Hyster 110FT Periodic Maintenance

PERIODIC MAINTENANCES80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS [G004]; H80, 90, 100, 110, 120FT [N005, P005] PART NO. 1624742 8000 SRM 1248 SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background. Periodic Maintenance Table of Contents TABLE OF CONTENTS General ................................................................................................................................................................. Serial Number Data ........................................................................................................................................ How to Move Disabled Lift Truck................................................................................................................... How to Tow Lift Truck ................................................................................................................................ How to Put Lift Truck on Blocks .................................................................................................................... How to Raise Drive Tires ............................................................................................................................ How to Raise Steering Tires ....................................................................................................................... How to Clean a Lift Truck............................................................................................................................... Maintenance Schedule....................................................................................................................................... Maintenance Procedures Every 8 Hours or Daily............................................................................................ How to Make Checks With Engine Stopped................................................................................................. Tires and Wheels ....................................................................................................................................... Safety Labels ............................................................................................................................................. Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... Operator Restraint System....................................................................................................................... Emergency Locking Retractor (ELR) ................................................................................................... Adjust Seat - Full Suspension .............................................................................................................. Adjust Seat - Internal Suspension ....................................................................................................... Hood and Seat Latches ............................................................................................................................. Engine Compartment................................................................................................................................ Paper Application ...................................................................................................................................... Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ Hydraulic Hoses ........................................................................................................................................ Coolant Hoses ............................................................................................................................................ Steering Column Gas Cylinder................................................................................................................. Transmission ............................................................................................................................................. Hydraulic System Oil ................................................................................................................................ Engine Oil .................................................................................................................................................. Air Filter .................................................................................................................................................... Forks .......................................................................................................................................................... Remove .................................................................................................................................................. Inspect ................................................................................................................................................... Install..................................................................................................................................................... Adjust..................................................................................................................................................... Integral Sideshift Carriage....................................................................................................................... How to Make Checks With Engine Running................................................................................................ Indicator Lights, Horn, Fuses, and Relays .............................................................................................. Service Brakes ........................................................................................................................................... Brake Oil Level ..................................................................................................................................... Operation, Check .................................................................................................................................. Parking Brake ........................................................................................................................................... Engine Oil Pressure .................................................................................................................................. Cooling System .......................................................................................................................................... Steering System ........................................................................................................................................ Control Levers and Pedals ........................................................................................................................ Lift System, Operate ................................................................................................................................. First Service After First 100 Hours of Operation ............................................................................................ GM 4.3L Engine Oil and Oil Filter ............................................................................................................... Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 1 1 1 1 3 3 3 4 11 21 21 21 22 22 23 23 24 25 26 26 26 27 27 27 27 28 28 28 32 32 32 33 33 34 34 35 35 37 37 38 38 38 39 39 40 40 41 41 41 42 42 ©2011 HYSTER COMPANY i Table of Contents Periodic Maintenance TABLE OF CONTENTS (Continued) Drive Belt ....................................................................................................................................................... GM 4.3L Engine ........................................................................................................................................ Fan and Alternator Drive Belt ............................................................................................................. Drain Tar From LPG Regulator.................................................................................................................... Drain Tar From LPG Converter ................................................................................................................... Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. Hydraulic System Oil .................................................................................................................................... Hydraulic Tank Breather .............................................................................................................................. Inspect........................................................................................................................................................ Battery ........................................................................................................................................................... Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) .................................................................... Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ............................................................. Controlled Venting .................................................................................................................................... Manual Bleeding ....................................................................................................................................... Drive Belt ....................................................................................................................................................... Cummins 4.5L and QSB 3.3L Diesel Engine........................................................................................... Fan and Alternator Drive Belt ............................................................................................................. Clean Debris From Radiator Core ................................................................................................................ Transmission Oil Level ................................................................................................................................. Wet Brake Center Body Oil Level Check ..................................................................................................... Forks............................................................................................................................................................... Mast Lubrication ........................................................................................................................................... Header Hose Checks...................................................................................................................................... Lift Chain Lubrication .................................................................................................................................. Tilt Cylinder Lubrication .............................................................................................................................. Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... Manual Hydraulic Levers Lubrication ......................................................................................................... Brake Oil ........................................................................................................................................................ Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)........................................................................................................................................ Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) ................................. Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... Valve Clearance, Check and Adjust.............................................................................................................. Ignition System.............................................................................................................................................. GM 4.3L Engine ........................................................................................................................................ LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Lift Chains Wear Check ................................................................................................................................ Lift Chain Lubrication .................................................................................................................................. Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) ...................................................................................................................... 42 42 42 43 43 44 44 44 44 45 45 46 46 46 48 49 49 49 50 50 50 51 51 52 54 54 56 57 57 58 58 59 59 60 60 61 61 61 61 61 61 61 62 62 62 64 64 64 65 ii Periodic Maintenance Table of Contents TABLE OF CONTENTS (Continued) Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)............ Control Levers and Pedals ............................................................................................................................ Inspect Engine Electrical System, Connectors ............................................................................................ Maintenance Procedures Every 2000 Hours or Annually ............................................................................... Hydraulic System .......................................................................................................................................... Hydraulic Filter, Replace .......................................................................................................................... Hydraulic Tank Breather, Replace ........................................................................................................... Ignition System; Distributor Cap, Rotor, and Spark Plug Wires ................................................................ Cooling System, GM 4.3L and Cummins 4.5L and QSB 3.3L Engines ...................................................... Air Filter ........................................................................................................................................................ Oxygen Sensor GM 4.3L LPG Engines Equipped with GFI Installed........................................................ LPG Regulator Fuel Filter, GM 4.3L Engines Equipped With GFI Installed............................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Gasoline Fuel Filter....................................................................................................................................... Remove and Replace ................................................................................................................................. LPG Fuel Injector, GM 4.3L Engines Equipped With GFI Installed.......................................................... Gasoline Fuel Injector, GM Engines ............................................................................................................. Fuel Injector, Cummins 4.5L and QSB 3.3L Engine ................................................................................... Forks............................................................................................................................................................... Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... Wet Brake Center Section Oil Change ......................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Brake Oil (Master Cylinder), Change........................................................................................................... Brake Oil (Dry Brake), Remove .................................................................................................................... Service Brakes (Dry Brake) .......................................................................................................................... Differential (Dry Brake) ................................................................................................................................ Test LPG/GAS Regulator Pressure............................................................................................................... Check Throttle Shaft for Sticking................................................................................................................. Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... Hydraulic Oil, Replace .................................................................................................................................. Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... Weld Inspection.............................................................................................................................................. Safety Procedures When Working Near Mast.................................................................................................. Fuel Filter Water Removal ................................................................................................................................ Hood Latch Check .............................................................................................................................................. Lift Chain Adjustments ..................................................................................................................................... Jump-Starting the Lift Truck............................................................................................................................ Jump-Starting Using a Battery Charger ..................................................................................................... Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... Welding Repairs ................................................................................................................................................. Overhead Guard Changes ................................................................................................................................. Wheel and Tire Replacement ............................................................................................................................ General ........................................................................................................................................................... Solid Rubber Tire, Change (S Series) ........................................................................................................... Remove and Install Tire on Wheel ........................................................................................................... Pneumatic Tire With Tube, Repair............................................................................................................... 65 66 66 66 66 66 67 67 68 68 70 71 71 71 71 71 72 72 72 72 72 73 75 75 75 76 77 78 78 79 79 79 79 81 81 82 84 87 89 90 91 92 92 92 93 93 94 94 94 94 95 iii Table of Contents Periodic Maintenance TABLE OF CONTENTS (Continued) Remove Wheels From Lift Truck.............................................................................................................. Remove Tire From Wheel ......................................................................................................................... Remove Tire From Two-Piece Wheel ................................................................................................... Remove Tire From Three- and Four-Piece Wheels ............................................................................. Install Wheel in Tire ................................................................................................................................. Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. Install Tire on Two-Piece Wheel ........................................................................................................ Install Two-Piece Wheel in Tire ......................................................................................................... Add Air to Pneumatic Tires With Tube...................................................................................................... Install the Wheels ................................................................................................................................... Dual Drive Wheels, Install ..................................................................................................................... Pneumatic Tubeless Tire, Repair................................................................................................................ Remove Wheels From Lift Truck............................................................................................................ Remove Tire From Wheel ....................................................................................................................... Install Tire on Wheel .............................................................................................................................. Add Air to Pneumatic Tubeless Tire ...................................................................................................... Wheels, Install......................................................................................................................................... Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... Remove Wheel From Tire ....................................................................................................................... Install Tire on Wheel .............................................................................................................................. Adhesives and Sealants ................................................................................................................................... This section is for the following models: S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS [G004]; H80, 90, 100, 110, 120FT [N005, P005] 95 96 96 97 98 99 100 100 101 101 102 103 103 103 105 107 108 108 108 110 112 iv The service intervals are given in both operating hours recorded on the lift truck hourmeter and in calendar time. Repairs and adjustments that are not correct can make a dangerous operating condition. See the nameplate of the disabled lift truck for the approximate total weight. A slope will also make the lift truck more difficult to stop. and maintenance will help your lift truck provide more efficient performance and operate for a longer period of time. put a DO NOT OPERATE tag in the operator’s area. The capacity of the lift truck used to move a disabled lift truck must have a load center equal to half the width of the disabled lift truck. there is no power available for the hydraulic steering system and the service brakes. The forks must extend the full width of the disabled lift truck. • Tires are damaged. A regular program of inspection. Be careful to not damage the underside of the lift truck. Report the need for repairs immediately. under the floor plate. lubrication. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: • The lift truck is used more than eight hours per day. Remove the key from the key switch. This condition can make the lift truck difficult to steer and stop. • Traction conditions are bad. Put the weight center of the disabled lift truck on load center of the forks. Some users have service personnel and equipment to do the inspection. Tow truck slowly. • Steering does not operate correctly. If the engine cannot run. The Maintenance Schedule has time intervals for inspection. 2. WARNING DO NOT operate a lift truck that needs repairs. lubrication. The recommendations for the time intervals given for eight hours of operation per day. Service Manuals are available from your dealer for Hyster lift trucks to help users who do their own maintenance. Your dealer for Hyster lift trucks has the equipment and trained service personnel to do a complete program of inspection. Poor traction can cause the disabled lift truck or towing vehicle to slide. The recommendation is to use the interval that comes first. The towed lift truck must have an operator. the application of the brakes will be more difficult. • The lift truck must be towed on a slope. A lift truck used to move a disabled lift truck MUST have a capacity rating equal to or greater than the weight of the disabled lift truck. • Poor ground conditions. • Intensive usage at high performance levels or other abnormal conditions will require more frequent servicing. If the lift truck uses power from the engine to help apply the brakes.8000 SRM 1248 General General WARNING DO NOT make repairs or adjustments unless you have both authorization and training. lubrication. 1 . SERIAL NUMBER DATA The serial number for the lift truck is on the nameplate. 1. and maintenance. HOW TO MOVE DISABLED LIFT TRUCK How to Tow Lift Truck WARNING CAUTION Disposal of lubricants and fluids must meet local environmental regulations. and maintenance Use extra caution when towing a lift truck if any of the following conditions exist: • Brakes do not operate correctly. shown in the Maintenance Schedule. lubrication. If repair is necessary. and maintenance of your lift truck. Never lift and move a disabled lift truck unless the disabled lift truck MUST be moved and cannot be towed. This section contains a Maintenance Schedule and the instructions for maintenance and inspection. It is also on the right side of the frame. • The lift truck must work in dirty operating conditions. Lift truck models that are equipped with a leaded counterweight.) from surface. Slowly and carefully remove the slack out of the towing link. If lift trucks are equipped with a leaded counterweight without a tow pin (see Figure 1). This 1/2 capacity load will increase traction of lift truck. S100FTBCS. Install chain around a mast crossmember and the carriage to prevent carriage and mast channels from moving. raise carriage and forks approximately 30 cm (12 in. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT) B. TOWING LINK 2. and S120FTPRS (G004). Using a lift truck or a lifting device that could be attached to the mast (I. Counterweight Types 3. that are covered in this SRM are S80FTBCS.E. TOW PIN 2 . 5. that lift truck must have an equal or larger capacity than the disabled lift truck. COUNTERWEIGHT WITH TOW PIN (STANDARD COUNTERWEIGHT) 1. use a 8000 SRM 1248 towing link made of steel that fastens to the tow pins in the counterweights of both lift trucks. 4. CENTER GRILL BARS Figure 1. Slowly and carefully remove the slack out of the towing link. use a towing link made of steel that fastens to the two center grill bars of both lift trucks. come-a-long). A. See Figure 1. 6.General 3. Keep load as low as possible. Install approximately 1/2 of a capacity load on forks of lift truck that is being used to tow disabled lift truck. If lift trucks are equipped with a tow pin in the counterweight (standard counterweight). S120FTS. If another lift truck is used to tow the disabled lift truck. Put jack under steering axle or frame to raise lift truck. Make sure jack has a capacity equal to at least half the weight of the lift truck. put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle. use a hydraulic jack under the side of the frame near the front. Put a block under each outer mast channel. one-piece units. 3. CAUTION These lift trucks are equipped with cowl lifting eyes. put blocks under the mast assembly so the lift truck cannot fall forward. How to Raise Steering Tires NOTE: Some lift trucks are equipped with lifting eyes for the purpose of lifting the entire lift truck. If hydraulic system will not operate. put blocks under the counterweight so the lift truck cannot fall backward. Put blocks under frame to support lift truck. The surface must be solid. The cowl lifting eyes are to be used to lift the front of the lift truck only. See Figure 2. 1. The removal of the following assemblies will cause large changes in the center of gravity: mast. If the lift truck is equipped with this type of lifting eyes. transmission. Put blocks on each side (front and back) of steering tires to prevent movement of lift truck. 3 . 4. Put blocks on both sides (front and back) of drive tires to prevent movement of lift truck. 1. drive axle. and counterweight. • Before removing the counterweight. Lifting more than the front of the lift truck with the cowl lifting eyes will damage the cowl section. and level when the lift truck is put on blocks. See Figure 2. Make sure jack has a capacity of at least 2/3 of total weight of lift truck as shown on the nameplate. Use hydraulic jack to raise steering tires. Make sure any blocks used to support the lift truck are solid. Put mast in vertical position. When the lift truck is put on blocks. engine. 2. 3. See Nameplate. Tilt mast fully forward until drive tires are raised from surface. 5. HOW TO PUT LIFT TRUCK ON BLOCKS How to Raise Drive Tires WARNING The lift truck must be put on blocks for some types of maintenance and repair. even.8000 SRM 1248 General 2. the lift truck can be lifted and blocks installed. Apply parking brake. Put additional blocks under frame behind drive tires. Ensure overspray does not come in contact with electrical components. Even sealed connectors may allow water egress under pressure or if connector is damaged. as condensation may form in electrical components causing damage or erratic behavior. do not spray water directly at electrical components. If it becomes necessary to clean the fork lift.General 8000 SRM 1248 1. refer to Paper Application section in the applicable Operating Manual and to available Service Gram/ Bulletin for more detail. DRIVE TIRES 2. 4. follow the guidelines listed below. If an electric truck. NOTE: Lift trucks used in paper applications may need cleaning beyond what is described here. 3. Put Lift Truck on Blocks HOW TO CLEAN A LIFT TRUCK WARNING Engine. so close contact direct spraying will not be necessary. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Disconnect the battery. Lightly spray a non-corrosive cleaning agent onto the areas to be cleaned. Please 4 . Steam cleaning is not recommended in most instances. Remove accumulated debris using a compressed air line and nozzle. 5. wiring connectors or electrical enclosures. STEERING TIRES Figure 2. 2. Be sure lift truck components are cool before starting inspection and cleaning. Be sure to avoid directing the spray into electrical panel compartment. exhaust system components and other components are hot to the touch. Make sure that the path of the compressed air is away from all personnel. remove the traction battery. 1. Assure truck components are cool before starting the cleaning procedure. CAUTION Units may be washed with a non-heated pressure washer. or personal injury may occur. Wear protective goggles or a face shield to prevent injury to the eyes. This will help loosen grime. DO NOT pressure wash lift chains. Dry with compressed air. For cleaning traction batteries. 10. immediately start and run the lift truck to dry out components. refer to the Battery section of the Service Manual. Do not use hot water. After cleaning. DO NOT pressure wash the battery. Sheaves and Load Rollers maintenance section in the Service Manual for proper cleaning procedures. Clean the battery compartment by using a clean cloth to wash the battery with water. 9. Care should be taken to keep moisture at a minimum as some units have a traction or hydraulic motor directly below the battery compartment. sheaves or load rollers in the mast assembly. General 8. Refer to the Chains.8000 SRM 1248 6. 5 . Avoid spraying in areas containing electrical components such as: • Floor Plates • Battery Compartment • Dash/cowl assembly • Armrests with electrical components 7. 3L LPG Trucks With GFI Installed 6 .General 8000 SRM 1248 Figure 3. GM 4. 3L LPG Trucks With PSI Installed 7 .8000 SRM 1248 General Figure 4. GM 4. GM 4.General 8000 SRM 1248 Figure 5.3 Gasoline Trucks 8 . Cummins 4. 120FT (N005) 9 .5L Diesel for Lift Truck Models H80.8000 SRM 1248 General Figure 6. 90. 110. 100. 90. 110. 120FT (P005) 10 .General 8000 SRM 1248 Figure 7. Cummins QSB 3.3L Diesel for Lift Truck Models H80. 100. 100. Radiator. and Figure 7 represent H80. and Seat Rails Hood and Seat Latches Engine Compartment X X See Parts Manual See Parts Manual X X X Paper Application: Engine Compartment. and S120FTPRS (G004) lift trucks. 120FT. NOTE: The 250-hour. Table 1. Maintenance Schedule Item No. Radiator Screen if equipped. Water Hydraulic Hoses 13 Coolant Hoses X X Check for Leaks See NOTE 1. 100FTBCS. S80. 110. Carriage. Check Condition Check Condition See Parts Manual See Parts Manual X X X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 11 . 90. and 1000-hour/6month maintenance services are performed either at the specified hours or at 6 months whichever occurs first. Truck Components. and Figure 5 represent SSE 100. Figure 6. Figure 4.8000 SRM 1248 Maintenance Schedule Maintenance Schedule NOTE: The lift trucks shown in Figure 3. Figure 4. S120FTS. 500-hour. Header Hoses. Belly Pan if equipped Check for Leaks Fuel. 120FT (N005. 25 Item Tires and Wheels 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Check Condition Replace as Necessary Check Condition and Lubrication Check Condition and Operation Check Condition and Operation Remove Combustible Materials See NOTE 5. 29 Mast. NOTE: The lift trucks shown in Figure 3. P005) lift trucks. Figure 5. Check Condition Clean as Required Replace as Required See NOTE 8. Oil. Attachment Seat Belt. Lift Chains. Hip Restraints. Exhaust Wraps. Specification See Nameplate Safety Labels 28. 8 gal) Diesel No. 110. 100. P005) Horn.4 kg LPG . 120FT (N005.3L (Diesel) H80.5 gal) Diesel No. 90.45. 100. Maintenance Schedule (Continued) Item No. 90. 110.3 liter (26.5L and QSB 3. 120FT (N005. 120FT.S.3L (Gasoline) [S80. S120FTS. 100.5L and QSB 3. Lights. 110.7 liter (11. 90. P005) U.3 liter (26. Alarms. and Relays CIL 16 CIL 79 liter (20.0 lb) Full 44. 120FT (N005.5 .S.8 gal) 86 Octane Minimum 16 CIL 100.Maintenance Schedule 8000 SRM 1248 Table 1. Only Fuel Tank (Short Wheel Base) Cummins 4. HD 10 (33. 110.S. P005) Fuel Tank (Long Wheel Base) Cummins 4. 100FTBCS.1 . 100. 90.3L (Gasoline) H80. 2 X Check Operation Check Operation Check Operation 1 23 Service Brakes Parking Brake X X X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 12 .] S80.20.3L (Gasoline) H80. 16 Item Fuel Tank (LPG) 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity CIL Specification 15.HD 5. Only Fuel Tank (Short Wheel Base) GM 4. 100. Only Fuel Tank (Long Wheel Base) GM 4.3L (Diesel) H80. Fuses. P005) U. S120FTPRS (G004) U.5 gal) 86 Octane Minimum 16 CIL 79 liter (20.Gasoline Minimum 16 Fuel Tank GM 4. 120FT (N005.8 gal) 86 Octane . 2 16 CIL 100. 110. 90. Clean 4. X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 13 . 120FT (N005. 120FT (N005. 90. 110. 100. Maintenance Schedule (Continued) Item No.6 qt) See NOTE 2 and NOTE 3. 100. S120FTPRS (G004) Hydraulic Oil (Short Wheel Base) H80.3L Engine C 1 Filter See NOTE 4 and NOTE 5. 120FT]. Item Steering Controls and Steering Column Gas Cylinder 22 22 3 Transmission Transmission Hydraulic Oil GM 4.0 liter (65. ISO VG 46 Hydraulic Oil 15°C (5°F) and Above John Deere JDM J20C Specification X X X 3 X X C 62. S120FTS.7 liter (5.0 liter (82.4 qt) See NOTE 2 and NOTE 3 1 Filter Inspect and Replace as Required See NOTE 5.3L Engine (Gasoline/LPG) X CIL C X 7°C (20°F) and Below SAE 5W-20 16°C (60°F) and Below SAE 5W-30 18°C (0°F) and Above SAE 10W-30 API SM ILSAC GF4 SAE J2362 See Parts Manual 19 Engine Oil Filter GM 4. S80.5 qt) See NOTE 2 and NOTE 3 78.3L [S80. P005) Hydraulic Oil Filter Hydraulic Tank Breather X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Check Condition and Operation Check for Leaks Check Operation X C 39.4 liter (41. 100.0 qt) See NOTE 4 and NOTE 5. P005) Hydraulic Oil (Long Wheel Base) H80.8000 SRM 1248 Maintenance Schedule Table 1. ISO VG 46 Hydraulic Oil 15°C (5°F) and Above ISO VG 46 Hydraulic Oil 15°C (5°F) and Above See Parts Manual See Parts Manual 3 X X C 6 10 C C 8 9 Battery and Cable Terminals Engine Oil GM 4. 100FTBCS. 7 qt) See NOTE 4 and NOTE 5.0 liter (13. NOTE 6.5L Engine (Diesel) 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X CIL C 13. 9 Item Engine Oil Cummins 4. NOTE 6. and NOTE 12.5 liter (8 qt) See NOTE 4 and NOTE 5. 19 Engine Oil Filter Cummins 4. C 1 Filter See NOTE 5. and NOTE 12.5L and QSB 3.3L (Diesel) Air Filter (with premium monitoring) Air Filter CIL C 1 Filter See NOTE 4 and NOTE 5. Specification 0°C (32°F) and Below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10-30 15°C (5°F) and Above SAE 5W-40 or 15W-40 API CH-4 or CI-4 0°C (32°F) and Below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10-30 15°C (5°F) and Above SAE 5W-40 or 15W-40 API CH-4 or CI-4 See Parts Manual 9 Engine Oil Cummins QSB 3.3L Engine (Diesel) X CIL C 7. 1 Filter See NOTE 5.Maintenance Schedule 8000 SRM 1248 Table 1. Maintenance Schedule (Continued) Item No. 18 See Parts Manual 18 X C See Parts Manual X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 14 . 3L LPG Engine With PSI Installed Engine Idle Speed GM 4. Maintenance Schedule (Continued) Item No.5L (Diesel) Engine Idle Speed Hot Engine Cummins 4. No Adjustment Needed. No Adjustment Needed.3L (Diesel) LPG Regulator GM 4.5L Diesel Engine at High Idle 207 kPa (30 psi) at Low Idle 69 kPa (10 psi) Cummins QSB 3.5L and QSB 3.3L (Gasoline/LPG) Engine Governed Speed GM 4. See NOTE 5. Drain Tar See NOTE 5. Drain Tar See NOTE 5.3L Diesel Engine 49 kPa (7 psi) Minimum 15 Drive Belt GM Engine X Check for Wear and Damage. 750 ±25 rpm 15 Drive Belt Cummins 4.8000 SRM 1248 Maintenance Schedule Table 1. See NOTE 5.5L (Diesel) X X X 2400 ±25 rpm X Coolant Temperature Less than 77°C (170°F) Coolant Temperature Greater than 77°C (170°F) 770 ±50 rpm X 800 ±50 rpm X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 15 . Item Engine Oil Pressure 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity CIL Check Oil Pressure Specification GM Engine 207 to 380 kPa (30 to 55 psi) Cummins 4.3L (Gasoline/LPG) Engine Idle Speed Cold Engine Cummins 4. X Check for Wear and Damage.3L Engine With GFI Installed X 33 LPG Converter 4. 014 in.3L Diesel Engines X Adjust as Intake Required 0.3L Engine With GFI Installed 4 4 Valve Adjustment GM 4.3L Engine Valve Adjustment Cummins 4.) Cold 4 Valve Adjustment Cummins QSB 3.508 mm (0.5L and QSB 3.3L (Diesel) Oxygen Sensor GM 4.254 mm (0.3L (Diesel) Engine Idle Speed Hot Engine Cummins QSB 3.50 mm (0.010 in. Cold Exhaust 0.020 in.) See NOTE 13.3L Engine with GFI Installed Engine Idle Speed Cold Engine Cummins QSB 3.3L Diesel Engine CIL C C C 1 Filter 1 Filter Drain Water from Filter as Required X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 16 . Maintenance Schedule (Continued) Item No. LPG (GM) Fuel Filter Gasoline (GM) Fuel Water Separator Filter Cummins 4.35 mm (0.Maintenance Schedule 8000 SRM 1248 Table 1. Item Engine Governed Speed (No Load) Cummins 4.02 in.5L Diesel PCV Valve GM 4.3L (Diesel) Engine Governed Speed Cummins QSB 3.) Cold Exhaust 0.5L Diesel Engines X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Specification 2250 ±50 rpm X Replace as Necessary See NOTE 14 Coolant Temperature Less than 30°C (86°F) Coolant Temperature Greater than 30°C (86°F) See Parts Manual X 1000 ±25 rpm X 800 ±25 rpm X 2230 ±25 rpm X CIL Replace as Necessary Not Adjustable Adjust as Required Intake 0.) Cold 1 Filter See Parts Manual See Parts Manual See Parts Manual 17 17 17 Fuel Filter. 9 qt) 13. 20 liter (21 qt) 1 Filter 1 Breather See NOTE 4. John Deere JDM J20C See Parts Manual 7 21 Transmission Oil Dry Brake Transmission Oil Filter and Breather Forks Fork Latches X 26 26 X L X Lift System.3L Diesel Engine Fuel Injectors GM 4. C See NOTE 15. Operate X X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 17 .5 liter (14.3L Gas C 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity C 1 Filter Specification See Parts Manual 17 1 Filter See Parts Manual 20 X Check and Replace If Required 6 Injectors Check and Replace If Required 6 Injectors Check Plug Wires 6 Plugs See NOTE 9.8000 SRM 1248 Maintenance Schedule Table 1. C See NOTE 15.3L Diesel Engine Clean Debris From Radiator Core X CIL X CIL X CIL C X 5 12. Check Condition Lubricate as Necessary Check Operation Multipurpose Grease See NOTE 7.1 liter (15. Maintenance Schedule (Continued) Item No. 17 Item In-Line Fuel Filter Cummins 4. 14 12.3L Engine Cooling System GM 4.3L LPG With GFI Installed Spark Plugs GM 4.3L Engine Cooling System Cummins 4. 14 C 15.5L Diesel Engine Cooling System Cummins QSB 3. X X C C See NOTE 5.2 qt) 10.4 liter (11 qt) See NOTE 15.5L Diesel Engine Final Fuel Filter Cummins QSB 3. 14 12. 20 Fuel Injectors GM 4. 100FTBCS. 2 Fittings SAE 30W Engine Oil SAE 30W Engine Oil Multipurpose Grease See NOTE 7. 27 28 X 28 Lift Chains Mast Pivots Mast Integral Sideshift Carriage Sliding Surfaces Tilt Cylinder Ends X L L X Lube as Required. 8 Fittings 4 Bearing Strips 4 Fittings L Multipurpose Grease See NOTE 7 SAE 10W-30 API SM ILSAC GF4 SAE J2362 SAE 10W-30 API SM ILSAC GF4 SAE J2362 Brake Master Cylinder Rod End Pin Manual Hydraulic Hand Levers L L 24 11 Brake Oil (Master Cylinder) Steering Axle Spindle Bearings Steering Axle Tie Rods [S80. Lube as Required. S120FTPRS (G004) CIL X L C 0. 27 Item Mast Sliding Surfaces and Load Roller Surfaces Header Hoses Lift Chains X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity L Lubricate as Required See NOTE 10 and NOTE 11.] S80. See NOTE 11. L L.Maintenance Schedule 8000 SRM 1248 Table 1.74 pt) 4 Fittings Dexron III from Sealed Container Multipurpose Grease See NOTE 7. Check Condition Check Lubrication. 120FT. X Check for Wear. 100. S120FTS. Maintenance Schedule (Continued) Item No.35 liter (0. Multipurpose Grease See NOTE 7. Multipurpose Grease See NOTE 7 Specification Multipurpose Grease See NOTE 7. 11 L 2 Fittings X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 18 . 110. 120FT (N005. Maintenance Schedule (Continued) Item No. Hood Latch Service Brakes (Dry Brake) Parking Brake L 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity L 4 Fittings Specification Multipurpose Grease See NOTE 7. FTS. 100.3 qt) 7/30 Transmission and Wet Brake Planetary Carrier Housing Oil S80FT. S120FTS. 90.8 liter (30.0 liter (6. Hinges.0 mm (0. 100. 90. 100. 2 L Lubricate as Necessary Use Silicone Spray Hyster Part No. Seat Rails. P005) X C 28. P005) Pedals. FTBCS S120FT. 100. Levers.0 liter (2.4 qt) John Deere JDM J20C X C 31.8000 SRM 1248 Maintenance Schedule Table 1. FTPRS (G004) 7/30 Transmission and Wet Brake Planetary Carrier Housing Oil H80. 120FT (N005.1 qt) SAE 80W-90 X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 19 . 110.) Minimum Use Silicone Spray (Hyster Part Number 328388) SAE 80W-90 or 85W-140 John Deere JDM J20C 1 23 X Check Lining Thickness Lubricate as Necessary 30 Differential and Drive Axle Oil (Dry Brake) X C 6. P005) 30 Wet Brake Center Section Oil [S80.0 qt) John Deere JDM J20C X C 2.] S80.1 qt) SAE 80W/90 30 X C 2.040 in. 110.0 liter (2. 120FT) (N005. 100FTBCS. Cables. 120FT.8 liter (31. Linkages.4 qt) X C 29. FTBCS (G004) 7/30 Transmission and Wet Brake Planetary Carrier Housing Oil S100FT. 90. 11 Item Steering Axle Tie Rods H80.3 liter (33. 328388 1. S120FTPRS (G004) Wet Brake Center Section Oil H80. Connectors Inspect Engine Vacuum. Maintenance Schedule (Continued) Item No. Fuel Lines. and Fittings Inspect Lock-Off for Leaks. X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation 20 . and Ensure Lock-Off Closing Test LPG/GAS Regulator Pressure Check Air Induction System for Leaks Check Manifold for Vacuum Leaks Check Throttle Shaft for Sticking Check Injectors and Rails for leaks Inspect Exhaust Manifolds and Piping for Leaks Inspect Catalyst Inlet and Outlet 31 Ignition System Distributor. and Spark Plug Wires Inspect Muffler Inlet and Outlet Mast and Carriage with Paper Roll Clamp 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Specification X X X X X X X X X C Replace X X Replace as Required Inspect See NOTE 16 Dye Penetrant NOTE 1: Check fuel system for leaks prior to any service or maintenance activity. Item Inspect Engine Electrical System. NOTE 2: Heavy-duty or high-temperature operations require more frequent checks. Rotor.Maintenance Schedule 8000 SRM 1248 Table 1. NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours. In large diameter paper-roll production applications.8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily Table 1. Use hour interval only. NOTE 16: Inspect after an impact likely to cause damage. NOTE 12: Do not open the air filter canister except to change the air filter element. strapping. Maintenance Schedule (Continued) Item No. NOTE 13: Initial valve adjustment is at 250 hours or 3 months. Open the hood and check for leaks and conditions that are not normal. Lower the carriage and forks. Check the tread and remove any objects that will cause damage. At your request your Hyster dealer will advise you of the appropriate service intervals based on an application survey. Change transmission oil filter after first 500 hours of operation . and organic dust or fibers (paper. or other material that is wrapped around the axle. NOTE 8: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire.see 2000 Hr/1 Yr service procedures. remove the key from the key switch. Report the need for repairs immediately. intensive usage at high performance levels. NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Tires and Wheels Check the tires for damage. etc. X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation Maintenance Procedures Every 8 Hours or Daily HOW TO MAKE CHECKS WITH ENGINE STOPPED WARNING DO NOT operate a lift truck that needs repairs. At your request. NOTE 6: In dirty or dusty environments. put a DO NOT OPERATE tag in the operator’s area. See Maintenance Procedures Every 2000 Hours or Annually to change air filter element. Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity Specification NOTE 4: Change engine oil and filter after first 100 hours of operation. agricultural grass/grain. NOTE 10: Lubricate mast every three months if unit has less than 1000 hours. Use compressed air and steam clean as necessary. depending upon operating environment. This should be done at least once every 8 hours or more frequently. If the lift truck is equipped with a key switch. 21 . NOTE 11: Lubricate at first sign of visible surface rust. Ensure all surfaces are free of oils. Purchase a pre-diluted 50/50 solution. Remove any wire. and apply the parking brake. cotton. Clean any oil or fuel spills. NOTE 14: Replace after 3000 hours.). inspect at first 4000 hours with subsequent inspection at 2000 hour intervals. Subsequent adjustments must be performed at 2000hour/2-year intervals. NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide. or mix 50% concentrate with 50% distilled or deionized water. Check for bent or damaged rims. Applications involving contaminated environments such as high levels of air borne debris (dust and waste paper). chemical or abrasive compounds. fuel. replace at 1000 hours or as needed. lubricants. wood. Check for loose or missing hardware. whichever comes first. NOTE 5: Recommended service intervals are based on a normal application in a clean environment. stop the engine. If repair is necessary. or other abnormal conditions will require more frequent servicing. your Hyster dealer will advise you of the appropriate service intervals based on an application survey. poor ground conditions. Put the lift truck on a level surface. See Figure 8. NOTE 9: See Capacities and Specifications 8000 SRM 1249 for spark plug gap and type of spark plugs to use. CHECK TIRE PRESSURE (PNEUMATIC TIRES) Figure 8. 2. See Mast Repairs. Use SAE 30 engine oil as necessary to lubricate the lift chains. Adjust/repair/replace hose/components as necessary. GLASS AND OTHER OBJECTS FROM THE TREAD) 2. Carriage. replace the forks as a set. hose cover for cuts. Forks are made of special steel using special procedures. 8. MAKE SMOOTH EDGES 3. Lift Chains.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 1. 6. 2. 5. It is important that all safety labels are installed on the lift truck and can be read. Visually inspect hoses/fittings for hydraulic leaks. Inspect the lift chains for cracks or broken links. Never repair damaged forks by heating or welding. cracks or exposed reinforcement.and 3-Stage Masts 4000 SRM 1250 for quick disconnect procedures. Check that the lift chains are correctly lubricated. Mast. inspect the parts for cracks and wear. Make sure that the capscrews and nuts are tight. CHECK FOR DAMAGE (REMOVE NAILS. Inspect the rollers for wear or damage. 7. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Model Description section in the Operating Manual or the section Frame 100 SRM 1243 for the correct location of the safety labels. Inspect the chain anchors and pins for cracks and damage. DO NOT try to correct the alignment of the fork tips by bending the forks or adding shims. Attachment WARNING Lower the lift mechanism completely. Never allow any person under a raised carriage. 4. and worn or turned pins. Tire Check Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. Check that all safety labels are installed in the correct location on the lift truck. 22 . Inspect the welds on the mast and carriage for cracks. See the Parts Manual. Make sure the parts that fasten the integral sideshift carriage or attachment to the carriage are in good condition. defective/broken clamping devices or sheaves. If either fork is damaged. 1. Header Hoses. See Figure 9. 3. proper tracking during operation. If the lift truck is equipped with an integral sideshift carriage or attachment. Inspect the load backrest extension for cracks and damage. See the Parts Manual for the part numbers of the safety labels. Inspect the channels for wear in the areas where the rollers travel. The end of the belt must fasten correctly in the latch. See Figure 10. If the truck tips. travels off a dock. with the hood in the open position. Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. and is in good condition. 10. pull the seat belt slowly from the retractor assembly. If the seat belt can be pulled from the retractor. replace the seat belt assembly. LOOSE LEAVES 6. the belt will permit slight operator repositioning without activating the locking mechanism. 9. If the seat belt can be pulled from the retractor. functions correctly.8000 SRM 1248 9. hood. Hood and Seat Check 23 . hip restraint. 8. NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly. pull the seat belt with a sudden jerk. or comes to a sudden stop. 7. CORROSION Figure 9. Make sure the seat belt will not pull from the retractor assembly. TURNED PIN 7. A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. Each item must be checked to make sure it is fastened correctly. 6. 2. Lift Chain Check Operator Restraint System The seat belt. Replace the seat belt if damage or wear is seen. 2. when it is pulled with a sudden jerk. 4. the locking mechanism will be activated and hold the operator’s lower torso in the seat. 11. replace the seat belt assembly. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract. replace the seat belt assembly. LATCH STRIKER HOOD LATCH FORWARD/BACKWARD ADJUSTMENT HOOD OPERATOR WEIGHT ADJUSTMENT SEAT RAIL ARM REST SEAT BELT SEAT HIP RESTRAINT HOOD HINGE Figure 10. When the ELR style seat belt is properly buckled across the operator. Make sure the lift chains are adjusted so that they have equal tension. 4. Make sure the seat belt pulls out and retracts smoothly. 3. Maintenance Procedures Every 8 Hours or Daily The seat belt must be in good condition. Adjustments or replacement of the lift chains must be done by authorized personnel. WORN PIN CRACKS EDGE WEAR HOLE WEAR 5. 5. seat. 3. • With the hood closed and in the locked position. • With the hood closed and in the locked position. make sure the seat belt will not pull from the retractor assembly. • With the hood in the open position. 1. 1. and hood latch are all part of the operator restraint system. See Figure 10. This ensures that the operator is set at the midpoint of the 80mm suspension. 2. Swivel Seat Controls NOTE: The seat is designed for maximum weight of 135 kg (298 lb).Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 to the ground so that the best ergonomic position is achieved. FORWARD/BACKWARD ADJUSTMENT SWIVEL ADJUSTMENT OPERATOR WEIGHT ADJUSTMENT SEAT POSITION ADJUSTMENT (SEAT RAIL) SEAT BELT Figure 11. NOTE: It is important to adjust the weight setting for each operator. 5. 3. NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE 1. • The handle can be turned as shown to increase or decrease the weight resistance. See Figure 10. pull handle out before turning. • The seat swivels 5 degrees to the left to allow as easier exit of the truck. • The neutral position is shown in Figure 12.Full Suspension Seat Position Adjustment (Standard Seat) • Fore and aft adjustment . As the handle is turned the "stiffness" of the suspension can be felt to increase or decrease on which way the handle is turned. • The target is for the "ride indicator" to fall between the arrows when the operator sits upright in the seat with the feet positioned on the pedals.It is recommended that the seat be adjusted so that the thigh is horizontal 24 . Seat Position Adjustment (Swivel Seat) • The seat swivels 12 degrees to the right to allow the operator a more ergonomic position when driving in reverse. Adjust Seat . 4. Seat Adjustment for Operator Weight CAUTION A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his/her weight. • The seat swivels 5 degrees to the left to allow as easier exit of the truck.Internal Suspension Seat Position Adjustment (Swivel Seat) • The seat swivels 10. NOTE: It is important to adjust the weight setting for each operator. • The weight adjustment knob can be turned left or right to increase or decrease the weight resistance. As the weight adjustment knob is turned the "stiffness" of the suspension can be felt to increase or decrease on which way the weight adjustment knob is turned. SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER B. Seat Adjustment Adjust Seat . 4. SWIVEL LATCH RELEASE LEVER Figure 12. • The target is for the "ride indicator" to fall between the arrows when the operator sits upright in the seat with the feet positioned on the pedals. 2.8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily A. 3. STANDARD. CAUTION A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his/her weight.57 in. • The neutral position is shown in Figure 13. This ensures that the operator is set at the midpoint of the 40 mm (1. FULL SUSPENSION SEAT 5. NON SUSPENSION SEAT 1. ARMREST 7. 25 .) suspension. BACKREST ANGLE ADJUSTMENT LEVER 6.5 degrees to the right to allow the operator a more ergonomic position when driving in reverse. Seat Adjustment for Operator Weight NOTE: The seat is designed for maximum weight of 135 kg (298 lb). With engine off and lift truck components cooled. muffler and catalytic converter for paper scraps. transmission. SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER 5. dust and oil accumulation. Paper Application Vehicles used in paper applications require regular inspection and cleaning to minimize the risk of fire. Try to lift the hood to make sure it is fastened correctly and will not move. 4. etc.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 1. 26 . SWIVEL LATCH RELEASE LEVER Figure 13. Remove any combustible materials. The seat rails must be correctly fastened to the hood and the hood fastened to the hinges on the frame. and inside frame ledges to avoid paper. check and clean the radiator and if equipped. Engine Compartment Check for the presence of any combustible material such as paper. 3. ARMREST 7. Remove any debris. fan shroud. exhaust pipes. go to Hood Latch Check. leaves. Be sure lift truck components are cool before starting inspection and cleaning or personal injury may occur. Seat Adjustment Hood and Seat Latches Make sure the seat rails and latch striker are not loose. Check axle and cowl openings for paper buildup and bailing wire. WARNING Engine and exhaust system components are hot to touch. 2. Ensure the truck engine cools properly by allowing it to idle for several minutes. Shutting the truck down while hot will not allow the engine to cool quickly due to the loss of coolant circulation. The paper application option will help limit the contact of paper or tissue scraps to hot surfaces under the hood. See Figure 10 and Figure 11. Check and clean the engine compartment components. but frequent maintenance is required. Check engine manifold. Clean as required. radiator screen. belly pan if equipped. BACKREST ANGLE ADJUSTMENT LEVER 6. The heat trapped under the hood may actually increase the engine temperature because of no heat transfer through the radiator. This should be done at least once every 8 hours or more frequently depending upon operating environment. If adjustment is required. The seat rails must lock tightly in position. but move freely when unlocked. 8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. steam clean to remove any persistent accumulation of material or oil. Paper removal can generally be accomplished using a compressed air line and nozzle. Steering Column Gas Cylinder Make sure the gas cylinder for the steering column operates correctly. The cylinder must NOT allow the column to move unless the tilt lever is released. proper fit. Hydraulic Hoses Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage. Never expose your skin to steam. Take care to maintain the integrity of the exhaust wraps when cleaning with compressed air and use caution to not force debris into openings. Check to insure that the hydraulic hoses are not leaking. see the section HOW TO ADD FUEL TO THE LIFT TRUCK in the Operating Manual. 27 . and Coolant Leaks. Check the condition of exhaust wraps for wear. Check to insure that the coolant hoses are not leaking. Do not spray exhaust wraps directly with high pressure steam. Soft or cracked hoses need to be replaced before a major leak occurs. Fuel. Make a visual check for leaks on and under the lift truck. Do not reuse wraps if they have been removed for some other service operation. Paper dust and scraps will adhere to wet surfaces. Fuel leaks MUST be repaired IMMEDIATELY. gaps in coverage. CAUTION Air pressure. usually a strong odor. If compressed air did not adequately remove debris. If there is a leak in the fuel system. Remove floor plates and side covers for better access to engine compartment. If any hose is leaking. report it to maintenance for repair. Leaks often indicate a need for repair of damaged or worn components. nozzle or extension tube may cause damage to exhaust wraps and radiator fins. Open or removed belly pan. failed fasteners and replace as necessary. See Figure 14. Do not reuse wraps if they have been removed for some other service operation. Assure that air pressure. extra care must be used during the repair. Coolant Hoses Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage. gloves. failed fasteners and replace as necessary. If any hose is leaking. Protect electrical components from moisture when steam cleaning. if equipped. Check the fuel system for leaks and the condition of parts. Wear protective clothing. contamination with oil or antifreeze. report it to maintenance for repair. nozzle or extension tube does not damage exhaust wraps or radiator fins. If possible. DO NOT operate the lift truck until a leak is repaired. Check the condition of exhaust wraps for wear. When fuel is added to the lift truck. Clean components with compressed air. Allow lift truck to air dry before returning to work in a contaminated environment. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. Steam can cause serious burns. Oil. contamination with oil or antifreeze. Wear protective goggles or a face shield to prevent injury to the eyes. proper fit. Make sure that the path of the compressed air is away from all personnel. gaps in coverage. Check WARNING All fuels are very flammable and can burn or cause an explosion. Leaks in the LPG fuel system are usually not visible unless ice is present. WARNING Be careful when cleaning with steam. An extension may be helpful to access hard to reach places. There is however. find and report the leak to maintenance for repair. and eye protection. Also check the condition of the radiator or heater hoses that are not leaking. Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. After the engine has stopped, wait one minute before checking the oil level. Keep the hydraulic oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule. Check the hydraulic system for leaks and damaged or loose components. Heavy-duty or high-temperature operations can require more frequent checks. Engine Oil 1. TILT LEVER 2. GAS CYLINDER WARNING At operating temperature, the engine oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn. Figure 14. Steering Column Gas Cylinder and Tilt Lever Transmission CAUTION Check the transmission for leaks and damaged or loose components. Heavy-duty or high temperature operations can require more frequent checks. DO NOT permit dirt to enter the engine when the oil level is checked or the filter is changed. Never operate the engine without oil. The operation of the engine without oil will damage the engine. After the engine has stopped, wait one minute before checking the oil level. See Figure 15, Figure 16, and Figure 17. Keep the oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule. Hydraulic System Oil WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn. CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. 28 8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily Legend for Figure 15 A. TOP VIEW B. RIGHT HAND SIDE SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP WATER SEPARATOR AIR FILTER LIFT PUMP FUEL INJECTION PUMP ENGINE OIL FILL CAP INLINE FUEL FILTER DIPSTICK ENGINE OIL FUEL INJECTOR DRIVE BELT Figure 15. Cummins 4.5L Diesel Engine Maintenance Points for Lift Truck Models H80, 90, 100, 110, 120FT (N005) 29 Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 A. RIGHT SIDE FRONT VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. DIPSTICK TURBOCHARGER OIL FILL CAP AIR INLET HOUSING FUEL PRIMER PUMP FUEL/WATER SEPARATOR ECM FUEL FILTER STARTER FUEL RAIL ELECTRONIC FUEL PUMP WATER PUMP CRANK POSITIONING SENSOR CAM POSITIONING SENSOR B. LEFT SIDE FRONT VIEW 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. ALTERNATOR ALTERNATOR BELT ADJUSTMENT TEMPERATURE SENDING UNIT WATER INLET/THERMOSTAT HOUSING TURBOCHARGER AIR INLET TURBOCHARGER WASTEGATE TURBOCHARGER EXHAUST TURBOCHARGER EXHAUST MANIFOLD OIL FILTER TURBOCHARGER OIL DRAIN LINE TURBOCHARGER OIL FEEL LINE OIL PAN OIL PAN DRAIN PLUG DRIVE BELT Figure 16. Cummins QSB 3.3L Diesel Engine Maintenance Points for Lift Truck Models 30 DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT B. 2. 10. 11. 4. 9.8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily A. GAS ENGINE 1. 3. GM Engine Maintenance Points With GFI Installed 31 . 8. AIR FILTER FUEL FILTER ENGINE OIL FILTER SPARK PLUGS FUEL INJECTOR Figure 17. LPG ENGINE 7. 6. 5. 8. 3. Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch. GM 4. NOTE: Forks are to be replaced only in sets and not individually. 1. the manual air flow indicator is red • The specified number of hours has passed since the last filter element replacement Do not operate the lift truck until the air filter element has been replaced. An air filter element replacement is required when one of the following occurs: • The optional air flow restriction indicator light on the dash illuminates • If equipped. Each hook fork for these lift trucks can weigh 45 to 115 kg (99 to 253 lb). 4.3L Engine Maintenance Points With PSI Installed Air Filter The air filter canister should not be opened until an air filter element replacement is required. These lift trucks have hook forks. Remove WARNING DO NOT try to move a fork without a lifting device. A fork can be removed from the carriage for replacement of the fork or other maintenance. 11. 2. See Figure 20. 6. DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT 7. 32 . The identification of a fork describes how the fork is connected to the carriage.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 1. AIR FILTER ENGINE OIL FILTER SPARK PLUGS ENGINE LABEL LPG CONVERTER Figure 18. 5. 9. See Figure 19 and Figure 20. Lift the lock pin and slide a hook fork to the fork removal notch on the carriage. 10. Lower the carriage further so that the top hook of the fork is Forks NOTE: Forks must be removed or installed by trained personnel only. Inspect the forks for cracks and wear.) 1524 mm (60 in. MAXIMUM ANGLE 93° 8. CARRIAGE BARS 2. Check that the bottom of the fork is not worn.) 1067 mm (42 in. Maintenance Procedures Every 8 Hours or Daily 1. or use a lifting device to move the fork away from the carriage. BLOCKS Figure 19.10 in.26 in.) 1372 mm (54 in.46 in. CARRIAGE 6. Engage the lock pin with a notch in the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch.81 in. item 4. Hook Fork Removal Inspect 1.) 3% Dimension 27 mm 32 mm 37 mm 41 mm 46 mm 55 mm (1. HOOK FORK 3. FORK REMOVAL NOTCH Figure 20.17 in. LOAD BACKREST EXTENSION 7.61 in.8000 SRM 1248 disengaged from the top carriage bar. 2.) 1830 mm (72 in.) 1220 mm (48 in. See Figure 20. Check that the fork tips are aligned as shown in Figure 20.) (1. Move the carriage away from the fork.) (2.) (1. Slide the fork on the carriage so that both upper and lower hooks engage the carriage. Fork Tip Alignment Length of Forks 915 mm (36 in.) (1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2.) Install Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar. Replace any damaged or broken parts that are used to keep the forks locked in position.) (1. HEEL OF FORK (MUST BE 90% OF DIMENSION X) 5. Forks Check 33 . LATCH DAMAGE 4. CRACKS 3. 1. 2. wear and damage. If pin does not remain engaged in carriage slot. 4. If damaged.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 Adjust NOTE: During the adjustment of the forks.and 3-Stage Masts 4000 SRM 1250 for repair procedures. Integral Sideshift Carriage Figure 21. 10. 11. Integral Sideshift Carriage Check for cracks. If necessary. WEDGE 6. The lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. LOCK PIN ASSEMBLY 1. Raise the lock pin in each fork to slide the fork on the carriage bar. 3. 8. 12. KNOB 7. 2. 2. FORK LOCK PIN SPRING WASHER 5. 6. 5. 1. 7. see Mast Repairs. 9. See Figure 22. See Figure 19 and Figure 21. Adjust the forks as far apart as possible for maximum support of the load. 3. 4. CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS UPPER BEARING STRIPS GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHINGS SEAL FIXED FRAME Figure 22. Fork Lock Pin Assembly 34 . The forks are connected to the carriage by hooks and lock pins. lubricate sliding surfaces at grease fittings with multipurpose grease shown in the Maintenance Schedule. replace with new pin. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made. the heel of the forks should not be touching the ground. Hook forks will slide along the carriage bars to adjust for the load to be lifted. remove the key. Indicator Lights. Horn. and Relays If lift truck is equipped with a key switch. Make the checks carefully. Report the need for repair immediately. turn key to ON position. If lift truck is equipped with a Power ON/OFF button. Start the engine by turning the key switch to the Start position. The fuses are located in the Power Distribution Module (PDM) which is under the hood next to the battery on the right side. Check the operation of the horn. apply 35 . If lift truck is equipped with a key switch. All warning light and indicator lights will light up for two seconds (start check) when system power is turned ON. If the lift truck is stationary during a check. press button to turn system power on. If any indicator lights do not operate correctly. WARNING FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if the lift truck tips over. if truck is equipped with a key switch. or press the engine start button.8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily the parking brake and put the transmission in NEUTRAL. See Figure 24. Fuses. HOW TO MAKE CHECKS WITH ENGINE RUNNING WARNING DO NOT operate a lift truck that needs repairs. check the fuses. IT CAN ONLY HELP IF IT IS FASTENED. Be careful when making the checks. Check all indicator lights for correct operation as described in the Operating Manual. put a DO NOT OPERATE tag in the operator’s area. if lift truck is equipped with this button. See Figure 23. Make sure that the area around the lift truck is clear before starting the engine or making any checks of the operation. If repair is necessary. Brake Oil Level Malfunction Indicator Warning Light. Parking Brake Malfunction Indicator Warning Light. Transmission Oil Temperature Malfunction Indicator Warning Light. Engine Coolant Temperature Malfunction Indicator Warning Light. 1st Gear Locking (Duramatch Plus 2™ Transmissions) Indicator Light. Water Separator (Diesel Only) Indicator Light.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Warning and Indicator Light Warning Light. Engine Malfunction Light Warning Light. Cold Start (Diesel Only) Figure 23. System Malfunction Light Indicator Light. Warning and Indicator Lights 36 . Air Filter Restriction Indicators Light. Coolant Level in Radiator Malfunction Indicator Warning Light. Fuel Level Indicator Malfunction Indicator Indicator Light. Engine Oil Pressure Malfunction Indicator Warning Light. Direction and Transmission Warning Light. Alternator Malfunction Indicator Warning Light. Fasten Seat Belt Malfunction Indicator Warning Light. 8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily NOTE: HOOD REMOVED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. BATTERY PDM RESISTOR (68 OHM) START RELAY STARTER (30-AMP FUSE) IGNITION 3 RELAY BACKUP RELAY BACKUP (20-AMP FUSE) IGNITION (30-AMP FUSE) SPARE FUEL PUMP (20-AMP FUSE) 11. 12. 13. 14. 15. 16. 17. 18. 19. SPARE FUEL PUMP RELAY BATTERY (25-AMP FUSE) FRONT WORK LIGHT (20-AMP FUSE) FRONT/REAR WORK LIGHT RELAYS BATTERY (25-AMP FUSE) REAR WORK LIGHT (20-AMP FUSE) IGNITION 1 (20-AMP FUSE) IGNITION RELAY BATTERY (25-AMP FUSE) Figure 24. PDM Showing Fuses and Relays Service Brakes Brake Oil Level using the lift truck. Replace the brake oil in the system if there is dirt or water in the system. DO NOT use "DOT" fluid, only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury. There is an indicator light on the Display Switch Cluster for the brake oil. The red light is ON when the key switch is in the START position or the Power ON/OFF button is pressed, and must go OFF when the engine is running. If the light is on when the engine is running, the brake fluid oil in the reservoir is too low. WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. DO NOT allow water entry. Ensure that the sealed reservoir lid is properly replaced. The brake system has a boosted master cylinder, braking will be more difficult if the engine is not running. Loss of oil from the brake oil reservoir indicates a leak. Repair the brake system before 37 Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 Operation, Check Check the operation of the service brakes. Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate. The pedal must stop firmly and must not move slowly down after the brakes are applied. The service brakes must apply equally to both drive wheels. The service brakes must not pull the lift truck to either side of the direction of travel when they are applied. The service brakes are automatically adjusted when the transmission is in reverse and the lift truck is moving and the brakes are firmly applied. Full application of the inching/brake pedal applies the service brakes and puts the transmission in NEUTRAL. Lift trucks with a MONOTROL® pedal. When the inching/brake pedal is fully applied, a switch in the starting circuit is closed so that the engine can be started. Parking Brake Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake is adjusted. Lift trucks with a MONOTROL® pedal. The switch energizes the seat warning circuit when hand lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction solenoid. There is also a switch on the left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied. NOTE: Make sure parking brake is released before making adjustment. 1. Turn the adjustment knob to raise the equalized link and tighten the parking brake cables shown in Figure 25. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parking brake is released. 2. For burnished brakes, test the operation of the parking brake. The lift truck with a capacity load must not move when parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)]. 1. 2. 3. 4. LOCK BUTTON RELEASE OFF POSITION ON POSITION ADJUSTMENT KNOB Figure 25. Parking Brake Engine Oil Pressure NOTE: The engine will enter shutdown mode after a warning buzzer sounds and a 30 second countdown, if engine oil pressure is less than 34.5 kPa (5 psi) on lift trucks with powertrain protection system. Lift trucks equipped with a Cummins diesel engine will enter the shutdown mode when the engine oil pressure is less than 49 kPa (7 psi) on lift trucks with powertrain protection system. See the Engine Shutdown procedures in the Operating Manual. There is an indicator light for the engine oil pressure on the Display Switch Cluster. During normal operation, the red indicator light will illuminate when the key switch is turned to ON, if the truck is equipped with a key switch, or when the power ON/OFF button is pressed, if the truck is equipped with a keyless option, and will stay illuminated until correct oil pressure is obtained, at which time the light will go off. 38 8000 SRM 1248 If the light continues to stay on when engine is running, the engine oil pressure is low. Stop the engine and check the oil level. See Figure 17 for lift truck models S80, 100, 120FT; S80, 100FTBCS; 120FTS; S120FTPRS) (G004) and Figure 15, Figure 16, and Figure 17 for lift truck models H80, 90, 100, 110, 120FT) (N005, P005) Do not restart the engine until the low pressure condition has been corrected. Maintenance Procedures Every 8 Hours or Daily WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Check the radiator fins. Clean the radiator with compressed air or water as needed. Check for and remove any debris on the radiator core. If the indicator light turns on again after restarting, shut down the lift truck and do not operate the lift truck until the problem is corrected. Cooling System WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. NOTE: The engine will enter shutdown mode after a warning buzzer sounds and a 30-second countdown if coolant temperature reaches 118°C (245°F) or above for GM 4.3L lift trucks with powertrain protection system. Lift trucks equipped with a Cummins 4.5L or QSB 3.3L diesel engine will enter the shutdown mode when the coolant temperature reaches 114°C (238°F) or above on lift trucks with powertrain protection system. See the Engine Shutdown procedures in the Operating Manual. There is an indicator light on the Display Switch Cluster for the coolant temperature. The red light is on when the key switch is in the START position or the Power ON/OFF button is pressed, and must go off when the engine is running. If the light is on when the engine is running, the coolant and engine are too hot. Stop the engine and check the coolant level in the coolant recovery reservoir. Make sure the coolant level is between the ADD and FULL marks on the auxiliary coolant reservoir. See Figure 26. The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase. 1. 2. 3. 4. FILL CAP FULL HOT MARK FULL COLD MARK ADD COLD MARK Figure 26. Auxiliary Coolant Reservoir Steering System WARNING The lift truck has hydraulic power steering. The steering can be difficult if the engine is not running. Make sure the steering system operates smoothly and provides good steering control. Make sure the steering column can be adjusted and the gas cylinder function is correct. CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. If coolant is added, see Maintenance Schedule for correct solution. 39 Lower the load to approximately 0. mast. Tilt the mast forward and backward. Operate WARNING When working on or near the mast. If the mast cannot be lowered. The inner weldments and the carriage must lower completely.Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248 Perform the following checks and inspections: 1. The mast must tilt smoothly and both tilt cylinders must stop evenly. Check that the controls for the attachment operate the functions of the attachment. Make sure the moving parts are attached to a part that does not move.3 m (1 ft). Lower the mast. Never allow any person under a raised carriage. Lift System. Raise the mast 1 m (3 ft) with a capacity load. 4. Hydraulic oil can be injected into the body by the pressure. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Hose must track properly during operation. Check for leaks in the hydraulic system. Check that the pedals operate correctly as described in Operating Manual. 40 . Lower the lift mechanism completely. use chains on the mast weldments and carriage so that they cannot move. All moving components must lower smoothly. 2. see Safety Procedures When Working Near Mast at the end of this section. 5. Check the condition of the hydraulic hoses and tubes. 6. DO NOT try to find hydraulic leaks by putting hands on pressurized hydraulic components. Raise the mast to its full height at least once. Slowly raise and lower the mast several times without a load. See the symbols by each of the controls. and attachment operate as described in Operating Manual. The inner weldments and the carriage must raise smoothly. The mast components must raise and lower smoothly in the correct sequence. 3. Control Levers and Pedals Check that the control levers for the transmission. NOTE: Some parts of the mast move at different speeds during raising and lowering. Make sure all of the hydraulic lines are connected correctly and do not leak. Turn filter until gasket touches. then tighten 1/2 to 3/4 turn with your hand. NOTE: ALL OIL FILL COMPONENTS LISTED IN LEGEND FOR GM 4. Check area around oil filter for leaks. GM 4. Engine Oil Filter Change. Install new filter. OIL FILTER DRAIN PLUG ENGINE OIL DIPSTICK ENGINE OIL FILL NOTE: BOTTOM LEFT-HAND SIDE SHOWN 1.8000 SRM 1248 First Service After First 100 Hours of Operation First Service After First 100 Hours of Operation GM 4. Fill engine with oil as specified in Maintenance Schedule until full mark reached on the dipstick. CUMMINS 4.5L AND QSB 3. Check area around oil filter for leaks. Install new filter. shut engine off and check oil dipstick. shut engine off and check oil dipstick. Apply clean oil to gasket of new filter. OIL FILTER 2.3L ENGINES EQUIPPED WITH GFI OR PSI ARE LOCATED IN THE SAME AREA. Start engine. until full mark reached on the dipstick. 2. if low add oil. See Figure 28. Cummins 4.5L Diesel (Shown) Figure 27. See Figure 27. DRAIN PLUG Figure 28. 1. 3. Change engine oil and oil filter. Turn filter until gasket touches.3L ENGINE OIL AND OIL FILTER Change engine oil and oil filter. Fill engine with oil as specified in Maintenance Schedule. then tighten 1/2 to 3/4 turn with your hand. Apply clean oil to gasket of new filter. 4. if low add oil. Start engine.3L Engine Filter Oil Change 41 .3L ENGINE OIL AND OIL FILTER NOTE: The engine oil and oil filter must also be changed after the first 100 hours of operation for a newly installed engine. See Figure 31 for the drive belt arrangement.3L ENGINE OIL AND OIL FILTER NOTE: Change the oil and oil filter for the engine at the first 100 hours of operation on new lift trucks. A belt with cracks that run length of belt or a belt with missing pieces is not acceptable. Check area around oil filter for leaks. 1. Change engine oil and engine oil filter. GM 4. 3. GM 4. Install new filter.3L Engine GM 4. A few small cracks that run across belt are acceptable. Fan and Alternator Drive Belt Check drive belt for wear and damage. ACCEPTABLE CRACKS 2. Start engine. See Figure 29. 2. then tighten 1/2 to 3/4 turn with your hand.Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1248 Maintenance Procedures Every 250 Hours or 6 Months NOTE: Perform the 8-hour checks prior to performing the procedures in this section.3L ENGINES EQUIPPED WITH GFI OR PSI ARE LOCATED IN THE SAME AREA. Use the correct oil according to the Maintenance Schedule.3L Drive Belt Arrangement 42 . See Figure 30. OIL FILTER DRAIN PLUG ENGINE OIL DIPSTICK ENGINE OIL FILL Figure 29. DRIVE BELT GM 4. Apply clean oil to gasket of new filter. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 30. Turn filter until gasket touches. Drive Belt Inspection NOTE: ALL OIL FILL COMPONENTS LISTED IN LEGEND FOR GM4. 1.3L Engine Oil Change Figure 31. 4. Start the engine. Remove tar drain screw from regulator. 5. Warm engine to operating temperature. If fuel continues to flow check to make sure the LPG tank valve is completely closed. Allow tar to drain from regulator. LPG CONVERTER INLET LINE OUTLET HOSE MOUNTING BOLTS Figure 33.8000 SRM 1248 Legend for Figure 31 NOTE: GM 4. 3. 4. and disconnect the negative terminal on the battery. 1. 6. Close the valve on the LPG tank. and ensure no external ignition sources are present. Remove the mounting bolts and LPG converter from the mounting bracket. Move the lift truck to a well ventilated area. turn key or keyless switch to OFF position. 3. See Figure 33. Disconnect the inlet line and outlet hose from the LPG converter. 6. 5. See Figure 32. When tar has completely drained. 43 . GM LPG Regulator 1. 4. When the engine runs out of fuel. LPG Converter Removal DRAIN TAR FROM LPG CONVERTER NOTE: The following procedure is to be used on lift trucks equipped with a GM 4. To prevent the possibility of burns wear gloves and eye protection. 1.3L ENGINES HAVE SELF-ADJUSTING TENSIONERS. 2.3L LPG Engine with PSI installed. CAUTION A small amount of fuel may remain in the fuel line. Shut fuel valve off and run engine until the engine runs out of fuel and stops. 2. TAR DRAIN SCREW Figure 32. 2. DRAIN TAR FROM LPG REGULATOR 1. FAN PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY SERPENTINE BELT TENSIONER CENTERING PULLEY ALTERNATOR PULLEY Maintenance Procedures Every 250 Hours or 6 Months 1. 3. Raise the hood. 4. 3. install tar drain screw in regulator. 2. 4. CAUTION Engine components may be hot. contact your local Hyster dealer. See Figure 34. Check the hydraulic oil level when the oil is at operating temperature with the mast in a vertical position. Using compressed air. Direct air pressure away from filter element. If any leaks are found. connect the two cooling hoses. DO NOT permit the hot oil to touch the skin and cause a burn. the hydraulic oil will leak from the breather during operation. 10. the hydraulic oil is HOT. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. install the LPG converter on the mounting bracket. Add hydraulic oil only as needed. Make sure that the path of the compressed air is away from all personnel. remove any dirt and debris in the frame cavity around the breather. Start the engine and recheck for leaks at the converter. accurate when the oil temperature is 53 to 93°C (130 to 200°F). replace with a new breather element. 3. 2. The oil level indicated by the dipstick is most CAUTION Direct air pressure on the filter element can cause damage. unscrew and replace the breather if oil has accumulated in the cavity or on the 44 . Open the valve on the LPG tank and check for leaks on the LPG converter using soapy water or a leak detector. and the engine stopped. Wear protective goggles or a face shield to prevent injury to the eyes. See Figure 41 and Figure 42. Rotate the LPG converter sightly so that outlet opening is pointing toward the container and allow tar to drain from LPG converter. If the LPG converter cannot be rotated a sufficient amount to drain the tar. If hydraulic oil is above the FULL level. 7. Using mounting bolts. The operation of the hydraulic pump without oil will damage the pump.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 8. If disconnected. If it is damaged. tighten fittings or replace hose clamps as applicable. Connect the fuel line and outlet hose to the LPG converter. the carriage lowered. Use gloves when handling the LPG Converter to prevent the possibility of burns. Connect the negative terminal on the battery. Raise the hood and remove the right rear side panel See Figure 34. disconnect the two cooling hoses. The breather element is a non serviceable part. 9. Before using additives. CAUTION Drain the tar into a container and dispose in accordance with local environmental regulations. Never operate the hydraulic pump without oil in the hydraulic system. HYDRAULIC TANK BREATHER Inspect NOTE: When inspecting the breather. 12. 11. HYDRAULIC SYSTEM OIL WARNING At operating temperature. If necessary. do not remove it. CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. 1. Maintenance Procedures Every 500 Hours or 6 Months NOTE: Perform the 8-hour and 250-hour checks prior to performing the procedures in this section. CAUTION Additives may damage the hydraulic system. See Figure 34. See Figure 35. SIDE PANEL 3. DRAIN PLUG Figure 35. clean the terminals with a wire brush. Use the correct oil according to the Maintenance Schedule. Using a damp cloth clean the case of the battery. Connect the negative and positive cables to their respective terminals.3L ENGINE OIL AND OIL FILTER NOTE: Change the oil and oil filter for the engine at the first 100 hours of operation on new lift trucks. Install new filter. CUMMINS 4. 1. NOTE: BOTTOM LEFT HAND SIDE. or if dirt has accumulated at the breather passages at the bottom of the breather 4.5L Diesel (Shown) 45 . Apply clean oil to gasket of new filter. use water to flush the area. Change engine oil and engine oil filter. OIL FILTER 2. 1. Use a solution of sodium bicarbonate (soda) to make the acid neutral. WARNING Batteries generate explosive fumes. Turn filter until gasket touches. Hydraulic Tank Breather BATTERY WARNING The acid in the electrolyte can cause injury. Engine Oil Change Cummins 4. then tighten 1/2 to 3/4 turn with your hand. Install right rear side panel and close hood. DO NOT make sparks from the battery connections. Maintenance Procedures Every 500 Hours or 6 Months Disconnect the negative and positive terminals of the battery. If the electrolyte is spilled. Start engine.5L AND QSB 3. HYDRAULIC TANK BREATHER Figure 34. Check area around oil filter for leaks. Keep sparks or open flame away from the battery area.8000 SRM 1248 breather. Wear eye protection. If the terminals are corroded. HOOD/SEAT ASSEMBLY 2. Acid in the eyes must be flushed with water immediately. Disconnect the battery ground cable when doing maintenance. Keep the vents in the caps clean. Remove 1. 5. 7. 2. See Priming the Fuel System (Cummins 4.3L ENGINE CAUTION Disposal of lubricants and fluids must meet local environmental regulations. fill the filter element with diesel fuel. 9.5L AND QSB 3. FRONT VIEW 6. CUMMINS 4. See Figure 36. Stop engine and allow it to cool. 6. Remove and discard fuel filter element. Disconnect fuel filter sensor connector from the fuel filter element. 5. 4. Before installing the filter element.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 FUEL/WATER SEPARATOR FILTER REPLACEMENT. FUEL FILTER ELEMENT DRAIN VALVE LIFT PUMP FUEL PUMP IN-LINE FUEL FILTER B. 3. 4. Open the fuel supply valve.3L Engine). 3. 3. Connect air inlet elbow hose. Clean the fuel filter head mounting surface and apply a small amount of diesel fuel to the gasket on the new fuel filter element. CAUTION Drain the water/fuel into a container and dispose in accordance with local environmental regulations. Install 1. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. 2. See Figure 36 and Figure 37. This method will aid in bleeding the fuel system. Check for fuel leaks. CAUTION DO NOT overtighten the filter element.5L and QSB 3. Overtightening the filter element may distort the threads. 8. Connect the fuel sensor connector to fuel filter element 5. Drain until fuel filter element is empty. Open the drain valve by turning the valve counterclockwise approximately 3 1/2 turns until draining occurs. Legend for Figure 36 A. 8. Install the new fuel filter element until it contacts the fuel filter head mounting surface. Prime the fuel system. Disconnect air inlet elbow to access the fuel filter element. RIGHT SIDE VIEW 1. Tighten one additional turn. 2. 7. FUEL SUPPLY VALVE FUEL SENDING UNIT FUEL FILTER SENSOR CONNECTOR AIR INLET ELBOW FUEL LINE INJECTOR FITTINGS (4) 46 . 10. 4. 5L Engine Fuel System 47 .8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months Figure 36. Cummins 4. Clean the gasket surface. 19. 2. RIGHT VIEW B. 15. TURBO HEAD BELL HOUSING FLYWHEEL OIL PAN ENGINE BLOCK ELECTRONIC FUEL PUMP FUEL FILTER WATER OUTLET HOUSING WATER PUMP BELT WATER INLET HOUSING OIL FILL CAP WATERGATE AIR INLET HOUSING OIL DIPSTICK EXHAUST MANIFOLD EXHAUST OUTLET ENGINE ECM STARTER FUEL/WATER SEPARATOR PRIMER PUMP INTAKE MANIFOLD AIR INLET INJECTOR LINE FINAL FUEL FILTER REPLACEMENT (CUMMINS QSB 3. 2.3L Engine Fuel System 3. 21. 20. 6. 24.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 Legend for Figure 37 A. Figure 37. 17.3L ENGINE) CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Cummins QSB 3. 10. 12. 3. 48 . 22. 5. 7. 11. 9. TOP VIEW 1. 4. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. 4. Remove the fuel filter. Clean the area around the fuel filter head. 1. Close any OEM fuel valves (if applicable) to prevent fuel from draining. CAUTION Drain the fuel into a container and dispose in accordance with local environmental regulations. 16. 8. 18. 13. 23. 14. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically if the fuel filter element is changed and filled prior to installation. See Figure 36. CAUTION DO NOT pour fuel directly into the center of the filter. 6. turn the key to the ON position. Wait for the "Wait to Start" light to go out. Controlled venting is provided at the injection pump through the fuel drain manifold. 7. • The fuel filter is not filled prior to installation. Tighten filter until gasket contacts filter head surface. since this will allow unfiltered fuel to enter the system and may cause damage to fuel system components.8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months • The fuel injection pump is replaced. 6. with clean fuel prior to assembly. Crank the engine until fuel is expelled from the loosen fittings. 1. Install fuel filter. or lines are replaced. WARNING The pressure spray released by the fuel injectors can penetrate the skin and cause serious personal injury. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 4. 5. 5. • It is an initial engine start up after an extended period of no engine operation. 2. both pressure side and suction side. Tighten the injector line fittings while cranking.3L ENGINE) Controlled Venting CAUTION When using the starting motor to vent the system. The lack of blue or white smoke indicates the lack of fuel being supplied to the engine.3L). DO NOT engage it for more than 30 seconds. 49 . • The high pressure fuel line connections are loosened. If equipped with electronic fuel pump (Cummins QSB 3. The engine should fire. PRIMING THE FUEL SYSTEM (CUMMINS 4. or starter motor damage will occur. Start the truck. Operate the hand lever until fuel is expelled from the loosened fitting. 3. Pre-fill new filters. Manual Bleeding Manual Bleeding will be required if one of the following conditions exist.5L AND QSB 3. Crack open the fuel line to the injector pump. Crack open one of more of the injector lines located on the cylinder head. Lubricate the gasket with clean engine oil. 8. If the engine does not start after 3 attempts. Use the clean side block off plug packed with the filter. Wipe up any fuel that may have spilled and dispose of the fuel and rags in accordance with local directives. See Figure 36. Wait 2 minutes before engaging the starter again. Start engine and check for leaks around the fuel filter. Wear clothes and protective clothing. with the accelerator pedal or lever in the idle position. Tighten filter an additional 3/4 turn after contact. check fuel supply system. Tighten the fuel line to the injector pump to 9 N•m (80 lbf in). 5L Diesel Engine Drive Belt Arrangement 50 . NOT ACCEPTABLE CRACKS AND DAMAGE Figure 38. 4. 1. Drive Belt Inspection 1.3L Diesel Engine Drive Belt Arrangement Figure 39. Cummins QSB 3.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 Legend for Figure 39 NOTE: CUMMINS 4. A belt with cracks that run length of belt or a belt with missing pieces is not acceptable. ALTERNATOR PULLEY CAMSHAFT PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY TENSIONER CENTERING PULLEY DRIVE BELT Cummins 4. A few small cracks that run across belt are acceptable.5L and QSB 3. Cummins 4. 5. 4. 2.3L Diesel Engine Fan and Alternator Drive Belt Check drive belt for wear and damage.5L ENGINES HAVE SELF-ADJUSTING TENSIONERS. 2. ACCEPTABLE CRACKS 2. See Figure 38. ALTERNATOR BELT ADJUSTMENT BRACKET DRIVE BELT CAMSHAFT PULLEY CRANKSHAFT PULLEY ALTERNATOR PULLEY Figure 40. 3. 1. 5. See Figure 39 and Figure 40 for the drive belt arrangement. 3. and blow debris from core and fan shroud. the engine must be shut down for one minute or longer prior to checking the oil level. Clean with compressed air. HYDRAULIC OIL DIPSTICK 2.8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months CLEAN DEBRIS FROM RADIATOR CORE Check the radiator core for restrictions and remove material causing radiator core to be plugged or restricted. NOTE: Transmission oil temperature should be at least 50°C (120°F) when checking oil level. Make sure that the path of the compressed air is away from all personnel. TRANSMISSION OIL LEVEL WARNING At operating temperature. add oil to transmission at the dipstick tube at the correct level as indicated on the dipstick. If the transmission oil is low. adjusted to a maximum output of 103 kPa (15 psi). Use the correct oil as shown in the Maintenance Schedule. the transmission oil is HOT. Transmission and Hydraulic Oil Check 51 . If engine has been running. CAUTION DO NOT permit dirt to enter the transmission when the oil level is checked or the filter is changed. TRANSMISSION OIL DIPSTICK Figure 41. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. 1. Wear protective goggles or a face shield to prevent injury to the eyes. DO NOT permit the hot oil to touch the skin and cause a burn. See Figure 41 or Figure 42. NOTE: IRON TRANSMISSION HOUSING SHOWN. Remove the center body fill/level plug. HYDRAULIC OIL DIPSTICK 2. 52 . the center section oil is HOT. 90. If necessary. S80. 100. 3. 2. 110. S120FTPRS (G004) and Figure 44 for lift truck models H80. The Correct oil is shown in the Maintenance Schedule. 100. 1. Install center body oil/level fill level plug and tighten to 30 to 50 N•m (22 to 37 lbf ft). 120FT. TRANSMISSION OIL DIPSTICK Figure 42. 120FT (N005. Visually check oil level. add oil at the fill/level port until the oil/fill level port has overflowed. P005). See Figure 43 for lift truck models S80. DO NOT permit the hot oil to touch the skin and cause a burn. CAUTION DO NOT permit dirt to enter the center body when the oil level is checked. Dirt will contaminate the oil and cause damage to the center body of the axle. 1. 100.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN. 120FTBCS. Transmission and Hydraulic Oil Check WET BRAKE CENTER BODY OIL LEVEL CHECK WARNING At operating temperature. P005) 53 . CENTER SECTION DRAIN PLUG 4. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. FRONT VIEW SHOWN 1. FRONT VIEW SHOWN 1. S80. REAR VIEW SHOWN B. 120FT. CENTER SECTION DRAIN PLUG 5. PLANETARY CARRIER HOUSING (LH) 7. 100. CENTER SECTION FILL/LEVEL PLUG 5. CENTER SECTION FILL/LEVEL PLUG 4. 90. 100FTBCS. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models S80. 120FT (N005. CENTER SECTION Figure 43. S120FTS. 110. PLANETARY CARRIER HOUSING DRAIN PLUGS 3.8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months A. REAR VIEW SHOWN B. 100. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models H80. PLANETARY CARRIER HOUSING (RH) 6. S120FTPRS (G004) A. CENTER SECTION Figure 44. UPPER LOAD ROLLERS B. weld. LUBRICATE LOAD ROLLER SURFACES 3. Now measure thickness at heel of fork (see Figure 20). and tilt the mast fully back. Place blocks under the outer mast channels to within 13 mm (0. BLOCK 2. LUBRICATE STRIP BEARING SURFACES 2. Tilt the mast fully forward. Blocking the Mast 54 . the load must be removed from the normal A. Lubricate the mast pivot bushings at grease fittings on outer mast. See Figure 47 and Figure 48. FORKS WARNING Never repair damaged forks.) of the channels See Figure 46. MAST Figure 46. Replace damaged forks as a complete set. Mast Lubrication NOTE: When lubricating the mast mounting/pivot pins.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 contact surface to allow grease to properly lubricate the normal contact surfaces of the mast bushings 2. 4. A. Measure thickness of forks with a fork arm caliper (Hyster Part No. 3. Raise the carriage about 61 cm (2 ft). LOAD ROLLER Figure 45. 1. MAST TILTED FULLY BACK B. replace fork. or bend the forks. See Figure 46. see Safety Procedures When Working Near Mast in this section. MAST LUBRICATION WARNING When working on or near the mast. Lubricate sliding surfaces and load roller surfaces along full length of channels as shown in Figure 45. LOWER LOAD ROLLERS 1. NOTE: The load rollers and sheaves have sealed bearings and do not need additional lubrication. Forks are made of special steel using special methods. 3020387) at a vertical section where there is no wear. Use multipurpose grease shown in the Maintenance Schedule. MAST TILTED FORWARD 1. If the thickness of the heel is not greater than 90% of dimension X. DO NOT heat. This thickness is dimension X.5 in. 8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months 1. Mast Mounting Hanger Lubrication 5. If a sideshift carriage is installed. 8. 10. 11. MAST HANGER BUSHINGS LUBE FITTINGS MAST BUSHING PLUGS TILT PIN ROD END ANCHOR PIN 7. 55 . Tilt mast fully back. 6. lubricate sliding surfaces at grease fittings with multipurpose grease shown in the Maintenance Schedule. 2. 9. 12. 4. CAPSCREW NUT WASHER ROD END BUSHING TILT CYLINDER ASSEMBLY MAST MOUNTING CAP Figure 47. 3. See Figure 49. Remove the blocks from under the channels 6. 5. OUTER MAST 2. crushed. kinked. proper hose tensioning. 9. Integral Sideshift Carriage 56 . See Mast Repairs. LUBRICATION FITTING Legend for Figure 49 CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS 5. 8. 6. MAST PIVOT BUSHING Figure 48. Pivot Pin Lubrication 3.and 3-Stage Masts 4000 SRM 1250 for quick disconnect procedures. 4. 3. stiff or charred hose. hard. 2. UPPER BEARING STRIPS 1. 12. GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHING SEAL FIXED FRAME HEADER HOSE CHECKS Daily inspection plus. 2. flattened or twisted hose. 11. 7. 10. Figure 49. hose fitting slippage. Adjust/repair/replace hose/components as necessary.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 1. ANCHOR PIN 4. both lift chains must be replaced. Use multipurpose grease shown in the Maintenance Schedule. DO NOT USE STEAM TO CLEAN THE LIFT CHAINS. The best procedure is to remove the chains from the lift truck and soak them in engine oil. There are four lubrication fittings. CAPSCREW 2. TILT SPACER Figure 50. NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months Lubricate lift chains with SAE 30 engine oil. NOTE: The 500 Hour/6 Months Lift Chain Lubrication should not be performed in combination with the 1000 Hour/6 Months Lift Chain Lubrication. TILT CYLINDER LUBRICATION NOTE: The floor plate must be removed in order to lubricate the rear tilt cylinder lubrication fittings. LUBRICATION FITTING 5. Tilt Cylinder Lubrication 57 . If a lift chain is worn or damaged. Lubricate the tilt cylinder ends. 1. DO NOT repair worn or damaged lift chains. RETAINER 3. See Figure 50. see Safety Procedures When Working Near Mast in this section. LIFT CHAIN LUBRICATION WARNING When working on or near the mast. Be sure to clean any dirt or grease from chains before lubricating. 3. BUSHINGS ROD END PIN HYDRAULIC LEVERS LOCKING RING (COTTER PIN) Figure 52. Use engine oil shown in the Maintenance Schedule. See Figure 51. 1. 4. Use spray lubricant as listed in the Maintenance Schedule. MANUAL HYDRAULIC LEVERS LUBRICATION Lubricate the bushings for the manual hydraulic levers. See Figure 52. 2. Manual Hydraulic Levers Lubrication 58 . Master Brake Cylinder Rod End Pin Lubrication NOTE: FOUR FUNCTION LEVERS WITH DETENT SHOWN. 1.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 MASTER BRAKE CYLINDER ROD END PIN LUBRICATION Lubricate the master brake cylinder rod end pin. ROD END PIN 2. COTTER PIN (LOCKING) Figure 51. S80. 100FTBCS. 3. S120FTPRS (G004) Figure 53. LUBRICATION FITTING (TIE ROD) 3. 1. 10. S120FTPRS (G004) Lubricate the tie rods. 120FT. 9.8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months Legend for Figure 53 1. 5. 100FTBCS. Ensure that the sealed reservoir lid is properly replaced. only use Dexron III oil from sealed container to prevent possible damage to the brake system. Replace the brake oil in the system if there is dirt or water in the system. LUBRICATION FITTING (SPINDLE) Figure 54. See Figure 53. Remove the dash board from the cowl. The brake oil reservoir is located on the cowl. Brake Oil Reservoir 59 . 11. Use the brake fluid shown in the Maintenance Schedule. Tie Rod Lubrication for Lift Truck Models S80. 100. DO NOT allow water entry. 8. 12. as necessary. STEERING AXLE 2. RESERVOIR CAP BRAKE OIL RESERVOIR RESERVOIR MOUNTING BRACKET COWL UPPER BRAKE OIL SUPPLY HOSE CYLINDRICAL BLOCK OUTLET FITTING LOWER BRAKE OIL SUPPLY HOSE NIPPLE MASTER CYLINDER CYLINDRICAL BLOCK DRAIN PLUG CYLINDRICAL BLOCK CYLINDRICAL BLOCK MOUNTING BRACKET CAPSCREW BRAKE OIL WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. CAUTION DO NOT use "DOT" fluid. There is one lubrication fittings on each tie rod. TIE ROD LUBRICATION FOR LIFT TRUCK MODELS S80. 7. 100. S120FTS. Use multipurpose grease shown in the Maintenance Schedule. 6. 4. S80. See Figure 54. S120FTS. at the master cylinder. Add brake oil. 120FT. 2. If oil is low. Install fill plug and check for leaks. DRIVE AXLE 2. 110.40 in. DRAIN PLUG Figure 56. LUBRICATION FITTING (TIE ROD) 2. See Figure 56 and Figure 57.Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248 TIE ROD LUBRICATION FOR LIFT TRUCK MODELS H80. S120FTPRS (G004) 1. DRAIN PLUG 3. P005) DIFFERENTIAL AND DRIVE AXLE OIL. 120FT. The fill hole for checking the oil level is on the front of the differential housing. 120FT (N005. P005) 60 . S120FTS.40 in. 90. 120FT (N005.) below the bottom edge of fill hole. There is one lubrication fittings on each tie rod. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models S80. P005) Lubricate the tie rods. 120FT (N005. 100. STEERING AXLE Figure 55. 100. Remove fill plug and check fluid level by sticking a finger into the fill hole to feel if the fluid level is at the bottom edge of the fill hole. The oil level must be between 0 to 10 mm (0 to 0. LUBRICATION FITTING (SPINDLE) 3. See Figure 55.) below the bottom edge of fill hole. 100FTBCS. add oil shown in the Maintenance Schedule until the oil level is between 0 to 10 mm (0 to 0. 90. 100. 100. CHECK/FILL PLUG 3. Use multipurpose grease shown in the Maintenance Schedule. 1. CHECK/FILL PLUG 2. 1. S80. 110. LIFT TRUCK MODELS WITH DRY BRAKES The differential and drive axle use the same oil supply. DRIVE AXLE Figure 57. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models H80. 110. 90. Tie Rod Lubrication for Lift Truck Models H80. 5 mm (0. Install the new fuel filter and fuel filter O-ring. 3. 2. VALVE CLEARANCE. Disconnect negative battery cable.3L gasoline and LPG engines have an electronic control unit (ECU) that controls the ignition timing. Close fuel valve on tank. 5. Remove fuel filter and fuel filter O-ring. 4. Remove and discard housing O-ring. and 500-hour checks prior to performing the procedures in this section. Additional engine information is available in the following sections: • GM Engines. 2.3L engine has hydraulic valve lifters and does not require valve clearance adjustments during normal service. Discard seal washer. 250-hour. CHECK AND ADJUST The GM 4. DO NOT permit any sparks or open flames in the work area. The correct spark plug gap is 1. See the Maintenance Schedule for valve clearances. 3.3L Engine The GM 4. Use gloves to prevent burns and wear eye protection. GM 4.3 Liter V-6 600 SRM 1251 IGNITION SYSTEM GM 4. Run engine until it stops. check to make sure the manual valve is fully closed. 4. 6. Install bolt and new seal washer. Install top section of fuel filter housing. BOLT SEAL WASHER FUEL FILTER HOUSING TOP SECTION FUEL FILTER FUEL FILTER O-RING HOUSING O-RING FUEL FILTER HOUSING BOTTOM SECTION Figure 58.). Tighten bolt to 13 N•m (115 lbf in). 3. Install 1.059 in. 61 . Remove top section of fuel filter housing. Clean and inspect the fuel filter housing for contamination or damage. WARNING A small amount of fuel may still be present in the fuel line. See Figure 58. 6. 1. 2. 5. 4. Install new housing O-ring. If liquid fuel continues to flow from the connections when loosened.8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months Maintenance Procedures Every 1000 Hours or 6 Months NOTE: Perform the 8-hour. Change the spark plugs every 1000 hours. There are no adjustments. See Figure 58. Fuel Filter Removal and Installation 4. Remove the bolt and seal washer retaining the top section of the fuel filter housing. 1. 5. LPG FUEL FILTER ELEMENT REPLACE. 7.3L ENGINE Remove WARNING LPG can cause an explosion. This will reset the excess fuel valve. Loosen clamps and disconnect two fuel lines from the inline fuel filter.Maintenance Procedures Every 1000 Hours or 6 Months NOTE: Opening the fuel valve too quickly can cause the internal excessive flow valve to close. 8. Slowly open the fuel valve on tank. 4. Close fuel supply valve located on the fuel sending unit. FUEL SUPPLY VALVE FUEL SENDING UNIT FUEL FILTER SENSOR CONNECTOR AIR INLET ELBOW FUEL LINE INJECTOR FITTINGS (4) 62 . 2. 7. Remove and discard the inline fuel filter IN-LINE FILTER REPLACEMENT. 3. Install inline fuel filter by connecting the two fuel lines and tighten clamps. and then slowly open the fuel valve again. 8000 SRM 1248 Remove 1. Turn the key to the ON position and back to the OFF position to pressurize the fuel system. CUMMINS 4. If this happens. Stop Engine and allow it to cool. restricting the flow of fuel. Check for leaks. 2. Legend for Figure 59 A. 10. If leaks are detected. 8. 9. See Figure 59. FRONT VIEW 6.5L ENGINE CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. 5. Check for fuel leaks. 3. 7. FUEL FILTER ELEMENT DRAIN VALVE LIFT PUMP FUEL PUMP INLINE FUEL FILTER B. close the fuel valve. wait a few seconds. 3. Check for leaks at connections by using soapy solution or electronic leak detector. 2. Install 1. make proper repairs. See Figure 59. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. RIGHT SIDE VIEW 1. Open the fuel supply valve. CAUTION Drain the fuel into a container and dispose in accordance with local environmental regulations. Cummins 4.8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months Figure 59.5L Engine Fuel System 63 . ) mm in. INTEGRAL SIDESHIFT CARRIAGE. Lift Chains Check 1. 2. 10.1 mm (0.0 (15. GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHING SEAL FIXED FRAME LIFT CHAIN LUBRICATION WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation.4 523. Integral Sideshift Carriage 64 .0 508. CHECK SLIDING SURFACES 1. Remove the lift chains. Remove the chains from the oil.) 15. Using a chain scale. When using Figure 61. Hang the chains for one hour so excess oil will drain from the chains. Use compressed air.75 in.5 381. Hyster P/N 871796 check lift chains as shown in Figure 60. CHAIN WEAR SCALE Figure 60.) mm in. Measure chain for wear where it moves over sheaves.) 19.) mm in.9 392.0 (12. and if necessary lubricate sliding surface at the grease fittings with multipurpose grease shown in the Maintenance Schedule.) 25.6 mm in.) 12.6 (10. 9. 7.) 1. Make sure that the path of the compressed air is away from all personnel. Compressed air can move particles so they cause injury to the user or to other personnel. CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS 5. adjusted to a maximum output of 103 kPa (15 psi). 12. 3.00 in. Pitch Total Length of 20 Links (Pitch) of New Chain 254. to completely dry the chains when they are clean.63 in. Wear protective goggles or a face shield to prevent injury to the eyes. 8.Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248 cleaning solvents.) mm in.0 (10.4 mm (1. 11.3 (20.) Wear Limit (The Maximum Length of 20 Links) 261.9 mm (0. 4.0 317. See Figure 61.) mm in. always follow the recommendations of the manufacturer. Clean the lift chains by soaking them in a solvent that has a petroleum base for at least 30 minutes.5 (12. the chain is worn and must be replaced.7 mm (0.4 (15.3 327. LIFT CHAINS WEAR CHECK If a section of chain is 3% longer than a similar section of new chain. UPPER BEARING STRIPS 6.0 (20. Check the sideshift carriage sliding surfaces.0 mm in. Lubricate the lift chains by soaking them in 30W engine oil for at least 30 minutes.) mm in.50 in. 100. 1. 100FTBCS. There are four lubrication fittings. STEERING AXLE 2. LUBRICATION FITTING (TIE ROD) 3. 110. S120FTPRS (G004) Lubricate the spindle bearings on the steering axle. See Figure 63. 100FTBCS. S80. 120FT (N005. There are four lubrication fittings. 100. Use multipurpose grease as shown in the Maintenance Schedule. two on each side of the steering axle. 90. Lubricate Spindle Bearings for Lift Truck Models H80. LUBRICATION FITTING (SPINDLE BEARINGS) Figure 62. 120FT. 100. 90. LUBRICATION FITTING (TIE ROD) 2. two on each side of the steering axle. Lubricate Spindle Bearings for Lift Truck Models S80. P005) 65 .8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months STEERING AXLE (SPINDLE BEARINGS) FOR LIFT TRUCK MODELS S80. 100. 120FT (N005. S120FTS. P005) Lubricate the spindle bearings on the steering axle. STEERING AXLE (SPINDLE BEARINGS) FOR LIFT TRUCK MODELS H80. S80. STEERING AXLE Figure 63. Use multipurpose grease as shown in the Maintenance Schedule. S120FTPRS (G004) 1. See Figure 62. LUBRICATION FITTING (SPINDLE BEARINGS) 3. 110. 120FT. S120FTS. Put lift truck on a level surface and lower the carriage. cracking. INSPECT ENGINE ELECTRICAL SYSTEM. Add oil. Unscrew and remove filter lid. Inspect gasket for damage. 328388. and spring from head. pinching. see Hydraulic Oil. Tighten connections at both ends. If damaged.8 lbf in). Lubricate new O-ring with hydraulic oil and install it on the bottom of the new filter element. if necessary. See Figure 64. and oil pressure lights for operation by starting the engine and checking that the light illuminates before turning out. To change the hydraulic oil. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Replace if necessary. CONNECTORS When inspecting the electrical system. • Check the MIL. Start the truck. Ensure that connections are tight. 500-hour. Use hydraulic oil shown in the Maintenance Schedule. hood. • Check that all electrical components are securely mounted and retained to the engine or chassis. 4. 66 . Lubricate gasket with hydraulic oil and seat it on filter lid and install spring and lid onto head. Cover the head to prevent any foreign materials from getting into the hydraulic tank. Before using additives. Dirt can cause damage to the components of the hydraulic system. pedal shafts. parking brake). Replace. • Check ignition coil wire and spark plug wires for hardening. CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. the hydraulic oil is HOT. • Check battery for damage or cracks to the case. DO NOT permit the hot oil to touch the skin and cause a burn. Remove the hydraulic filter element and O-ring from the bowl and place into the container. Tighten lid to 15 N•m (132. and allow it to run for 30 seconds. Use a silicone spray lubricant. Install the new filter element into the bowl. 1. 2. Check for leaks. split boot covers. Check to ensure connectors are fitted and locked by pushing the connectors together. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. control cables (throttle. CAUTION Additives may damage the hydraulic system.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 • Check engine wire harness for rubbing. Replace WARNING At operating temperature. replace. • Check positive and negative cables for corrosion. and cracks or breaks in the wiring. Pull on the connector halves to make sure they are locked. Maintenance Procedures Every 2000 Hours or Annually NOTE: Perform the 8-hour. Replace spark plugs at the recommended interval as shown in the Maintenance Schedule. HYDRAULIC SYSTEM Hydraulic Filter. NOTE: Have container large enough to hold the filter element and allow for final hydraulic oil draining. separation. 6. Hyster Part No. chaffing. rubbing. CONTROL LEVERS AND PEDALS Lubricate linkages. Lift the hydraulic filter element enough to allow the hydraulic oil to drain. and 1000-hour checks prior to performing the procedures in this section. 250-hour. 5. and chaffing. arching. check the following: • Check and clean battery connection. gasket. and proper fit. • Check engine harness connectors. chaffing. Stop engine and check hydraulic oil level. charging. 3. and seat rails. contact your local Hyster dealer. and Rotor Disassemble. Replace 1. and replace with new hydraulic tank breather. Install right rear side panel and close hood. SIDE PANEL 3. See Figure 65. AND SPARK PLUG WIRES NOTE: Make sure the key is in the OFF position and the negative battery cable has been removed from the battery before removing the ignition system. distributor cap. FITTING QUAD RING FILTER ELEMENT BOWL Figure 64. coil wire.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually 2. 1. 1. See Figure 65. 3. Hydraulic Filter Hydraulic Tank Breather. ROTOR. HYDRAULIC TANK BREATHER Figure 65. Ignition Coil Wire Removal. Hydraulic Tank Breather IGNITION SYSTEM. and rotor.7L LPG EPA Compliant Engine 2200 SRM 1097 for Spark Plug Wire Removal/Installation. Distributor Cap Removal/Installation. DISTRIBUTOR CAP. 9. LID SPRING O-RING CAPSCREW HEAD 6. 2. For procedures see High Voltage Switch (HVS) Ignition. Unscrew and remove old hydraulic tank breather. 7. 5. 8. spark plugs. 67 . GM 4. and Spark Plug Replacement. Remove and discard spark plug wire assembly. HOOD/SEAT ASSEMBLY 2. Raise the hood and remove the right rear side panel.3L EPA Compliant Engines and GM 5. 3. 4. 2. the pressure is released from the system. as needed. Close drain valve. gently move the end back and forth to help break the seal. Connect the hose back on the fitting at the top of the radiator. Fill the auxiliary reservoir to a level between the ADD and FULL marks on the reservoir. WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed. Before using additives. Replace with new hoses. and drain the reservoir into the same container used for the radiator coolant. Stop engine.9 qt) under the radiator drain valve which could be located on either the lower left or right side of the radiator on the engine side of the radiator.3L AND CUMMINS 4. CAUTION Additives may damage the cooling system. Shut off the engine. Open drain valve and remove radiator cap. To assist removal.5L AND QSB 3. Fill cooling system with a solution of ethylene glycol boron-free antifreeze. Check the reservoir for contaminants and flush. the steam and boiling coolant can cause burns. COOLING SYSTEM. Unlatch and remove the cover. Start engine. 3. An air filter element replacement is required when one of the following occurs: • The optional air flow restriction indicator light on the dash illuminates • The optional manual air flow indicator button pops up • The specified number of hours has passed since the last filter element replacement CAUTION Disposal of lubricants and fluids must meet local environmental regulations.1 liter (15. Flush cooling system. 5. Never open the air filter canister or remove the filter element with the engine running. contact your local Hyster dealer. 1. See Figure 66. Place a container with a minimum capacity of 15. Drain coolant into the container. Check hoses for damage. Put lift truck on a level surface. A small amount of dirt could cause engine damage.3L ENGINES 1. CAUTION DO NOT to allow dirt to enter the engine air intake when replacing the air filter element. as necessary. Check for leaks. See Maintenance Schedule for correct solution.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 4. 68 . AIR FILTER The air filter canister should not be opened until an air filter element replacement is required. If the system is hot. Coolant level should be between the ADD and FULL marks on the reservoir. 2. DO NOT remove the cover for the radiator when the engine is running. GM 4. Add coolant to auxiliary coolant reservoir as needed. To remove filter element. Install radiator cap. press and rotate filter element counterclockwise about 1/8 turn until the filter element is free. Disconnect the hose leading from the auxiliary reservoir to fitting at the top of the radiator under the radiator cap. It will fit snugly into and be centered in the canister. 4. Always use a Hyster-approved filter element. 6. TWIST TO LOCK Figure 67. replace the liner and O-ring assembly. FILTER ELEMENT 5. Make sure the liner assembly is properly seated in the canister. replace the secondary element with every 2 to 3 primary element replacements. NOTE: Proper element installation is required to allow the cover to be installed correctly. Install the new filter element into the canister. LINER ASSEMBLY 4. An improperly installed element may allow dirt and dust to enter and damage the engine. Gently pull the filter element from the canister. Press and rotate the filter element 1/8 turn clockwise until fully engaged in the canister. Air Filter 3. tears or indentations in the urethane-sealing surfaces. Clean well around the locking tabs that retain the element. 7. COVER Figure 66. Never reinstall a used element. CANISTER 2. See Figure 67. Install the liner assembly into the canister by pushing in. clean the inside surface of the canister. Remove the liner assembly to make cleaning easier. If your air filter assembly is equipped with a secondary element in place of the liner assembly. soft rag. Inspect the new filter element for voids. Be careful not to knock any contaminants into the outlet tube to the engine. If damaged. PUSH IN 2. 1.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually 1. With a clean. Air Filter Label 69 . Inspect the liner and O-ring assembly for damage. 5. Avoid dislodging contaminants from the element or knocking it against the canister. DUST EVACUATION VALVE 3. 8. CAUTION The element must be properly installed to ensure adequate engine protection. Do not use if damage is detected. cuts. Clean tabs make new filter element installation easier. Never install a damaged element. 120FT) (N005. OXYGEN SENSOR (PRE-CATALYTIC) Figure 69. Install the cover into the canister and ensure the INLET arrow is in line with the canister inlet.3L LPG ENGINES EQUIPPED WITH GFI INSTALLED Check that the oxygen sensor electrical connector is seated and locked. To do so will result in damage to the filter element.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 CAUTION During cover installation. cover. Make sure the latches penetrate the slots in both the canister and the cover. OXYGEN SENSOR (POST-CATALYTIC) 2. Inspect all hoses for damage. Do not use a cover that is bent. 100FTBCS (G004) 70 . 120FT. Oxygen Sensor (BCS Only) for Lift Truck Models S80. 1. 90. and possibly the canister. Inspect the dust evacuation valve for damage. DO NOT force the cover on the canister. Replace damaged hoses. EXHAUST PIPES TO EXHAUST MANIFOLD Figure 68. ELECTRICAL CONNECTOR 3. the filter element is not installed properly. 11. 10. replace the dust evacuation valve. repair.. If damaged. the cover will fit easily into the canister with no gap between the cover and the canister. chaffing. S120FTS. MUFFLER 3. 100FTBCS. Oxygen Sensor Location for Lift Truck Models H80. 1. OXYGEN SENSOR 2. Inspect the entire air intake system for leaks. Check wires for cracks. P005) and S80. damaged. or burn through. or missing latches. 100. Inspect all clamps for tightness and tighten if necessary. 110. If the cover does not fit easily. S80. S120FTPRS (G004) OXYGEN SENSOR GM 4. 100. See Figure 68 and Figure 69. the element is not installed correctly. NOTE: If the filter element is properly installed. If necessary. splits. NOTE: Do not use the latches to pull the cover down against the canister. 9. If the cover does not fit completely against the canister with no gaps. Fasten the latches to secure the cover to the canister. Fuel Filter Replacement (GM 4.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually LPG REGULATOR FUEL FILTER.3L ENGINES EQUIPPED WITH GFI INSTALLED Remove 1. Run engine until it stops. 9. Install new O-ring on the inlet fitting. Remove the inlet fitting from the LPG regulator. foam filter. install the outlet fitting on the LPG regulator. Remove and discard the screen from the LPG regulator. Install inlet fitting into the LPG regulator and connect hose to the inlet fitting. Install 1. 1. 5. 2. 2. LPG REGULATOR INLET FITTING O-RING PLASTIC CAP FOAM FILTER 6. Raise the hood and disconnect the negative terminal of the battery.3L) 71 . Install a new screen in the LPG regulator. 8. paper filter. GM 4. 4. 3. 3. Install the new fuel filter and tighten the clamp screws to 2. See Figure 71. Remove three screws and the outlet fitting from the LPG regulator. 6. See Figure 70. Using three screws. Install new rubber washer. Disconnect the hose from the inlet fitting. 5. Discard the O-ring. 2. and plastic cap in the LPG regulator. Disconnect the hose from the outlet fitting. 4. Discard the O-ring. 7. 5. foam filter. Connect the negative terminal of the battery and close the hood. 3. Open shutoff valve on LPG tank and check for leaks. Install a new O-ring on the outlet fitting. GASOLINE FUEL FILTER Remove and Replace 1.45 to 2. 10. 4. paper filter. Figure 71.77 N•m (22 to 25 lbf in). PAPER FILTER RUBBER WASHER SCREWS OUTLET FITTING SCREEN Figure 70. 2. Remove and discard the fuel filter. Remove and discard the plastic cap. and rubber washer from the LPG regulator. GM LPG Regulator 4. 3. Close shutoff valve on tank. This will reduce the oil that will run out of the filter and onto the transmission when the filter is removed.3L ENGINE For removal and cleaning instructions for lift truck models H80. 6. 4. 1. FUEL INJECTOR.Maintenance Procedures Every 2000 Hours or Annually Legend for Figure 71 1. cut. 100. FORKS WARNING Never repair damaged forks. Before removing the oil filter. see the section LPG Fuel System. DO NOT permit the hot oil to touch the skin and cause a burn. 72 . TRANSMISSION OIL AND FILTER (DRY BRAKE). Remove drain plug. FUEL PUMP/SENDER UNIT 8000 SRM 1248 CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Forks are made of special steel using special methods. 3. 1. GM 4. NOTE: ALL MAJOR COMPONENTS AND FRAME COMPONENTS REMOVED FOR THE SAKE OF CLARITY. weld. GM 4. Drain oil into a container. make a hole at the top of the filter and allow five minutes for the oil to drain down into the transmission. LPG FUEL INJECTOR.3L Engine with GFI 900 SRM 1242. 5. contact your local Hyster dealer or see Hyster Hypass Online. spring. FUEL FILTER 2.3L Engine 900 SRM 1244. GM ENGINES For removal and cleaning instructions. Dirt can cause damage to the transmission components. Transmission Oil Change CAUTION DO NOT permit dirt to enter the transmission when the oil level is checked or the filter is changed. and screen. GASOLINE FUEL INJECTOR. the transmission oil is HOT. NOTE: The drain plug for the transmission is on the lower right side of the cover of the transmission. Check heel and attachment points of forks with a penetrant or by magnetic particle inspection. 90. P005) equipped with the Cummins 4. NOTE: Change the transmission oil filter at the first 500 hours of operation on new lift trucks. or bend the forks. CUMMINS 4.3L diesel engine. 7. REPLACE WARNING At operating temperature. toward the rear of the lift truck. Replace damaged forks as a set. 110. GM 4. 120FT) (N005. see the section Gasoline Fuel System.5L AND QSB 3. DO NOT heat.3L ENGINES EQUIPPED WITH GFI INSTALLED For removal and cleaning instructions.5L or QSB 3. See Figure 72. drill. TRANSMISSION TRANSMISSION DRAIN PLUG SPRING SCREEN TRANSMISSION OIL FILTER TRANSMISSION DIPSTICK TRANSMISSION BREATHER Figure 72. 2. Wear protective goggles or a face shield to prevent injury to the eyes. NOTE: Transmission oil temperature should be at least 50°C (120°F) when checking oil level. then spring. Add oil to transmission at the dipstick tube. With the truck in the ON position. 2. 4. Make sure the path of the compressed air is away from all personnel. 1. NOTE: Transmission oil temperature should be at least 50°C (120°F) when checking oil level. 8. Before removing the oil filter. Compressed air can move particles so they cause injury to the user or to other personnel. Apply clean oil to gasket of new filter. CAUTION DO NOT permit dirt to enter the transmission or wet brake planetary carrier housing when the oil level is checked or the filter is changed. NOTE: Change the transmission oil filter at the first 500 hours of operation on new lift trucks. See Maintenance Schedule to add additional oil at the transmission dipstick tube that will need to be added to properly fill the wet brake portion of the drive axle center section and transmission. If necessary. make a hole at the top of the filter and allow five minutes for the oil to drain down into the transmission. Install new transmission breather and hand tighten. Remove and discard old oil filter. spring. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. the oil must be drained and replaced with new oil. Remove drain plug. Install new filter and hand tighten. 7. 5. 6. and dry with compressed air. the transmission and wet brake planetary carrier housing oil is HOT. When oil has drained. Dirt will contaminate the oil and cause damage to the transmission and wet brake planetary carrier housing components. and screen. Turn the key to the OFF position and check for leaks and check oil level. reinstall drain plug. The correct oil is shown in the Maintenance Schedule. adjusted to a maximum output of 103 kPa (15 psi). See Figure 73. 73 . If either the wet brake planetary carrier housings and/or transmission oil becomes contaminated. TRANSMISSION AND WET BRAKE PLANETARY CARRIER HOUSING OIL CHANGE WARNING The oil used for the wet brake drive axle or transmission should not be contaminated. once oil is completely drained. toward the rear of the lift truck. DO NOT permit the hot oil to touch the skin and cause a burn. Start and run the engine for approximately 5 minutes after fill to allow oil to lubricate parts within the transmission and wet brake portion of the drive axle center section. always follow the solvent manufacturer’s recommended safety procedures. Remove and discard transmission breather. 3. This will reduce the oil that will run out of the filter and onto the transmission when the filter is removed. Drain oil into a container. See Figure 73. and drain plug. first install screen. When using cleaning solvents.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. The drain plug for the transmission is on the lower right side of the cover of the transmission. Clean screen with cleaning solvent. WARNING At operating temperature. top off oil. 120FT (N005. and dry with compressed air. 110. P005) see Figure 75. then spring. first install screen. 3. For lift truck models S80. 100FTBCS. PLANETARY CARRIER HOUSING (RH) 6. 3. 4. S120FTS. 120FT. 120FT. Drain oil into a suitable container. always follow the solvent manufacturer’s recommended safety procedures. CENTER BODY Figure 74. When oil is completely drained. 74 . PLANETARY CARRIER HOUSING (LH) 7. 90. S80. Tighten to 30 to 50 N•m (22 to 37 lbf ft). CENTER BODY DRAIN PLUG 4. Remove planetary carrier housing drain plug and fill/level plug. S120FTS. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models S80. A. For lift truck models H80. 4. 2. S120FTPRS (G004) WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. 1. S80. 5.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 Make sure the path of the compressed air is away from all personnel. When using cleaning solvents. CENTER BODY FILL/LEVEL PLUG 5. 6. Wear protective goggles or a face shield to prevent injury to the eyes. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. S120FTPRS (G004) see Figure 74. NOTE: ALL MAJOR COMPONENTS AND FRAME COMPONENTS REMOVED FOR CLARITY. Compressed air can move particles so they cause injury to the user or to other personnel. and drain plug. Clean screen with cleaning solvent. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. 7. 100. adjusted to a maximum output of 103 kPa (15 psi). When oil has drained. TRANSMISSION TRANSMISSION SPRING SCREEN TRANSMISSION TRANSMISSION TRANSMISSION DRAIN PLUG OIL FILTER DIPSTICK BREATHER Figure 73. FRONT VIEW SHOWN 1. reinstall drain plug and fill/level plug. 100FTBCS. 100. REAR VIEW SHOWN B. 100. Transmission Oil Change 2. S80. S120FTPRS (G004) see Figure 74. Start and run the engine for approximately 5 minutes after fill to allow oil to lubricate parts within the transmission and wet brake planetary carrier housings. S120FTS. The correct oil is shown in the Maintenance Schedule. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models H80. 7. FRONT VIEW SHOWN 1. 110. CAUTION Before adding oil. Add oil at the fill/level port for the center body until the oil/fill level port has overflowed. P005) see Figure 75. For lift truck models S80. 120FT (N005. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. S120FTPRS 75 . NOTE: Transmission oil temperature should be at least 50°C (120°F) when checking oil level. and wait until oil has drained completely. Removing the fill/level plug will allow the oil to drain at a faster rate. 100. PLANETARY CARRIER HOUSING (LH) 7. Turn the key to the OFF position and check for leaks and check oil level. S120FTS. P005). Install new filter and hand tighten. 3. 120FT (N005. Add oil to transmission at the dipstick tube. P005) see Figure 75. 90.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually 8. 2. 6. CENTER BODY DRAIN PLUG 5. 90. P005) 5. 100FTBCS. WET BRAKE CENTER SECTION OIL CHANGE Remove 1. Apply clean oil to gasket of new filter. Install new transmission breather and hand tighten. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. 9. 100. S120FTS. S80. Remove the center body drain plug. CENTER BODY FILL/LEVEL PLUG 4. See Maintenance Schedule to add additional oil at the transmission dipstick tube that will need to be added to properly fill the planetary carrier housings and transmission. 100FTBCS. 120FT. Remove and discard transmission breather. 110. 100. 110. 120FT. 100. 120FT. S80. S80. Install drain plug for the center body. Remove and discard old oil filter. For lift truck models H80. 100. see Figure 75. With the truck in the ON position. 90. For lift truck models H80. The correct oil is shown in the Maintenance Schedule or Figure 76. see Figure 74. 2. For lift truck models S80. For lift truck models H80. For lift truck models S80. S120FTS. 100. CENTER BODY Figure 75. 120FT (N005. 110. PLANETARY CARRIER HOUSING (RH) 6. Place and empty container under the center body drain plug. 90. Install 1. A. REAR VIEW SHOWN B. 100FTBCS. ensure the truck is parked and on level ground. 120FT (N005. S120FTPRS (G004). 120FT. S120FTPRS (G004) see Figure 74. 100. Tighten to 30 to 50 N•m (22 to 37 lbf ft). For lift truck models S80. 100FTBCS. 100. Remove the center body fill/level plug. 110. WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. Install the cylindrical block drain plug. Ensure that the sealed reservoir lid is properly replaced. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Install the reservoir into the bracket located on the cowl. 76 . Tighten to 30 to 50 N•m (22 to 37 lbf ft). 4.USE JDM J20C C. only use Dexron III oil from a sealed container to prevent possible damage to the brake system. A. LEFT PLANETARY CARRIER HOUSING . CAUTION DO NOT use "DOT" fluid. CHANGE 1. Pour the oil into a suitable container with a 0. CENTER BODY Figure 76. See Figure 77. Remove the dashboard from the cowl. Refill the reservoir with clean oil from a sealed container and install the cover on the reservoir. PLANETARY FILL/LEVEL PLUGS PLANETARY DRAIN PLUGS CENTER BODY FILL/LEVEL PLUG CENTER BODY DRAIN PLUG 5. CENTER BODY .USE JDM J20C B.35 liter (0. 2.USE SAE 80W/90 1. 90. Remove the brake oil reservoir cover and cylindrical block drain plug. 120FT (N005. DO NOT allow water entry. RIGHT PLANETARY CARRIER HOUSING 6.Maintenance Procedures Every 2000 Hours or Annually (G004) see Figure 74. 3. 4. 100. For lift truck models H80. 2. Install oil fill/level plug. The correct oil is shown in the Maintenance Schedule.74 pt) minimum capacity. RIGHT PLANETARY CARRIER HOUSING . LEFT PLANETARY CARRIER HOUSING 7. 3. P005) see Figure 75. Remove the brake oil reservoir from the bracket on the cowl. 8000 SRM 1248 3. Oil Application Diagram BRAKE OIL (MASTER CYLINDER). as the color will be more clear than the used oil which will be darker. 6. NOTE: The new brake oil will be easily recognized. REMOVE Perform the following procedure to remove used brake oil from the remainder of the brake system. Figure 77. RESERVOIR CAP 2. Loosen the bleed screw at the wheel cylinder one turn so that the used brake oil can be removed from the brake system. CYLINDRICAL BLOCK OUTLET FITTING 7. RESERVOIR MOUNTING BRACKET 4. NOTE: This procedure cannot be performed by one person. 2. 1. Check the level of the brake oil in the reservoir for the master cylinder during the procedure. 3. Repeat the procedure for the other wheel cylinder. CYLINDRICAL BLOCK MOUNTING BRACKET CAPSCREW 5. 1. COWL 5. BRAKE OIL RESERVOIR 3.8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually BRAKE OIL (DRY BRAKE). Slowly push the brake pedal and hold it at the end of its stroke. NIPPLE 9. Ensure that the master cylinder reservoir is filled with brake oil. Put the other end of the hose into a empty container. Repeat Step 1 through Step 3 until there is new brake oil in the container. Release the brake pedal. 4. UPPER BRAKE OIL SUPPLY HOSE 6. Make sure to keep the brake oil at the correct level. Brake Oil Change 77 . CYLINDRICAL BLOCK 12. Close the bleed screw. MASTER CYLINDER 10. CYLINDRICAL BLOCK DRAIN PLUG 11. Put one end of a rubber hose on the bleed screw of the wheel cylinder. LOWER BRAKE OIL SUPPLY HOSE 8. When the brake drums are removed. Follow the cleaning procedure in this section. SERVICE BRAKES (DRY BRAKE) Check brake lining and parts of the brake assembly for wear or damage.040 in. DO NOT sand. 2. DO NOT release brake lining dust from brake linings into the air when brake drum is removed. Inspect brake drums for cracks or damage. DO NOT create dust! DO NOT clean brake parts with compressed air or by brushing. 1. See Figure 78 and Figure 79. 3. Install the fill plug and check for leaks. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Place the lift truck on blocks. 2. When the brake lining dust is wet. or change linings in any way that will create dust. S120FTS. DIFFERENTIAL (DRY BRAKE) NOTE: Additional information on the differential can be found in the section Drive Axle and Differential Assembly Repair. DO NOT permit oil or grease in the brake fluid or on the brake linings. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 4. Use a solvent approved for cleaning of brake parts to wet lining dust. Install fill plug and rotate the drive wheels in order to get oil pumped into the axle. Brake cleaning procedures are as follows: CAUTION DO NOT use an oil solvent to clean the wheel cylinder. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. Replace any damaged parts. Remove the fill plug and check the oil level. Breathing the dust from these brake linings is a cancer or lung disease hazard.0 mm (0. do not create brake lining dust with the spray. replace the brake linings. 3. If the brake linings or brake shoes are worn or damaged. The fill hole is on the front of the differential housing. Add oil shown in the Maintenance Schedule until the oil level is at the lower edge of the fill hole. Figure 78. chisel. DO NOT create dust. 120FT. S80.3 qt) under the differential.). See the section Brake System 1800 SRM 1247 for the removal and installation procedures of the drive wheels and brake drums. 100. Place a container with a minimum capacity of 5 liter (5. The differential and drive axle use the same oil supply. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air. Install the drain plug. 100FTBCS. See How to Raise Drive Tires in this manual. as necessary. Add oil. (Dry Brake) 1400 SRM 1245. WARNING Brake linings can contain dangerous fibers. Remove the drain plug located in the bottom of the differential and drain the oil from the differential completely. Any changes to brake linings must be done in a restricted area with special ventilation. The minimum acceptable brake lining thickness is 1. hammer. clean parts. Protective clothing and a respirator must be used. S120FTPRS (G004) 78 . they must be replaced. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models S80. 1. grind. If the brake linings are worn thinner than the specification. Use a solvent approved for cleaning of brake parts. Brake shoes must be replaced in complete sets. To adjust the valve clearances do the following: 1. GM 4. CHECK/FILL PLUG 3. 90. 100. CRANKSHAFT PULLEY 2. Adjust ONLY the valves shown in Figure 81. ENGRAVE TIMING MARK Figure 80. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models H80.3L engine does not require valve clearance adjustments during normal service. DRAIN PLUG 3. • Check exhaust pipe fasteners to manifold for leaks to ensure they are tight.3L DIESEL ENGINE The Cummins QSB 3.8000 SRM 1248 Legend for Figure 78 1. perform the following: • Check the exhaust manifold at the cylinder head for leaks. INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS To check the exhaust manifold and piping for leaks. DRIVE AXLE Figure 79. Repair if necessary. by loosening the locknut with a wrench and adjusting the valve clearance using a screwdriver or Allen wrench. DRIVE AXLE 2. CHECK/FILL PLUG 2. GM 4. CHECK AND ADJUST FOR CUMMINS QSB 3. P005) 2. TEST LPG/GAS REGULATOR PRESSURE For more information regarding the Test LPG/GAS Regulator Pressure.3L Engine with GFI 900 SRM 1242 and Gasoline Fuel System. if necessary. 110. 1. Align the TDC mark on the crankshaft pulley with the engraved mark on the block. • Visually inspect converter for correct muffler mounting and tail pipe mounting. 120FT (N005.3L Engine 900 SRM 1244. Check the valve clearance and make adjustments as needed.3L TDC Mark 79 . See Figure 80. VALVE CLEARANCE. DRAIN PLUG Maintenance Procedures Every 2000 Hours or Annually • Check all exhaust pipe extension connectors for leaks and tighten. • Check for any leaks at the inlet and outlet of the converter. See the Maintenance Schedule for valve clearances. Ensure that all bolts and shields are in place. Repair if necessary. 1. see the section LPG Fuel System. DRIVE BELT 3. CHECK THROTTLE SHAFT FOR STICKING Check Throttle body return action to ensure throttle shaft is not sticking. Cummins QSB 3. Tighten the lock nut to 24 N•m (212 lbf in) and measure valve lash. Cummins Valve Adjustment 1. CYLINDER 4 Figure 81. 4. See the Maintenance Schedule for valve clearances. Mark the vibration damper and rotate the crankshaft 360 degrees. Cummins Valve Adjustment 3. CYLINDER 3 6. 1. Figure 83. See Figure 82. INTAKE VALVE 3. EXHAUST VALVE 2. CYLINDER 1 4. Perform Step 2 and Step 3 to adjust ONLY the valves shown in Figure 83. INTAKE VALVE 3. TIMING PIN 2. CYLINDER 2 5.Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248 5. Cummins Vibration Damper 80 . EXHAUST VALVE 2. CYLINDER 1 4. VIBRATION DAMPER Figure 82. CYLINDER 4 1. CYLINDER 3 6. CYLINDER 2 5. 81 . See Figure 84. When the oil level is correct. The operation of the hydraulic pump without oil will damage the pump. and 2000-hour checks prior to performing the procedures in this section. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 2. clean the inside of the tank in accordance with the instructions found in the section Frame 100 SRM 1243. 1000hour. When either the inspection or the cleaning of the tank is completed. NOTE: Replace the hydraulic oil filter at the same time the oil is changed. remove the drain plug from the bottom of the hydraulic tank. When the tank is empty. DO NOT permit the hot oil to touch the skin and cause a burn. Fill hydraulic tank with oil specified in the Maintenance Schedule. 1. 250-hour. REPLACE WARNING At operating temperature the hydraulic oil is HOT. inspect the inside of the tank for any foreign matter or possible fungus. contact your local Hyster dealer. Place a container with a minimum capacity of 39. 3. operate system and check for leaks.8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years Maintenance Procedures Every 4000 Hours or 2 Years NOTE: Perform the 8-hour. 500-hour. Never operate the hydraulic pump without oil in the hydraulic system. NOTE: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours. If necessary. Before using additives.4 liter (42 qt) under the drain plug at the bottom of the hydraulic tank. CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. To drain the oil. Dirt can cause damage to the components of the hydraulic system. HYDRAULIC OIL. install the drain plug in the bottom of the hydraulic tank. CAUTION Additives may damage the hydraulic system. Check the valve clearance and make adjustments as needed. 6. by loosening the lock nut with a wrench and adjusting the clearance using a screwdriver or Allen wrench. HYDRAULIC TANK 2. 82 . See Figure 87. Rotate the engine until it is at TDC for cylinder number one (intake and exhaust valves closed). do the following: 1. 3. Insert timing pin. To adjust the valve clearance. Adjust ONLY the valves shown in Figure 86. See Figure 85. See Figure 85. DRAIN PLUG Figure 84. CHECK AND ADJUST FOR CUMMINS 4. See the Maintenance Schedule for valve clearances. Remove the timing pin. 2. Tighten the lock nut to 24 N•m (18 lbf in) and measure valve lash. 4.5L DIESEL ENGINE The Cummins 4. Mark the vibration damper and rotate the crankshaft 360 degrees.5L engine does not require valve clearance adjustments during normal service. 5.Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248 1. Perform Step 2 and Step 3 to adjust ONLY the valves shown in Figure 88. Hydraulic Oil Change VALVE CLEARANCE. INTAKE VALVE 3. Cummins Vibration Damper Figure 86. FUEL/WATER SEPARATOR FILTER 3. EXHAUST VALVE 2. Timing Pin Location. CYLINDER 3 6.8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years 1. Cummins Valve Adjustment 83 . TIMING PIN 2. VIBRATION DAMPER Figure 87. TIMING BELT Figure 85. INSERT TIMING PIN HERE 2. CYLINDER 2 5. CYLINDER 4 1. CYLINDER 1 4.5L Diesel Engine 1. Cummins 4. then applying penetrant and developer. b.Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248 the area to be inspected. See Figure 90. Carriage inspection: welded joints between cast insert and top and vertical carriage bars. Welded joints around tilt anchor and intermediate cross member. c. See Figure 90. CYLINDER 2 5. to perform inspection. If a crack is present. NOTE: The welded boss for tilt lock option is typically located on right side of mast channel above tilt anchor bracket. EXHAUST VALVE 2. 2. Welded joints of lower crossmember of mast outer channel and related gussets. but recommended. NOTE: Visual inspection supported by dye penetrant application is recommended with focus on areas defined below. with subsequent inspections at 2000 hour intervals. CYLINDER 4 Figure 88. CYLINDER 1 4. See Figure 89. Mast inspection: 1. WELD INSPECTION Initial inspection is suggested at 4000 hours. Contact your local Hyster dealer for instructions if a crack is detected. it will show up as a well-defined maroon/red line as the dye penetrant is drawn out into the white developer coating. Follow manufacturers instructions for cleaning 84 . NOTE: Dye penetrant checks are made in a threestep process using a cleaner. Removal of attachment is recommended for access to carriage. penetrant. Removal of carriage from mast is not required. CYLINDER 3 6. See Figure 90. INTAKE VALVE 3. Right side rail of outer mast channel in area of welded boss for optional tilt lock rod. 1. Cummins Valve Adjustment a. and developer. Carriage Bar Welds for Inspection 85 .8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years A. FRONT VIEW 1. REAR VIEW Figure 89. WELDS B. Mast Welds for Inspection 86 . TYPICAL "XM" MAST B.Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248 A. TYPICAL "FT" MAST C. WELDED BOSS FOR TILT LOCK OPTION 1. WELDS Figure 90. OR 2. the moving part is the inner weldment. install a safety chain to restrain the moving parts of the mast. the forks can be at a height to cause an injury. Put mast in vertical position. See the correct Service Manual section for the specific mast being repaired. Apply parking brake. three-stage. Connect moving parts to a part that does not move. Follow these procedures: a. Raise mast to align bottom crossmember of weldment that moves in outer weldment with a crossmember on outer weldment. hoses. Lower the mast until there is tension in the safety chain and the free-lift cylinder (freelift. Install another safety chain (3/8-in. Put the hook on the back side of the mast. Use a ladder or personnel lift to work on the mast. • DO NOT climb on the mast or lift truck at any time. minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. Make sure the hook is completely engaged with a link in the chain. See the Operating Manual for the procedures to lower a load using the emergency load lowering valve. stop engine. When the mast is raised. it is the intermediate weldment. there is an emergency load lowering valve located on the hoist/lower valve section of the main control valve. 3. Apply parking brake. If parts of the mast must be in a raised position. On the two-stage and free-lift mast. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. • DO NOT use blocks to support the mast weldments nor to restrain their movement. • Be careful of the forks. After lowering or restraining the mast. c. Put a DO NOT OPERATE tag in the operator’s compartment. Make sure the safety chain does not touch lift chains or chain sheaves. On the three-stage mast. b. Use a 3/8-in. or other parts on the mast. fittings. shut off power and remove key. • Never put any part of the body into or under the mast or carriage unless all parts of the mast are completely lowered or a safety chain is installed. e. Install a DO NOT REMOVE tag on the safety chain(s). Lower mast and carriage completely. Put a DO NOT OPERATE tag in the operator’s compartment. Distances between parts are small. Also make sure that the power is off and the key is removed.8000 SRM 1248 Safety Procedures When Working Near Mast Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. and four-stage masts only) is completely retracted. tubes. 1. 87 . Push lift/ lower control lever forward and make sure there is no movement in the mast. NOTE: If there is no power to lower the mast on lift trucks equipped with Electronic Hydraulic System. Follow the repair procedures in the correct Service Manual for the mast. Make sure all parts of the mast that move are fully lowered. See Figure 91. WARNING Mast parts are heavy and can move. d. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. Additional precautions and procedures can be required when repairing or removing the mast. If running. minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Three-Stage. and Four-Stage Masts 88 .Safety Procedures When Working Near Mast 8000 SRM 1248 Figure 91. Free-Lift. Two-Stage. 5L and QSB 3. THREE-STAGE FFL MAST D.3L diesel engines. 7. Close the drain valve by lifting and turning clockwise until it is hand-tight. FREE-LIFT CYLINDER CARRIAGE BAR CROSSMEMBER FIRST INTERMEDIATE MAST Fuel Filter Water Removal NOTE: The following procedure only pertains to lift trucks equipped with Cummins 4. 3. DRAIN VALVE Figure 92. Turn the drain valve clockwise approximately 3 1/2 turns. 1. 4. 4.8000 SRM 1248 Legend for Figure 91 A. OUTER MAST INNER MAST INTERMEDIATE MAST HOOK Fuel Filter Water Removal C. 2. Overtightening can damage the threads. To access the fuel filter element and drain valve. 2. 1. TWO-STAGE FFL MAST 1. TWO-STAGE LFL MAST B. 8. FOUR-STAGE FFL MAST 5. FUEL FILTER ELEMENT 3. See Figure 92.5L Shown) 89 . Shut off the engine. CAUTION Drain water/fuel into a container and dispose in accordance with local environmental regulations. NOTE: The drain valve is located on the bottom of fuel filter element. CAUTION DO NOT overtighten when closing the drain valve. remove the air inlet elbow. 3. 6. Engine Fuel Filter Drain Valve Location (Cummins 4. Drain fuel filter until clear fuel is visible. AIR INLET ELBOW 2. 3. BUMPER 3. 4. Tighten capscrews so that hood latch can still move when hood is closed. and latch striker must be correctly adjusted for the correct operation of the operator restraint system. Check operation of hood latch. Make sure latch striker is still in center of hood latch. LATCH STRIKER 2. If necessary. Have an operator sit in the seat. 2. HOOD LATCH 6. Push down until hood just touches rubber bumper. HOOD 4. Carefully close hood to fully-closed position. The hood latch is fully closed after two clicks of the latch. 1. Make sure hood is fully closed (two clicks). 1. Hood Latch Check 90 . See Figure 93. Install hood latch on frame of hood. HOOD RELEASE HANDLE 5. Check that latch striker is in center of jaws of hood latch when hood closes. Install latch striker in highest slot position. FRAME Figure 93. hood latch. The hood latch has two positions. Also check that hood touches rubber bumper.Hood Latch Check 8000 SRM 1248 Hood Latch Check WARNING The hood. 5. repeat Step 4. Open hood and tighten capscrews for latch. When adjusting lift chains on forklift trucks equipped with the forks installed. • Chains must travel freely through complete cycle. Adjust chain anchors which support the carriage until bottom of the fork heel is 6 ±3 mm (0. make sure forklift truck is parked on a level surface and the mast is in the vertical position. During test procedures for the hydraulic system. Keep all personnel away from the lift truck during the tests. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR Figure 95. Never allow anyone under a raised carriage. Lift Chain Adjustments With Forks Installed 91 . 4. NOTE: Prior to performing adjustment procedures. • Chain length will be correct.8000 SRM 1248 Lift Chain Adjustments Lift Chain Adjustments WARNING When working on or near the mast.) above floor level.) ABOVE THE FLOOR LEVEL.12 in. 2.24 ±0. See Figure 95. See Figure 94. Figure 94. When lift chains are correctly adjusted: • Tension will be the same on each chain of chain set. Chain anchors must be able to move on their mounting. fasten the load to the carriage with chains to prevent it from falling. If forklift truck is equipped with an attachment without forks. Adjust chain anchors which support carriage until the bottom of lower carriage bar is above the floor level as shown in Table 2. 1. MAST CARRIAGE FORK HEEL OF FORK IS 6 ±3 mm (0. Check tension by pushing on both chains at the same time. 3. make sure the threads on the nuts of the chain anchors are completely engaged.24 ±0. 3. NOTE: When chain adjustments are complete. 1. CARRIAGE 3. 2. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Make sure all adjustment is not removed from the chain anchors. go to Step 3. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. see Safety Procedures When Working Near Mast in this section. Hydraulic oil can be injected into the body by the pressure. Lift Chain Adjustment Without Forks Installed 1. MAST 2. go to Step 2.12 in. 3. Always connect jumper cables to discharged battery before connecting them to booster battery. that is the ground cable. Always connect jumper cable.12 in. Damage to the hydraulic system can occur if engine is started by pushing or towing lift truck. The Class II mast would have the lift capability of 2.5-4. JUMP-STARTING A LIFT TRUCK USING ANOTHER LIFT TRUCK WARNING To prevent possible arcing between the two lift trucks. 3.0 tons. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal.0-7. make sure that the lift trucks are not touching. If the battery becomes discharged and requires a booster battery to start the engine. Always connect jumper cable. 4.5 ±3 mm (3. Always connect jumper cables to discharged lift truck battery before connecting them to the fullycharged lift truck battery. the masts are divided by class. 8000 SRM 1248 Table 2. last.5-3. Disconnect the negative battery terminal of the lift truck being started.0 tons. and Class IV has the lift capability of 4.5 ±3 mm (5. 1. 2.) Jump-Starting the Lift Truck JUMP-STARTING USING A BATTERY CHARGER CAUTION DO NOT try to start the engine by pushing or towing the lift truck. Carriage Chain Adjustment.) 133. Each class is determined by the lifting capability of the lift cylinders. last. follow these procedures carefully when connecting the jumper cables: 1. Forks Not Installed Class II and Class III Class IV 82.Jump-Starting the Lift Truck In Table 2.12 in.5 tons. 2. 92 . that is the ground cable.25 ±0.26 ±0. Class III has the lift capability of 3. Damage to the hydraulic system can occur if engine is started by pushing or towing lift truck. CAUTION DO NOT try to start the engine by pushing or towing the lift truck. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal. Connect the ground clamp for the arc welder as close as possible to the weld area. Forks are made of special steel using special methods. Overhead Guard Changes WARNING DO NOT weld mounts for lights or accessories to the legs of the overhead guard. If an acetylene or arc welder is used. or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. This action will prevent damage to a bearing from the large current from the welder. Make sure there is no fuel. Get information from your dealer for Hyster lift trucks before welding on a mast.1 . AWS Z 49. The strength of the overhead guard can be reduced by welding or heating. burning. See your dealer for Hyster lift trucks BEFORE performing any changes to the overhead guard. or bend forks. Should work be performed. local ventilation.8000 SRM 1248 Overhead Guard Changes Welding Repairs WARNING Welding can cause a fire or an explosion. weld. oil. These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure may occur without odor warning. make sure procedures in previous WARNING and CAUTION are done. utilize good industrial hygiene practices including removal of all paint (prime and finish coats) to the metal around the area to be welded. CAUTION When an arc welder is used. always disconnect the ground cable from the battery in the lift truck. or grease near the weld area. This action will prevent damage to the alternator or the battery. No welding or drilling on legs of overhead guard is permitted as per previous WARNING. 93 . Make sure there is good ventilation in the area where the welding must be done. Some repairs require welding.1999. ing. and/or supplied-air respiratory protection. Always follow the instructions in the Frame section if a fuel or hydraulic tank must be welded. DO NOT heat. Forklift frames and components may be painted with a catalyzed paint such as Weldpolyurethane or a two-part primer. See the American National Standard Safety in Welding and Cutting. Changes that are made by welding or by drilling holes that are too big or in the wrong location can reduce the strength of the overhead guard. Wheels must be changed and tires repaired by trained personnel only. OUTSIDE OF SOLID RUBBER TIRE B. tighten wheel nuts to a torque value of 610 to 680 N•m (450 to 502 lbf ft).000 to 400. STEERING TIRE AND WHEEL 1. The tread on the sold rubber tires can be either smooth or it can have lugs. check the Nameplate of the lift truck for the correct tire size and tread width. WHEEL C. Make sure the Nameplate is correct for the type of tires on the lift truck. WIDE TREAD 3. Do not mix types of tires or tread on lift truck. SOLID RUBBER TIRE. 2. Tires and Wheels for S80. Also. CHANGE (S SERIES) NOTE: Solid rubber tires made from softer or harder material can be installed as optional equipment. 120FT. see the Nameplate. OVERHANG Figure 96. 1. The 12000 lb. When the drive wheels are installed on the lift truck. The H series lift trucks have pneumatic tires or solid rubber tires that look like pneumatic tires. See Figure 96. The correct tools. S120FTS. Remove wheel nuts and remove wheel from lift truck. These variations in tires also cause a variation in the types of wheels and the disassembly and assembly procedures. 100FTBCS. Lift truck wheels are heavy. Use a press to push wheel from rim and tire. The capacity of the press must be approximately 355 to 1779 kN (80. Remove and Install Tire on Wheel NOTE: Make sure the tires are installed on the wheels so that the outside edges of the tire and wheel are as shown in Figure 96. S120FTPRS (G004) Lift Trucks 94 . DRIVE TIRES AND WHEELS 2. For the tire sizes.Wheel and Tire Replacement 8000 SRM 1248 Wheel and Tire Replacement GENERAL The S series lift trucks have solid rubber tires (often called cushion tires) that are pressed onto the rim. 100.000 lbf). A. and a press ring must be used for each size of wheel. 2. 1. Raise lift truck as described in How to Put Lift Truck on Blocks in this manual. equipment. Always wear safety glasses. WARNING The type of solid rubber tire is shown on the Nameplate. capacity solid rubber tired fork lift must be equipped with high load capacity steering tires. S80. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire. Make sure inner and outer bearings are correctly lubricated with grease. Lift truck tires and wheels are heavy. 3. If the cotter pin cannot be installed. Wheel and Tire Replacement sure the nameplate is correct for the type of tires on the lift truck. Remove air from tire. REPAIR Remove Wheels From Lift Truck WARNING A solid rubber tire that is the same shape as a pneumatic tire can be installed on a threepiece or four-piece wheel for a pneumatic tire. Install cap for bearings. WARNING The type of tire and the tire pressure (pneumatic tires) are shown on the nameplate. PNEUMATIC TIRE WITH TUBE.8000 SRM 1248 3. Tighten castle nut up to 203 N•m (150 lbf ft) while rotating hub in both directions to properly seat the bearings. Tighten castle nut to 34 N•m (25 lbf ft). Install outer bearing cone and castle nut. Push a wire through valve stem to make sure valve stem does not have a restriction. Remove valve core to make sure all air is out of inner tube. Deflate tire completely before removing the wheel from the lift truck. Changes to the parts of the rim can cause a failure of the wheel and cause an accident. Install inner bearing assembly and wheel on spindle. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at the beginning of this section. If dual wheels are used. DO NOT make changes in the parts of the rim if this type of solid rubber tire is installed instead of a pneumatic tire. loosen the castle nut until wheel hub turns freely with no end play. Air pressure in the tires can cause the tire and rim parts to explode. WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. causing serious injury or death. 2. Make 95 . loosen the castle nut to the first position where the cotter pin can be installed. Remove wheel nuts and remove wheel and tire from lift truck. 1. deflate both tires. The steering wheels are fastened to the spindle of the steering axle with a large castle nut. TWO-PIECE WHEEL B. Remove nuts that fasten wheel rims together. FOUR-PIECE WHEEL 3.Wheel and Tire Replacement 8000 SRM 1248 Remove Tire From Wheel NOTE: When you disassemble the wheels. THREE-PIECE WHEEL D. Types of Pneumatic Wheels Remove Tire From Two-Piece Wheel WARNING Make sure all the air pressure is removed from the tire before a wheel is disassembled. 96 . causing serious injury or death. it can move with enough force to cause an injury. SIDE FLANGE C. see Figure 97. STEP 1. OPTIONAL RIM ASSEMBLY 1. FLANGE SEAT Figure 97. Keep tire tools in firm contact with the wheel parts. WHEEL RIM 2. There are several types of wheels used on this series of lift trucks. LOCK RING 4. If the tool slips. A. Air pressure in the tires can cause the tire and rim parts to explode. Remove Tire From Three.and Four-Piece Wheels WARNING Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the tires can cause the tire and rim parts to explode. causing serious injury or death. Remove wheel rims from tire. Wheel and Tire Replacement STEP 3. 97 . Keep tire tools in firm contact with the wheel parts. STEP 1. Remove inner tube and flap. If the tool slips. Loosen tire bead from wheel rim.8000 SRM 1248 STEP 2. Loosen tire bead from side flange. it can move with enough force to cause an injury. Wheel and Tire Replacement STEP 2. Make sure the side ring is in the correct position. If there is a flange seat. plastic. Make sure rim is the correct size for tire. Lubricate part of wheel that contacts bead and flap. Remove wheel from tire.5 to 1. Remove lock ring and side flange. Install Wheel in Tire 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 a steel hammer on the wheel. or wheel assemblies of different manufacturers on any one lift truck. • DO NOT mix parts between different types or manufacturers of wheels. Paint any parts that have rust or corrosion. 4.) after it is installed. 5. If the clearance is wrong. 3.0 in. Install new inner tube in tire. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0. • DO NOT mix types of tires. 98 . Use a rubber. • Make sure all parts of the wheel are the correct parts for that wheel assembly. 1. Install new tire flap. The ends of the side ring must not touch. or brass hammer to put parts together. the wrong part has been used. 2. lead. 8000 SRM 1248 STEP 3. Clean and inspect all parts of wheel. Remove valve stem from wheel. Apply a rubber lubricant or a soap solution to the tire bead and tube. STEP 4. type of tire tread. Used tubes and flaps can cause tire failure. Put tire tool into slot between lock ring and wheel rim. remove it. Loosen bead from other side of wheel rim. • DO NOT use any damaged or repaired wheel parts. Install Three-Piece or Four-Piece Wheel in Tire WARNING Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Install inner tube and rubber flap in tire. Keep tire tools in firm contact with the wheel parts. Install wheel rim in tire. If the tool slips. Put blocks under rim so rim is 8 to 10 cm (3 to 4 in. Spinning may occur.8000 SRM 1248 Wheel and Tire Replacement 6. it can move with enough force to cause an injury. Turn over rim and tire. 99 . STEP 3. STEP 1. Make sure stem of inner tube is aligned with slot in rim.) above floor. Install the three-piece or four piece wheel in the tire a shown in Install Three-Piece or Four-Piece Wheel in Tire. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death. Install the two-piece wheel in the tire as shown in Install Tire on Two-Piece Wheel. solid tires on two-piece bolt together drive wheels. CAUTION DO NOT use pneumatic-shaped. Install flange seat (if used) and lock ring. STEP 2. 7. Apply a rubber lubricant or a soap solution to tire bead and tube. Use a rubber.5 to 1. Install new inner tube in tire.) after it is installed. Add air pressure to tire as described in Install Wheel in Tire. lead. Install new tire flap. the wrong part has been used. WARNING Wheels can explode and cause injury or death if the following procedures are not followed: • Clean and inspect all parts of the wheel before installing the tire. • Make sure all parts of the wheel are the correct parts for that wheel assembly. The ends of the side ring must not touch. 4. 100 . Used tubes and flaps can cause tire failure. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0. DO NOT use a steel hammer on the wheel. Make sure stem of inner tube is aligned with slot in rim. • DO NOT use any damaged or repaired wheel parts. or brass hammer to put parts together. Make sure the side ring is in the correct position.0 in. Paint any parts that have rust or corrosion. WARNING DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Install inner tube and rubber flap in tire. 2. Spinning may occur. 1. type of tire tread.Wheel and Tire Replacement STEP 4. or wheel assemblies of different manufacturers on any one lift truck. plastic. • DO NOT mix types of tires. Make sure rim is the correct size for tire. Install Two-Piece Wheel in Tire STEP 1. If the clearance is wrong. 8000 SRM 1248 Install Tire on Two-Piece Wheel CAUTION DO NOT use pneumatic-shaped solid tires on two-piece bolt together drive wheels. Clean and inspect all parts of wheel. Install both halves of wheel rim in tire. • DO NOT mix parts between different types or manufacturers of wheels. Put lock ring in the correct position on rim. 3. Lubricate part of wheel that contacts bead and flap. 5. Vapors from these liquids can cause an explosion during inflation or use. make sure nuts that fasten rim halves together are toward brake drum when they are installed. 2. When air pressure is added. If installation is not correct. See Figure 98. Remove valve core to make sure all air pressure has been removed and then make adjustments. If installation is correct. If the wheels are the two-piece rims. add air pressure to tire to the specified pressure.) when the tire has the correct air pressure. Check that all wheel parts are correctly installed. Add air pressure to tire (see nameplate). Put tire in a 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). 5. Install the Wheels Install wheel on the hub. use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. Tighten nuts in a cross pattern to a torque value of 610 to 680 N•m (450 to 502 lbf ft) for drive wheel nuts and 610 to 680 N•m (450 to 502 lbf ft) for steer wheel nuts.5 to 1. 3. Hit lock ring lightly to make sure it is in the seat. Add 20 kPa (3 psi) of air pressure to tire. 4. remove all air pressure from tire. DO NOT sit or stand by the safety cage. Inspect the safety cage for damage before use. Check that all wheel parts are correctly installed.0 in. Add Air to Tires 101 . Wheel and Tire Replacement ADD AIR TO PNEUMATIC TIRES WITH TUBE WARNING Add air pressure to the tires only in a safety cage. 1.8000 SRM 1248 STEP 2. Tighten nuts that hold rim halves together to 175 N•m (130 lbf ft). Figure 98. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0. Install outer wheel on dual hub assembly. 6. 1. 2. See Figure 99. 4. TIRE DUAL HUB ASSEMBLY WHEEL NUT WHEEL WHEEL ADAPTER SPACER VALVE EXTENSION BRACKET Figure 99. make sure nuts that fasten rim halves together are toward brake drum when they are installed. Dual Drive Wheels Installation 102 . If the wheels are the two-piece rims. make sure nuts that fasten rim halves together are toward brake drum when they are installed. The following procedures describe the steps to install the dual sets of wheels. Install inner wheel on hub. 3. Install wheel adapter spacers on the inner wheel studs and tighten spacers to 100 to 125 N•m (74 to 92 lbf ft). 4. Install the valve extension bracket and tighten the attaching nut to 8 N•m (70 lbf in). 3.Wheel and Tire Replacement 8000 SRM 1248 Dual Drive Wheels. 5. 2. Install the dual hub assembly and inner wheel nuts on the spacers and tighten the wheel nuts to 610 to 680 N•m (450 to 502 lbf ft). Install the valve extension hose into the bracket. 1. 7. See Figure 99. Install NOTE: Some lift trucks have dual drive wheels. Tighten nuts to a torque value of 610 to 680 N•m (450 to 502 lbf ft). If the wheels are the two-piece rims. or four-piece rim. STEP 1.8000 SRM 1248 Wheel and Tire Replacement The Tubeless Bead Seal (TBS) enables tubeless tires to be used on wheel rims that were designed to be used with a tube. deflate both tires. Keep tire tools in firm contact with the wheel parts. If wheel rim is a three. 103 . PNEUMATIC TUBELESS TIRE. see Figure 97. Air pressure in tires can cause the tire and rim parts to explode causing serious injury or death. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death. Remove Tire From Wheel WARNING Make sure all of the air pressure is removed from the tire before a wheel is disassembled. When disassembling wheels. it can move with enough force to cause injury. Deflate tire completely before removing the wheel from the lift truck. Put lift truck on blocks as described in at beginning of this section. NOTE: There are several types of wheels used on these lift trucks. 2. Lift truck tires and wheels are heavy. 1. If the tool slips. REPAIR Remove Wheels From Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. Remove the wheel nuts and remove the wheel and tire from the lift truck. 3. If dual wheels are used. The main component of a TBS is a special rubber ring that fits inside the tire between the tire beads to ensure the air tightness of the existing wheel and the tubeless tire assembly. See Figure 97. Never loosen the nuts that hold the inner and outer wheels halves together when there is air pressure in the tire. Remove the valve cap and core to remove all air from the tire. turn the valve 1/4 turn and remove valve from wheel. Always wear safety glasses. Put wheel and tire assembly on the press. Push the TBS toward the inside of the tire to remove it. Press down on loose flange to expose the locking ring. Position the feet of the press on the loose flange. Remove the press and remove the loose flange locking ring and the advance band (four-piece wheel only) from the tire and wheel assembly. STEP 4. Remove the loose flange locking ring and the advance band (four-piece wheel only) using a tire tool. STEP 5.Wheel and Tire Replacement STEP 2. 104 . 8000 SRM 1248 STEP 3. Use a rubber. • Make sure that all parts of the wheel are the correct parts for that wheel assembly. up to the tire shoulders. plastic. 105 . Apply lubricant to the needle valve and the valve hole that will be used (see NOTE) by inserting and removing the lubricated valve several times. STEP 2. The valve hole that is not used should be sealed with a small plastic plug. • DO NOT mix parts between different types or manufacturers of wheels. type of tire tread. Apply lubricant to the entire underside of the TBS. If the wheel rim width is greater than six inches. If the TBS has two-valve holes. leave valve in valve hole. lubricate the plastic plug and insert into valve hole that will not be used. If a two-piece wheel is being used. remove the valve. WARNING DO NOT use a steel hammer on the wheel. WARNING DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. the TBS will have two holes for the needle valve. • DO NOT mix types of tires. to ensure the correct positioning of the valve in the valve slot. the TBS will contain one valve hole to accommodate the needle valve. Clean interior and exterior bead of the tire. • DO NOT use any damaged or repaired wheel parts. or brass hammer to put parts together. Vapors from these liquids can cause an explosion during inflation or use. Lubricate tire beads and the inside of the tire.8000 SRM 1248 Wheel and Tire Replacement Install Tire on Wheel WARNING Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow procedures: • Clean and inspect all parts of the wheel before installing the tire. lead. STEP 1. One hole is centrally located and the other is offset. If a three. or wheel assemblies of different manufacturers on any one lift truck.or four-piece wheel is being used. NOTE: If the wheel rim width is less than six inches. Line up the valve hole in the TBS with the valve slot in the wheel. the following parts: • Advance band (four-piece wheel only) • Loose flange • Locking ring 106 . lubricate the advance band. Turn the valve a 1/4 turn to lock the collar under the edges of the rim valve slot. 8000 SRM 1248 STEP 4.Wheel and Tire Replacement STEP 3. Place the wheel and tire assembly on a flat surface. Lubricate and insert the valve into the valve hole. Place the TBS inside the tire. Slide the tire and the TBS onto the wheel. Apply lubricant to the rim. STEP 6. If a four-piece wheel is being used. Insert in wheel assembly. Make a mark on the tire to note the position of the valve hole in the TBS. Raise the tire and position the base and threaded stem of the press through the hole in the center of the wheel. Make sure it is fully inserted. STEP 5. making sure that the wings of the TBS are not folded over. Release the press and check that all component parts are correctly positioned. 2. STEP 9. Position the arms of the press onto the loose flange. When air pressure is added. Install valve cap to ensure air stays in the tire. Add air to tire to the recommended air pressure that is shown on the Nameplate. Push down on the press to depress the tire beads until locking ring groove is fully exposed. 1. Figure 100. and a vise grip on other end. Tap wheel with a mallet to ensure all components are correctly sealed. Inflate tire to 103 kPa (15 psi). Position the advance band. See Figure 100. Add Air to Pneumatic Tubeless Tire WARNING Add air pressure to tires only in safety cage. Wheel and Tire Replacement STEP 8. Make sure there is enough hose to permit operator to stand away from safety cage when air pressure is added to tire. Replace the valve core. Insert tire tool into the locking ring groove. Inspect safety cage for damage before use. Add Air to Tires 107 . Ensure that it does not go in too far and damage the valve. Put tire in safety cage. use a chuck that fastens onto valve stem.8000 SRM 1248 STEP 7. Remove vise grip. DO NOT sit or stand by safety cage. Remove the press from wheel and tire assembly. it can move with enough force to cause serious injury. Put cage in position on tire. Always wear safety glasses. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at the beginning of this section. SOLID RUBBER TIRES ON PNEUMATIC WHEELS. CHANGE WARNING Wheels must be changed and tires repaired by trained personnel only.Wheel and Tire Replacement 8000 SRM 1248 Wheels. see Figure 97. 1. Install Install wheel on hub. STEP 1. Remove wheel nuts and remove wheel and tire from lift truck. Remove Wheel From Tire NOTE: When you disassemble the wheels. If the tool slips. If wheels are two-piece rims. 2. Tighten nuts in a cross pattern to a torque value of 610 to 680 N•m (450 to 502 lbf ft) for drive wheel nuts and 610 to 680 N•m (450 to 502 lbf ft) for steer wheel nuts. Put wheel rim on bed of press. Always wear safety glasses. Lift truck tires and wheels are heavy. Use press to push tire away from side flange. make sure nuts that fasten rim halves together are toward brake drum when they are installed. There are several types of wheels used on these series of lift trucks. WARNING Keep tire tools in firm contact with the wheel. 108 . Put a support under wheel rim. Put cage in position on tire. 109 .8000 SRM 1248 STEP 2. Turn tire over. Use press to push tire from wheel rim. Make sure wheel rim is at least 150 to 200 mm (6 to 8 in. Put tire tool into slot between lock ring and wheel rim. STEP 4. Wheel and Tire Replacement STEP 3.) from bed of press. Remove lock ring and side flange. • DO NOT use any damaged or repaired wheel parts. Use a rubber. type of tire tread. WARNING Damage to tire and wheel assembly and injury or death can occur if you do not do the following procedures. see Figure 97. or wheel assemblies of different manufacturers on any one lift truck. the wrong part has been used. 110 . DO NOT use a steel hammer on the wheel. Lubricate wheel rim and inner surface of tire with tire lubricant or soap. • DO NOT mix parts between different types or manufacturers of wheels. If the clearance is wrong. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0. or brass hammer to put parts together. plastic. The ends of the side ring must not touch. There are several types of wheels used on these series of lift trucks.Wheel and Tire Replacement 8000 SRM 1248 Install Tire on Wheel NOTE: When you assemble the wheels. CAUTION Too much lubricant can cause the tire to slide and move around the wheel rim.5 to 1. Make sure the side ring is in the correct position. DO NOT use a two-piece pneumatic wheel for solid rubber tires. • DO NOT mix types of tires.0 in. lead. STEP 1. • Make sure all parts of the wheel are the correct parts for that wheel assembly.) after it is installed. • Clean and inspect all parts of the wheel before installing the tire. Put cage in position on tire. Use a tire tool to make sure lock ring is in the correct position. Wheel and Tire Replacement STEP 3. and lock ring in position on wheel rim. Use press to install tire on wheel rim. install lock ring. STEP 4. Install cage on tire. Remove cage and put flange seat (if used). Put tire over wheel rim. side ring.8000 SRM 1248 STEP 2. While the cage is holding the tire on the wheel rim. Use press to push tire onto wheel rim so side flange and lock ring can be installed. Put wheel rim on bed of press. 111 . 112 . 360387 318702* 226414* 318996 318650 251099 355844* 350830 313022* 273338* 318705 318701* 341959 226415 251979 360053-10 318700 767 Loctite® Part No. Inc.02 oz 50 ml 3 ml 6 ml 50 ml 50 ml 100 ml 10 ml 50 ml 6 oz 1 lb 18 oz *Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700.Aerosol Antiseize Compound Chisel Gasket Remover (10 Aerosol cans per case) Adhesive and Sealant Kit (Contains one each of * items) Size 50 ml 10 ml 10 ml 50 ml 0. 222 242 271 277 290 290 422 515 515 567 595 609 680 Description Small Screw Threadlock (Purple) Removable Threadlock (Blue) High Strength Threadlock (Red) High Viscosity Threadlock (Red) Low Viscosity Threadlock (Green) Low Viscosity Threadlock (Green) SuperBonder® Adhesive Gasket Eliminator (Purple) Gasket Eliminator (Purple) Pipe Sealant with Teflon® Super Flex® Silicone Retaining Compound Retaining Compound Primer T . Teflon® is a registered trademark of Du Pont de Nemours Co.Adhesives and Sealants 8000 SRM 1248 Adhesives and Sealants Hyster Part No. Super Flex®. and Super Bonder® are registered trademarks of the Loctite Corporation.. Loctite®. . S.TECHNICAL PUBLICATIONS 8000 SRM 1248 8/11 (1/11)(12/10)(8/10)(7/10)(6/10)(2/10)(6/09)(5/08)(10/07)(7/07)(3/07) Printed in U.A. .