ASSEMBLY GUIDE

PART NO. 1586990 8000 SRM 1181

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

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

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

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

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

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................2
Weight and Dimensions .......................................................................................................................................... 2
Loading Procedures ...............................................................................................................................................11
Loading A Truck on a Transport ......................................................................................................................11
Loading Disassembled Components ................................................................................................................ 11
Unloading Procedures ........................................................................................................................................... 12
Unloading Complete Truck or Basic Truck From Transport ......................................................................... 12
Lifting ............................................................................................................................................................12
Driving On/Off a Trailer ...............................................................................................................................13
Unloading Disassembled Components .............................................................................................................13
Removal of Forks Attached to Basic Truck ..................................................................................................... 13
Removal of Forks Attached to the Carriage .................................................................................................... 14
Truck Assembly ..................................................................................................................................................... 15
Safety procedures When Working Near the Mast ...........................................................................................15
Mast Installation ...............................................................................................................................................16
Preparations ..................................................................................................................................................16
Adjusting the Tilt Cylinders ........................................................................................................................ 18
Connecting the Lift Cylinders ......................................................................................................................18
Connecting the Mast Supply Hoses ............................................................................................................. 19
Carriage and Forks ........................................................................................................................................... 20
Installing the Carriage .................................................................................................................................20
Connecting the Header Hoses to the Carriage ............................................................................................20
Install the Forks ........................................................................................................................................... 20
Installing Pin-Type Forks ........................................................................................................................ 20
Installing Quick Disconnect DFSSFP Forks .......................................................................................... 22
Installing Integrated DFSSFP Forks ......................................................................................................23
Adjusting the Carriage .................................................................................................................................23
Adjusting Header Hose Tension .................................................................................................................. 24
Adjusting the Electrical Cable Tension .......................................................................................................25
Installing the Cab Lights ..................................................................................................................................25
Adding the Mast Labels ....................................................................................................................................26
Lubrication Points .............................................................................................................................................26
Pre-Delivery Inspection ........................................................................................................................................ 27
Empty Seat Engine Shut Down ....................................................................................................................... 27
Pre-Delivery Inspection ................................................................................................................................27
Wheels and Tires ...................................................................................................................................................28
Remove Wheels From Lift Truck ..................................................................................................................... 28
Remove Pneumatic Tire From Wheel .............................................................................................................. 29
Install Pneumatic Tire on Wheel ..................................................................................................................... 31
Adding Air Pressure to the Tires ..................................................................................................................... 33
Remove Solid Rubber Tire From Wheel .......................................................................................................... 34
Install Solid Rubber Tire on Wheel ..................................................................................................................36
Install Wheels on Lift Truck ............................................................................................................................ 38
Moving and Towing ............................................................................................................................................... 38
Moving a Disabled Lift Truck ...........................................................................................................................38
Precautions ................................................................................................................................................... 38
Towing A Lift Truck ..........................................................................................................................................39

©2017 HYSTER COMPANY i

Table of Contents

This section is for the following models:

ii
8000 SRM 1181 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This section is for the following models:

Series Code European Model Americas Model

G007, H007 H8.00-12.00XM H170-280HD
J007 H8.0-12.0XM-6 H190-280HD2
K007 H8-12XM-6, H10XMS-6 H190-280HD2, H230HDS)
F019, G019 H13.00-14.00XM H300-330HD
F019, G019 H16.00XM-6 H360HD
F019, G019 H10.00-12.00XM-12EC H360HD-EC
H019 H13.0-14.0XM-6 H300-330HD2
H019 H16.0XM-6 H360HD2
H019 H10.0-12.0XM-12EC H360HD2-EC
J019 H13-16XM-6, H10-12XM-12EC H300-360HD2, H360HD2-EC

1
General 8000 SRM 1181

General
This manual contains the information that is re-
WARNING quired for transportation and reassembly of truck
Read all the instructions contained in this manual series G007, H007, J007, F019, G019, and H019.
before starting any work on the unit. Also read all The information covers each component that may
procedures contained in the Operating Manual be- have been disassembled for transportation purpo-
fore operating the truck. Make sure to check all ses. Select the appropriate assembly procedures ac-
fluid levels and tire pressures before moving the cordingly.
truck from the trailer.

Weight and Dimensions

A. HEIGHT SEE NOTE IN TABLE 1 C. WIDTH

B. LENGTH SEE NOTE IN TABLE 1

Figure 1. Complete Truck

2
8000 SRM 1181 Weight and Dimensions

Table 1. Complete Truck

Model Carriage Length Width

Standard pin-type 4,234 mm (166.6 in.) 2,245 mm (88 in.)
H8-9XM With fork positioner 4,284 mm (168.6 in.) 2,245 mm (88 in.)
H170-210HD2 Sideshift carriage 4,296 mm (169 in.) 2,245 mm (88 in.)
Add 115 mm (4 in.) for 3-stage mast.
Standard pin-type 4,474 mm (176 in.) 2,446 mm (96.2 in.)
H10-12XM With fork positioner 4,519 mm (177.9 in.) 2,446 mm (96.2 in.)
H230-280HD2 Sideshift carriage 4,526 mm (178.1 in.) 2,446 mm (96.2 in.)
Add 95 mm (3.7 in.) for 3-stage mast.
Standard pin-type 4,962 mm (195.3 in.) 2,607 mm (102.6 in.)
H13-16XM With fork positioner 4,962 mm (195.3 in.) 2,607 mm (102.6 in.)
H300-360HD2 3-stage Sideshift carriage 4,997 mm (196.7 in.) 2,607 mm (102.6 in.)
Add 100 mm (3.9 in.) for 3-stage mast.
H13-16XMEC
Total width too large for road transport.
H300-360EC
NOTE: The total weight of the truck must be calculated by adding up the weights shown in Table 2,
Table 3, Table 4 and Table 5.

NOTE: The total length of the truck must be calculated by adding up the length in Table 1 with the length
shown in Table 5.

NOTE: The total height of the truck is shown in Table 3, column Truck Height.

3
Weight and Dimensions 8000 SRM 1181

A. HEIGHT C. WIDTH
B. LENGTH

Figure 2. Basic Truck

Table 2. Basic Truck

Model Length Width Height "MIN" Weight "MAX" Weight

H190HD2 3,763 mm 2,425 mm 2,972 mm 9,400 kg 10,150 kg
H8.00-12.00XM (148 in.) (94.5 in.) (117 in.) (20,723 lb) (22,376 lb)
H210HD2 3,763 mm 2,425 mm 2,972 mm 9,700 kg 10,450 kg
H8.00-12.00XM (148 in.) (94.5 in.) (117 in.) (21,384 lb) (23,038 lb)
H230HD2 3,963 mm 2,425 mm 2,972 mm 10,700 kg 11,450 kg
H8.00-12.00XM (156 in.) (95.4 in.) (117 in.) (23,589 lb) (25,242 lb)
H250HD2 3,963 mm 2,446 mm 2,972 mm 10,900 kg 11,600 kg
H8.00-12.00XM (156 in.) (96.2 in.) (117 in.) (24,030 lb) (25,573 lb)
H280HD2 3,963 mm 2,446 mm 2,990 mm 11,550 kg 12,300 kg
H8.00-12.00XM (156 in.) (96.2 in.) (117.7 in.) (25,463 lb) (27,116 lb)
H300HD 4,363 mm 2,607 mm 3,021 mm 12,500 kg 13,700 kg
H13.00-14.00XM (171.7 in.) (102.6 in.) (118.9 in.) (27,557 lb) (30,203 lb)
H330HD 4,363 mm 2,607 mm 3,021 mm 13,200 kg 14,350 kg
H13.00-14.00XM (171.7 in.) (102.6 in.) (118.9 in.) (29,101 lb) (31,636 lb)

4
8000 SRM 1181 Weight and Dimensions

Table 2. Basic Truck (Continued)

Model Length Width Height "MIN" Weight "MAX" Weight

H360HD H16.00XM-6 4,363 mm 2,607 mm 3,201 mm 14,250 kg 15,400 kg
(171.7 in.) (102.6 in.) (118.9 in.) (31,415 lb) (33,951 lb)
H16.00XM-12EC 4,363 mm 2,607 mm 3,201 mm 13,200 kg 14,350 kg
H10.00-12.00XM-12EC (171.7 in.) (102.6 in.) (118.9 in.) (29,101 lb) (31,636 lb)
H12.00XM-12EC / 4,363 mm 2,607 mm 3,201 mm 14,900 kg 16,050 kg
H360HD-EC4 (171.7 in.) (102.6 in.) (118.9 in.) (32,848.8 lb) (35,384 lb)
NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank.

NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The
maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total
weight of the basic truck include the weight of following options:
• Add 200 kg (440.9 lb) for a closed cab.
• Add 50 kg (110 lb) for air conditioning.
• Add 90 kg (198.4 lb) for a completely topped up fuel tank.

NOTE: The total height of the basic truck is for trucks with an open cab and pneumatic tires.

Add 43 mm (1.6 in.) to the total height for trucks with a closed cab without air conditioning.

Add 78 mm (3 in.) to the total height for trucks with a closed cab with air conditioning.

5
Weight and Dimensions 8000 SRM 1181

Figure 3. Mast and Carriage

Table 3. Mast

Lift Height Length Width Height Weight Truck Height

2 Stage NFL H8-9XM
3,686 mm 3,066 mm 1,220 mm 567 mm 1,510 kg 3,361 mm
(145 in.) (120.7 in.) (48 in.) (22.3 in.) (3,328 lb) (132.3 in.)
4,586 mm 3,520 mm 1,220 mm 567 mm 1,670 kg 3,811 mm
(180.5 in.) (138.5 in.) (48 in.) (22.3 in.) (3,681 lb) (150 in.)
5,336 mm 3,895 mm 1,220 mm 567 mm 1,840 kg 4,186 mm
(210 in.) (153.3 in.) (48 in.) (22.3 in.) (4,056 lb) (164.8 in.)
2 Stage NFL H10-12XM
3,686 mm 3,368 mm 1,220 mm 597 mm 2,060 kg 3,642 mm
(145 in.) (132.5 in.) (48 in.) (23.5 in.) (4,541 lb) (143.4 in.)
4,586 mm 3,808 mm 1,220 mm 597 mm 2,270 kg 4,086 mm
(180.5 in.) (149.9 in.) (48 in.) (23.5 in.) (5,004 lb) (160.8 in.)
5,336 mm 4,193 mm 1,220 mm 597 mm 2,510 kg 4,461 mm
(210 in.) (165 in.) (48 in.) (23.5 in.) (5,533 lb) (175.6 in.)

6
8000 SRM 1181 Weight and Dimensions

Table 3. Mast (Continued)

Lift Height Length Width Height Weight Truck Height

6,130 mm 4,593 mm 1,220 mm 597 mm 2,670 kg 4,861 mm
(241.3 in.) (180.8 in.) (48 in.) (23.5 in.) (5,886 lb) (191.3 in.)
6,630 mm 4,843 mm 1,220 mm 597 mm 2,780 kg 5,111 mm
(261 in.) (190.6 in.) (48 in.) (23.5 in.) (6,128 lb) (201.2 in.)
3 Stage FFL H8-12XM
5,525 mm 2,845 mm 1,420 mm 590 mm 3,600 kg 3,055 mm
(217.5 in.) (97.8 in.) (55.9 in.) (23.2 in.) (7,936 lb) (120.2 in.)
5,925 mm 2,978 mm 1,420 mm 590 mm 3,600 kg 3,188 mm
(233.2 in.) (117.2 in.) (55.9 in.) (23.2 in.) (7,936 lb) (125.5 in.)
6,425 mm 3,145 mm 1,420 mm 590 mm 3,600 kg 3,355 mm
(252.9 in.) (123.8 in.) (55.9 in.) (23.2 in.) (7,936 lb) (132 in.)
6,925 mm 3,311 mm 1,420 mm 590 mm 3,600 kg 3,521 mm
(272.6 in.) (130.3 in.) (55.9 in.) (23.2 in.) (7,936 lb) (138.6 in.)
2 Stage NFL H13-16XM
3,660 mm 3,440 mm 1,220 mm 684 mm 2,506 kg 3,623 mm
(144 in.) (135.4 in.) (48 in.) (26.9 in.) (5,524 lb) (142.6 in.)
4,560 mm 3,890 mm 1,220 mm 684 mm 2,771 kg 4,073 mm
(179.5 in.) (153 in.) (48 in.) (26.9 in.) (6,109 lb) (160.3 in.)
5,310 mm 4,262 mm 1,220 mm 684 mm 3,119 kg 4,448 mm
(209 in.) (167.7 in.) (48 in.) (26.9 in.) (6,876 lb) (175.1 in.)
6,110 mm 4,661 mm 1,220 mm 684 mm 3,313 kg 4,848 mm
(240 in.) (183.5 in.) (48 in.) (26.9 in.) (6,862 lb) (190.8 in.)
6.610 mm 4,912 mm 1,220 mm 684 mm 3,439 kg 5,098 mm
(260.2 in.) (193.3 in.) (48 in.) (26.9 in.) (7,581 lb) (200.7 in.)
6,920 mm 5,151 mm 1,220 mm 684 mm 3,500 kg 5,365 mm
(272.4 in.) (202.7 in.) (48 in.) (26.9 in.) (7,716 lb) (211.2 in.)
9,910 mm 6,646 mm 1,220 mm 696 mm 4,000 kg 6,859 mm
(390 in.) (261.6 in.) (48 in.) (27.4 in.) (8,818 lb) (270 in.)
3 Stage FFL H13-16XM
4,310 mm 2,880 mm 1,500 mm 760 mm 3,262 kg 3,062 mm
(169.6 in.) (113.3 in.) (59 in.) (29.9 in.) (7,191 lb) (120.5 in.)
4,910 mm 3,080 mm 1,500 mm 760 mm 3,385 kg 3,262 mm
(193.3 in.) (121.2 in.) (59 in.) (29.9 in.) (7,462 lb) (128.4 in.)
5,910 mm 3,413 mm 1,500 mm 760 mm 3,591 kg 3,595 mm
(232.6 in.) (134.3 in.) (59 in.) (29.9 in.) (7,916 lb) (141.5 in.)
6,910 mm 3,747 mm 1,500 mm 760 mm 3,997 kg 3,930 mm
(272 in.) (147.5 in.) (59 in.) (29.9 in.) (8,811 lb) (154.7 in.)

7
Weight and Dimensions 8000 SRM 1181

Table 4. Carriage

Model Type Height Width Length Weight

Standard 1,225 mm 2,400 mm 370 mm 762 kg
(48.2 in.) (94.4 in.) (14.5 in.) (1,679.9 lb)
Standard with 1,125 mm 2,400 mm 420 mm 970 kg
H8-9XM fork positioner (48.2 in.) (94.4 in.) (16.5 in.) (2,138.4 lb)
H170-210HD Sideshift carriage 1,410 mm 2,400 mm 432 mm 1,266 kg
(55.5 in.) (94.4 in.) (17 in.) (2,791 lb)
Sideshift with 1,415 mm 2,400 mm 432 mm 1,358 kg
fork positioner (55.7 in.) (94.4 in.) (17 in.) (2,987 lb)
Standard 1,470 mm 2,400 mm 390 mm 912 kg
(57.8 in.) (94.4 in.) (15.3 in.) (2,993.8 lb)
Standard with 1,470 mm 2,400 mm 435 mm 1,160 kg
H10-12XM fork positioner (57.8 in.) (94.4 in.) (17.1 in.) (2,552 lb)
H230-280HD Sideshift carriage 1,470 mm 2,400 mm 442 mm 1,311 kg
(57.8 in.) (94.4 in.) (17.4 in.) (2,557.3 lb)
Sideshift with 1,470 mm 2,400 mm 442 mm 1,429 kg
fork positioner (57.8 in.) (94.4 in.) (17.4 in.) (3,150.4 lb)
Standard 1,590 mm 2,550 mm 465 mm 1,382 kg
(62.5 in.) (100.3 in.) (18.3 in.) (3,046.7 lb)
Standard with 1,590 mm 2,550 mm 465 mm 1,450 kg
H13-16XM fork positioner (62.5 in.) (100.3 in.) (18.3 in.) (3,196.7 lb)
H300-360XM Sideshift carriage 1,600 mm 2,550 mm 500 mm 1,784 kg
(62.9 in.) (100.3 in.) (19.6 in.) (3,993 lb)
Sideshift with 1,600 mm 2,550 mm 500 mm 3,485 kg
fork positioner (62.9 in.) (100.3 in.) (19.6 in.) (7,683 lb)

8
8000 SRM 1181 Weight and Dimensions

Legend for Figure 4

A. WIDTH
B. HEIGHT
C. LENGTH

Figure 4. Forks

Table 5. Forks

Model Type Width Height Length Weight

H8-9XM Pin-Type Fork 400 mm 934 mm 2,550 mm 528 kg
H170-210HD (15.7 in.) (36.7 in.) (100.3 in.) (1,164 lb)
Pin-Type Fork 400 mm 934 mm 2,550 mm 692 kg
H8-12XM (15.7 in.) (36.7 in.) (100.3 in.) (1,525 lb)
H170-280HD DF-SS-FP Fork 400 mm 941 mm 2,643 mm 630 kg
(15.7 in.) (37 in.) (104 in.) (1,388 lb)
Pin-Type Fork 400 mm 1,069 mm 2,560 mm 844 kg
H13-16XM (15.7 in.) (42 in.) (100.7 in.) (1,860 lb)
H300-360HD DF-SS-FP Fork 400 mm 1.070 mm 2,668 mm 894 kg
(15.7 in.) (42.1 in.) (105 in.) (1,970 lb)

9
Weight and Dimensions 8000 SRM 1181

A. WIDTH C. HEIGHT
B. LENGTH

Figure 5. Container Attachment

Table 6. Container Attachment

Model Length Height Width Weight

ECH Attachment 6,100 mm 2,551 mm 850 mm 4,100 kg
(240 in.) (100.4 in.) (33.4 in.) (9,038.9 lb)

10
8000 SRM 1181 Loading Procedures

Loading Procedures
LOADING A TRUCK ON A TRANSPORT
WARNING
Stay a safe distance from the edge of docks,
ramps, platforms, and other similar working surfa-
ces. Watch the "tail swing". Remember when trav-
eling in the forward direction and the steering
wheel is turned to move the lift truck away from
the edge of the dock, the rear will swing toward
the edge. This can cause the lift truck to fall off
the dock.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO
NOT JUMP OFF! HOLD FIRMLY TO STEERING
WHEEL, BRACE YOUR FEET, AND LEAN FOR-
WARD AND AWAY FROM THE POINT OF IMPACT.
LOADING DISASSEMBLED
COMPONENTS
1. Put blocks under the disassembled components
for stability during transport and to allow load-
ing and unloading with a fork lift.
2. When lifting the components with slings and/or
hooks, attach these at the indicated lifting
points and/or lifting eyes. Make sure the lifting
device has the required capacity. See Table 1
through Table 5 for the weights of the compo-
nents and the suggested location for the slings
and hooks.

Before the lift truck is moved on transport, check

the selected route to make sure there is enough
clearance for the lift truck as loaded on the trans-
port vehicle. Bridges, overpasses, power lines, and
natural barriers can prevent clearance. Removal of
the mast can be necessary.

If a trailer is the method of transportation, use

blocks in front and back of the trailer tires to pre-
vent movement of the trailer when the lift truck is
loaded and unloaded. If a loading ramp is used,
make sure that the ramp is the correct design and
capacity.

A crane can only be used to load or unload the lift

truck with the mast assembled. When lifting a com-
plete truck, use rear lifting eyes in combination 1. TIE DOWN POINT
with mast lifting eyes. If the mast has been re-
moved, the lift truck must be driven on or off the Figure 6. Lift Truck Tie Down Placement
transport.

11
Loading Procedures 8000 SRM 1181

Legend for Figure 7

1. SLING OR TIE DOWN POINT

2. WOODEN BLOCKS OR PALLETS

Figure 7. Mast and Carriage Tie Down Placement

Unloading Procedures
UNLOADING COMPLETE TRUCK OR 6. Using lifting devices with required capacity at-
BASIC TRUCK FROM TRANSPORT tach to lifting points shown in Figure 8.

Lifting

WARNING
Use rear lifting eyes in combination with mast lift-
ing eyes when lifting complete truck. DO NOT lift
basic truck with mast removed.

To lift the complete truck with the mast, use the

lifting points and/or lifting eyes as indicated on Fig-
ure 8. For the required capacity of the lifting devi-
ces, Table 2.

1. If used, remove any protective cover.

2. Make sure the parking brake is applied.

3. Disconnect the slings or chains that secure the 1. LIFTING POINTS (LOCATED ON BOTH SIDES
truck to the trailer. OF LIFT TRUCK)

4. Remove the wheel blocks. Figure 8. Complete Truck Lifting Points

5. Check that all switches and accessories are

switched OFF.

12
8000 SRM 1181
Driving On/Off a Trailer
When the truck will be driven from a trailer make
sure to have read and understood the Starting Pro-
cedures as described in the Operating Manual.
1. Make sure the parking brake is applied.
2. Disconnect the straps or chains that attach the
truck to the trailer.
3. Remove the wheel blocks.
4. Start the truck, release the park brake and let
a assistant provide directions when driving off
the trailer.
5. Park the truck. Apply the hand brake and turn
the ignition OFF.
See the procedures under Moving a Disabled Lift
Truck if the truck cannot be started and must be
moved.
See the procedures under Adding Air Pressure to
the Tires if air pressure in one of the tires is less
than 80% of the pressure as indicated on the name-
plate.
UNLOADING DISASSEMBLED
COMPONENTS
To lift the components from a transport either use a
fork lift or attach hooks and/or slings to the lifting
eyes and slinging points as indicated on Figure 6
through Figure 7.
WARNING
DO NOT use the bores for the mast pivot and the
tilt cylinder mounting as a slinging point.
Use rear lifting eyes in combination with mast lift-
ing eyes when lifting complete truck. DO NOT lift
basic truck with mast removed.
Unloading Procedures
For the required capacity of the lifting device. Ta-
ble 2 through Figure 4 for the weights of the compo-
nents.
Use blocks to support the component when tempo-
rarily storing the component on the ground.
The blocks for the attachment must be high enough
to keep the twistlocks from the ground.
The blocks for the carriage must be high enough to
keep the fork guides from the ground.
REMOVAL OF FORKS ATTACHED TO
BASIC TRUCK
1. Put blocks under the tips of the forks.
2. Support the plate under the forks and remove
the four attaching nuts and capscrews. Remove
the plate. See Figure 9.
3. Position a lifting device with a pallet under the
two forks and support the weight of the forks.
Remove the blocks under the tips of the forks.
4. Remove the two bolts that attach the two upper
plates to the lift truck frame.
5. Lower the pallet with the forks.
6. Remove the two rod ends that are attached to
the mast mounting pins.
7. Remove the four plates that connect between
forks and frame. Secure the mast mounting
pins.
8. Remove the tube from the forks and move the
forks away from the truck.
13
Unloading Procedures 8000 SRM 1181

1. NUT AND CAPSCREW 5. BOLT

2. PLATE 6. PLATE
3. BLOCK 7. ROD END
4. MAST MOUNTING PIN 8. TUBE

Figure 9. Forks to Basic Truck

REMOVAL OF FORKS ATTACHED TO 2. Lower the fork on a pallet.

THE CARRIAGE 3. Remove the securing bolt from the bracket and
1. Put a lifting device under the upper fork and slide the bracket out of the fork.
lift the fork until the bracket at the carriage 4. Remove the rubber plate on the lower fork.
has released. While lifting, pay attention that
the bracket moves over the carriage plate. See
Figure 10.

1. BRACKET 4. RUBBER PLATE

2. SECURING BOLT 5. BRACKET
3. CARRIAGE PLATE
Figure 10. Forks to Carriage

14
8000 SRM 1181
5. Remove the lower fork by following Step 1
through Step 3.
Truck Assembly
SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST
The following procedures must be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast. Follow the repair
procedures in this section.
•
WARNING
Mast parts are heavy and can move.
Distance between parts are small. Se-
rious injury or death can result if part
of the body is hit by parts of the mast
or the carriage.
• Never place any part of the
body into or under the mast or
carriage unless all parts are
completely lowered or a safety
chain is installed. Also make
sure that the power is OFF and
the key is removed. Place a DO
NOT OPERATE tag in the oper-
ators compartment.
• Be careful of the forks. When
the mast is raised, the forks
can be at a height to cause an
injury.
• DO NOT climb on the mast or
lift truck at any time. Use a lad-
der or personnel lift to work on
the mast.
• DO NOT use blocks to support
the mast weldments nor to re-
strain their movement.
• Mast repairs can require disas-
sembly and removal of parts
and can require removal of the
mast or carriage. Follow the re-
pair procedures in the correct
Service Manual for the mast.
Unloading Procedures
6. Remove the bracket that hooks on the lower
carriage bar.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make
sure there is no movement in the mast. Make
sure that all parts of the mast that move are
fully lowered.
OR
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving
parts of the mast. Connect moving parts to a
part that does not move. Follow these proce-
dures:
a. Place the mast in a vertical position.
b. Raise the mast to align the bottom cross-
member of the inner weldment with a
crossmember on the outer weldment. See
Figure 11.
c. Use a safety chain, which can hold a
minimum of 20,000 kg (44,093 lb), with a
hook to fasten the cross member together
so that the movable member cannot
lower. Place the hook on the back side of
the mast. Make sure the hook is com-
pletely engaged with a link in the chain.
Make sure the safety chain does not
touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the
mast. See Figure 11.
d. Lower the mast until there is tension in
the safety chain. If running, stop the en-
gine. Apply the parking brake. Install a
DO NOT REMOVE tag on the safety
chain(s). e.
e. Install another safety chain (½ inch min-
imum) between the top or bottom cross-
member of the carriage and a crossmem-
ber on the outer weldment.
15
Truck Assembly 8000 SRM 1181

4. Turn the key switch to the ON position.

5. Operate the lift and tilt levers completely for-

ward and backward to remove any trapped hy-
draulic pressure.

6. Apply and release the brake pedal until no re-

sistance is felt when fully depressing the brake
pedal.

7. Turn the key switch to the OFF position.

8. Place blocks against both sides (front and back)

of the tires to prevent movement of the lift
truck.

9. Connect a lifting device to the lifting eyes on

the outer mast. See Figure 12.

1. OUTER MAST 10. Position the mast in front of the truck.

2. HOOK
11. Lower the mast hanger on the mast mounting
Figure 11. Mast Safety Chains pins. See Figure 13.

3. Apply the parking brake. After lowering or re-

straining the mast, shut off the power and re-
move the key. Place a DO NOT REMOVE tag
in the operators compartment.

MAST INSTALLATION

WARNING
When working on or near the mast, review and fol-
low the Safety procedures When Working Near
the Mast.

Verify that the mast lifting device has the correct

capacity rating to lift the mast assembly. See Ta-
ble 3.

Preparations
1. Place the lift truck on a solid, level surface.
1. LIFTING EYES
2. Apply the parking brake.
Figure 12. Lifting Eyes
3. Switch the engine OFF.

16
8000 SRM 1181 Truck Assembly

c. Operate the lifting device and position

the mast so the tilt cylinder holes in the
mast bracket and tilt cylinder rod can be
aligned.
d. Lift the tilt cylinders to align the holes in
the rods with the holes in the mast, and
install the tilt cylinder pins to connect
the tilt cylinders to the mast. See Fig-
ure 14.
e. Install the cap screws and large washers
to retain the tilt cylinder keepers to the
tilt cylinder pins.
f. Install the cap screws and washers to re-
tain the tilt cylinder keepers to the mast.

14. Disconnect the lifting device from the lifting

eyes of the outer mast.

15. Remove the caps at the base of the lift cylinders

and the plugs in the hydraulic hoses.
1. MAST 16. Connect the hydraulic hose at the base of each
2. CAP SCREWS lift cylinder.
3. GREASE FITTING
4. SHIM 17. Remove plugs at the end of the hydraulic
5. FRAME
6. BUSHING header hoses.
7. MAST MOUNTING PIN
18. Remove the caps from the fittings at the lower
Figure 13. Mast Mount to Frame mast bracket.

19. Connect the hydraulic header hoses to the

NOTE: Make sure that before installation, the lower mast bracket.
mast mounting pins are completely free of grease at
20. Connect the mast cable with the frame harness
the conical faces that contact the frame, respec-
connector.
tively the outer cap.
21. Install the carriage to the mast if delivered sep-
12. Connect mast pins with hangers using 4 cap
arately. Refer to the section Carriage, Install.
screws.
a. For lift truck models H007, J007, and 22. Start the engine and operate the hydraulic sys-
K007, tighten caps crews to tem. Check that the mast and carriage operate
435 N•m (321 lbf ft). correctly.
b. For lift truck models G019, H019, and
J019, tighten cap screws to WARNING
522 N•m (385 lbf ft). DO NOT try to locate hydraulic leaks by placing
hands on pressurized hydraulic components. Hy-
13. Connect the tilt cylinders to the mast as fol-
draulic oil can be injected into the body by pres-
lows:
sure.
a. Start the engine.
b. Extend the tilt cylinders until the rods 23. Check for leaks.
are almost in the correct position. 24. Remove blocks on both sides (front and back) of
the tires.

17
Truck Assembly 8000 SRM 1181

6. Make sure the dimension "X" is about

13 mm (0.51 in.). The maximum allowable dis-
tance is 15 mm (0.59 in.).

7. If one of the threads extends more than

15 mm (0.59 in.), turn both cylinder rods into
the rod end.

8. After the adjustments have been completed,

make sure the wrench flats of the rods are at
the upper and lower side. Having the wrench
flats at the sides of the rods increases stress
level.

9. Tighten the nuts to secure the rod end to

225 N•m (166 lbf ft).

Connecting the Lift Cylinders

1. Before connecting the lift cylinders, remove hy-
draulic pressure from the system. Follow the
procedures in chapter Before Starting Repairs
1. TILT CYLINDER To The Hydraulic System Always.
2. ROD END
3. CAP SCREW 2. Remove the caps at the base of the lift cylinders
4. ANCHOR PIN and the plugs in the hydraulic hoses.
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (K007 ONLY)
10. HYDRAULIC LINES
11. PLUG

Figure 14. Tilt Cylinder

Adjusting the Tilt Cylinders

1. Slowly tilt the mast backward until one rod is
against its stop. Adjust the opposite cylinder if
it stops more than 1.0 mm (0.04 in.) later.

2. To adjust the tilt cylinder, loosen the nuts on

the rod end. See Figure 15.

3. Insert a wrench on the wrench flat to turn the

tilt cylinder rod out of the rod end.

4. Repeat the procedure until both rods stop at

the same time within 1.0 mm (0.04 in.) in the NOTE: X = ROD END THREAD DISTANCE
maximum back tilted position.
1. ROD
5. Check that the tilt angles are correct as speci- 2. WRENCH FLAT
fied on the nameplate of the lift truck. A limited 3. NUTS
tilt angle correction can be made by turning 4. ROD END
both cylinder rods the same amount. Figure 15. Tilt Cylinder Adjustment

18
8000 SRM 1181 Truck Assembly

3. Connect the hydraulic hoses at the base of each 3. Connect the hydraulic header hoses to the
lift cylinder. lower mast bracket.

Connecting the Mast Supply Hoses 4. Connect the electrical supply cable to the con-
nector for the mast cable.
1. Remove plugs at the end of the three hydraulic
header hoses.

2. Remove the caps from the fittings at the lower

mast bracket. See part A. Mast Side from Fig-
ure 16.

A. MAST SIDE
Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply T3 T Yellow
2 Supply A (AUX) P Green
4 Breather Hose N/A N/A White/Green
5 Electric Cable N/A N/A CRP139/ CPS148
B. CARRIAGE SIDE
Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply Aux B B1 Green/Green
2 Supply Aux A A1 Green/Yellow
3 Drain T (AUX) T0 White/Green
5 Electric Cable N/A N/A CRP139/ CPS148

Figure 16. Header Hoses

19
Truck Assembly 8000 SRM 1181

CARRIAGE AND FORKS

Installing the Carriage
1. Place blocks at the front and the back of all
tires to prevent movement of the lift truck.
WARNING
DO NOT try to locate hydraulic leaks by placing
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.

2. Attach a lifting device to the carriage.
3. Lift the carriage and move it in front of the
mast. Make sure that the upper and lower load
rollers are aligned with the inner mast channel.
Correct the carriage position as necessary
5. Start the engine and operate the hydraulic
functions on the carriage. Make sure that the
functions operate correctly. Check for leaks.
6. Remove the blocks that have been placed at
both sides of the tires.

4. Start the engine and operate the lift cylinders Install the Forks
to raise the inner mast until the mast channels
are well above the upper bearing blocks. Tilt Installing Pin-Type Forks
the mast backward until the mast and carriage
have the same tilt position. 1. Put the mast in a vertical position and lower
the carriage almost completely.
5. Move the carriage to position the upper bearing
blocks into the inner mast channels. 2. Position the fork guides half way the carriage,
in front of the lift chains.
6. Lower the mast slowly and carefully align the
upper bearing blocks with the mast channels.
DO NOT damage the bearing blocks when they
enter the mast channel.

7. Lower the mast further and align the lower

bearing blocks with the mast channels.

8. Lower the mast to enter the lower load rollers

into the mast channels.

9. Lower the mast completely.

10. Connect the lift chains to the chain anchors by

installing the chain pin and snap ring at both
sides of the carriage.

11. Lower the lifting device, detach and remove it

from the carriage.

Connecting the Header Hoses to the Carriage

1. Remove caps and plugs from the header hoses
and the fittings on the carriage bracket.
1. HEADER HOSES
2. Connect the header hoses to the fittings on the 2. MAST CABLE CLAMP
carriage bracket. See part B. Carriage Side of 3. MAST CABLE CONNECTOR
Figure 16. 4. LOCKING BOLT
5. ADJUSTMENT BOLT
3. Maintain tension on the electric mast cable and
Figure 17. Carriage Bracket
tighten the cable clamp. See Figure 17.

4. Attach the electrical connector.

20
8000 SRM 1181 Truck Assembly

3. Attach a lifting strap to a lifting device and to
the fork guide. The fork guide weighs
23.8 kg (52.5 lb). Put tension on the lifting
strap until it carries the weight of the fork
guide.
4. Remove the cap screws and the bracket that re-
tain the fork pin to the carriage. The fork pin
weighs 63 kg (139 lb). See Figure 18.
a. For carriages with manual fork positioning,
attach a lifting device to the fork pin with a
sling about one foot from the inner end of the
pin. Move the pin until there is sufficient
space to install the fork.
b. For carriages with hydraulic fork position-
ing, move the fork pin out of the carriage un-
til its inner end is still inside the side plate
of the fork guide.
5. Place each fork on a separate pallet. For fork
weights, see Table 5.
6. Use a hydraulic jack or hand pallet wagon to
position a fork in the fork guide, while the back
of the fork touches the carriage.
7. Make sure the retainer bracket at the heel of
the fork has passed the edge at the underside of
the carriage.
8. Lift the fork on the pallet until the fork pin
aligns with the pin tube of the fork.
9. Slide the fork pin through the fork pin tube to
its final mounting position in the carriage.
10. A spacer may have been installed between the
two fork pins in the central carriage bracket
that holds the two inner ends of the fork pins.
Make sure that this possibly installed spacer is
put back.
11. Install the bracket with the four cap screws
that retain the fork pin to the carriage. Torque
the bolts to 66 N•m (49 lbf ft).

12. Lift the fork bracket at the heel of the fork and
install the fork locking pin. Install the retainer
pin to secure the fork locking pin. See Fig-
ure 19.

1. CAP SCREW
2. PIN RETAINER BRACKET
3. FORK PIN
4. FORK GUIDE 1. CARRIAGE
5. FORK 2. FORK
6. CARRIAGE 3. FORK LOCKING PIN
4. RETAINER PIN
Figure 18. Pin-Type Fork 5. BRACKET
Figure 19. Locking Pin

21
Truck Assembly 8000 SRM 1181

13. Apply grease to the brackets of the fork guide

and the fork positioning cylinder.

14. Extend the fork positioning cylinder and install

the bracket pin to connect the cylinder with the
fork guide. See Figure 20.

15. Install the split pin to secure the bracket pin.

16. On carriages with manual fork positioning: put

the forks into the desired position and install
the clamps against the forks to secure the forks.
See Figure 21.

17. Repeat Step 1 through Step 16 to install the re-

maining fork.

Installing Quick Disconnect DFSSFP Forks

NOTE: For fork weights see Table 5.

1. Place each fork on a pallet. Install the forks one

at a time.
1. FORK CLAMP
2. Tilt the mast about five degrees forward and 2. CARRIAGE
3. FORK
lower the mast completely.
Figure 21. Fork Clamps

3. Move the truck until one fork hanger aligns

and touches a fork.

4. Carefully raise the mast until the fork tip is

slightly lifted.

5. Make sure that the fork is properly seated and

that the fork retainer bracket at the heel of the
fork is correctly positioned.

6. Tilt the mast completely backwards.

7. Install the locking pin at the heel of the fork

and secure it with the retainer pins. See Fig-
ure 22.

8. Make sure the ring of the retaining pin springs

back and is seated against the locking pin.

9. Repeat Step 1 through Step 8 to install the

other fork.
1. FORK POSITIONER CYLINDER
2. BRACKET PIN
3. SPLIT PIN
4. CARRIAGE
5. FORK GUIDE

Figure 20. Fork Guide

22
8000 SRM 1181 Truck Assembly

1. CARRIAGE 1. CAP SCREW

2. FORK 2. DOWEL BUSHING
3. LOCKING PIN 3. WASHER
4. RETAINER RING 4. CAP SCREW
5. FORK HANGER 5. BRACKET PIN
6. FORK POSITIONER CYLINDER
Figure 22. Quick Disconnect DFSSFP Fork 7. FORK BRACKET

Figure 23. Integrated DFSSFP Fork

Installing Integrated DFSSFP Forks
NOTE: For fork weights see Table 5. Adjusting the Carriage

1. Place a hand pallet wagon at the side of and

parallel to the carriage.
2. Connect a lifting device to the lifting eye on the
fork, raise the fork and align it with the car-
riage bars. Raise the hand pallet wagon if nec-
essary.
3. Slide the fork on the carriage by simultane-
ously moving the lifting device and the wagon.
4. Reinstall the fork positioner bracket to the fork.
See Figure 23.
5. Repeat Step 1 through Step 4 to install the re-
maining fork.
CAUTION
The carriage can be set higher and lower on the
lift chain anchor, however the carriage load rollers
must remain within the inner mast channel both in
the lowest and in the highest carriage positions to
avoid damage to the lift truck.
NOTE: The purpose of carriage adjustment is to
align the carriage in the inner mast and to position
the forks at the required height when the carriage
is completely lowered. Carriage alignment is re-
quired when chains, chain anchors or carriage is re-
placed. Carriage alignment is also required when
the carriage does not lift and lower smoothly. A
symptom is that one of the chains has a lower ten-
sion and shows bigger deflection compared with the
other chain. Incorrect carriage alignment causes
premature wear of bearing blocks. Alignment of the
carriage is obtained by adjusting two chain anchors
individually.

23
Truck Assembly 8000 SRM 1181

1. Put the mast in a vertical position and lower

the carriage completely.

2. Side shift the carriage until it is at the centered

line of the mast.

3. Move both forks into the maximum extended

position.

4. Loosen the chain anchor securing nut. See Fig-

ure 24.

5. Make sure that the clearance between the forks

or the attachment and the ground has at least
1 cm (0.40 in.). Turn the large nuts on both
chain anchors if necessary.

6. Measure that the vertical carriage bar runs

parallel with the inner mast channel. Apply an
accuracy of 0.5 mm per 50 cm (0.025 in. per 2
feet). See Figure 25.

A. MEASURING POINT
B. MEASURING POINT
1. CARRIAGE
2. INNER MAST
3. OUTER MAST

Figure 25. Lift Chain Adjustment

7. Tighten the large nut of the chain anchor that

is in the lowest position to align the vertical
carriage bar with the inner mast channel.

8. Tighten the lock nuts to

150-200 N•m (110-150 lbf ft).

Adjusting Header Hose Tension

1. Make sure that the lift chains are tensioned
and correctly adjusted.

2. Remove the locking bolt for the carriage

1. CARRIAGE bracket and loosen the adjustment bolts.
2. CHAIN ANCHOR
3. CHAIN ANCHOR NUT
4. RETAINER WASHER 3. Put the carriage bracket in the highest position.
5. RETAINER NUT
6. WASHER 4. If necessary, adjust the fittings on the carriage
7. RETAINER BRACKET bracket to match the different hose lengths.
8. WASHER
9. CHAIN ANCHOR SECURING NUT 5. Slide the carriage bracket down to put the
10. RETAINER BOLT header hoses under tension. The required elon-
gation is between 1% and 2%. Move the bracket
Figure 24. Chain Anchor on Carriage
in a position that best matches with the hole for
the locking bolt.

24
8000 SRM 1181 Truck Assembly

6. Insert and tighten the bolt that locks the hose
bracket to the carriage. Tighten the two adjust-
ment bolts.
7. Check tension on the electric mast cable and
adjust if necessary.
Adjusting the Electrical Cable Tension
INSTALLING THE CAB LIGHTS
NOTE: Cab lights may have been removed, or in-
stalled upside down for transport.
1. Remove the hardware that retains the bracket
of the light assembly, or remove the plugs that
cover the threads.

1. Make sure that the lift chains and header hoses 2. Install the light assemblies in the correct posi-
are adjusted and tensioned. tion. See Figure 27.

2. Loosen the mast cable clamp at the carriage 3. Connect the electrical connectors and check the
bracket. lights for correct operation.

3. Pull and hold the cable at the same tension as 4. Tighten the bolts to 35 N•m (26 lbf ft).
the header hoses.

4. Tighten the cable clamp at the carriage

bracket.

1. DRIVE LIGHTS
2. REAR LIGHTS
3. BEACON

Figure 27. Cab Lights

1. HEADER HOSES
2. MAST CABLE CLAMP
3. MAST CABLE CONNECTOR
4. LOCKING BOLT
5. ADJUSTMENT BOLT

Figure 26. Carriage Bracket

25
Truck Assembly 8000 SRM 1181

ADDING THE MAST LABELS

WARNING
When working on or near the mast, review and fol-
low the Safety Procedures When Working Near
Mast.

NOTE: The mast labels are stored in the card box

located inside the operator’s cab. The labels were
not installed prior to shipment to prevent damage.

1. Clean the mast in the areas of label placement

prior to affixing the labels. Clean the mast with
a solvent or high pressure washer using a wa-
ter soluble degreaser with warm water.

2. Attach the Hyster label to the left-hand and

right-hand outer mast channel. See Figure 28,
item 1.

3. Attach the mast warning label to the left-hand

and right-hand outer channel as shown in Fig- 1. HYSTER LABEL
ure 28, item 2. 2. MAST WARNING LABEL
3. MAST WARNING LABEL
4. Attach the mast warning label to the left-hand
and right-hand outer channel as shown in Fig- Figure 28. Mast Labels
ure 28, item 3.

LUBRICATION POINTS
Apply lubricant to the following items. See the Op-
erating Manual for the location of these mainte-
nance points and for Approved Oils, Fluids and
Grease.

Lift Chains 2 Chains Lubricate with engine oil SAE 15W-40

Mast Pivot Pins 2 Fittings Lubricate under no load condition with
multi-purpose grease with MoS2 additive
Tilt Cylinder Pivot Pins 4 Fittings Grease fittings with multi-purpose grease
Fork Pin and Guides Sliding Surfaces Lubricate pins and contact surfaces using
multipurpose grease for metal to metal
contact areas.
DFSSFP Forks Pad Wear Area Grease with Molykote EM-30L for plastic
wear pads on DFSSFP carriages.

26
8000 SRM 1181 Pre-Delivery Inspection

Pre-Delivery Inspection
EMPTY SEAT ENGINE SHUT DOWN

The engine will automatically shut down 15 mi-

nutes after the operator has left the truck seat.
Verify which timing for engine shut down has been
ordered by the customer and adjust the timer ac-
cordingly. The timer for empty seat engine shut
down is located in the side console. Remove the fuse
panel cover and unhook the relay from its bracket.
See Figure 29 for its location. Adjust the relay by
turning the phillips screw that is visible through
the top cover of the relay.

The relay can be adjusted between 30 seconds in

the farthest anti-clockwise position and 15 minutes
in the farthest clockwise position. Never adjust the
shut down time to a value lower than 5 minutes to
make sure that the engine turbo will cool down suf-
ficiently before the engine is turned off automati-
cally. Measure and eventually re-adjust the shut
down time. Reposition the timer and close the fuse
cover.

Pre-Delivery Inspection

Perform a Pre-delivery Inspection and complete the

Pre-delivery Inspection Report, per the Dealer
Service Operations Manual’.

1. RELAY
2. ADJUSTMENT SCREW

Figure 29. Engine Shut Down Timer Relay

27
Wheels and Tires
Wheels and Tires
REMOVE WHEELS FROM LIFT TRUCK
WARNING
The type of tire and tire pressure are shown on
the nameplate. Make sure the nameplate is correct
for the type of tires on the lift truck.
Wheels and tires must be changed and repaired
by trained personnel only.
Always wear safety glasses.
Always use a tire inflator with a clip-on chuck
when deflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) length.
During deflation or when adjusting the tire pres-
sure, the technician must not stand in-line with
the axis of the wheel. See Figure 30.
Adjusting tire pressure is allowed only if residual
air pressure exceeds 80% of the pressure as indi-
cated on the nameplate.
If the tire is removed from the truck and flat on the
ground, the technician should not have any body
part within the diameter of the tire when adjusting
the tire pressure. See Figure 31.
Wheels can explode and cause injury or death if
the above procedures are not followed.
1. ACCURATE IN-LINE PRESSURE GAUGE
Figure 30. Adjusting and Deflating Position
28
8000 SRM 1181
1. HOSE LONG ENOUGH FOR USER TO STAND
OUTSIDE POTENTIAL TRAJECTORY OF EX-
PLOSION
Figure 31. Adjusting Tire Pressure Position
CAUTION
Lift truck wheels are very heavy, use caution
when removing wheels or personal injury may oc-
cur.
1. Raise the lift truck as described in Periodic
Maintenance 8000SRM1939, Putting a Lift
Truck on Blocks.
2. Attach a tire inflator as described above. Note
tire pressure. After air is drained from tire,
check the tire pressure to ensure there is no re-
sidual pressure. Remove chuck. Remove the
tire stem valve core. Push a wire through the
valve stem to make sure that the stem does not
have a blockage causing a flow restriction. For
dual tires, remove air pressure from both tires
using the described procedure before loosening
the wheel nuts.
WARNING
Lift truck wheels are heavy and can cause per-
sonal injury.
3. Remove the wheel nuts and remove the wheel
from the lift truck. Be careful NOT to damage
the studs when removing the wheels.
4. Use a tire jack to remove the wheel assembly.
8000 SRM 1181 Wheels and Tires

REMOVE PNEUMATIC TIRE FROM WHEEL

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 32 and Remove Pneumatic Tire From Wheel.

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

WARNING
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause serious injury. See Figure 32.

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

Figure 32. Types of Wheels

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

29
Wheels and Tires 8000 SRM 1181

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

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

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

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

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

30
8000 SRM 1181 Wheels and Tires

INSTALL PNEUMATIC TIRE ON WHEEL

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 32.

WARNING
Wheels can explode and cause injury or death if the following procedures are not followed:
• Clean and inspect all parts of the wheel before installing the tire.
• Inspect all wheel components for deformation, corrosion and fractures.
• Look for fractures at the contact area between tire and wheel parts in particular.
• Unacceptable deformation includes progressed wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the above defects, and replace by new ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.

Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts to-
gether. Make sure that the lock ring is in the correct position. The ends of the lock ring must not touch.
The clearance at the ends of the lock ring will be approximately 4 to 14 mm (0.15 to 0.55 in.) after it is
installed. If the clearance is wrong, the wrong part has been used.

STEP 1.
Clean and inspect all parts of the wheel. If the wheel has rust or corrosion, remove loose rust and corrosion
and paint the parts.

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

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

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

31
Wheels and Tires 8000 SRM 1181

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

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

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

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

32
8000 SRM 1181 Wheels and Tires

ADDING AIR PRESSURE TO THE TIRES
WARNING
Add air pressure to the tires only in a safety cage.
Inflating or adjusting tire pressure outside of a
cage is allowed only if residual air pressure ex-
ceeds 80% of the pressure as indicated on the
nameplate.
5. Check that all wheel parts are correctly instal-
led. If installation is not correct, remove all of
the air pressure from the tire. Remove the
valve core to make sure all of the air pressure
has been removed and make adjustments. The
clearance at the ends of the lock ring will be 4
to 14 mm (0.15 to 0.55 in.) when the tire has
the correct air pressure.

Inspect the safety cage for damage before use.

Always use a tire inflator with a clip-on chuck

when inflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in length.
During inflation the technician must stand away
from the safety cage. See Figure 33.

Do not use a hammer to try and correct the posi-

tion of the side flange or lock ring when the tire
has air pressure greater than 20 kPa (3 psi).

WARNING
Wheels can explode and cause injury or death if
the above procedures are not followed.

1. Put the tire in a safety cage. See Figure 33.

2. Add 20 kPa (3 psi) of air pressure to the tire. 1. QUICK-RELEASE COUPLING

3. Check that all wheel parts are correctly instal- Figure 33. Adding Air Pressure to the Tire
led. Hit the side ring and/or lock ring lightly to Position
make sure that it is in the seat.

4. If installation is correct, add air pressure to the

tire. The correct pressure is shown on the
Nameplate.

33
Wheels and Tires 8000 SRM 1181

REMOVE SOLID RUBBER TIRE FROM WHEEL

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 32.

WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to cause
serious injury. See Figure 32.

Always use a cage when removing the solid rubber tire from the rim or personal injury may occur.

STEP 1.
Put the wheel rim on the bed of the press. Put the
cage in position on the tire. Use the press to push
the tire away from the side ring.

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

34
8000 SRM 1181 Wheels and Tires

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

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

35
Wheels and Tires 8000 SRM 1181

INSTALL SOLID RUBBER TIRE ON WHEEL

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Types of Wheels.

WARNING
Wheels can explode and cause injury or death if the following procedures are not followed:
• Clean and inspect all parts of the wheel before installing the tire.
• Inspect all wheel components for deformation, corrosion and fractures.
• Look for fractures at the contact area between tire and wheel parts in particular.
• Unacceptable deformation includes progressed wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the above defects, and replace by new ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.

Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts to-
gether. Make sure that the lock ring is in the correct position. The ends of the lock ring must not touch.
The clearance at the ends of the lock ring will be approximately 4 to 14 mm (0.15 to 0.55 in.) after it is
installed. If the clearance is wrong, the wrong part has been used.

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

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

36
8000 SRM 1181 Wheels and Tires

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

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

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

37
Wheels and Tires 8000 SRM 1181

INSTALL WHEELS ON LIFT TRUCK

Align and Install the wheel(s) and tire(s) on the

hub.

CAUTION
Check all wheel nuts after 2 to 5 hours of opera-
tion, when new lift trucks begin operation, and on
all lift trucks when the wheels have been removed
and installed. Tighten the nuts as shown in Fig-
ure 34. When the nuts stay tight for 8 hours, the
interval for checking the torque can be extended
to 250 hours.

Start with the wheel nut at the top and tighten the
nuts to 68 to 136 N•m (50 to 100 lbf ft) in the se-
quence shown in Figure 34 Check to make sure Figure 34. Wheel Nut Tightening Sequence
that the wheel(s) is tight against the hub, then
tighten the nuts to 615 to 710 N•m (454 to
524 lbf ft).

Moving and Towing

MOVING A DISABLED LIFT TRUCK 2. Remove the screw cap. See Figure 35.

3. Loosen the lock nut.

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

WARNING
When the parking brake is manually released, the
lift truck does not have any brake function. Block
the wheels to prevent the lift truck from moving. If
the wheels are not blocked, serious personal in-
jury and damage to components can occur.

The parking brake caliper is mounted on a support

bracket at the differential carrier assembly. To
manually release the parking brake, perform the
following steps:
1. PLASTIC SCREW CAP
1. Place blocks on both sides (front and rear) of 2. ADJUSTING SCREW
the drive and steering tires to prevent move- 3. LOCK NUT
ment of the lift truck. Figure 35. Parking Brake Release

38
8000 SRM 1181
5. Tighten the lock nut and install the screw cap
hand tight.
TOWING A LIFT TRUCK
WARNING
DO NOT tow the lift truck if a load is attached.
Use extra caution when moving a lift truck if any
of the following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be towed on a slope.
If the engine cannot run, there is no hydraulic
pressure available for the steering system and
service brake system. This can make the control
of the lift truck difficult. Poor traction can cause
the disabled lift truck or towing vehicle to slide.
Steep grades will increase the required brake ef-
fort.
NEVER lift and move a disabled lift truck unless
the disabled lift truck MUST be moved and cannot
be towed.
1. The towed lift truck must have an operator.
Moving and Towing
2. Make sure transmission oil level is above mini-
mum. Observe a maximum towing speed of 5
km/hr and a maximum towing distance of 5 km
(3 miles).
3. Use a lifting device to raise the carriage ap-
proximately 30 cm (12 in.) from the surface. In-
stall a chain around the mast crossmember and
the carriage to prevent the carriage and mast
channels from moving.
4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or
larger capacity than the disabled lift truck. In-
stall an approximate half-capacity load on the
forks of the lift truck that is being used to tow
the disabled lift truck. This half-capacity load
will increase the traction of the lift truck. Keep
the load as low as possible.
5. Use a towing link made of steel that fastens to
both lift trucks. Connect the towing link to an
adequate provision, such as a towing pin or lift-
ing eye.
6. After towing is completed, place blocks on both
sides (front and rear) of all drive and steering
tires and re-apply the parking brake
39
 NOTES

40
 TECHNICAL PUBLICATIONS

8000 SRM 1181 10/16 (3/15)(12/14)(5/14)(12/13)(8/12)