Periodic Maintenance: J45-70XN (A276)

PERIODIC
MAINTENANCE
J45-70XN [A276]
PART NO. 1689281 8000 SRM 1372
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 authorizedHyster® 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 instructions 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 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.
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
©2014 HYSTER COMPANY
TABLE OF CONTENTS
General
Serial Number Data
Discharging the Capacitors
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
TABLE OF CONTENTS
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily
How to Make Checks With Key or Keyless Switch OFF
Tires and Wheels
Forks
General
Inspect
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments
Safety Labels
Steering Column Adjustments
Tilt Adjust Feature
Tilt Memory Feature
Telescopic Feature
Operator Restraint System
Emergency Locking Retractor (ELR)
Seat Adjustments
Seat Position Adjustment (Standard Seat)
Seat Position Adjustment (Swivel Seat)
Seat Adjustment for Operator Weight
Battery
Hydraulic System
How to Make Checks With Key or Keyless Switch ON
Horn, Lights, and Backup Alarm
Motion Alarm
Steering System
Service Brakes
Hydraulic Control Levers and Pedals
Direction and Speed Control Pedals
Lift System Operation
Oil Leaks
Maintenance Procedures Every 500 Hours or Three Months
Forks
Remove
Inspect
Install
Adjustment
Header Hose Checks
Mast Lubrication
Operator Presence System Check
Tilt Cylinder Rod End Pins
Lift Chains
Wear Check
Lift Chain Lubrication
Fork Pins and Guides
TABLE OF CONTENTS
Check Upper and Lower Bearings, Integral Sideshift Carriage
Check Lower Mounting Hook, Integral Sideshift Carriage
Hydraulic Tank Breather, Check
Other Lubrication
Maintenance Procedures Every 2000 Hours or Yearly
Hydraulic System
Hydraulic Filter Element, Replace
Hydraulic Tank Breather, Change
Forks
Integral Sideshift Carriage, Replace Upper and Lower Bearings
Lift Chains
Maintenance Procedures Every 4000 Hours or Two Years
Hydraulic Oil Change
Steering Direction Sensor Inspection
Fixed Steering Column
Telescopic Steering Column
Telescopic Steering Column Lubrication
Drive Axle Unit Assembly, Gear Oil Change
Drive Axle Unit Assembly, Wet Brake Oil Change
Battery Maintenance
How to Charge Battery
How to Change Batteries
General
Install the Battery
Lift and Tilt System Leak Check
Lift Cylinder Leak Check
Tilt Cylinder Leak Check
Safety Procedures When Working Near Mast
WHEN WORKING NEAR THE MAST ALWAYS:
Lift Chain Adjustments
Welding Repairs
Overhead Guard Changes
Wheels and Tires
General
Pneumatic Tires Repair
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 Two-Piece Wheel in Tire
Install Three- or Four-Piece Wheel in Tire
Add Air to Pneumatic Tires With Tube
Wheels, Install
TABLE OF CONTENTS
Solid Rubber Tires on Pneumatic Wheels, Change
Install Tire on Wheel
Wheels, Install
This section is for the following models:
(J45-70XN) [A276]
General
WARNING
DO NOT make repairs or adjustments unless you have both
authorization and training. Repairs and adjustments that are not correct
can make a dangerous operating condition.
DO NOT operate a lift truck that needs repairs. Report the need for
repairs immediately. If repair is necessary, put a DO NOT OPERATE tag
in the operator's area. Remove the key from the key switch or cover the
keyless switch if lift truck is equipped with one. Disconnect the battery
connector.
DO NOT work under a raised carriage. Lower the carriage or use a chain
to prevent the carriage and the inner or intermediate weldments from
lowering when doing maintenance. Make sure that the moving parts are
attached to parts that cannot move.
CAUTION
Disposal of lubricants and fluids must meet local environmental
regulations.
CAUTION
Disposal of batteries must meet local environmental regulations.
This section contains a Maintenance Schedule and the instructions for maintenance
and inspection.
The Maintenance Schedule has time intervals for inspection, lubrication, and
maintenance for your lift truck. The service intervals are provided in both operating
hours recorded on the lift truck hourmeter, and in calendar time. Use the interval that
occurs first.
The recommendation for the time intervals are for operation per day. The time
intervals must be decreased from the recommendations in the Maintenance
Schedule for the following conditions:
• The lift truck is used more than per day.
• The lift truck must work in dirty operating conditions.
• Poor ground conditions.
• Intensive usage at high performance levels or other abnormal conditions will require more

frequent servicing.
Your dealer for Hyster lift trucks will advise you on the maintenance time intervals
based on their survey of the application.
Your dealer for Hyster lift trucks has the equipment and trained service personnel to
do a complete program of inspection, lubrication, and maintenance. A regular
program of inspection, lubrication, and maintenance will help your lift truck provide
more efficient performance and operate for a longer period of time.
Some users have service personnel and equipment to do the inspection, lubrication,
and maintenance shown in the Maintenance Schedule. Service Manuals are available
from your dealer for Hyster lift trucks to help users who do their own maintenance.
SERIAL NUMBER DATA
The serial number code for the lift truck is on the Nameplate and stamped into right
side rear bulkhead.
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you have been properly
trained and authorized to do so. Improper repairs and adjustments can
create dangerous operating conditions. DO NOT operate a lift truck that
needs repairs. Report the need for repairs to your supervisor
immediately. If repair is necessary, attach a DO NOT OPERATE tag on
the steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to discharge before
opening any compartment covers or inspecting or repairing the
electrical system. DO NOT place tools on top of the battery. If a tool
causes a short circuit, the high current flow from the battery can cause
personal injury or property damage.
Some checks and adjustments are performed with the battery
connected. DO NOT connect the battery until the procedure instructs
you to do so. Never wear any metallic items on your fingers, arms, or
neck. Metal items can accidentally make an electrical connection and
cause injury.
Before performing any tests or adjustments, block the lift truck to
prevent unexpected movement.
The capacitor in the transistor controller(s) can hold an electrical charge
for about 10 seconds after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge the capacitor(s) before
inspecting or repairing any component in the drive unit compartment.
Make certain that the battery has been disconnected.
DO NOT short across the motor controller terminals with a screwdriver
or jumper wire.
Make certain the Emergency Disconnect Switch has not been activated.
This will isolate the controller and prevent the capacitors from
discharging properly. The proper way to disconnect the battery is by
separating the battery connectors.
1.
Ensure the capacitors are discharged by performing Step 2 through Step 6 below.
2.
Turn the key or keyless switch to the OFF position.
3.
Disconnect the battery by separating the connectors.
4.
Block drive wheels to prevent lift truck from moving.
5. Make sure the Emergency Disconnect Switch HAS NOT been activated. If the Emergency

Disconnect Switch is activated, rotate the switch to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.
HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra care when towing 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 moved on a steep grade.
If the hydraulic pump motor, which includes the steering control
functions, does not operate, steering control of the lift truck can be
slow. DO NOT tow the lift truck if there is no power. Poor traction can
cause the disabled lift truck or towing vehicle to slide. Steep grades will
require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and
cannot be towed. The lift truck used to carry the disabled lift truck MUST
have a rated capacity equal to or greater than the weight of the disabled
lift truck. The capacity must be for a load center equal to half the width
of the disabled lift truck. See the Nameplate of the disabled lift truck for
the approximate total weight. The forks must extend the full width of the
disabled lift truck. Put the weight center of the disabled lift truck on the
load center of the forks. DO NOT damage the underside of the lift truck.
1. The towed lift truck must have an operator.
2. Raise the carriage and forks approximately 300 mm (12 in.) from the surface. Install a

chain to prevent the carriage and mast channels from moving.
3. Tow with another lift truck of equal or greater capacity than the disabled lift truck. Install
a load of approximately half-capacity on the forks of the lift truck that is being used to tow

the disabled lift truck. The half-capacity load will increase the traction of the lift truck.
Keep the load as low as possible.
4. Use a towing link made of steel that fastens to the tow pins in the counterweights of both

lift trucks.
5. Tow the lift truck slowly.
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. The removal of the following assemblies will cause large changes
in the center of gravity: mast, drive axle, battery, or counterweight.
When the lift truck is put on blocks, put additional blocks in the
following positions to maintain stability:
a. Before removing the mast and drive axle, put blocks under the counterweight so the lift

truck cannot fall backward.
b. Before removing the counterweight, put blocks under the mast assembly so the lift truck

cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on
blocks. Make sure that any blocks used to support the lift truck are
solid, one-piece units.
NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the
lift truck so that blocks can be installed.
1. Put blocks on each side (front and back) of the steering tires to prevent movement of the
lift truck. See Figure 1.
2. Put the mast in a vertical position. Put a block under each outer mast channel.
3. Tilt the mast fully forward until the drive tires are raised from the surface.
4. Put additional blocks under the frame behind the drive tires.
5. If the hydraulic system will not operate, use a hydraulic jack under the side of the frame
near the front. Make sure that the jack has a capacity equal to at least half the weight of the
lift truck as shown on the Nameplate.
How to Raise Steering Tires
1. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift

truck. See Figure 1.
2. Use a hydraulic jack to raise the steering tires. Make sure that the jack has a capacity of at

least 2/3 of the total weight of the lift truck as shown on the Nameplate.
3. Put the jack under the steering axle or frame to raise the lift truck. Put

blocks under the frame to support the lift truck.
1. DRIVE TIRES 2. STEERING TIRES
Figure 1. Put Lift Trucks on Blocks

HOW TO CLEAN A LIFT TRUCK
WARNING
Compressed air can move particles so that they cause injury to the user
or to other personnel. Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
CAUTION
Units may be washed with a non-heated pressure washer. Steam
cleaning is not recommended in most instances, as condensation may
form in electrical components causing damage or erratic behavior.
NOTE: Lift trucks used in paper applications may need cleaning beyond what is
described here. Please refer to Paper Application section in the applicable Operating
Manual and to available Service Gram/Bulletin for more detail.
If it becomes necessary to clean the fork lift, follow the guidelines listed below.
1. Assure truck components are cool before starting the cleaning procedure.
2. Disconnect the battery. If an electric truck, remove the traction battery.
3. Remove accumulated debris using a compressed air line and nozzle.
4. Lightly spray a non-corrosive cleaning agent onto the areas to be cleaned. This will help

loosen grime, so close contact direct spraying will not be necessary.
5. Be sure to avoid directing the spray into electrical panel compartment. Ensure over-spray
does not come in contact with electrical components; DO NOT spray water directly at
electrical components, wiring connectors or electrical enclosures. Even sealed connectors
may allow water egress under pressure or if connector is damaged.
6. Avoid spraying in areas containing electrical components such as:
• Floor Plates
• Battery Compartment
• Dash/cowl assembly
• Armrests with electrical components
7. Clean the battery compartment by using a clean cloth to wash the battery with water. Dry
with compressed air. Care should be taken to keep moisture at a minimum as some units
have a traction or hydraulic motor directly below the battery compartment.
8. DO NOT pressure wash the battery. DO NOT use hot water. For cleaning traction

batteries, refer to the Battery section of the Service Manual.
9. DO NOT pressure wash lift chains, sheaves or load rollers in the mast assembly. Refer to
the Chains, Sheaves and Load Rollers maintenance section in the Service Manual for
proper cleaning procedures.
10. After cleaning, immediately run the lift truck to dry out components.
Maintenance Schedule
The Maintenance Schedule has time intervals for inspection, lubrication, and
maintenance for your lift truck. The service intervals are provided in both operating
hours recorded on the lift truck hourmeter, and in calendar time. The recommendation
is to use the interval that comes first. The approximate locations of the items indicated
in the Maintenance Schedule are shown in Figure 2.
The Maintenance Schedule has the maximum service intervals for usage under normal
conditions. Inspect and lubricate more frequently if the lift truck operates in dirty,
dusty, wet, or difficult conditions.
Figure 2. Maintenance Points
Table 1. Maintenance Schedule
Brake
18 Lift Chains X Check condition/ lube if SAE 30W engine oil.
necessary. See NOTE 3.
16 Forks X X X Check condition/ replace
if necessary.
4 Direction and X Check operation. Use multipurpose grease.
Speed Control Lubricate as necessary. See NOTE 1.
Pedals
11 Hydraulic Oil X C 29.0 liter (31.0 qt) . 0 to 50°C (32 to 120°F)
(Total Capacity See NOTE 7. hydraulic oil ISO VG46.
- Nylon Tank)
11 Hydraulic Oil X C 35.0 liter (37.0 qt) . 0 to 50°C (32 to 120°F)
(Total Capacity See NOTE 7. hydraulic oil ISO VG46.
- Metal Tank)
Horn, Lights, X Check operation.
and Alarm
Oil Leaks X Check for leaks.
Safety Labels X Replace as necessary. See Parts Manual.
Battery and X Check condition. See NOTE 4 and NOTE
Battery 9.
Restraint
System
Hood Latch X Lubricate as necessary. See NOTE 8.
and Release L Check operation.
Handle
Manual Control X Lubricate as necessary. See NOTE 8.
Lever Release L Check operation.
Latch
Steering X Lubricate as necessary. Use multipurpose grease.
Column Tilt Check operation. See NOTE 1.
Memory Lever
Operator X Check condition.
Restraint CIL
System
Lift System X Check operation.
Operation
Check
Operator X Check operation
Presence
System Check
20 Pivots (Mast) X L 2 fittings, lubricate as Use multipurpose grease.
required. See NOTE 1.
14 Mast Sliding X L Lubricate as required. Use multipurpose grease.
Surfaces See NOTE 5. See NOTE 1.
17 Integral X L 2 fittings. Use multipurpose grease.
Sideshift See NOTE 5. See NOTE 1.
Carriage
17 Integral L Lubricate as required. 2 Use multipurpose grease.
Sideshift fittings. SeeNOTE 2. See NOTE 1.
Carriage
Fork

Positioner
Header Hoses, X X Inspect for kinked, Replace if necessary.
Hose Fittings flattened, stiff, or
and Clamps charred hoses.
Hydraulic X Check operation.
Control Levers
and Pedals
Steering X Check operation.
System
19 Drive Axle X Check oil Use gear oil SAE 80W-90
Unit Assembly level. 1.0 liter (1.1 qt) API GL-5 or SAE 85W-
Gear Oil total for both chambers. 140 API GL-5
19 Drive Axle X Check oil Dexron® III Transmission
Unit Assembly level. 3.25 liter (3.4 qt) Fluid
Wet

Brake Oil
3 Tilt Cylinder X L Use multipurpose grease.
Rod End Pins See NOTE 1.
12 Brake Pedal L Lubricate linkage and Use multipurpose grease.
Linkage and shafts. See NOTE 1 and NOTE
Shafts See NOTE 2. 8.
18 Lift Chains L Check stretch and SAE 30W engine oil.
lubricate.
SeeNOTE 2 and NOTE
3.
18 Lift Chains X X Check adjustment and
length.
See NOTE 2.
15 Fork Pins and X L Lubricate as necessary. Use SAE 10W-30 engine
Guides See NOTE 2. oil.
10 Hydraulic Tank X C Clean or replace. See Parts Manual.
Breather See NOTE 2.
17 Integral X Check wear. 2.5 mm (0.098 in.)
Sideshift 4 bearings. minimum thickness.
Carriage See NOTE 5
(Upper/Lowe

r Bearings)
17 Integral X Check for wear and 0.76 mm (0.03 in.)
Sideshift clearance. SeeNOTE 2. minimum wear limit.
Carriage
Lower
Mounting
Hooks
8 Line Contactor X Check condition. See Parts Manual.
See NOTE 9.
6 Steering King L 4 fittings, Use multipurpose grease
Pins lubricate as required. See NOTE 1.
See NOTE 2.
7 Steering Tie L 4 fittings, Use multipurpose grease
Rods lubricate as required. See NOTE 1.
See NOTE 2.
Hinges, Levers, L Lubricate as required. Use multipurpose grease.
Linkage, See NOTE 2. See NOTE 1 and NOTE
Pedals, Seat 10.
Rails, and
Latches
Hydraulic L Lubricate as required. Use silicone lubricant
Control Levers spray
Heater- Air C Replace air filters. See Parts Manual.
Filter Quantity of 2.
Heater- Heater X Clean heater element. Use compressed air.
Element
Heater- X Check operation and
Operating heater condition.
Condition
17 Integral Side- C Replace bearings/ 4 2.5 mm (0.098 in.)
Shift Carriage bearings. minimum thickness.
(Upper/Lowe See Parts Manual.

r Bearings)
2 Steer Wheel L Check grease. Use multipurpose grease.
Bearings See NOTE 1.
9 Hydraulic Oil C 1 filter. See Parts Manual.
Filter See NOTE 2 and NOTE
7.
19 Drive Axle C Change Use gear oil SAE 80W-90
Unit Assembly oil. 1.0 liter (1.1 qt) total API GL-5 or SAE 85W-
Gear Oil both chambers. 140 API GL-5
19 Drive Axle C Change Dexron® III Transmission
Unit Assembly oil. 3.25 liter (3.4 qt) Fluid
Wet

Brake Oil
18 Lift Chains L Remove lift chains to SAE 30W engine oil.
clean and lubricate.
Steering X Check sensor assembly Replace sensor or column
Position Sensor and column gear teeth. gear as required.
Telescopic L Lubricate. Use manual steering gear
Steering grease. See NOTE 6.
Column
NOTE 1: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 2: Recommended service intervals are based on a normal application in a clean

environment. Applications involving contaminated environments such as high levels of air
borne debris (dust and waste paper); chemical or abrasive compounds; poor ground conditions;
intensive usage at high performance levels; or other abnormal conditions will require more
frequent servicing. At your request your dealer will advise you of the appropriate service
intervals based on an application survey.
NOTE 3: Lubricate if dry or at first sign of visible surface rust
NOTE 4: Equalization charge is required approximately each month.
NOTE 5: Maximize life of surface by lubricating every 250 hours for first 1000 hours.
NOTE 6: Multipurpose lithium base grease.
NOTE 7: Hydraulic oil sampling and analysis is a recommended practice. See for oil
cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or
highly contaminated environments, take oil samples every 500 hours. Normal Operating
conditions may allow for less frequent oil sampling. Oil sampling should be done just prior to
all oil and filter changes.
NOTE 8: Lubricate with anti-seize grease compound for lift trucks equipped with Outdoor
Protection/ Wash-down Package.
NOTE 9: Spray electrical connections with rust inhibitor-ignition sealer, after components are
properly tightened, for lift trucks equipped with Outdoor Protection/ Wash-down Package.
NOTE 10: Coat all brake linkage pivot points, exposed brake cables, pivot shafts and bushing
with anti-seize lubricant, for lift trucks equipped with Outdoor Protection/ Wash-down Package.
Maintenance Procedures Every 8 Hours or Daily
WARNING
DO NOT operate a lift truck that needs repairs. Report the need for
repairs immediately. If repair is necessary, put a DO NOT OPERATE tag
in the operator's area. Remove the key from the key switch or cover the
keyless switch
Inspect the lift truck after every eight hours or daily before use. Put the lift truck on a
level surface. Lower the carriage and forks and turn the key or keyless switch to
the OFF position. Remove the floor mat and floor plate and inspect for leaks and
conditions that are not normal. Clean any oil spills. Make sure that lint, dust, paper
and other materials are removed from the compartments. Make the additional checks
as described in the following paragraphs of How to Make Checks With Key or
Keyless Switch OFF and How to Make Checks With Key or Keyless Switch ON.
HOW TO MAKE CHECKS WITH KEY OR KEYLESS SWITCH OFF
Tires and Wheels
Inspect the tires for wire, rocks, glass, pieces of metal, holes, cuts and other damage.
Remove any object that will cause damage. Check for loose or missing hardware.
Remove any wire strapping or other material that is wrapped around the axle.
See Figure 3.
Figure 3. Tires Check
Forks
General
NOTE: Forks must be removed and installed by trained personnel.

The identification of a fork describes how the fork is connected to the carriage. These
lift trucks have hook forks.
Inspect
WARNING
DO NOT try to correct fork tip alignment by bending the forks or adding
shims. Replace bent forks.
Never repair damaged forks by heating or welding. Forks are made of
special steel using special procedures. Replace damaged forks. Forks
are to be replaced only in sets and not individually.
1. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown

in Figure 4.
2. Check that the bottom of the fork is not worn (item 4 in Figure 4).
1. TIP ALIGNMENT (MUST BE WITHIN 3%

OF FORK LENGTH)
2. CRACKS
3. LATCH
4. HEEL OF FORK (MUST BE 90% OF DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 4. Forks Check
CAUTION
Remove fork latch pins if adding a fork positioner attachment. Damage
to forks and other carriage components can occur if fork latch pins are
not removed prior to using attachment.
3. Replace any damaged or broken parts that are used to keep the forks locked in position.

See Figure 5.
NOTE: ONLY LIFT TRUCK MODELS NOT EQUIPPED WITH A FORK

POSITIONER ATTACHMENT USE FORK LOCK PIN ASSEMBLY TO LOCK
FORKS IN POSITION.
1. FORK
2. LOCK PIN
3. SPRING
4. WASHER
5. WEDGE
6. KNOB
7. LOCK PIN ASSEMBLY
8. TOP FORK HOOK
9. LOWER FORK HOOK
Figure 5. Fork Lock Pin Assembly
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments
WARNING
Lower the lift mechanism completely. Never allow any person under a
raised carriage. DO NOT put any part of your body in or through the lift
mechanism unless all parts of the mast are completely lowered and the
lift truck traction motor is OFF.
1. Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the

capscrews and nuts are tight.
2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for

wear or damage.
3. Inspect the load backrest extension for cracks and damage.
4. If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for
cracks and wear. Make sure the parts that fasten the sideshift carriage or attachment to the
carriage are in good condition.
WARNING
Always wear the proper protective equipment including eye protection
and petroleum-resistant gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as possible.
WARNING
Never check for leaks by putting hands on hydraulic lines or
components under pressure. Hydraulic oil under pressure can be
injected into the skin.
5. Visually inspect hoses/fittings for hydraulic leaks; hose covers for cuts, cracks, or exposed
reinforcement; defective/broken clamping devices or sheaves; and proper tracking during
operation. Adjust/repair/replace hose/components as necessary.
6. Check that lift chains are correctly lubricated. Use SAE 30W engine oil to lubricate lift

chains.
7. Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must

be replaced as a set. See Figure 6.
NOTE: Chain anchor pins MUST be replaced anytime chains are replaced.
8. Inspect the chain anchors and pins for cracks and damage.
9. Make sure the lift chains are adjusted so that they have equal tension. Adjustments or

replacement of the lift chains must be done by authorized personnel.
1. WORN PIN
2. CRACKS
3. EDGE WEAR (MAXIMUM 5% OF NEW)
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
Figure 6. Lift Chains Check
Safety Labels
WARNING
Safety labels are installed on the lift truck to provide information about
possible hazards. It is important that all safety labels are installed on the
lift truck and can be read.
Check that all safety labels are installed in the correct locations on the lift truck. See
the Parts Manual or the service manual section for the correct locations of the safety
labels.
Steering Column Adjustments
Make sure the steering column adjustment features are functioning properly. If lift
truck is equipped with the optional telescoping steering column, make sure the tilt
memory and telescoping features are operating correctly. The tilt memory lever
must NOT allow the column to move unless the tilt memory lever is released.
See Figure 7.
NOTE: OPTIONAL TELESCOPIC STEERING COLUMN SHOWN.
1. TILT POSITION LEVER
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 7. Steering Column Tilt Memory Lever
Tilt Adjust Feature
The column tilt angle should be locked in position whenever the tilt position lever is
released. Use multipurpose grease as shown in the Maintenance Schedule and
lubricate the lever and pivots as needed.
Tilt Memory Feature
After the tilt memory lever is released, tilt the column down until the column locks
into position. The column should remain locked in place and NOT move. Use
multipurpose grease as shown in the Maintenance Schedule and lubricate the lever
and pivots as needed.
Telescopic Feature
NOTE: DO NOT use multipurpose grease to lubricate the sliding surfaces of the
telescopic column.
When the telescopic column locking handle is tightened to 6 N•m (53 lbf in), the
steering wheel should remain locked in place. Use multipurpose grease as shown in
the Maintenance Schedule and lubricate the lever and pivots as needed.
Operator Restraint System
There is an indicator icon on the display panel for the seat belt. The icon is ON as
described in the Operating Manual. The indicator icon can help the operator
remember to fasten the seat belt.
NOTE: The seat belt may be either black or red.
The seat belt, hip restraint brackets, and the seat and seat mounting components are
the parts of the operator restraint system. If the lift truck is equipped with manual
hydraulic control levers, the control lever assembly and latch are also part of the
operator restraint system. Each item must be checked to make sure it is attached
securely, functions correctly and is in good condition. See Figure 8.
Make sure the seat rails are not loose. The seat rails must lock securely in position, but
move freely when unlocked. The seat rails must be securely attached to the mounting
surface. See Figure 8.
NOTE: STANDARD SEAT SHOWN. AN OPTIONAL SWIVEL SEAT IS

AVAILABLE. SWIVEL SEAT ARRANGEMENT IS THE SAME. HIP
RESTRAINTS FOR LIFT TRUCKS WITH MANUAL HYDRAULIC SYSTEM
SHOWN.
A. LEFT VIEW B. RIGHT VIEW
1. SEAT BELT 6. FORWARD/BACKWARD ADJUSTMENT
LEVER
2. HIP RESTRAINT BRACKET
7. RIDE POSITION INDICATOR
3. MOUNTING HARDWARE
8. WEIGHT ADJUSTMENT KNOB
4. SEAT RAILS
9. SEAT HARNESS
5. BACKREST ANGLE ADJUSTMENT
LEVER
Figure 8. Seat Components and Operator Restraint System
Emergency Locking Retractor (ELR)
When the ELR style seat belt is properly buckled across the operator, the belt will
permit slight operator repositioning without activating the locking mechanism. If the
truck tips over, travels off a dock, or comes to a sudden stop, the locking mechanism
will be activated and hold the operator's lower torso in the seat. See Figure 8.
A seat belt that is damaged, worn, or does not operate properly will not provide
protection when it is needed. The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the seat belt if it is damaged or worn.
The following seat belt operation checks must be performed three times before
replacing the seat belt assembly:
• With the hood closed and in the locked position, pull the seat belt slowly from the retractor
assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt does not
pull out of the retractor assembly the internal latch may be locked. Pull firmly on the seat

belt and hold for a moment to remove slack from the belt in the retractor. Release the seat
belt. Seat belt will retract and the internal latch will unlock. If the seat belt cannot be pulled
from the retractor assembly or the belt will not retract, replace the seat belt assembly.
• With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make
sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled
from the retractor when it is pulled with a sudden jerk, replace the seat belt assembly.
• With the hood in the open position, make sure the seat belt will not pull from the retractor
assembly. If the seat belt can be pulled from the retractor, with the hood in the open
position, replace the seat belt assembly.
Seat Adjustments
Seat Position Adjustment (Standard Seat)
Fore and aft adjustment - it is recommended that the seat be adjusted so that the thigh
is horizontal to the ground in order to achieve the best ergonomic position.
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.
• The seat swivels 5 degrees to the left to allow easier exit of the truck.
• The neutral position is shown in Figure 9.
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.
NOTE: It is important to adjust the weight setting for each operator.
NOTE: The seat is designed for a maximum weight of 135 kg (298 lb).
• The target is for the "ride indicator" to fall between the arrows when the operator sits
upright on the seat with the feet positioned on the pedals. This ensures that the operator is
set at the midpoint of the80 mm (3.5 in.) suspension. See Figure 9.
• The handle can be turned as shown to increase or decrease the weight resistance, pull
handle out before turning. As handle is turned the "stiffness" of the suspension can be felt
to increase or decrease depending on which way the handle is turned.
A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT

1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT
LEVER
2. WEIGHT ADJUSTMENT KNOB
6. ARMREST
3. RIDE POSITION INDICATOR
4. FORWARD/BACKWARD ADJUSTMENT 7. SWIVEL LATCH RELEASE LEVER
LEVER
Figure 9. Seat Adjustment
Battery
WARNING
Never put tools or other metal on the battery. Metal on the battery can
cause a short circuit and possible damage or injury.
The acid in the electrolyte can cause injury. If the electrolyte is spilled,
use water to flush the area. Make the acid neutral with a solution of
sodium bicarbonate (soda). Acid in the eyes must be flushed with water
immediately.
Batteries generate explosive fumes. Keep the vents in the caps clean.
Keep sparks or open flames away from the battery area. Do not make a
spark from the battery connections.
Disconnect the battery when doing maintenance.
NOTE: There can be one of two types of batteries. One type is a flooded cell with
removable cell caps. The other type is maintenance free. The maintenance free
batteries require a different charger, the electrolyte level or specific gravity cannot be
checked and water cannot be added to the electrolyte.
Make sure that the voltage and the weight of the battery are correct as shown on the
Nameplate. See the Operating Manual to check for correct battery dimensions.
Keep the battery case, top cover and the area for the battery clean and painted.
Leakage from the battery and corrosion can cause a malfunction in the electric
controls of the lift truck. Use a water and sodium bicarbonate (soda) solution to clean
the battery and the battery area. Keep the top of the battery clean, dry and free of
corrosion.
Make sure the battery is charged and has the correct voltage and ampere hour rating
for the lift truck. See the Nameplate.
Inspect the battery case, connector and cables for damage, cracks or breaks. See the
battery dealer in the area to repair any damage.
On batteries with cell caps, check the level of the electrolyte daily on a minimum of
one cell. Add only distilled water, as necessary, to all cells that do not have the correct
electrolyte level. The correct level is halfway between the top of the plates and the
bottom of the fill hole.
On lift trucks equipped with Outdoor Protection/ Wash-down Package, spray battery
terminals with rust inhibitor-ignition sealer after battery terminal connections are
properly tightened.
Hydraulic System
WARNING
At operating temperature the hydraulic oil is HOT. DO NOT permit the oil
to contact the skin and cause a burn.
WARNING
Always wear the proper protective equipment including eye protection
and petroleum-resistant gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as possible.
CAUTION
DO NOT permit dirt to enter the hydraulic system when the oil level is
checked or the filter is changed.
Never operate the pump without oil in the hydraulic system. The
operation of the hydraulic pump without oil will damage the pump.
Turn lift truck power OFF and wait one minute before checking the hydraulic oil
level.
Check the hydraulic oil level when the oil is at operating temperature, the carriage is
lowered, the mast is vertical, and the key or keyless switch is in the OFF position.
Add hydraulic oil, shown in Maintenance Schedule, only as needed. If more hydraulic
oil is added than the MAX level, the hydraulic oil will leak from the breather during
operation.
Inspect the hydraulic system for leaks and damaged or loose components. Check the
condition of the hydraulic hoses for serviceability by inspecting for cracks or other
obvious damage. Check to insure that the hydraulic hoses are not leaking. If any hose
is leaking, report it to maintenance for repair.
HOW TO MAKE CHECKS WITH KEY OR KEYLESS SWITCH ON
WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed to help the
operator stay on the truck if the lift truck tips over. IT CAN ONLY HELP
IF IT IS FASTENED.
Make sure the area around the lift truck is clear before moving the lift truck. Be
careful when making the checks.
Horn, Lights, and Backup Alarm
1. If lift truck is equipped with lights and a strobe light, check the operation of the lights and
strobe light by using the appropriate rocker switch, located on the right side of the steering

column. See theOperating Manual. The lights and strobe light will operate when the key
or keyless switch is either ON or OFF.
2. Check the backup alarm on lift trucks equipped with a direction control switch by sitting in
the seat and turning the key or keyless switch to the ON position. Pushing down on the
direction control switch to put it in reverse will sound the alarm.
3. Check the backup alarm on lift trucks equipped with a pedal by sitting in the seat, turning

the key or keyless switch to the ON position and pressing the reverse arrow on the pedal.
Motion Alarm
If equipped, check the motion alarm by sitting in the seat, turning the key or keyless
switch to the ON position, and putting the lift truck in motion.
Steering System
WARNING
Because the lift truck has hydraulic power steering, steering can be
difficult when the power steering pump is not operating.
Make sure that the steering system operates smoothly and provides good steering
control.
Service Brakes
NOTE: Lift trucks manufactured after June, 2012 have a removable floor plate and
DO NOT require any tools to remove.
There is an indicator icon on the display panel for the brake fluid level. The icon is
illuminated as described in the Operating Manual. If the icon is illuminated during
operation, the fluid in the reservoir for the brake master cylinder is too low. Add brake
fluid and check for leaks. The reservoir is under the brake pedal and floor plate. Clean
the area around the fill cap so that no dirt enters the reservoir.
Check the operation of the service brakes. Push on the brake pedal. The brakes must
be applied before the pedal reaches the floor plate. The brake pedal must stop firmly
and must not move slowly down after the brakes are applied. The brakes must apply
equally to both drive wheels with no noticeable pull to either side.
Hydraulic Control Levers and Pedals
Check that the hydraulic control levers for the mast and attachment operate as
described in the Operating Manual. The brake pedals are checked as described in the
preceding Service Brakes and paragraphs with the operation of the brakes.
Direction and Speed Control Pedals
Check that the direction and speed control pedals operated as described in
the Operating Manual. Lubricate the pedal or accelerator pedal joints as needed. See
the Maintenance Schedule.
Lift System Operation
WARNING
NEVER work under a raised carriage or forks. Lower the carriage or use
chains on the mast weldments and carriage so that they cannot move.
Make sure the moving parts are attached to a part that does not move.
DO NOT try to locate hydraulic leaks by putting hands on pressurized
hydraulic components. Hydraulic oil can be injected into the body by
pressure.
NOTE: Some parts of the mast move at different speeds during raising and lowering.
Slowly raise and lower the mast several times without a load. The mast components
must raise and lower smoothly in the correct sequence. The carriage raises first, then
the inner weldment and intermediate weldment (three-stage masts only).
The inner and intermediate weldments and the carriage must lower completely.
Raise the forks 1 m (3 ft), with a capacity load. The inner weldment and carriage must
raise smoothly. Lower the forks. All moving components must lower smoothly.
With the load lowered, tilt the mast backward and forward. 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. See
the symbols by each of the controls. Make sure all of the hydraulic lines are connected
correctly and do not leak.
Oil Leaks
WARNING
DO NOT try to locate hydraulic leaks by putting hands on pressurized
hydraulic components. Hydraulic oil can be injected into the body by
pressure.
Visually check the hydraulic system, steering system, brake system and for leaks.
Maintenance Procedures Every 500 Hours or Three Months

NOTE: Perform the checks in the Maintenance Procedures Every 8 Hours or
Daily section prior to performing the procedures in this section.
FORKS
NOTE: Forks must be removed and installed by trained personnel.

The identification of a fork describes how the fork is connected to the carriage. These
lift trucks have hook forks.
Remove
WARNING
DO NOT try to move a fork without a lifting device. The forks can
weigh 45 to 115 kg (99 to 254 lb).
CAUTION
NOTE: Forks are to be replaced only in sets and not individually.
NOTE: If lift truck is equipped with a fork positioner attachment,
perform Step 1 and Step 2. If lift truck is not equipped with a fork positioner
attachment, go to Step 2.
NOTE: Depending on the size and configuration of the forks installed on the lift
trucks equipped with a fork positioner, there may be a spacer bar between the inner
and outer fork carriers. See Figure 10.
1. OUTER FORK CARRIER 3. SPACER BAR*
2. CAPSCREW 4. INNER FORK CARRIER
*SPACER BAR USED ON 977 mm (38.5 in.) AND 1067 mm (42 in.) CLASS II CARRIAGES.
Figure 10. Fork Carrier Spacer Bar
1. Lower the carriage and remove the four capscrews from inner fork carriers. Slide inner

fork carriers down cylinder shell to remove forks. See Figure 11.
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. SIDESHIFT CARRIAGE ASSEMBLY
Figure 11. Fork Removal, Lift Trucks Equipped With Fork Positioner
Attachment
2. A fork can be removed from the carriage for replacement of the fork or other maintenance.

Slide a hook fork to the fork removal notch on the carriage.
See Figure 11 for lift trucks equipped with a fork positioner attachment.
See Figure 12 for lift trucks not equipped with a fork positioner attachment.
Lower the fork onto blocks so that the lower fork hook moves through the fork
removal notch. See Figure 13. Lower the carriage further so that the top fork hook is
disengaged from the top carriage bar. Move the carriage away from the fork, or use a
lifting device to move the fork away from the carriage.
Fork Tip Alignment
Length of Forks 3% Dimension
915 mm (36 in.) 1067 mm (42 in.) 1220 mm ( 27 mm (1.10 in.) 32 mm (1.26 in.) 37 mm (1
48 in.) 1372 mm (54 in.) 1524 mm (60 in.)183 .46 in.) 41 mm (1.61 in.) 46 mm (1.81 in.)55
0 mm (72 in.) mm (2.17 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH)
2. CRACKS
3. LATCH
4. HEEL OF FORK (MUST BE 90% OF DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 12. Forks Check
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 13. Remove Hook Fork
Inspect
WARNING
DO NOT try to correct fork tip alignment by bending the forks or adding
shims. Replace bent forks.
Never repair damaged forks by heating or welding. Forks are made of
special steel using special procedures. Replace damaged forks. Forks
are to be replaced only in sets and not individually.
1. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown

in Figure 12.
2. Check that the bottom of the fork is not worn (item 4 in Figure 12).
3. Replace any damaged or broken parts that are used to keep the forks locked in position.

See Figure 14.
Install
WARNING
DO NOT try to move a fork without a lifting device. The forks can
weigh 45 to 115 kg (99 to 254 lb).
CAUTION
NOTE: Forks are to be replaced only in sets and not individually.
NOTE: If lift truck is not equipped with fork positioner attachment, go to Step 1. If
lift truck is equipped with fork positioner attachment, go to Step 2.
1. Move the fork and carriage so that the top fork hook can engage the top carriage bar. Raise
the carriage to move the lower fork hook through the fork removal notch. Slide the fork on

the carriage so that both upper and lower fork hooks engage the carriage. Engage the lock
pin with a notch in the top carriage bar. See Figure 14.
NOTE: ONLY LIFT TRUCK MODELS NOT EQUIPPED WITH A FORK

POSITIONER ATTACHMENT USE FORK LOCK PIN ASSEMBLY TO LOCK
FORKS IN POSITION.
1. FORK
2. LOCK PIN
3. SPRING
4. WASHER
5. WEDGE
6. KNOB
7. LOCK PIN ASSEMBLY
8. TOP FORK HOOK
9. LOWER FORK HOOK
Figure 14. Fork Lock Pin Assembly
2. Install forks to outer fork carriers. Secure inner fork carriers to outer fork carriers using

four capscrews. Tighten capscrews to 35 N•m (25 lbf ft). See Figure 11.
Adjustment
NOTE: During the adjustment of the forks, the heel of the forks should not be
touching the ground.
NOTE: The procedures below apply only to lift trucks not equipped with fork
positioner attachment.
The forks are connected to the carriage by hooks and lock pins. See Figure 14. These
lock pins are installed through the top fork hooks and fit into slots in the top carriage
bar. Adjust the forks as far apart as possible for maximum support of the load. Hook
forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock
pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is
engaged in the carriage bar to lock the fork in position after the width adjustment is
made.
HEADER HOSE CHECKS
Inspect for kinked, crushed, flattened, or twisted hoses; hard, stiff or charred hoses;
hose fitting slippage; proper hose tensioning. See Figure 15. Adjust/repair/replace
hoses/components as necessary. See for the procedures.
NOTE: FOUR-STAGE FULL FREE-LIFT MAST SHOWN.
1. THIRD FUNCTION HOSE
2. LIFT FUNCTION HOSE
3. FOURTH FUNCTION HOSE
4. CHAIN ANCHORS
5. LOWERING CONTROL VALVE
Figure 15. Header Hoses
MAST LUBRICATION
WARNING
Cleaning solvents can be flammable and toxic and can cause skin
irritation. When using cleaning solvents, always follow the
recommendations of the manufacturer.
When working on or near the mast, see Safety Procedures When
Working Near Mast in this service manual.
Metal particles can fall into the eyes during the operation of the mast.
Failure to remove these particles can cause eye injury. Remove metal
particles that are attached to the edges of mast parts with a disc sander
if necessary. Always wear hearing protection, gloves, and eye protection
when using a disc sander.
CAUTION
DO NOT use steam or high-pressure water to clean the load rollers or
the lift chains. Steam and high-pressure water can remove the
lubrication from the bearings in the load rollers. Water in the bearings of
the sheaves and the link pins of chains can also shorten the service life
of these parts.
NOTE: Some applications will require more frequent cleaning and lubrication of the
mast assembly. DO NOT use a lubricant spray on the surfaces of the mast channels
where the load rollers make contact. The use of the correct lubricant is important. Use
multipurpose grease (Hyster Part Number 3020381), or an equivalent grease, with 2 to
4 percent molybdenum disulfide. The load rollers and sheaves have sealed bearings
and do not need additional lubrication.
1. Clean the mast assembly. Inspect the mast channels in the areas where the rollers travel. If
there are loose particles or metal particles that are attached to the edges of mast parts,
remove these particles.
2. Lubricate the sliding surfaces and the load roller surfaces along the full length of the
channels as shown in Figure 16. Only apply lubricant to surfaces that are clean and dry.
Only apply lubricant to the darker areas as indicated by (1) and (2) in Figure 16.
NOTE: MAST IS DIFFERENT, BUT LUBRICATION AREAS ARE THE SAME.
A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 16. Mast Lubrication
NOTE: When lubricating the mast mounting/pivot pins, the load must be removed
from the normal contact surface to allow grease to properly lubricate the normal
contact surfaces of the mast bushings.
3. Raise the carriage about 61 cm (2 ft), and tilt the mast fully back. Place blocks under the

outer mast channels to within 13 mm (0.5 in.) of the channels. See Figure 17.
4. Tilt the mast fully forward. See Figure 17.
A. MAST TILTED FULLY BACK
B. MAST TILTED FULLY FORWARD
1. BLOCK
2. MAST
Figure 17. Blocking the Mast
5. Lubricate the mast pivot bushings at grease fittings on outer mast. Use multipurpose grease

shown in the Maintenance Schedule. See Figure 18.
NOTE: FOUR-STAGE FULL FREE-LIFT MAST SHOWN.
1. PIVOT PIN
2. CAPSCREW
3. OUTER MAST
4. GREASE FITTING
Figure 18. Pivot Pin Lubrication
6. Tilt mast fully back. Remove the blocks from under the channels.
7. If an integral sideshift carriage is installed, lubricate sliding surfaces at lube fittings with

multipurpose grease shown in the Maintenance Schedule.
See Figure 19 for early model lift trucks equipped with an integral sideshift carriage.
See Figure 20 for later model lift trucks equipped with an integral sideshift carriage.
See Figure 21 for lift trucks equipped with an integral sideshift carriage with fork
1. UPPER BEARINGS
2. LOWER HOOK
3. LOAD ROLLER
4. SNAP RING
5. SIDESHIFT CYLINDER
6. LOWER BEARINGS
7. SHIMS
8. INNER CARRIAGE
9. LUBE FITTING
10. OUTER FRAME
Figure 19. Sideshift Carriage, Early Lift Truck Models
1. INNER FRAME 11. LUBE FITTING
2. OUTER FRAME 12. PIN
3. SIDESHIFT CYLINDER 13. CHAIN ANCHOR
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. COTTER PIN
6. LOWER HOOK 16. LOAD ROLLER
7. CAPSCREW 17. SHIMS
8. WASHER 18. SPACER
9. CLEVIS PIN 19. FORK REMOVAL NOTCH
10. PIN
Figure 20. Sideshift Carriage, Later Model Lift Trucks
8. If a fork positioner is installed, lubricate sliding surface at lube fittings with multipurpose

grease shown the Maintenance Schedule. See Figure 21.
1. LUBE FITTING, SIDESHIFT CARRIAGE 4. UPPER FORK POSITIONER CYLINDER
2. LUBE FITTING, FORK POSITIONER 5. LOWER FORK POSITIONER CYLINDER
3. FORK CARRIER 6. INTEGRAL SIDESHIFT CYLINDER
Figure 21. Fork Positioner Lubrication
OPERATOR PRESENCE SYSTEM CHECK
Check the operation of the Operator Presence System (OPS). Turn the lift truck
power ON while sitting in the seat. Once lift truck power is ON, get up off the seat. If
the OPS is working correctly, a switch in the operator's seat will automatically disable
all hydraulic and electrical functions. If the lift truck can travel forward or backward,
or the hydraulic functions operate, when the operator is not on the seat, the OPS
system is not working properly. See the section to replace the seat switch that makes
up the OPS system. See the Operating Manual for more information on how the
OPS works.
TILT CYLINDER ROD END PINS
Lubricate the tilt cylinder rod end pins with multipurpose grease shown in the
Maintenance Schedule. See Figure 22.
1. LUBE FITTING 4. CAPSCREW
2. ANCHOR PIN 5. CAPSCREW
3. PIN
Figure 22. Tilt Cylinder Rod End Pins Lubrication
LIFT CHAINS
Wear Check
WARNING
DO NOT repair a worn or damaged lift chain. Replace a worn or damaged
lift chain with a new chain. If a pair of lift chains is used in the mast, both
lift chains must be replaced.
If a section of chain is 3 percent longer than a similar section of new chain, the chain
is worn and must be replaced. Check the chain at a section of chain that goes over a
chain sheave. If a chain scale is available , check the lift chains as shown in Figure 23.
If a chain scale is not available, measure 20 links of chain. Measure from the center of
a pin to the center of another pin 20 links away. Compare the length with the chart
in Figure 23. Replace the chain if the length of 20 links of the worn section is more
than the WEAR LIMIT.
Pitch
Total length of 20 links Wear Limit The maximum
(pitch) of new chain length of 20 links.
12.7 mm (0.50 in.) 15.9 mm 254.0 mm (10.0 in.) 317.5 mm 261.6 mm (10.3 in.) 327.0 mm

(0.63 in.) 19.1 mm (0.75 in.) (12.5 in.) 381.0 mm (15.0 in.) 5 (12.9 in.) 392.4 mm (15.4 in.)52
25.4 mm (1.00 in.) 31.8 mm 08.0 mm (20.0 in.) 635.0 mm 3.25 mm (20.6 in.) 654.1 mm (
(1.25 in.)44.5 mm (1.75 in.) (25.0 in.)889.0 mm (35.0 in.) 1 25.75 in.) 915.7 mm (36.05 in.)
50.8 mm (2.00 in.) 016.0 mm (40.0 in.) 1046.5 mm (41.2 in.)
NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE
SHOWN ON THE CHAIN WEAR SCALE.
1. CHAIN WEAR SCALE
Inspect the lift chains for edge wear. Make sure the edge wear of the chain is not
greater than 5 percent compared to a chain link that is not worn. See Figure 24.
1. WORN PIN
2. CRACKS
3. EDGE WEAR (MAXIMUM 5% OF NEW)
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
LIFT CHAIN LUBRICATION
WARNING
Working Near Mast in this SRM.
DO NOT repair worn or damaged lift chains. If a lift chain is worn or
damaged, both lift chains must be replaced.
NOTE: Perform this maintenance only if not performing the 2000 hour or Yearly
maintenance procedures, otherwise go to the Maintenance Procedures Every 2000
Hours or Yearly for lift chain lubrication procedures.
Lubricate lift chains with SAE 30W engine oil. The best procedure is to remove the
chains from the lift truck and soak them in engine oil. Be sure to clean any dirt or
grease from chains before lubricating. DO NOT USE STEAM TO CLEAN THE
LIFT CHAINS.
FORK PINS AND GUIDES
CAUTION
NOTE: The information below applies only to lift trucks not equipped with fork
Lubricate the fork pins and guides with clean 10W-30 motor oil as shown in the
maintenance schedule. If the lift truck is used in dirty, dusty, or difficult conditions,
lubrication of the fork pins and guides may be required more frequently. Inspect the
forks for wear. See the fork inspection procedures in the Maintenance Procedures
Every 8 Hours or Daily section.
CHECK UPPER AND LOWER BEARINGS, INTEGRAL SIDESHIFT CARRIAGE
1. Lower the carriage completely and remove the forks.
2. Remove the backrest and the lower mounting hooks from the sideshift carriage.
3. Use a crane with a capacity of at least 450 kg (1000 lb) to lift the outer frame away from

the inner carriage.
4. Clean the bearing areas. Inspect the sideshift bearings for wear as follows:
a. If either upper bearing is worn to less than 2.5 mm (0.098 in.) thickness, replace both

upper bearings by driving the upper bearings out of the carriage bar.
See Figure 25 for early model lift trucks.
See Figure 26 for later model lift trucks.
b. If either lower bearing is worn to less than 2.5 mm (0.098 in.) thickness, replace both

lower bearings by prying the lower bearings from the lower carriage bar.
See Figure 25 for early model lift trucks.
See Figure 26 for later model lift trucks.
NOTE: TWO- AND THREE-STAGE FULL FREE-LIFT CARRIAGE SHOWN.
1. UPPER BEARING
2. LOWER HOOK
3. LOAD ROLLER
4. SNAP RING
5. SIDESHIFT CYLINDER
6. LOWER BEARING
7. SHIMS
8. INNER CARRIAGE
9. LUBE FITTING
10. OUTER FRAME
Figure 25. Integral Sideshift Carriage, Early Lift Truck Models
1. INNER FRAME 11. LUBE FITTING
2. OUTER FRAME 12. PIN
3. SIDESHIFT CYLINDER 13. CHAIN ANCHOR
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. COTTER PIN
6. LOWER HOOK 16. LOAD ROLLER
7. CAPSCREW 17. SHIMS
8. WASHER 18. SPACER
9. CLEVIS PIN 19. FORK REMOVAL NOTCH
10. PIN
Figure 26. Sideshift Carriage, Later Model Lift Trucks
CHECK LOWER MOUNTING HOOK, INTEGRAL SIDESHIFT CARRIAGE
Inspect the lower mounting hooks for wear. Replace the hooks if they are worn
beyond the wear limit. The wear limit clearance range is 0.76 mm (0.03 in.) minimum
and 1.52 mm (0.06 in.) maximum. See Ain Figure 27.
A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
Figure 27. Lower Mounting Hooks Wear Limit and Clearance Adjustment
HYDRAULIC TANK BREATHER, CHECK
NOTE: When inspecting or cleaning the breather, do not disassemble it. The breather
element is a non serviceable part. If it is damaged, replace with a new breather
element. See Parts Manual.
WARNING
CAUTION
Direct air pressure on the filter element can cause damage. Direct air
pressure away from filter element.
1. Using compressed air, remove any dirt and debris in the area around the hydraulic tank

breather.
WARNING
Cleaning solvents can be flammable and toxic, and can cause skin
2. Remove hydraulic tank breather from breather hose. Wash breather in solvent and use
compressed air to dry.
3. Inspect hydraulic tank breather. If hydraulic tank breather is worn or damaged, replace
with new hydraulic tank breather. See the Parts Manual. If breather is not worn or
damaged, install clean hydraulic tank breather onto hydraulic tank breather hose.
The hydraulic tank breather cap allows air to enter the hydraulic tank when the
hydraulic oil is pumped out to the cylinders. When the hydraulic oil returns to the
tank, air is expelled through the hydraulic breather cap. A filter in the cap protects the
hydraulic system from particles of dirt and other contaminants. If the filter becomes
excessively dirty, air flow can be restricted, causing pressures and vacuums to build
inside the tank. If air flow becomes restricted through the hydraulic breather cap,
replace the assembly. Keep the hydraulic tank area clean and DO NOT overfill the
hydraulic tank.
OTHER LUBRICATION
Lubricate hinges, pins, linkages, cables, pedals, and lever joints as necessary. Use
multipurpose grease as shown in the Maintenance Schedule.
Coat all brake linkage pivot points, exposed brake cables, pivot shafts and bushing
with anti-seize lubricant, for lift trucks equipped with Outdoor Protection/ Wash-
down Package.
Maintenance Procedures Every 2000 Hours or Yearly

HYDRAULIC SYSTEM
Hydraulic Filter Element, Replace
WARNING
At operating temperature, the hydraulic oil is HOT. DO NOT permit the
hot oil to touch the skin and cause a burn.
CAUTION
checked or the filter is changed. Dirt can cause damage to the
components of the hydraulic system.
Never operate the hydraulic pump without oil in the hydraulic system.
The operation of the hydraulic pump without oil will damage the pump.
CAUTION
regulations.
1. Put lift truck on a level surface and lower the carriage. Unscrew and remove filter lid with

spring and O-ring from head. See .
NOTE: Have a container large enough to hold the filter assembly and allow for
hydraulic oil draining from element.
2. Remove the hydraulic filter element from the filter housing and place into the container.

Cover the head to prevent any foreign materials from getting into the hydraulic tank.
3. Install the new hydraulic filter element into filter housing.
4. Lubricate new O-ring with clean hydraulic oil and install it on head. Inspect spring and

filter lid. If worn or damaged, replace with new parts. See Parts Manual.
5. Install spring and filter lid onto head. Tighten filter lid to 13.6 N•m (120 lbf in). See .
CAUTION
Additives may damage the hydraulic system. Before using additives,
contact your local Hyster dealer.
6. Turn lift truck power ON, operate hydraulic functions, and check for leaks. Turn lift truck
power OFF and check hydraulic oil level. Add oil if necessary. If using filtered
oil: remove tank level sensor or tank level sensor plug and add oil. If using non-filtered

oil: remove filter lid and pour hydraulic oil into tank through filter housing; install filter
lid, tighten lid to 13.6 N•m (120 lbf in). Use hydraulic oil shown in the Maintenance
Schedule.
7.
Hydraulic Tank Breather, Change
1.
WARNING
CAUTION
Direct air pressure on the filter element can cause damage. Direct air
pressure away from filter element.
2. Using compressed air, remove any dirt and debris in the area around the hydraulic tank

breather.
WARNING
Cleaning solvents can be flammable and toxic, and can cause skin
3. Remove the hydraulic tank breather from breather hose. Wash breather in solvent and use

compressed air to dry.
4. Inspect the hydraulic tank breather. If hydraulic tank breather is worn or damaged, replace
with new hydraulic tank breather. See the Parts Manual. If hydraulic tank breather is not
worn or damaged, install clean hydraulic tank breather onto hydraulic tank breather hose.
5. Turn lift truck power ON and check for leaks in the hydraulic system.
FORKS
WARNING
Never repair damaged forks. DO NOT heat, weld, cut, drill, or bend forks.
Forks are made of special steel using special methods. Replace
damaged forks as a pair.
Check the heel and attachments points of forks with a penetrant or by magnetic
particle inspection.
INTEGRAL SIDESHIFT CARRIAGE, REPLACE UPPER AND LOWER BEARINGS
Replace all four bearings regardless of wear. See the section Check Upper and Lower
Bearings, Integral Sideshift Carriage of this manual for the procedures.
LIFT CHAINS
WARNING
Cleaning solvents can be flammable and toxic and can cause skin
Compressed air can move particles so 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.
NOTE: Cleaning and lubrication of lift chains will be needed more frequently in very
dirty, dusty, or contaminated applications.
Remove the lift chains. Clean the lift chains by soaking them in a solvent that has a
petroleum base for at least 30 minutes. Use compressed air to completely dry the
chains when they are clean.
Lubricate the lift chains by soaking them in SAE 30W engine oil for at least 30
minutes. Remove the chains from the oil. Hang the chains for one hour so excess oil
will drain from the chains.
Maintenance Procedures Every 4000 Hours or Two Years

HYDRAULIC OIL CHANGE
WARNING
At operating temperature, the hydraulic oil is HOT. DO NOT permit the
hot oil to touch the skin and cause a burn.
CAUTION
checked or the filter is changed. Dirt can cause damage to the
components of the hydraulic system.
Never operate the hydraulic pump without oil in the hydraulic system.
The operation of the hydraulic pump without oil will damage the pump.
1. Put the lift truck up on blocks. See the General section at the front of this SRM for

procedures to put the lift truck on blocks.
2. Remove two capscrews, washers, tow pin, and counterweight cover from counterweight.

See Figure 28.
1. TOW PIN
2. CAPSCREW
3. WASHER
4. COUNTERWEIGHT COVER
5. COUNTERWEIGHT
Figure 28. Counterweight Cover Removal
CAUTION
regulations.
3. Put a drain pan with a capacity of approximately 33 liter (35 qt) for nylon tank

or 35 liter (37 qt) for metal tank under the drain hose beneath the lift truck.
4. Open drain valve. Hydraulic oil will run through drain hose, emptying the hydraulic tank.

See Figure 29.
NOTE: HYDRAULIC PUMP AND MOTOR NOT SHOWN FOR CLARITY.
1. HYDRAULIC TANK
2. DRAIN VALVE
3. DRAIN HOSE
Figure 29. Drain Hydraulic Oil
5. When oil has drained completely, close the drain valve.
6. If filling the tank with filtered oil: remove hydraulic tank level sensor or tank level
sensor plug and fill hydraulic tank with oil. If filling the tank with non-filtered

oil: remove hydraulic oil filter lid and fill tank through the filter element. See Figure 30.
See Maintenance Schedule for specified hydraulic oil.
1. TOW PIN
2. COUNTERWEIGHT COVER
3. DIPSTICK
4. HYDRAULIC FILTER HOUSING
5. HYDRAULIC BREATHER
6. HYDRAULIC TANK
7. TANK LEVEL SENSOR
Figure 30. Add Hydraulic Oil
7. Turn lift truck power ON and operate hydraulic functions for 30 seconds until hydraulic oil
reaches operating temperature. Remove dipstick and check the hydraulic oil level. If more

oil is needed, add oil that is shown in the Maintenance Schedule until the oil is at the
correct level.
8. Install the counterweight cover using two capscrews and install tow pin. See Figure 28.
STEERING DIRECTION SENSOR INSPECTION
Fixed Steering Column
NOTE: Tag all electrical connectors during removal to aid in installation.
1. Disconnect battery connector. Discharge the capacitors. See Discharging the Capacitors in

the General section of this manual.
2. Remove horn button, nut, and rod from steering wheel. See Figure 31.
3. Remove hex nut and steering wheel from steering column. If necessary, use puller tool to

remove steering wheel. See Figure 31.
NOTE: TELESCOPIC STEERING COLUMN SHOWN.

1. STEERING COLUMN
2. HORN BUTTON
3. NUT
4. ROD
5. HEX NUT
6. STEERING WHEEL
Figure 31. Steering Wheel
4. Remove steering column upper cover by pressing from both sides near the bottom and

pulling up. Clips should remain attached to cover. See Figure 32.
1. STEERING COLUMN UPPER COVER
2. FIXED STEERING COLUMN
3. SPRING
4. SENSOR ASSEMBLY
Figure 32. Fixed Steering Column Covers
5. Disconnect spring from sensor assembly. See Figure 32.
6. Swing sensor assembly 30 degrees with the lower cover installed. See Figure 33.
1. SENSOR ASSEMBLY
2. MAGNET GEAR TEETH
3. COLUMN GEAR TEETH
Figure 33. Steering Gears
7. Inspect magnet gear teeth. See Figure 33. Replace sensor assembly if magnet teeth are

cracked or missing. See for sensor replacement procedures.
8. Connect battery connector, turn lift truck ON, and rotate steering column to fully inspect
column gear teeth. See Figure 33. Replace column gear if teeth are cracked or missing. See
for column gear replacement procedure. Disconnect battery connector.
9. Swing sensor assembly back to original position.
10. Connect spring to sensor assembly.
11. Install steering column upper cover by pressing from both sides and pushing against lower

cover until snapped in place. See Figure 32.
12. Install steering wheel and hex nut onto steering column. Tighten hex nut to 40 to

54 N•m (30 to 40 lbf ft). See Figure 31.
13. Install rod, nut, and horn button onto steering wheel. See Figure 31.

14. Connect battery connector.
Telescopic Steering Column

1. Disconnect battery connector.

4. Telescope steering column to fully UP position.
5. Remove steering column top cover, by pressing both sides near the bottom and pulling up.

Clips should remain attached to cover. See Figure 34.
1. TELESCOPIC STEERING COLUMN
2. STEERING COLUMN TOP COVER
3. STEERING COLUMN TELESCOPING COVER
4. STEERING COLUMN UPPER COVER
5. CAPSCREW
6. WASHER
7. SPRING
8. SENSOR ASSEMBLY
Figure 34. Telescopic Steering Column Covers
6. Remove steering column telescoping cover from telescopic steering column.

See Figure 34.
7. Remove capscrew, washer, and steering column upper cover from telescopic steering

column. See Figure 34.
8. Disconnect spring from sensor assembly. See Figure 34.
9. Swing sensor assembly 30 degrees with the lower cover installed. See Figure 33.
10. Inspect magnet gear teeth. See Figure 33. Replace sensor assembly if magnet teeth are

cracked or missing. See for sensor replacement procedures.
11. Reconnect battery connector, turn lift truck ON, and rotate steering column to fully
inspect column gear teeth. See Figure 33. Replace column gear if teeth are cracked or
missing. See for column gear replacement procedure. Disconnect battery connector.
12. Swing sensor assembly back to original position.
13. Connect spring to sensor assembly.
14. Install steering column upper cover, washer, and capscrew onto telescopic steering

15. Install steering column telescoping cover onto telescopic steering column. See Figure 34.
16. Install steering column top cover, by pressing down onto telescopic steering column.

See Figure 34.
17. Lower telescopic steering column to fully DOWN position.

Telescopic Steering Column Lubrication

1. Disconnect battery connector. Discharge the capacitors. See Discharging the Capacitors in

the General section of this manual.

4. Telescope column to fully UP position.
5. Remove steering column top cover from telescopic steering column by pressing both sides

near the bottom and pulling up. Clips should remain attached to cover. See Figure 34.
6. Remove steering column telescoping cover from telescopic steering column.

See Figure 34.
7. Remove capscrew, washer, and steering column upper cover from telescopic steering

8. Lubricate telescopic steering column with manual steering gear grease as shown in

the Maintenance Schedule. See Figure 35.
NOTE: BOLD ARROW INDICATES GREASE APPLICATION LOCATION.
Figure 35. Telescopic Steering Column Lubrication
9. Install steering column upper cover, washer, and capscrew onto telescopic steering

10. Install steering column telescoping cover onto telescopic steering column. See Figure 34.
11. Install steering column top cover, by pressing down onto telescoping cover.

See Figure 34.
12. Lower telescopic steering column to fully DOWN position.

DRIVE AXLE UNIT ASSEMBLY, GEAR OIL CHANGE
WARNING
The drive axle unit assembly oil is HOT at normal operating
temperatures and can cause serious burns and injury. Be careful when
draining oil and wear protective clothing and gloves.
CAUTION
regulations.
NOTE: Operate the lift truck for five minutes or until the drive axle unit assembly is
warm to the touch. Oil is thick and will drain easier and move more thoroughly when
it is warm. Each drive axle unit assembly uses a separate, self-contained oil supply.
1. Put the lift truck up on blocks. See the General section of this service manual for
procedures. Remove the wheels and tires for access to the oil level check and oil fill plugs.
See the Wheels and Tiressection in this manual for procedures. Disconnect the battery.
2. Place a drip pan with a capacity of at least 0.5 liter (0.5 qt) under each side of the drive

axle unit assembly.
3. Remove the fill and drain plugs and sealing rings from each side of the drive axle unit

assembly. Discard sealing rings. See Figure 36.
NOTE: UNSEALED DRIVE AXLE SHOWN. SEALED DRIVE AXLES ARE

SIMILAR.
NOTE: LEFT SIDE SHOWN. LOCATION OF PLUGS ON THE RIGHT SIDE
IS THE SAME.
1. OIL DRAIN PLUG 4. OIL LEVEL CHECK PLUG
2. OIL FILL PLUG 5. SEALING RING
3. TRANSMISSION
Figure 36. Remove Plugs
4. After each side has drained completely, install new sealing rings and fill and drain plugs.

Tighten the drain plugs and remove the drip pans.
5. Add 0.5 liter (0.5 qt) of oil through the fill plug hole. Use the oil shown in the Maintenance

Schedule.
6. Install new sealing ring and oil fill plug. Tighten the oil fill plug.
7. Install the wheels and tires and remove lift truck from blocks. Connect the battery.
DRIVE AXLE UNIT ASSEMBLY, WET BRAKE OIL CHANGE
WARNING
The drive axle unit assembly wet brake oil is HOT at normal operating
temperatures and can cause serious burns and injury. Be careful when
draining oil and wear protective clothing and gloves.
CAUTION
Use only Dexron® III transmission fluid from a sealed container in the
wet brake chamber. Use of automotive or other unapproved fluids can
damage the brake system.
CAUTION
regulations.
1. Raise and safely chain the mast for access to the wet brake oil plugs. See the section Safety
Procedures When Working Near Mast. Disconnect the battery and block the wheels to
prevent unexpected movement.
2. Place a drip pan with a capacity of at least 3.25 liter (3.4 qt) under wet brake oil drain plug

on bottom of drive axle unit assembly. See Figure 37.
3. From the front of the lift truck, remove the wet brake oil fill and drain plugs and sealing
rings from the top and bottom of drive axle unit assembly. Discard sealing rings.
See Figure 37.
4. After wet brake oil has drained completely, install sealing ring and oil drain plug. Tighten

the wet brake oil drain plug and remove the drip pan.
5. Remove the wet brake oil level check plug and sealing ring.
6. Add oil through the wet brake oil fill plug hole. Use the oil shown in the Maintenance

Schedule.
7. Fill until oil begins to come out of the wet brake oil level check plug. See Figure 37.
8. Install new sealing rings, oil fill plug, and the level check plug. Tighten the wet brake oil

fill plug and the level check plug.
9. Lower the mast, connect the battery and remove blocks from wheels.
NOTE: UNSEALED DRIVE AXLE SHOWN. SEALED DRIVE AXLES ARE
SIMILAR.
A. FRONT VIEW B. BOTTOM VIEW
1. WET BRAKE OIL FILL PLUG 4. RIGHT TRACTION MOTOR ASSEMBLY
2. WET BRAKE OIL LEVEL CHECK PLUG 5. LEFT TRACTION MOTOR ASSEMBLY
3. WET BRAKE OIL DRAIN PLUG 6. SEALING RING
Figure 37. Drive Axle Unit Assembly, Wet Brake Oil Change
Battery Maintenance
HOW TO CHARGE BATTERY
WARNING
The acid in the electrolyte can cause injury. If electrolyte is spilled, use
water to flush the area. Make the acid neutral with a solution of sodium
bicarbonate (soda) and water. Acid in the eyes must be immediately
flushed with water.
Batteries generate explosive fumes when they are being charged. Keep
fire, sparks and burning material away from the battery charger area.
Prevent sparks from the battery connectors.
Charge batteries only in the special area for charging batteries. When
charging the batteries, keep the vent caps clean. The battery charger
area must have ventilation so that explosive fumes are removed. Open
the hood over the battery or remove the cover if the battery has a cover.
Disconnect the battery when doing cleaning and maintenance.
CAUTION
Never connect the battery charger plug to the plug of the lift truck. You
can damage the traction control circuit. Make sure the charger voltage is
the correct voltage for the battery.
Use only battery chargers approved by the battery manufacturer or
dealer.
CAUTION
Always make sure the color in the window of the charger connector is
the same as the color in the window of the battery connector.
NOTE: This series of trucks can have one of two types of batteries. One type has
removable cell caps. A green key for battery voltage shows in the window of the
battery connector for batteries with cell caps. The other type has sealed cells and the
electrolyte cannot be checked. A gray key for battery voltage shows in the window of
the battery connector for sealed batteries. These sealed batteries also require a
different charger.
NOTE: Many installations have battery chargers that can follow a program to
automatically charge a battery according to recommendations of the battery
manufacturer. Use the recommendations of the battery manufacturer for charging the
battery.
Correct use of the hydrometer and proper operation of the battery charger is
important. See Figure 38. Follow the instructions of the charger manufacturer. Never
let the battery discharge below the minimum value given by the battery manufacturer.
A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25°C (77°F).
See Figure 38. Never charge a battery at a rate that will raise the electrolyte
temperature above 49°C (120°F). Never let a battery stay discharged for long periods.
Normal Charge: This charge is normally given to a battery that is discharged from
normal operation. Many customers charge the battery at regular intervals that depend
on use. This procedure will keep the battery correctly charged if the battery is not
discharged below the limit. Always use a hydrometer to check the battery if the
battery is charged at regular intervals and has cell caps. Frequent charging of a battery
that has a 2/3 or more charge can decrease the life of the battery.
Equalizing Charge: This charge is at a low rate and balances the charge in all of the
cells. The equalizing charge is normally given approximately once a month. It is a
charge at a slow rate for three to six hours in addition to the regular charging cycle.
Do not give an equalizing charge more than once a week. The most accurate specific
gravity measurements for a charged battery will be after an equalizing charge. If the
specific gravity difference is more than 0.020 between cells of the battery after an
equalizing charge, there can be a defective cell. Consult your battery dealer.
Also, see the service manual section , for additional information on the charging and
maintenance of a battery.
Specific Gravity Reading Electrolyte Temp. Correction Points Correct Value

1.210 31°C (87°F) +0.003 1.213
1.210 27°C (80°F) +0.001 1.211
1.210 25°C (77°F) 0.000 1.210
1.210 18°C (64°F) -0.004 1.206
+0.001 or -0.001 for each 2 degree C from the 25° base value.
NOTE: CHECK ONLY BATTERIES THAT DO NOT HAVE SEALED CELLS.
Figure 38. Check Specific Gravity
HOW TO CHANGE BATTERIES
General
WARNING
Batteries are heavy and can cause an injury. Use care to avoid injury.
DO NOT put hands, arms, feet and or legs between the battery and a
solid object.
Make sure the capacity of the crane and spreader bar is greater than the
weight of the battery. The weight of the battery is normally shown on the
battery case. The maximum battery weight is shown on the lift truck
Nameplate. The spreader bar must NOT be made of metal or it must have
insulated straps.
The replacement battery must fit the battery area correctly. Adjust the
front spacer plate to prevent battery movement in the battery
compartment. Make sure that the battery voltage and weight of the
replacement battery is correct as shown on the Nameplate.
Before connecting the battery, make sure the key or keyless switch is in
the OFF position and the is set.
CAUTION
Batteries must be discarded according to local environmental
regulations.
Before removing the battery, observe previous WARNING and CAUTION.
Install the Battery
1. When a replacement battery is installed, make sure the battery fits the battery compartment
width with a maximum of 13 mm (0.50 in.) clearance in both side-to-side and fore-aft
direction.
If lift truck is equipped with a standard battery restraint system, use a spreader bar and
crane and install battery into lift truck. See
2. Adjust the front spacer plate by adding or removing spacers to prevent the battery from
moving more than a total of 13 mm (0.50 in.) forward or backward. There must be enough
clearance for battery removal.
3. Connect the battery connector.
4. On lift trucks equipped with Outdoor Protection/ Wash-down Package, spray battery
terminals with rust inhibitor-ignition sealer after battery terminal connections are properly
tightened.
5. Install the side panels.
Lift and Tilt System Leak Check
LIFT CYLINDER LEAK CHECK
WARNING
Never allow any person under a raised carriage. Do not put any part of
your body in or through the lift mechanism unless all parts of the mast
are completely lowered, the key is in the OFF position, and the key is
removed.
Before making any repairs, use chains on the mast weldments and
carriage so that they cannot move. Make sure the moving parts are
attached to the parts that cannot move.
DO NOT try to find hydraulic leaks by putting your hand on hydraulic
components under pressure. Hydraulic oil can be injected into the body
by pressure.
During test procedures for the hydraulic system, fasten the load to the
carriage with chains to prevent it from falling. Keep all personnel away
from the lift truck during the tests.
1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load
several times. Lower the load and tilt the mast forward and backward several times. Check
for leaks.
2. Raise the carriage and load so that the rods of the main lift cylinders extend at
least 60 cm (2 ft). If the carriage lowers slowly with the control valve in the NEUTRAL
position, there are leaks inside the hydraulic system. The maximum speed that the carriage

is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30°C (86°F).
If the oil temperature is 70°C (160°F), the maximum speed that the carriage can lower
is 150 mm (6 in.) per 10 minutes.
3. If the leak rate is greater than the above specifications, check the lift cylinders for internal
leaks. Remove the load from the forks. Install a gate valve in the supply line between the
main control valve and the mast. Put a capacity load on the forks again. Raise the carriage

and load so that the rods of the main lift cylinders extend at least 0.60 m (2 ft). Close the
gate valve. If the carriage or mast weldments lower slowly, the seals in the lift cylinders
are worn.
4. If the carriage and mast weldments do not move, open the gate valve and check for
movement again. If the carriage lowers when the gate valve is open, check for leaks in the
hydraulic lines or fittings. If no leaks are found, the main control valve may have a defect.
See the service manual for procedures to repair the main control valve, or the Parts
Manual to replace the main control valve. Remove the load from the forks.
TILT CYLINDER LEAK CHECK
To check the tilt system for hydraulic leaks, see the service manual for the procedures.
Safety Procedures When Working Near Mast
WARNING
Mast parts are heavy and can move. Distances between parts are small.
Serious injury or death can result if part of the body is hit by parts of the
mast or the carriage.
• Never put 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. Put a DO NOT OPERATE tag in the operator's 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 ladder or personnel lift to work

on the mast.
• DO NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal of the mast
or carriage. Follow the repair procedures in the applicable Service Manual section for the
mast.
The following procedures must be used when inspecting or working near the mast.
Additional precautions and procedures can be required when repairing or removing
the mast. See the correct Service Manual section for the specific mast being repaired.
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
procedures:
a. Put the mast in a vertical position.
b. Use a 9.4 mm (0.370 in.) (3/8 inch) minimum safety chain with a hook to fasten the
crossmembers together so the movable member cannot lower. Put the hook on the back
side of the mast. Make sure the hook is completely 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.
c. Lower the mast until there is tension in the safety chain and the free-lift cylinder (free-lift
and three-stage masts only) is completely retracted. Install a DO NOT REMOVE tag on
the safety chain(s).
d. Install another safety chain, 9.4 mm (0.370 in.) minimum, between the top or bottom

crossmember of the carriage and a crossmember on the outer weldment.
3.
Lift Chain Adjustments
WARNING
Working Near Mast in this section.
Never allow anyone under a raised carriage. DO NOT put any part of
your body in or through the lift mechanism unless all parts of the mast
are completely lowered and the power is OFF.
DO NOT try to find hydraulic leaks by putting your hand on hydraulic
components under pressure. Hydraulic oil can be injected into the body
by the pressure.
During test procedures for the hydraulic system, fasten the load to the
carriage with chains to prevent it from falling. Keep all personnel away
from the lift truck during the tests.
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of the chain set. Check tension by pushing on

both chains at the same time.
• The chain length will be correct.
• The chains must travel freely through the complete cycle.
NOTE: When the lift chain adjustments are complete, make sure the threads on the
nuts of the chain anchors are completely engaged. Inspect the torque of the prevailing
torque nut (locknut) used to adjust the chain anchor with every lift chain adjustment.
After carriage and or mast section(s) are adjusted for proper ground clearance, prevent
the carriage and or mast section(s) from fully lowering (see Safety Procedures When
Working Near Mast). With slack chain(s), check locknut torque.
If 2.5 N•m (22.1 lbf in) for 1/2-20, 4.5 N•m (39.8 lbf in) for 5/8-18
nuts, 6.0 N•m (53.1 lbf in) for 3/4-16 of torque cannot be reached; replace locknut.
The chain anchors, after adjustment, must be able to move on their mountings.
1. When adjusting lift chains on forklift trucks equipped with either pin- or hook-type forks
installed, go to Step 2. If forklift truck is normally equipped with a hook-type carriage and
has an attachment without forks, go to Step 3.
NOTE: Prior to performing adjustment procedures, make sure the forklift truck is
parked on a level surface and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage until the bottom of the fork heel is 12

+3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above floor level. See Figure 39.
1. MAST
2. CARRIAGE
3. FORK
4. HEEL OF FORK IS 12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE FLOOR LEVEL.
Figure 39. Lift Chain Adjustment, Hook- or Pin-Type Forks
3. Adjust chain anchors which support the carriage until the bottom of the lower carriage bar

is above the floor level as shown in Table 2. See Figure 40.
Table 2. Hook-Type Carriage Chain
Adjustment
Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)

Class IV 133.5 ±3 mm (5.26 ±0.12 in.)
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR
Figure 40. Lift Chain Adjustment, Hook-Type Carriage
Welding Repairs
WARNING
Welding can cause a fire or an explosion. Always follow the instructions
in the Frame section of the service manual if a hydraulic tank must be
welded. Make sure there is no fuel, oil, or grease near the weld area.
Make sure there is good ventilation in the area where the welding must
be done.
DO NOT heat, weld, or bend forks. Forks are made of special steel using
special methods. Get information from your dealer for Hyster lift trucks
before welding on a mast.
WARNING
Forklift frames and components may be painted with a catalyzed paint,
such as polyurethane or a two-part primer. Welding, burning, or other
heat sufficient to cause thermal decomposition of the paint may release
isocyanates. These chemicals are allergic sensitizers to the skin and
respiratory tract and overexposure may occur without odor warning.
Should work be performed, utilize good industrial hygiene practices
including removal of all paint (prime and finish coats) to the metal
around the area to be welded, local ventilation, and/or supplied-air
respiratory protection.
CAUTION
When an arc welder is used, always disconnect the battery connector on
the lift truck. This action will prevent damage to the motor controllers.
Connect the ground clamp for the arc welder as close as possible to the
weld area. This action will prevent damage to a bearing from the large
current from the welder.
NOTE: Remove all electronic controllers prior to arc welding on these lift trucks.
The removal procedures for the electronic controllers are outlined in .
All welding repairs require special welding instructions. Talk to your dealer
for Hyster lift trucks before welding on the lift truck. If an acetylene or arc welder is
used, perform the procedures in the previousWARNING and CAUTION.
Overhead Guard Changes
WARNING
Do not operate the lift truck without the overhead guard correctly
fastened to the lift truck.
Do not make changes to the overhead guard by welding or drilling.
Welding or drilling holes that are too big in the wrong location can
reduce the strength of the overhead guard. See your dealer for Hyster lift
trucks before making any changes to the overhead guard.
Observe previous WARNING before doing any changes to overhead guard.
Wheels and Tires

GENERAL
WARNING
The type of tire and the tire pressure (pneumatic tires) are shown on the
Nameplate. Make sure the Nameplate is correct for the type of tires on
the lift truck.
Wheels must be changed and tires repaired by trained personnel only.
Always wear safety glasses.
NOTE: See for wheel and tire sizes.
The lift trucks covered in this manual are equipped with pneumatic tires or solid
rubber tires that look like pneumatic tires. These variations in the tires can cause a
variation in the types of wheels (see Figure 41) and the disassembly and assembly
procedures.
PNEUMATIC TIRES 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 three-piece or four-piece wheel for a pneumatic tire. DO
NOT make changes in parts of rim if this type of solid rubber tire is
installed instead of a pneumatic tire. Changes to parts of rim can cause
a failure of wheel and can cause an accident.
Type of tire and tire pressure (pneumatic tires) are shown on the
Nameplate. Make sure Nameplate is correct for type of tires on lift truck.
WARNING
Deflate tire completely before removing wheel from lift truck. Air
pressure in tires can cause tire and rim parts to explode, causing
serious injury or death.
Never loosen nuts that hold inner and outer wheel halves together when
there is air pressure in tire.
Lift truck tires and wheels are very heavy. Use caution when removing
or installing tires and wheels or personal injury may occur.
1. Put lift truck on blocks as described in the General section at beginning of this section.
2. Remove air from tire. Remove valve core to make sure that all air is out of inner tube. Push

a wire through valve stem to make sure that valve stem does not have a restriction.
3. Remove wheel nuts and remove wheel and tire from lift truck.
NOTE: When disassembling wheels, see Figure 41. There are several types of

wheels used on this series of lift trucks.
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL
B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 41. Types of Pneumatic Wheels
Remove Tire From Two-Piece Wheel
WARNING
Make sure all air pressure is removed from tire before wheel is
disassembled. Air pressure in tires can cause tire and rim parts to
explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move
with enough force to cause an injury.
STEP 1.
Remove nuts that fasten wheel rims
together.
STEP 2.

Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove
inner tube and flap.
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all air pressure is removed from tire before wheel is
disassembled. Air pressure in tires can cause tire and rim parts to
explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move
with enough force to cause an injury.
STEP 1.

Loosen tire bead from side flange.
STEP 2.
Put tire tool into slot between lock ring
and wheel rim. Remove lock ring and
side flange. If there is a flange seat,
remove it.
STEP 3.
Loosen bead from outer side of wheel
rim. Remove valve stem from wheel. If
there is a washer, keep it for
installation during assembly.
STEP 4.

Remove wheel from tire.
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 wheel before installing tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of wheel are 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 together. Make sure that side ring is in
correct position. Ends of side ring must not touch. Clearance at ends of
lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is
installed. If clearance is wrong, the wrong part has been used.
NOTE: There are two types of wheels used on this series of lift trucks.
See Figure 41. Make sure you use the correct procedure.
1. Clean and inspect all parts of wheel. Paint any parts that have rust or corrosion.
2. Install a new inner tube in tire. Used tubes and flaps can cause tire failure.
WARNING
Do not lubricate tire bead with antifreeze or petroleum-based liquid.
Vapors from these liquids can cause an explosion during inflation or
use.
3. Apply rubber lubricant or soap solution to tire bead and tube.
4. Install new tire flap.
WARNING
Do not lubricate tire bead with antifreeze or petroleum-based liquid.
Vapors from these liquids can cause an explosion during inflation or
use.
5. Make sure rim is correct size for tire. Lubricate part of wheel that contacts bead and flap.
6. Install two-piece wheel in tire as shown in Install Two-Piece Wheel in Tire. Install three-

piece or four-piece wheel in tire as shown in Install Three- or Four-Piece Wheel in Tire.
Install Two-Piece Wheel in Tire
WARNING
Damage to tire and wheel assembly and injury or death can occur if you
do not do the following procedures:
• DO NOT mix types of tires, type of tire tread, or types of wheel assemblies of different

Do not use a steel hammer on wheel. Use a rubber, lead, plastic, or
CAUTION
Do not use pneumatic-shaped solid tires on two-piece bolt together
drive wheels. Spinning may occur.
STEP 1.
Install inner tube and rubber flap in
tire. Install both halves of wheel rim in
tire. Make sure stem of inner tube is
aligned with slot in rim.
STEP 2.
Tighten nuts that hold rim halves

together to 175 N•m (129 lbf ft). Add
air pressure to tire. See Nameplate.
Install Three- or Four-Piece Wheel in Tire
WARNING

STEP 1.
Install inner tube and rubber flap in
tire.
STEP 2.
Install wheel rim in tire. Install the
washer on the stem (if removed during
disassembly). Make sure stem of inner
tube is aligned with slot in rim.
STEP 3.
Turn over rim and tire. Put blocks
under rim so rim is 8 to 10 cm (3 to
4 in.) above floor. Install flange seat (if
used) and lock ring.
STEP 4.
Put lock ring in correct position on rim.
Add air pressure to tire as described
in Add Air to Pneumatic Tires With
Tube.
Add Air to Pneumatic Tires With Tube

WARNING
Add air pressure to tires only in safety cage. Inspect safety cage for
damage before use. When air pressure is added, use a chuck that
fastens onto valve stem of inner tube. Make sure there is enough hose
to permit operator to stand away from safety cage when air pressure is
added to tire.
Do not sit or stand by safety cage. Do not use a hammer to try to correct
position of side flange or lock ring when tire has air pressure greater
than 20 kPa (3 psi).
1. Put tire in safety cage. See Figure 42.
Figure 42. Add Air to Tires

2. Add 20 kPa (3 psi) of air pressure to tire.
3. Check that all wheel parts are correctly installed. Hit lock ring lightly to make sure that it

is in seat.
4. If installation is correct, add air pressure to tire to specified pressure.
5. Check that all wheel parts are correctly installed. If installation is not correct, remove all
air pressure from tire. Remove valve core to make sure all air pressure has been removed

and then make adjustments. Clearance at ends of lock ring will be approximately 13 to
25 mm (0.5 to 1.0 in.) when tire has correct air pressure.
Wheels, Install
WARNING
Install wheel on hub. Tighten the steering wheel nuts in a cross pattern to a torque
value of 155 to 175 N•m (114 to 130 lbf ft). Tighten the drive wheel nuts in a cross
pattern to a torque value of 339 to 380 N•m (250 to 280 lbf ft). If wheels are two-
piece rims, make sure nuts that fasten rim halves together are toward brake drum
when they are installed.
SOLID RUBBER TIRES ON PNEUMATIC WHEELS, CHANGE
WARNING
1. Put lift truck on blocks as described in the General section at the beginning of this service

manual.
2. Remove wheel nuts and remove wheel and tire from lift truck.
WARNING
Keep tire tools in firm contact with wheel. If tool slips, it can move with
enough force to cause serious injury.
When disassembling wheels, see Figure 41. There are several types of wheels used on
these series of lift trucks.
WARNING
STEP 1.
Put wheel rim on bed of press. Put

cage in position on tire. Use press to
push tire away from side flange.
STEP 2.
Put tire tool into slot between lock ring

and wheel rim. Remove lock ring and
side flange.
STEP 3.
Turn tire over. Put a support under
wheel rim. Make sure wheel rim is at
least 150 to 200 mm (6 to 8 in.) from
bed of press.
STEP 4.
Put cage in position on tire. Use press
to push tire from wheel rim.
Install Tire on Wheel
WARNING

When assembling wheels, see Figure 41. There are several types of wheels used on
these series of lift trucks. Do not use a two-piece pneumatic wheel for solid rubber
tires.
CAUTION
Too much lubricant can cause tire to slide and move around wheel rim.
STEP 1.
Lubricate wheel rim and inner surface
of tire with tire lubricant or soap.
STEP 2.
Put wheel rim on bed of press. Put tire
over wheel rim. Put cage in position on
tire. Use press to install tire on wheel
rim.
STEP 3.
Remove cage and put flange seat (if
used), side ring, and lock ring in
position on wheel rim. Install cage on
tire. Use press to push tire onto wheel
rim so side flange and lock ring can be
installed.
STEP 4.
While cage is holding tire on wheel
rim, install lock ring. Use tire tool to
make sure lock ring is in correct
position.
Wheels, Install
WARNING
Install wheel on hub. Tighten the steering wheel nuts in a cross pattern to a torque
value of 155 to 175 N•m (114 to 130 lbf ft). Tighten the drive wheel nuts in a cross
pattern to a torque value of 339 to 380 N•m (250 to 280 lbf ft).

Periodic Maintenance: J45-70XN (A276)

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PERIODIC

PART NO. 1689281 8000 SRM 1372

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

Figure 1. Put Lift Trucks on Blocks

NOTE 2: Recommended service intervals are based on a normal application in a clean

NOTE 3: Lubricate if dry or at first sign of visible surface rust

NOTE 4: Equalization charge is required approximately each month.

NOTE 6: Multipurpose lithium base grease.

Maintenance Procedures Every 8 Hours or Daily

NOTE: Forks must be removed and installed by trained personnel.

1. TIP ALIGNMENT (MUST BE WITHIN 3%

NOTE: ONLY LIFT TRUCK MODELS NOT EQUIPPED WITH A FORK

NOTE: STANDARD SEAT SHOWN. AN OPTIONAL SWIVEL SEAT IS

A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT

Maintenance Procedures Every 500 Hours or Three Months

NOTE: Forks must be removed and installed by trained personnel.

1. OUTER FORK CARRIER 5. FORK POSITIONER

NOTE: ONLY LIFT TRUCK MODELS NOT EQUIPPED WITH A FORK

12.7 mm (0.50 in.) 15.9 mm 254.0 mm (10.0 in.) 317.5 mm 261.6 mm (10.3 in.) 327.0 mm

Maintenance Procedures Every 2000 Hours or Yearly

Maintenance Procedures Every 4000 Hours or Two Years

NOTE: TELESCOPIC STEERING COLUMN SHOWN.

NOTE: Tag all electrical connectors during removal to aid in installation.

NOTE: Tag all electrical connectors during removal to aid in installation.

NOTE: UNSEALED DRIVE AXLE SHOWN. SEALED DRIVE AXLES ARE

Specific Gravity Reading Electrolyte Temp. Correction Points Correct Value

Safety Procedures When Working Near Mast

Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)

Overhead Guard Changes

Wheels and Tires

NOTE: When disassembling wheels, see Figure 41. There are several types of

Remove Tire From Three- and Four-Piece Wheels

Install Wheel in Tire

Install Three- or Four-Piece Wheel in Tire

Add Air to Pneumatic Tires With Tube

Figure 42. Add Air to Tires

Install Tire on Wheel

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