of
the pump.
Test Cycles Using the Button on the Pump
Activating a Single Test Cycle
1. Switch ignition ON.
2. Push the test button on the pump for 2 – 6
seconds. The system will start a single greas-
ing cycle. The display in the cab will show
T1’ and the green LED will be flashing
slowly. The decimal dot on the display moves
from one digit to the next. At the pump itself
there are no indications.
Depending on ambient temperatures, the time for
one test cycle is between 2 and 20 minutes. After
the test has been completed, the controller will re-
sume operation with a Pause Phase.
Activating Multiple Test Cycles
1. Switch ignition ON.
Maintenance
2. Push the test button on the pump for more
than 6 seconds. The system will start and
continue performing greasing cycles until the
ignition is turned OFF. The greasing cycles
are performed without a pause phase. The
display in the cab will show T2’ and the
green LED will be flashing quickly. The deci-
mal dot on the display moves from one digit
to the next. At the pump itself there are no
indications.
3. Do not forget to switch the ignition to OFF
for stopping the test cycles.
After the ignition has been switched ON again, the
controller will resume operation with a Pause
Phase.
Bleeding the Pump
When the system malfunctions repeatedly due to
an empty grease reservoir, it is possible that the
pump needs to be bled. Use the following steps to
perform bleeding the pump:
WARNING
Make sure that the automatic greasing system is
depressurized before opening the system.
1. Make sure that the grease reservoir is filled.
2. Remove both primary lines from the pump.
3. Turn ignition switch ON.
4. Push the test push-button at the pump for at
least 6 seconds.
5. Turn ignition switch OFF as soon as pure
grease (without air-pockets) comes from one of
the pump outlets.
NOTE: After a few minutes still no grease exits the
pump outlet pump some oil into the reservoir along
the filler-coupling 500 cc (1/8 gal). This will help to
push aside the air-pockets around the pump piston.
The oil can also be pumped into the reservoir along
grease line B. Switch the ignition OFF before open-
ing grease line B.
6. Replace both primary lines to the pump.
7. Perform a single cycle test twice to check if the
system functions correctly. See Test Being Per-
formed.
29
Maintenance 8000 SRM 1533

8. When pressure build up in the system is still
insufficient it is possible that also the primary
lines need to be bled. See Bleeding the System.
NOTE: Install a pressure gauge of minimum
250 bar (3626 psi) along with 3 m (118 in.) high
pressure hose (HPH) onto the pump outlet. The
3 m (118 in.) HPH allows additional contents of
grease to cancel out small pressure fluctuations.
9. To make sure that the pump is still in good con-
dition also the grease pressure could be meas-
ured with a manometer, connected at one of the
pump outlets. During a pumping phase the
pressure should reach
230-250 bar (3336-3626 psi) and is not allowed
to fall below 200 bar (2901 psi) during the suc-
cessive "pressure retaining phase".
Bleeding the System
1. Make sure that the grease reservoir is filled.
2. Remove the end plugs from the divider blocks
that are at the end of each branch in the sys-
tem.
3. Turn ignition switchON.
4. Push the test push-button at the pump for 6
seconds. Because the end plugs are removed, no
grease pressure is built up. When the maxi-
mum pumping time has past, the system
switches automatically to the other primary
line. This is repeated until the ignition is
switched OFF.
5. Turn ignition switch OFF as soon as pure
grease (without air-pockets) comes from the pri-
mary lines.
6. Replace the end plugs into the divider blocks.

When the system malfunctions repeatedly due to 7. Repeat Step 4 through Step 6 until all branches
an empty grease reservoir, it is possible that one (or of the system are bled.
both) primary line(s) need(s) to be bled. Use the fol-
lowing steps to perform bleeding the system: 8. Perform a single cycle test twice to check that
the system functions correctly. See Activating a
Single Test Cycle.
WARNING
Make sure that the automatic greasing system is
depressurized before opening the system.

Repair
NOTE: When reassembling components that are the discharge side(s) of the assembled component.
greased by the automatic greasing system it is im- Reconnect the grease line after all air has been ex-
portant to first fill the cavities in these components pelled by grease.
with grease completely, before reconnecting the au-
tomatic greasing system.

To fill components with grease, install a normal

grease fitting and use a manual grease pump to fill.
All air has been expelled when grease escapes from

30
8000 SRM 1533 Repair

PUMP ASSEMBLY

Remove
STEP 1.
Disconnect electrical connector from the pump.

STEP 2.
Wait at least 15 minutes after the ignition switch has been switched OFF, before opening a grease line

STEP 3.
Remove grease line A & B from the pump.

STEP 4.
Remove four locknuts and bolts that attach the pump to the frame bracket.

Replace
STEP 1.
Insert the four bolts in the pump bracket, apply the locknuts and tighten.

STEP 2.
Attach grease line A & B but do NOT tighten

STEP 3.
Make sure grease level in the reservoir is above minimum.

STEP 4.
Attach the electrical connector to the pump and turn the ignition ON.

STEP 5.
Push the test button and pull the electrical connector as soon as grease escapes from one of the grease
lines.

STEP 6.
Tighten the fitting that was bleeding

STEP 7.
Reconnect the electrical connector and push the test button again. Pull the electrical connector when grease
escapes from the other grease line.

STEP 8.
Tighten the grease fitting that was bleeding

31
Repair 8000 SRM 1533

STEP 9.
Reconnect the electrical connector.

1. PUMP
2. LOCKNUTS
3. CAPSCREWS
4. RIGHT FENDER
5. LOCKNUTS
6. CAPSCREWS
7. BRACKET
8. ELBOW FITTINGS (NOT SHOWN)

GREASE RESERVOIR

Disassemble
STEP 1.
Remove the plug by inserting a screwdriver be-
tween the plug and the top cover.

32
8000 SRM 1533 Repair

STEP 2.
Loosen the bolt of the guide pin and remove the
top cover.

STEP 3.
Check the O-ring of the top cover and the O-ring
of the plug for damage. Discard O-rings.

STEP 4.
Remove the reservoir by tilting and lifting it. Re-
move any remaining grease from the reservoir.
Dispose of the grease an environmentally friendly
manner.

33
Repair 8000 SRM 1533

NOTE: Do not use pliers to hold the guide pin. Damage to guide pin may occur.

STEP 5.
To prevent the guide pin from turning as you
loosen its socket head screw, insert a 5mm into
the venting holes of the guide pin. Remove the
guide pin.

NOTE: A bent guide pin might cause the piston to get struck.

STEP 6.
Roll the guide pin over a flat surface. Check the guide pin to make sure it is still straight.

STEP 7.
Check the piston and its spring for damage. Check
that the spring has retained its strength and
shape.

34
8000 SRM 1533 Repair

STEP 8.
Remove the bridge from the pump body by remov-
ing its two 5mm socket head screws.

NOTE: The least amount of dirt in the pump may prevent it from operating properly.

STEP 9.
Clean all parts thoroughly.

STEP 10.
Underneath the bridge there is an O-ring. Check
the O-ring for damage. Discard O-rings.

35
Repair 8000 SRM 1533

STEP 11.
Using a 14mm open-end wrench remove the mixing gear. Check the mixing gear for damage and replace if
necessary.

STEP 12.
Remove the grid and check for damage. Replace if
necessary.

NOTE: The least amount of dirt in the pump may prevent it from operating properly.

STEP 13.
Clean all parts thoroughly.

Assemble
STEP 1.
Install the grid.

STEP 2.
Using a 14mm open-end wrench install the mixing
gear.

36
8000 SRM 1533 Repair

STEP 3.
Install new O-ring onto the bridge and replace the
bridge using two 5mm socket head screws. Torque
the socket head screws to 10 N•m (88 lbf in).

37
Repair 8000 SRM 1533

STEP 4.
Apply locktite (224 or 542) to the threads of the
guide pin.

Install the guide pin and piston onto the pump

body. Make sure that the ring is positioned over the
guide pin and between the spring. Torque the guide
pin to 30 N•m (265 lbf in).

STEP 5.
Install new O-ring between the pump body and the reservoir.

STEP 6.
Slide the reservoir over the piston onto the new O-
ring.

38
8000 SRM 1533 Repair

STEP 7.
Install new O-ring on the top cover of the of the
reservoir.

STEP 8.
Install the pump body onto the top cover and turn
the pump body upright.

STEP 9.
Install the cover with it's M8 socket head screw.
Torque the guide pin to 30 N•m (265 lbf in).

STEP 10.
Install new O-ring on the plug and press the plug into the top cover.

STEP 11.
Fill the grease reservoir up to the maximum level mark. See Refilling the Grease Reservoir

39
Repair 8000 SRM 1533

STEP 12.
Check for any leaking of grease.

MINIMUM-LEVEL SWITCH

Checking the Level-Switch

STEP 1.
Remove the protection cover of the pump unit by unscrewing its four socket head screws (5mm Allen key).

STEP 2.
Check the gasket of the protection cover for damage. If necessary, replace the gasket.

STEP 3.
Disconnect connector of the level-switch from the PCB of the control unit.

NOTE: With the level-switch actuated you should measure an open load.

If the level-switch is not actuated you should measure virtually no resistance (this is a normally-closed con-
tact).

STEP 4.
Using a multimeter, measure the resistance between the (white) wires of the level-switch. Replace the
level-switch if you measure other resistances. See Replacing the Level-Switch.

STEP 5.
If level-switch is OK, replace the connector on the PCB.

STEP 6.
Install the gasket into the protection cover. and mount the cover with its 4 socket head screws.

STEP 7.
Install the protection cover on the pump unit us-
ing four socket head screws (5mm Allen key).

40
8000 SRM 1533 Repair

Replacing the Level-Switch

STEP 1.
Using a 27mm pipe wrench, remove the level-switch. Discard the O-ring.

STEP 2.
Using a new O-ring, install the new level-switch.
Torque the level-switch to 30 N•m (265 lbf in).

STEP 3.
Check the level-switch for proper operation. See Checking the Level-Switch.

SOLENOID VALVE

Disassemble
STEP 1.
Remove the grease reservoir.

STEP 2.
Remove the protection cover from the pump unit.

STEP 3.
Remove the thread adapter.

41
Repair 8000 SRM 1533

STEP 4.
Remove the four socket head screws and remove
the pump.

STEP 5.
Check the gasket between the pump assembly and
the pump housing.

STEP 6.
Remove the nut and take out the solenoid valve.

42
8000 SRM 1533 Repair

STEP 7.
Check the O-rings and support rings for damage.
Discard O-rings.

STEP 8.
Before you replace the coil: remove the spring clip.

STEP 9.
Check the O-ring for damage. Discard O-ring.

43
Repair 8000 SRM 1533

STEP 10.
Clean all parts of the solenoid valve thoroughly
and apply some grease when assembling it again.

Assemble
STEP 1.
Install the coil, new O-ring, and the spring clip.

STEP 2.
Install the assembled solenoid valve into the
pump assembly. Torque to 40 N•m (354 lbf in).

44
8000 SRM 1533 Repair

STEP 3.
Install new O-ring.

STEP 4.
Install the pump assembly back in the pump
housing using four socket head screws. Torque to
10 N•m (88 lbf in).

STEP 5.
Install the thread-adapter.

STEP 6.
Replace the protection cover.

STEP 7.
Replace the grease reservoir.

PUMP UNIT

Disassemble
STEP 1.
Remove the grease reservoir.

STEP 2.
Remove the protection cover from the pump unit.

STEP 3.
Remove the thread adapter.

45
Repair 8000 SRM 1533

STEP 4.
Remove the pump assembly.

STEP 5.
Remove the solenoid valve.

STEP 6.
Remove the six socket head screws of the pump-
assembly.

STEP 7.
Install an M8 bolt into the shaft end (to prevent
damage to the shaft).

STEP 8.
Position the arms of the pulley puller underneath the nuts of the plungers.

46
8000 SRM 1533 Repair

STEP 9.
Inspect the bearing for damage and wear.

NOTE: The plungers and cylinders are matched sets. They may not be interchanged.

STEP 10.
Remove the plungers from their housing by un-
screwing the three nuts of the plungers.

STEP 11.
Remove the non-return valves. Inspect for dam-
age, clean them, and if necessary, replace them.

47
Repair 8000 SRM 1533

STEP 12.
Remove the plungers from their cylinders. Inspect for damage, clean them, and if necessary, replace them.

STEP 13.
Inspect the plunger-housing for damage.

STEP 14.
Replace the copper rings between the housing and
the cylinders.

STEP 15.
Install the plungers in their respective cylinders.
Install the cylinders in the plunger-housing. Tor-
que to

25 N•m (221 lbf in) .

48
8000 SRM 1533 Repair

STEP 16.
Remove the relief valve (watch the copper ring).

STEP 17.
Clean all parts thoroughly. Inspect for damage,
clean them, and if necessary, replace them.

Assemble
STEP 1.
Install the relief valve (mind the copper ring). Tor-
que to 20 N•m (177 lbf in).

49
Repair 8000 SRM 1533

STEP 2.
Inspect the O-ring of the grease channel.

NOTE: Make sure the grease channels coincide.

STEP 3.
Install the plunger-housing back into the pump
assembly. Replace the copper rings. Torque to
7.5 N•m (66 lbf in).

ELECTRIC PUMP MOTOR

Disassemble
STEP 1.
Remove the grease reservoir.

STEP 2.
Remove the protection cover from the pump unit.

STEP 3.
Remove the thread adapter.

STEP 4.
Remove the pump assembly.

STEP 5.
Remove the solenoid valve.

50
8000 SRM 1533 Repair

STEP 6.
Remove the big and small spring clips from the
shaft of the motor.

STEP 7.
Remove the eccentric and check it for damage
(mind the key).

STEP 8.
Remove the three socket head screws which at-
tach the motor on its aluminium base.

STEP 9.
Remove the motor and check the sealing ring for damage and ageing. If necessary, replace the sealing ring.

51
Repair 8000 SRM 1533

STEP 10.
Inspect the motor and motor shaft for damage. If
necessary, replace the motor.

STEP 11.
Discard O-rings.

Assemble
STEP 1.
Install new copper rings underneath three socket
head screws with which the motor is mounted on
its aluminium base. Torque three socket head
screws. Torque to 12.5 N•m (111 lbf in).

52
8000 SRM 1533 Repair

STEP 2.
Install the key and the eccentric.

STEP 3.
Install the small and the large spring clip.

STEP 4.
Install new O-ring in the grease channel.

NOTE: Make sure the grease channels are properly lined up.

53
Repair 8000 SRM 1533

STEP 5.
Install the plunger-housing onto the pump assem-
bly with new copper rings. Torque to
7.5 N•m (66 lbf in).

STEP 6.
Install the solenoid valve. Torque to
40 N•m (354 lbf in).

STEP 7.
Install new O-ring.

54
8000 SRM 1533 Repair

STEP 8.
Install the pump assembly into the pump housing.
Torque to 10 N•m (88 lbf in).

THREAD ADAPTER

Remove
STEP 1.
Using a 19mm socket, remove the thread-adapter.
Discard O-ring.

STEP 2.
Inspect the adapter and replace if necessary.

Replace
STEP 1.
Apply a small amount of grease to new O-ring,
place O-ring on thread adapter.

STEP 2.
Replace thread adapter.

STEP 3.
Using a 19mm socket, torque thread adapter to
30 N•m (22 lbf ft).

55
Troubleshooting 8000 SRM 1533

Troubleshooting
GENERAL INSTRUCTIONS AND SAFETY
INFORMATION WARNING
The technician must be aware of, and follow, all
general safety precautions that are published in
WARNING the Operating Manual and that are posted as
DO NOT add to or modify the lift truck. Any modi- Safety Decals on and in the lift truck.
fication that affects the safe operation of the truck
cannot be undertaken without written authoriza-
tion of the Hyster company.

Table 1. Fault Code Explanation

Fault Code Cause Solution

1.
One or all LED’s:
and/or display, do not
light up partially or com-
pletely the moment ignition
is switched ON.
2.
Decimal DOT does not flash,
but is continuously ON.
3.
In each of 10 consecutive
pump cycles, the pressure
switch did not close within
15 minutes during grease
cycle A.
a. No supply voltage at the dis-
play.
b. Ground wire disconnected.
c. Defective display or defec-
tive display components.
a. No signal received from the
seat switch.
a. Leaking primary line-A.
b. Metering unit allows inter-
nal bypass.
c. Air trapped in pump and/or
primary line-A.
a. Check fuse and/or wire con-
nection (yellow wire). Repair
as necessary.
b. Check the ground wire
(brown wire). Repair as nec-
essary.
c. Replace display.
a. Check the wiring from the
seat switch and the seat
switch itself.
a. Check condition of primary
lines and its connectors. Re-
pair as necessary.
b. Proceed with Procedure
when an internal system
leak is suspected.
c. 1. Refill and bleed reservoir.
c. 2. Bleed the pump and pri-
mary lines. See Bleeding the
Pump, and Bleeding the
System.

56
8000 SRM 1533
Table 1. Fault Code Explanation (Continued)
Fault Code
4.
In each of 10 consecutive
pump cycles, the pressure
switch did not close within
15 minutes during grease
cycle B.
5.
At the beginning of 10 con-
secutive pump cycles, the
pressure switch was still
closed at the beginning of
grease cycle A.
6.
At the beginning of 10 con-
secutive pump cycles, the
pressure switch was still
closed at the beginning of
grease cycle B.
7.
Minimum grease level
reached.
Cause
a. Leaking primary line-B.
b. Metering unit has internal
bypass.
c. Air trapped in pump and/or
primary line-B.
The pressure switch should close
during cycle A.
Possible causes:
a. Damaged pressure switch
wiring harness.
b. 5/2-way valve did not oper-
ate correctly.
c. Pressure switch failed/
broken.
The pressure switch should close
during cycle B.
Possible causes:
a. Interrupted pressure switch
wiring harness.
b. 5/2-way valve did not oper-
ate correctly.
c. Pressure switch failed/
broken.
a. After the low level warning
was activated, the maxi-
mum number of 10 cycles
have been completed.
b. During activation of the low
warning the pressure switch
did not close during a pump-
ing cycle.
Troubleshooting
Solution
a. Check condition of primary
lines and its connectors. Re-
pair as necessary.
b. Proceed with Procedure
when an internal system
leak is suspected.
c. 1. Refill and de-airate reser-
voir.
c. 2. Bleed the pump and pri-
mary lines. See Bleeding the
Pump, and Bleeding the
System.
a. Check wiring and connec-
tors. Replace or repair as
necessary.
b. Check operation of 5/2-way
valve. Repair as necessary.
c. Check and or replace pres-
sure switch.
a. Check wiring and connec-
tors. Replace or repair as
necessary.
b. Check operation of 5/2-way
valve. Repair as necessary.
c. Check and or replace pres-
sure switch.
a. Refill the reservoir.
b. Refill the reservoir. See
Bleeding the Pump.
57
Troubleshooting
Table 1. Fault Code Explanation (Continued)
Fault Code
8.
In each of 10 consecutive cy-
cles the controller encoun-
tered a serious voltage drop
while activating the pump
motor.
9.
The pressure switch did not
close during a greasing cy-
cle, while the controller
measured a deviating resist-
ance in the pressure switch
circuit.
10.
The pressure switch did not
close during a greasing cy-
cle, while the controller
measured a too low current
draw by the pump motor.
11.
Controller detected a too
high current draw by the
pump motor.
58
Cause
a. Faulty vehicle battery.
b. Faulty wiring (ground wire).
c. Corroded pin-contact in con-
nector.
a. Faulty wiring or connectors.
b. Defective pressure switch.
a. Interrupted wiring.
b. Defective motor.
c. Defective controller.
a. Short circuit in wiring of
motor.
b. Short circuit in motor.
c. Drive shaft obstructed.
d. Extreme low working tem-
perature in combination
with a grease not suitable
for these conditions.
8000 SRM 1533
Solution
a. Charge or replace battery.
b. Check wiring. Replace or re-
pair as necessary.
c. Check connections at pump
and in cabin. Replace or re-
pair as necessary.
a. Check wiring/connectors.
See Procedure to check pres-
sure switch (valve) and its
cable. Replace or repair
when necessary, see Repair.
b. Replace pressure switch.
a. Check wiring. Replace or re-
pair as necessary.
b. Check the resistance of the
motor. Replace as necessary.
c. Check controller. Replace as
necessary.
a. Check the wiring of motor.
Replace or repair when nec-
essary.
b. Check motor on wiring
faulty, check the resistance
of the motor. Replace when
necessary.
c. Check the drive shaft for ob-
struction Replace or repair
when necessary.
d. Replace the grease in the
reservoir and bleed the sys-
tem with a suitable grease
for the given working condi-
tions.
8000 SRM 1533
Table 1. Fault Code Explanation (Continued)
Fault Code
12.
In each of 10 consecutive cy-
cles the controller encoun-
tered a too low current draw
of the 5/2 valve while the
pressure switch was closed
during the preceding cycle.
13.
In each of 10 consecutive cy-
cles the controller encoun-
tered a too high current
draw of the 5/2 valve while
the pressure switch was
closed during the preceding
cycle.
14.
Communication error with
control unit
15.
Parameter checksum error
Cause
a. Interrupted wiring of the
coil.
b. Defective coil.
a. Short circuit in wiring of the
coil.
b. Defective coil.
a. No communication between
display & control unit.
b. No supply voltage at the
pump.
c. Defective Twin-3 display.
Control unit encountered corrup-
ted parameters during power up
and restored the production de-
fault settings.
Troubleshooting
Solution
a. Check wiring. Replace or re-
pair when necessary.
b. Check coil on wiring faulty,
check the resistance of the
coil. Replace or repair as
necessary.
a. Check wiring. Replace or re-
pair when necessary.
b. Check coil on wiring faulty,
check the resistance of the
coil. Replace or repair as
necessary.
a. Check the purple communi-
cation wire no. 6 between
display and pump (pump
connector pin no. 6). Repair
when necessary.
b. Check the fuse and red
power wire no. 1 to pump
connector no. 1 and the
black ground wire no. 2 to
the pump connector no. 2.
Replace or repair when nec-
essary.
c. When no issues found as
stated in solution 14a or
14b, replace display.
Replace control unit.
59
Troubleshooting
Table 1. Fault Code Explanation (Continued)
Fault Code
16.
Parameter checksum error
17.
Parameter checksum error
Control unit encountered a
corrupted real time clock
causing the events and er-
rors to be stored with inac-
curate time & dates.
18.
Unknown cause
Malfunction
1. All grease points do not re-
ceive sufficient grease and
no error codes have been
given.
2. All grease points are over
greased.
3. One or more grease points
do not show grease while
the other points receive suf-
ficient grease.
4. One or more grease points
receive excessive amount of
grease while the other
points do receive the right
amount of grease.
60
Cause
Real time clock battery low (2,2 V) Replace control unit.
at the control unit.
RTC battery empty.
Unknown
Table 2. General Malfunction
Cause
The interval clock does not run
(wiring).
Too high duty mode selected.
a. Squeezed or broken secon-
dary grease lines.
b. Metering unit is defect.
c. After a repair, the grease
line and/or the greasing
point cavity were insuffi-
ciently pre-filled with
grease.
Metering unit with internal leak.
8000 SRM 1533
Solution
Replace control unit.
Replace control unit.
Solution
Check the interval clock command
wiring and connection (green wire
no. 3 / pump connector pin no. 3).
Choose the “medium duty mode”
with the switch-button.
a. Check and replace the rele-
vant secondary line if neces-
sary.
b. Remove and clean the me-
tering unit or mount a new
one.
c. Install a normal grease fit-
ting and fill the line and/or
cavity with grease by using
a manual grease pump.
Remove the metering unit and
mount a new one.
8000 SRM 1533
Test Procedures
Procedure to check pressure switch (valve)
and its cable.
WARNING
Check whether the system is pressureless before
the system is opened.
1. Disconnect the 2-pole connector from the pres-
sure switch.
2. Using a DMM, measure the resistance between
the two contacts. When the system is pressure-
less, the resistance should be 22K ohm. If re-
quired, remove the switch to make sure that no
pressure below the pressure switch is present.
Remove only the upper part, the diverter valve
can be left in place.
3. If possible, mount a pressure gauge that is suit-
able for a grease pressure up to
250 bar (3626 psi) between the diverter valve
and the pressure switch and bleed this connec-
tion before use.
4. Turn ignition switch to ON.
5. Start a cycle test by pushing the test push-but-
ton at the pump.
6. Check the switching moment of the pressure
switch using the digital multi-meter. When the
adjusted pressure (see the side of the pressure
switch) is reached the contact should be closed,
the resistance should ± 0 ohm.
7. Turn ignition switch OFF for ending the cycle
test.
NOTE: If the pressure switch functions properly,
the cable should be checked for internal damage.
8. Connect both contacts of the connector of the
pressure switch using a jumper wire.
9. Disconnect the pump connector.
10. Using a DMM, measure the resistance between
pin 7 and 8 of the pump connector. The meas-
ured resistance should be ± 0 ohm.
11. Remove the jumper wire between the contacts
of the connector of the pressure switch. The
DMM should read an open load.
Troubleshooting
Procedure to check pump and 5/2-way valve.
WARNING
Check whether the system is pressureless before
the system is opened.
1. Disconnect both primary grease lines from the
pump outlet A and B.
2. Connect a pressure gauge to each channel of
the pump. Use pressure gauges that are suita-
ble for a grease pressure of 250 bar (3626 psi).
3. Turn ignition switch to ON.
4. Push the test push-button at the pump for
about 4 seconds to start a cycle test. The pump
now pumps grease from one of the channels.
The pressure reading of the gauge connected to
this channel should raise to the maximum at-
tainable pressure of 230 to 250 bar (3336 to
3626 psi).
NOTE: The pump is not switched OFF by the pres-
sure switch, because primary lines A and B have
been disconnected from the divider block with the
pressure switch.
5. If the pump does not reach the indicated pres-
sure, it has the following causes:
• Air lock in the grease (air bubbles). Dis-
connect the pressure gauge and let the
grease flow until no more air bubbles
come from the channel. If necessary, re-
fill the reservoir with some oil to remove
the air around the pumping element.
• Temperature too low and or grease is too
viscous. Therefore it is not sucked in by
the pumping piston. Replace the grease
in the reservoir and the primary grease
lines by more suitable grease for the
aimed temperature.
• Pump is faulty. Replace the pump.
6. End the cycle test by switching the ignition
OFF or by disconnecting the pump connector.
7. Turn ignition switch to ON.
61
Troubleshooting
8. Start another cycle test with the test push-but-
ton at the pump; The pump should start in the
other channel and the pressure gauge will
quickly increase to the maximum adjusted
grease pressure of 230 to 250 bar (3336 to
3626 psi). The first channel should become dep-
ressurised.
When the pressure in the first channel does not
drop and no pressure is built up in the other
channel, the 5/2-way valve is faulty. Replace the
5/2-way valve or the entire pump.
9. End the cycle test by switching the ignition
OFF or by disconnecting the pump connector.
Procedure when an internal system leak is
suspected.
WARNING
Check whether the system is pressureless before
the system is opened.
1. Disconnect the primary grease line of outlet B
of the pump.
2. Turn ignition switch to ON.
3. Push the test push-button at the pump for
about 4 seconds to start a cycle test. The pump
is started and pumps grease through one of the
grease channels. If this is not channel A, break
off the cycle test by switching the ignition OFF
or by momentarily disconnecting the pump con-
nector. Start another cycle test with the test
push-button at the pump. The pump starts au-
tomatically in the other channel (A).
While the pressure in channel A builds up, some
returning grease can come from the just discon-
nected grease line. However when grease keeps
flowing from this line there is an open connection
between both primary grease channels, most
likely caused by a missing or damaged O-ring
under one (or more) metering unit(s).
62
8000 SRM 1533
When a leak is established in the system, it has
to be determined in which divider block the leak
is present.
4. Disconnect the primary grease line from block
channel B, directly after the first divider block
after the pump.
5. Restart the pump in channel A.
When the grease leaks from outlet B of this first
divider block, the leak must be found in this
block. When the grease leaks from the disconnec-
ted primary grease line, the leak must be sought
farther down the system. Repeat this procedure
every time using the next divider block until the
leak is found.
NOTE: To determine which divider block channel
is connected to pump outlet A, you need to follow
the primary grease line to the pump.
6. When there is only little leak, it may be impos-
sible to establish the leak with the operating
pump. Therefore, switch OFF the pump when
the maximum pressure is reached. Turn igni-
tion switch OFF or momentarily disconnect the
pump connector. The pressure should be steady
(minimum 200 bar (2900 psi); this procedure
only works for channel A). The pressure may
only drop when the control unit opens the
valve, as soon as a new cycle test is started in
channel B.
7. When there is a pressure drop, but there is no
grease coming back, it indicates a leaking me-
tering unit. Therefore check all connected
grease points on an excessive grease collar indi-
cating an internal leakage.
8000 SRM 1533 Technical Data

Technical Data
PUMP UNIT
Maximum operating pressure 250 bar (3626 psi)
Operating temperature -20 + 70°C (-4 + 158°F)
Supply voltage 24 Vdc
Rating pump motor with valve (nominal at 72W
20°C (68°F))
Control unit absorption 40mA (24 Vdc)
Advised fusing 10A (24 Vdc)
Capacity grease reservoir 4 liter (1.05 gal)
Nominal grease output pump 12 cm3 / min
Pump material Hard anodised aluminium - nylon reinforced
Protection class IP67

Torque Specifications

Number of Screws/
Description N•m ( lbf in) kg ( lb) )
Nuts
Minimum Level-Switch 30 N•m (265 lbf in) 3 kg (6.6 lb) 1
Relief Valve 20 N•m (177 lbf in) 2 kg (4.4 lb) 1
Locknut Plunger Housing 25 N•m (221 lbf in) 2.5 kg (5.5 lb) 3
12.5 N•m
Mounting screws of Motor 1.25 kg (2.75 lb) 3
(111 lbf in)
Nut of Solenoid Valve 40 N•m (354 lbf in) 4 kg (8.8 lb) 1
Mounting screws Pump Unit 7.5 N•m (66 lbf in) 0.75 kg (1.65 lb) 5
Mounting screws Pump-Body 10 N•m (88 lbf in) 0.1 kg (0.22 lb) 4
Thread Adapter 30 N•m (265 lbf in) 0.3 kg (0.66 lb) 2
Lower Cover 4 N•m (35 lbf in) 0.4 kg (0.88 lb) 4
Stirring Gear 40 N•m (354 lbf in) 4 kg (8.8 lb) 1
Guide Pin Bridge 10 N•m (88 lbf in) 0.1 kg (0.22 lb) 2
Guide Pin 30 N•m (265 lbf in) 0.3 kg (0.66 lb) 1
Grease Filter 15 N•m (133 lbf in) 0.15 kg (0.33 lb) 1
Filler Coupling 15 N•m (133 lbf in) 0.15 kg (0.33 lb) 1

63
 NOTES

64
 TECHNICAL PUBLICATIONS

8000 SRM 1533 5/15 (1/15)(7/14)(3/12)(10/11)