Manutebção Periódica PDF

PERIODIC
MAINTENANCE
S40-70FT, S55FTS [F187];
H40-70FT [L177]
PART NO. 1580525 8000 SRM 1150

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Serial Number Data ........................................................................................................................................ 1
How to Move Disabled Lift Truck................................................................................................................... 1
How to Tow Lift Truck ................................................................................................................................ 1
How to Put Lift Truck on Blocks .................................................................................................................... 2
How to Raise Drive Tires ............................................................................................................................ 2
How to Raise Steering Tires ....................................................................................................................... 3
How to Clean a Lift Truck............................................................................................................................... 3
Maintenance Schedule....................................................................................................................................... 19
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 28
How to Make Checks With Engine Stopped................................................................................................. 28
Tires and Wheels ....................................................................................................................................... 28
Safety Labels ............................................................................................................................................. 29
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 29
Operator Restraint System....................................................................................................................... 30
Automatic Locking Retractor (ALR) .................................................................................................... 30
Emergency Locking Retractor (ELR) ................................................................................................... 30
Adjust Seat - Full Suspension .............................................................................................................. 32
Adjust Seat - Internal Suspension ....................................................................................................... 32
Hood and Seat Latches ............................................................................................................................. 34
Engine Compartment................................................................................................................................ 34
Paper Application ...................................................................................................................................... 34
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ 35
Hydraulic Hoses ........................................................................................................................................ 35
Coolant Hoses ............................................................................................................................................ 35
Steering Column Gas Cylinder................................................................................................................. 35
Transmission ............................................................................................................................................. 35
Hydraulic System Oil ................................................................................................................................ 35
Engine Oil .................................................................................................................................................. 36
Air Filter .................................................................................................................................................... 41
Forks .......................................................................................................................................................... 41
Remove .................................................................................................................................................. 41
Inspect ................................................................................................................................................... 41
Install..................................................................................................................................................... 42
Adjust..................................................................................................................................................... 42
How to Make Checks With Engine Running................................................................................................ 43
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 43
Service Brakes ........................................................................................................................................... 45
Brake Fluid Level ................................................................................................................................. 45
Operation, Check .................................................................................................................................. 46
Parking Brake ........................................................................................................................................... 46
Engine Oil Pressure .................................................................................................................................. 46
Cooling System .......................................................................................................................................... 47
Steering System ........................................................................................................................................ 47
Control Levers and Pedals ........................................................................................................................ 48
Lift System, Operate ................................................................................................................................. 48
First Service After First 100 Hours of Operation ............................................................................................ 48
Mazda and GM Engine Oil and Oil Filter.................................................................................................... 48
Yanmar Engine Oil and Oil Filter ................................................................................................................ 49
Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 50
Mazda and GM Engine Oil and Oil Filter.................................................................................................... 50
©2010 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Drive Belt ....................................................................................................................................................... 51
Mazda 2.0L and 2.2L Engines .................................................................................................................. 51
Fan and Alternator Drive Belt ............................................................................................................. 51
GM 2.4L Engine ........................................................................................................................................ 51
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) .............................. 52
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only).................................. 52
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 54
Hydraulic System Oil .................................................................................................................................... 54
Hydraulic Tank Breather .............................................................................................................................. 54
Inspect........................................................................................................................................................ 54
Battery ........................................................................................................................................................... 55
Yanmar Engine Oil and Oil Filter ................................................................................................................ 55
Drive Belt ....................................................................................................................................................... 55
Yanmar Diesel Engine............................................................................................................................... 55
PCV Valve ...................................................................................................................................................... 56
Clean Debris From Radiator Core ................................................................................................................ 56
Transmission Oil Level ................................................................................................................................. 56
Wet Brake Planetary Housing Oil Level Check........................................................................................... 58
Forks............................................................................................................................................................... 59
Mast Lubrication ........................................................................................................................................... 60
Header Hose Checks...................................................................................................................................... 62
Lift Chain Lubrication .................................................................................................................................. 63
Tilt Cylinder Lubrication .............................................................................................................................. 63
Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 64
Manual Hydraulic Levers Lubrication ......................................................................................................... 64
Brake Fluid .................................................................................................................................................... 65
Tie Rod Lubrication (H40-70FT)................................................................................................................... 66
Differential and Drive Axle Oil (Dry Brake) ................................................................................................ 66
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 66
Valve Clearance, Check and Adjust.............................................................................................................. 66
Ignition System.............................................................................................................................................. 67
GM 2.4L Engine ........................................................................................................................................ 67
Mazda 2.0L and 2.2L Engines .................................................................................................................. 67
LPG Fuel Filter Element Replace, GM 2.4L Engine ................................................................................... 67
Remove....................................................................................................................................................... 67
Install ......................................................................................................................................................... 67
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant
Engines) ......................................................................................................................................................... 68
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only ............................................... 68
Remove....................................................................................................................................................... 68
Clean/Inspect ............................................................................................................................................. 69
Install ......................................................................................................................................................... 69
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only ............................... 69
Remove and Replace ................................................................................................................................. 69
Fuel Filter Replacement, Yanmar Engine.................................................................................................... 70
Priming the Fuel System (Yanmar).............................................................................................................. 71
Lift Chains Wear Check ................................................................................................................................ 72
Lift Chain Lubrication .................................................................................................................................. 72
Integral Sideshift Carriage, Check Bearings ............................................................................................... 73
ii
Periodic Maintenance Table of Contents

Steering Axle.................................................................................................................................................. 73
Control Levers and Pedals ............................................................................................................................ 73
Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 74
Hydraulic System .......................................................................................................................................... 74
Hydraulic Filter, Replace .......................................................................................................................... 74
Hydraulic Tank Breather, Replace ........................................................................................................... 75
Air Filter ........................................................................................................................................................ 75
PCV Valve ...................................................................................................................................................... 77
Oxygen Sensor ............................................................................................................................................... 77
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ........... 78
LPG Regulator Fuel Filter, GM Engine ....................................................................................................... 79
Remove....................................................................................................................................................... 79
Install ......................................................................................................................................................... 79
Gasoline Fuel Filter....................................................................................................................................... 79
Timing Belt .................................................................................................................................................... 80
Mazda Engines .......................................................................................................................................... 80
GM 2.4L Engine ........................................................................................................................................ 80
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ......................... 80
Gasoline Fuel Injector, Mazda Engines........................................................................................................ 80
LPG Fuel Injector, GM Engines.................................................................................................................... 80
Gasoline Fuel Injector, GM Engines ............................................................................................................. 80
Fuel Injector, Yanmar Engines ..................................................................................................................... 80
Forks............................................................................................................................................................... 81
Integral Sideshift Carriage ........................................................................................................................... 81
Bearings, Replace ...................................................................................................................................... 81
Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 81
Iron Transmission Housing ...................................................................................................................... 81
Aluminum Transmission Housing ........................................................................................................... 82
Remove .................................................................................................................................................. 82
Clean and Inspect ................................................................................................................................. 83
Install..................................................................................................................................................... 83
Transmission Oil Change, Wet Brake Drive Axle ....................................................................................... 84
Wet Brake Axle Center Section and Planetary Housing, Oil Change ........................................................ 86
Brake Fluid (Master Cylinder), Change....................................................................................................... 89
Brake Fluid (Dry Brake), Remove ................................................................................................................ 91
Service Brakes (Dry Brake) .......................................................................................................................... 91
Differential (Dry Brake) ................................................................................................................................ 91
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. 92
Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 93
Hydraulic Oil, Replace .................................................................................................................................. 93
Cooling System .............................................................................................................................................. 94
Safety Procedures When Working Near Mast.................................................................................................. 95
Hood Latch Check .............................................................................................................................................. 98
Lift Chain Adjustments ..................................................................................................................................... 99
Jump-Starting the Lift Truck.......................................................................................................................... 100
Jump-Starting Using a Battery Charger ................................................................................................... 100
Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................. 100
Welding Repairs ............................................................................................................................................... 101
Overhead Guard Changes ............................................................................................................................... 101
iii
Table of Contents Periodic Maintenance

Wheel and Tire Replacement .......................................................................................................................... 102
General ......................................................................................................................................................... 102
Solid Rubber Tire, Change (S Series) ......................................................................................................... 102
Remove and Install Tire on Wheel ......................................................................................................... 102
Pneumatic Tire With Tube, Repair............................................................................................................. 103
Remove Wheels From Lift Truck............................................................................................................ 103
Remove Tire From Wheel ....................................................................................................................... 103
Remove Tire From Two-Piece Wheel ................................................................................................. 104
Remove Tire From Three- and Four-Piece Wheels ........................................................................... 105
Install Wheel in Tire ............................................................................................................................... 106
Install Three-Piece or Four-Piece Wheel in Tire ............................................................................... 106
Install Tire on Two-Piece Wheel ........................................................................................................ 107
Install Two-Piece Wheel in Tire ......................................................................................................... 108
Add Air to Pneumatic Tires With Tube...................................................................................................... 108
Install the Wheels ................................................................................................................................... 109
Dual Drive Wheels, Install ..................................................................................................................... 109
Pneumatic Tubeless Tire, Repair................................................................................................................ 110
Remove Wheels From Lift Truck............................................................................................................ 110
Remove Tire From Wheel ....................................................................................................................... 110
Install Tire on Wheel .............................................................................................................................. 112
Add Air to Pneumatic Tubeless Tire ...................................................................................................... 114
Wheels, Install......................................................................................................................................... 115
Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... 115
Remove Wheel From Tire ....................................................................................................................... 115
Install Tire on Wheel .............................................................................................................................. 117
Adhesives and Sealants ................................................................................................................................... 119
This section is for the following models:
S40-70FT, S55FTS [F187];

H40-70FT [L177]
iv
8000 SRM 1150 General
General
shown in the Maintenance Schedule. Service Man-
WARNING uals are available from your dealer for Hyster lift
DO NOT make repairs or adjustments unless trucks to help users who do their own maintenance.
you have both authorization and training. Re-
pairs and adjustments that are not correct can SERIAL NUMBER DATA
make a dangerous operating condition.
The serial number for the lift truck is on the name-
plate. It is also on the right side of the frame, under
WARNING the floor plate.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If re- HOW TO MOVE DISABLED LIFT TRUCK
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from How to Tow Lift Truck
the key switch.
WARNING
CAUTION Use extra caution when towing a lift truck if
Disposal of lubricants and fluids must meet lo- any of the following conditions exist:
cal environmental regulations. • Brakes do not operate correctly.
• Steering does not operate correctly.
This section contains a Maintenance Schedule and • Tires are damaged.
the instructions for maintenance and inspection. • Traction conditions are bad.
• The lift truck must be towed on a slope.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift If the engine cannot run, there is no power
truck. The service intervals are given in both oper- available for the hydraulic steering system
ating hours recorded on the lift truck hourmeter and and the service brakes. This condition can
in calendar time. The recommendation is to use the make the lift truck difficult to steer and stop.
interval that comes first. If the lift truck uses power from the engine to
help apply the brakes, the application of the
The recommendations for the time intervals given for
brakes will be more difficult. Poor traction can
eight hours of operation per day. The time intervals
cause the disabled lift truck or towing vehicle
must be decreased from the recommendations in the
to slide. A slope will also make the lift truck
Maintenance Schedule for the following conditions:
more difficult to stop.
• The lift truck is used more than eight hours per
day. Never lift and move a disabled lift truck unless
• The lift truck must work in dirty operating condi- the disabled lift truck MUST be moved and
tions. cannot be towed. A lift truck used to move
• Poor ground conditions. a disabled lift truck MUST have a capacity
• Intensive usage at high performance levels or rating equal to or greater than the weight of
other abnormal conditions will require more fre- the disabled lift truck. The capacity of the lift
quent servicing. truck used to move a disabled lift truck must
have a load center equal to half the width of
Your dealer for Hyster lift trucks has the equipment
the disabled lift truck. See the nameplate of
and trained service personnel to do a complete pro-
the disabled lift truck for the approximate
gram of inspection, lubrication, and maintenance. A
total weight. The forks must extend the full
regular program of inspection, lubrication, and main-
width of the disabled lift truck. Put the weight
tenance will help your lift truck provide more effi-
center of the disabled lift truck on load center
cient performance and operate for a longer period of
of the forks. Be careful to not damage the
time.
underside of the lift truck.
Some users have service personnel and equipment
1. The towed lift truck must have an operator.
to do the inspection, lubrication, and maintenance
2. Tow truck slowly.
1
General 8000 SRM 1150
3. Using a lift truck or a lifting device that could HOW TO PUT LIFT TRUCK ON BLOCKS
be attached to the mast (I.E. come-a-long), raise
carriage and forks approximately 30 cm (12 in.) How to Raise Drive Tires
from surface. Install chain around a mast cross-
member and the carriage to prevent carriage and WARNING
mast channels from moving. The lift truck must be put on blocks for some
4. If another lift truck is used to tow the disabled lift types of maintenance and repair. The removal
truck, that lift truck must have an equal or larger of the following assemblies will cause large
capacity than the disabled lift truck. Install ap- changes in the center of gravity: mast, drive
proximately 1/2 of a capacity load on forks of lift axle, engine, transmission, and counterweight.
truck that is being used to tow disabled lift truck. When the lift truck is put on blocks, put ad-
This 1/2 capacity load will increase traction of lift ditional blocks in the following positions to
truck. Keep load as low as possible. maintain stability:
• Before removing the mast and drive axle, put
5. Use a towing link made of steel that fastens to blocks under the counterweight so the lift
tow pins in counterweights of both lift trucks. truck cannot fall backward.
Slowly and carefully remove the slack out of the • Before removing the counterweight, put
towing link. See Figure 1. 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 any
blocks used to support the lift truck are solid,
one-piece units.
CAUTION
These lift trucks are equipped with cowl lifting
eyes. The cowl lifting eyes are to be used to
lift the front of the lift truck only. Lifting more
than the front of the lift truck with the cowl
lifting eyes will damage the cowl section.
1. Put blocks on each side (front and back) of steer-

ing tires to prevent movement of lift truck. See
Figure 2.
2. Put mast in vertical position. Put a block under

each outer mast channel.
3. Tilt mast fully forward until drive tires are raised

from surface.
4. Put additional blocks under frame behind drive

tires.
5. If hydraulic system will not operate, use a hy-

1. STEEL TOW LINK draulic jack under the side of the frame near the
2. TOW PIN front. Make sure jack has a capacity equal to at
least half the weight of the lift truck. See Name-
Figure 1. Towing the Lift Truck plate.
2
How to Raise Steering Tires 2. Use hydraulic jack to raise steering tires. Make
sure jack has a capacity of at least 2/3 of total
NOTE: Some lift trucks are equipped with lifting eyes weight of lift truck as shown on the nameplate.
for the purpose of lifting the entire lift truck. If the
lift truck is equipped with this type of lifting eyes, the 3. Put jack under steering axle or frame to raise
lift truck can be lifted and blocks installed. lift truck. Put blocks under frame to support lift
truck.
1. Apply parking brake. Put blocks on both sides
(front and back) of drive tires to prevent move-
ment of lift truck. See Figure 2.
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
HOW TO CLEAN A LIFT TRUCK CAUTION

Units may be washed with a non-heated pres-
WARNING sure washer. Steam cleaning is not recom-
Engine, exhaust system components and other mended in most instances, as condensation
components are hot to the touch. Be sure lift may form in electrical components causing
truck components are cool before starting in- damage or erratic behavior.
spection and cleaning, or personal injury may
occur. NOTE: Lift trucks used in paper applications may
need cleaning beyond what is described here. Please
WARNING refer to Paper Application section in the applicable
Operating Manual and to available Service Gram/
Compressed air can move particles so that they
Bulletin for more detail.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air If it becomes necessary to clean the fork lift, follow
is away from all personnel. Wear protective the guidelines listed below.
goggles or a face shield to prevent injury to the
eyes. 1. Assure truck components are cool before starting
the cleaning procedure.
3
2. Disconnect the battery. If an electric truck, re- • Dash/cowl assembly

move the traction battery. • Armrests with electrical components
3. Remove accumulated debris using a compressed 7. Clean the battery compartment by using a clean
air line and nozzle. cloth to wash the battery with water. Dry with
compressed air. Care should be taken to keep
4. Lightly spray a non-corrosive cleaning agent onto moisture at a minimum as some units have a
the areas to be cleaned. This will help loosen traction or hydraulic motor directly below the
grime, so close contact direct spraying will not be battery compartment.
necessary.
8. DO NOT pressure wash the battery. Do not use
5. Be sure to avoid directing the spray into electri- hot water. For cleaning traction batteries, refer
cal panel compartment. Ensure over-spray does to the Battery section of the Service Manual.
not come in contact with electrical components;
do not spray water directly at electrical compo- 9. DO NOT pressure wash lift chains, sheaves or
nents, wiring connectors or electrical enclosures. load rollers in the mast assembly. Refer to the
Even sealed connectors may allow water egress Chains, Sheaves and Load Rollers maintenance
under pressure or if connector is damaged. section in the Service Manual for proper clean-
ing procedures.
6. Avoid spraying in areas containing electrical
components such as: 10. After cleaning, immediately start and run the lift
• Floor Plates truck to dry out components.
• Battery Compartment
4
Figure 3. GM 2.4L Gas Trucks (Prior to Jan. 2011)
5
Figure 4. GM 2.4L LPG Trucks (Prior to Jan. 2011)
6
Figure 5. Mazda 2.0L and 2.2L Gas Trucks (Except 2007 Emission Compliant Engines)
7
Figure 6. Mazda 2.0L and 2.2L LPG Trucks (Except 2007 Emission Compliant Engines)
8
Figure 7. Mazda 2.0L and 2.2L Gas Trucks (2007 Emission Compliant Engines Only)
9
Figure 8. Mazda 2.0L and 2.2L LPG Trucks (2007 Emission Compliant Engines Only)
10
Figure 9. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
11
Figure 10. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
12
Figure 11. Yanmar 2.6L and 3.3L Diesel Trucks (Prior to Jan. 2011)
13
Figure 12. GM 2.4L Gas Trucks with Aluminum Case Transmission (After January, 2011)
14
Figure 13. GM 2.4L LPG Trucks with Aluminum Case Transmission (After January, 2011)
15
Figure 14. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (After January,
2011)
16
Figure 15. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (After January,
2011)
17
Figure 16. Yanmar 2.6L and 3.3L Diesel Trucks (After January, 2011)
18
8000 SRM 1150 Maintenance Schedule
Maintenance Schedule
NOTE: The lift trucks shown in Figure 3, Figure 4, The lift truck shown in Figure 11 represents H40-
Figure 5, Figure 6, Figure 7, Figure 9, Figure 8, and 70FT (L177) lift trucks only.
Figure 10 represent S40-70FT, S55FTS (F187) lift
trucks, H40-70FT (L177) are similar.
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 500 1000 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 hr/ hr/ hr/ 1 yr 2 yr Quantity
day 6 mo 6 mo 6 mo
27 Tires X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
30, Mast, Carriage, Header X Check Condition See Parts Manual
31 Hoses, Lift Chains, and Lubrication
Attachment
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat Latches X Check Condition
and Operation
Engine Compartment X Remove
Combustible
Materials
See NOTE 5
Paper Application: X Check Condition
Engine Compartment, Clean as
Truck Components, Required
Exhaust Wraps, Replace as
Radiator, Radiator Required
Screen if equipped, See NOTE 10
Belly Pan if equipped
Check for Leaks - Fuel, X Check for Leaks
Oil, Water See NOTE 1
Hydraulic Hoses X Check Condition See Parts Manual
13 Coolant Hoses X Check Condition See Parts Manual
18 Fuel Tank (Gas) CIL 40.5 liter 85 Octane Gasoline
S40-70FT, S55FTS (10.7 gal) Minimum
(F187)
18 Fuel Tank (Gas) CIL 52 liter (13.7 gal) 85 Octane Gasoline
H40-70FT (L177) Minimum
18 Fuel Tank (LPG) CIL 29.9 liter LPG - HD 5, HD 10
(7.9 gal)
15.2 kg (33.5 lb)
18 Fuel Tank (Diesel) CIL 52 liter (13.7 gal) Diesel No. 2
H40-70FT (L177)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
19
Maintenance Schedule 8000 SRM 1150
Table 1. Maintenance Schedule (Continued)
day 6 mo 6 mo 6 mo
Horn, Lights, Alarms X Check Operation
1 Service Brakes X Check Operation
25 Parking Brake X Check Operation
Steering Controls and X Check Condition
Steering Column Gas and Operation
Cylinder
24 Transmission X Check for Leaks
24 Transmission X Check Operation
3 Hydraulic Oil X X C 30.1 liter (32 qt) ISO VG 46
S40-70FT, S55FTS See NOTE 2 and Hydraulic Oil
(F187) NOTE 3 15°C (5°F) and
Above
3 Hydraulic Oil X X C 39.8 liter (42 qt) ISO VG 46
H40-70FT (L177) See NOTE 2 and Hydraulic Oil
NOTE 3 15°C (5°F) and
Above
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
10 Hydraulic Tank X C Inspect and See Parts Manual

Breather Replace as
Required
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 3.9 liter (4.1 qt) 7°C (20°F)
Mazda CIL See NOTE 4 and and Below
2.0L Engine NOTE 5. SAE 5W-20
(Gas/LPG) 16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
20
day 6 mo 6 mo 6 mo
Mazda 2.2L CIL See NOTE 4 and and Below
Engine NOTE 5. SAE 5W-20
(Gas/LPG) 16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
GM 2.4L Engine CIL See NOTE 4 and and Below
(Gas/LPG) NOTE 5. SAE 5W-20
16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
21 Engine Oil Filter C 1 Filter See Parts Manual
Mazda 2.0L See NOTE 4
and 2.2L and GM and NOTE 5.
2.4L Engines
(Gasoline)
9 Engine Oil X C 10.2 liter 20°C (68°F)
Yanmar 2.6L CIL (10.8 qt) and Over
and 3.3L See NOTE 4 SAE 40
Engine and NOTE 5. 10 to 30°C (50 to 86°F)
(Diesel) SAE 30
0 to 20°C (32 to 68°F)
SAE 20
16 to 40°C
(3 to 103°F)
SAE 15W-40
20 to 30°C
( 4 to 86°F)
SAE 10W-30
10 to 10°C
(14 to 50°F)
SAE 20W
20 to 10°C
( 4 to 50°F)
SAE 10W
21
day 6 mo 6 mo 6 mo
21 Engine Oil Filter C 1 Filter See Parts Manual
Yanmar 2.6L See NOTE 4
and 3.3L and NOTE 5.
(Diesel)
20 Air Filter CIL C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 13.
20 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 13.
16 Drive Belt X Check for Wear
Mazda 2.0L and Damage.
and 2.2L Adjust as
(Gas/LPG) Needed.
GM 2.4L Engines and Damage.
(Gas/LPG) No adjustment
needed.
Yanmar 2.6L and and Damage.
3.3L Engines Adjust as
(Diesel) Needed.
LPG Regulator X Drain Tar See
Mazda 2.0L NOTE 5.
and 2.2L Engines
Engine Idle Speed X See NOTE 5. 800 ±25 rpm
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
Engine Governed Speed X See NOTE 5. 2700 ±25 rpm
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
LPG Regulator GM X Drain Tar See
2.4L Engine NOTE 5.
GM 2.4L
(Gas/LPG)
GM 2.4L
(Gas/LPG)
22
day 6 mo 6 mo 6 mo
Yanmar 2.6L
and 3.3L
(Diesel)
Yanmar 2.6L
(Diesel)
Yanmar 3.3L
(Diesel)
17 PCV Valve X C Replace as See Parts Manual
Necessary
See NOTE 14.
Oxygen Sensor X Check Indicator Light
4 Valve Adjustment X Adjust as Intake
Mazda 2.0L Required 0.15 mm (0.006 in.)
and 2.2L Engines Cold
(Gas/LPG) Exhaust
0.35 mm (0.014 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Yanmar 2.6L Required 0.20 mm (0.008 in.)
and 3.3L Cold
Diesel Engines Exhaust
0.20 mm (0.008 in.)
Cold
Timing X Adjust as 6°±1° BTDC
Mazda 2.0L Required (Orange Mark)
and 2.2L Engines
(Gas)
Timing X Adjust as 6°±1° BTDC
Mazda 2.0L Required (Orange Mark)
and 2.2L Engines
(LPG)
19 LPG Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L Engines
(2007 Emission
Compliant Engines
Only)
23
day 6 mo 6 mo 6 mo
LPG Fuel Regulator C 1 Filter See Parts Manual
Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emis-
sion Compliant En-
gines)
19 LPG Fuel Injector C 1 Filter See Parts Manual
Vapor Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emis-
sion Compliant En-
gines)
19 Fuel Filter, LPG C 1 Filter See Parts Manual
GM 2.4L Engines
19 Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L (Except
2007 Emission Com-
pliant Engines) and
GM 2.4L Engines
(Gasoline)
19 Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L Engines
(2007 Emission
Compliant Engines
Only )
(Gasoline)
19 Fuel Water Separator C 1 Filter See Parts Manual
Yanmar 2.6L
and 3.3L Engines
(Diesel)
19 In-line Fuel Filter C 1 Filter See Parts Manual
Yanmar 2.6L and
3.3L Engines
(Diesel)
15 Timing Belt C Replace See Parts Manual
See NOTE 7.
22 Fuel Injector 1 Injector Check and Clean
Mazda 2.0L See NOTE 8. If Required
and 2.2L Engines
(LPG, Except 2007
Emission Compliant
Engines)
24
day 6 mo 6 mo 6 mo
22 Fuel Injectors 4 Injectors Check and Replace
See NOTE 8. If Required
Mazda 2.0L
and 2.2L Engines
(Gas)
5 Spark Plugs C Check See Parts Manual
Mazda 2.0L Plug Wires 0.8 ±0.1 mm (0.031
and 2.2L Engines 4 Plugs ±0.004 in.)
(Gas/LPG)
22 Fuel Injectors X 4 Injectors Check and Replace
GM 2.4L Engines If Required
Gas/LPG
5 Spark Plugs C Check See Parts Manual
GM 2.4L Engines Plug Wires 0.8 to 0.9 mm
(Gas/LPG) 4 Plugs (0.032 to 0.035 in.)
22 Fuel Injectors X 4 Injectors Check and Replace
Yanmar 2.6L If Required
and 3.3L Engine
(Diesel)
12, Cooling System X C 11.0 liter See NOTE 15
14 Mazda 2.0L CIL (11.6 qt)
and 2.2L Engines
(Serpentine
and Square
Wave)
14 Mazda 2.0L CIL (11.2 qt)
and 2.2L Engines
(Square Wave
w/Air Oil
Cooler)
14 GM 2.4L Engine CIL (11.2 qt)
14 Yanmar 2.6L CIL (12.1 qt)
and 3.3L Engines
Clean Debris From X See NOTE 5
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brakes- Iron JDM J20C
Case
Dry Brakes- Alu- JDM J20C
minum Case
25
day 6 mo 6 mo 6 mo
23 Transmission Oil Filter C 1 Filter See Parts Manual
See NOTE 4.
28 Forks X X X Check Condition
29 Mast L Lubricate Multipurpose Grease
Sliding Surfaces As Required See NOTE 9.
and Load Roller Sur- See NOTE 11.
faces
29 Header Hoses X Check Condition
30 Lift Chains L X, L Lube as SAE 30W
Required. Check Engine Oil
for Wear
30 Lift Chains X Check SAE 30W
Lubrication Engine Oil
See NOTE 12.
Mast X L Lube as Multipurpose Grease
Sideshift Required See NOTE 9.
Carriage 2 Fittings
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 9.
Mast L X C Lube as Multipurpose Grease
Integral Required See NOTE 9.
Sideshift 2 Fittings 2.5 mm (3/32 in.) is
Carriage 4 Bearings minimum thickness
(Upper/Lower
Bearings)
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 9.
Brake Master Cylinder L SAE 10W-30
Rod End Pin API SM
ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
26 Brake Fluid CIL X C 0.25 liter SAE J-1703
Master Cylinder (0.53 pt) DOT-3
Dry Brakes
26 Brake Oil CIL X C 0.35 liter Dexron III from
Master Cylinder (0.74 pt) Sealed Container
Wet Brakes
26
day 6 mo 6 mo 6 mo
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rod Ends H40- See NOTE 9.
70FT (L177)
King Pin See NOTE 9.
H40-70FT (L177)
Spindle See NOTE 9.
Bearings S40-70FT,
S55FTS (F187)
2 Pedals, Levers, Seat L Lubricate as Hyster Part No.
Rails, Cables, Hinges, Necessary 328388
Linkages, Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
Dry Brakes Thickness Minimum
32 Differential and Drive X C 5.0 liter (5.3 qt) SAE 80W-90 or
Axle Oil 85W-140
Dry Brakes
S40-70FT, S55FTS
(F187)
32 Differential and Drive X C 6.5 liter (6.9 qt) SAE 80W-90 or
Axle Oil 85W-140
Dry Brakes
H40-70FT (L177)
Wet Brakes- Iron JDM J20C
Case
H40-70FT (L177)
Wet Brakes- Alu- JDM J20C
minum Case
H40-70FT (L177)
32 Wet Brake Axle X C 0.5 liter (0.5 qt) John Deere
Planetary Housing JDM J20C
Oil, Left Side
32 Wet Brake Axle X C 2.0 liter (2.1 qt) John Deere
Planetary Housing JDM J20C
Oil, Right Side
32 Wet Brake Axle, Center X C 1.0 liter (1.1 qt) John Deere
Section Oil JDM J20C
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
27
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1150
day 6 mo 6 mo 6 mo
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours
of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications in-
volving 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 Hyster dealer will advise you of the appropriate service intervals based on
an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Replace timing belt on Mazda engines every 3500 hours. Use only hour interval.
NOTE 8: Check fuel injectors at 5000 hours or 7 years.
NOTE 9: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 10: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should
be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and
steam clean as necessary.
NOTE 11: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 12: Lubricate at first sign of visible surface rust.
NOTE 13: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every
2000 Hours or Annually to change air filter element.
NOTE 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled water or deionized water.
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE conditions that are not normal. Clean any oil or fuel
STOPPED spills. Ensure all surfaces are free of oils, lubricants,
fuel, and organic dust or fibers (paper, wood, cotton,
agricultural grass/grain, etc.).
WARNING
DO NOT operate a lift truck that needs repairs. Tires and Wheels
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE Check the tires for damage. See Figure 17. Check the
tag in the operator’s area. If the lift truck is tread and remove any objects that will cause damage.
equipped with a key switch, remove the key Check for bent or damaged rims. Check for loose or
from the key switch. missing hardware. Remove any wire, strapping, or
other material that is wrapped around the axle.
Put the lift truck on a level surface. Lower the car-
riage and forks, stop the engine, and apply the park-
ing brake. Open the hood and check for leaks and
28
8000 SRM 1150 Maintenance Procedures Every 8 Hours or Daily
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 17. Tire Check
Safety Labels 1. Inspect the welds on the mast and carriage for
cracks. Make sure that the capscrews and nuts
are tight.
WARNING
Safety labels are installed on the lift truck to 2. Inspect the channels for wear in the areas where
give information about operation and possible the rollers travel. Inspect the rollers for wear or
hazards. It is important that all safety labels damage.
are installed on the lift truck and can be read.
3. Inspect the load backrest extension for cracks
Check that all safety labels are installed in the cor- and damage.
rect location on the lift truck. See the Parts Man-
ual, Model Description section in the Operating 4. If the lift truck is equipped with an integral
Manual or the section Frame 100 SRM 1120 for the sideshift carriage or attachment, inspect the
correct location of the safety labels. See the Parts parts for cracks and wear. Make sure the parts
Manual for the part numbers of the safety labels. that fasten the integral sideshift carriage or
attachment to the carriage are in good condition.
Mast, Carriage, Lift Chains, Header Hoses,
5. Visually inspect hoses/fittings for hydraulic
Attachment leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
WARNING or sheaves; proper tracking during operation.
Lower the lift mechanism completely. Never Adjust/repair/replace hose/components as nec-
allow any person under a raised carriage. DO essary. See Mast Repairs, 2-, 3-, and 4-Stage
NOT put any part of your body in or through Masts 4000 SRM 1148 for quick disconnect pro-
the lift mechanism unless all parts of the mast cedures.
are completely lowered and the engine is
STOPPED. DO NOT try to correct the align- 6. Check that the lift chains are correctly lubri-
ment of the fork tips by bending the forks or cated. Use SAE 30 engine oil as necessary to
adding shims. Never repair damaged forks by lubricate the lift chains.
heating or welding. Forks are made of special
7. Inspect the lift chains for cracks or broken links,
steel using special procedures. If either fork is
and worn or turned pins. See Figure 18.
damaged, replace the forks as a set.
29
8. Inspect the chain anchors and pins for cracks and The seat belt must fasten securely. Make sure the
damage. seat belt extends and retracts smoothly and is not
frayed or torn. If the seat belt is damaged or does not
9. Make sure the lift chains are adjusted so that operate properly, it must be replaced. See Figure 19.
they have equal tension. Adjustments or re-
placement of the lift chains must be done Emergency Locking Retractor (ELR)
by authorized personnel.
NOTE: Lift trucks produced after November 2005
are equipped with the Emergency Locking Retractor
(ELR) style seat belt.
When the ELR style seat belt is properly buckled

across the operator, the belt will permit slight op-
erator repositioning without activating the locking
mechanism. If the truck tips, 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.
A seat belt that is damaged worn or does not operate

properly will not give 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 damage or wear is seen. See Figure 19.
NOTE: The following seat belt operation checks must

be performed three times before replacing the seat
1. WORN PIN 5. LOOSE LEAVES belt assembly.
2. CRACKS 6. TURNED PIN
3. EDGE WEAR 7. CORROSION • With the hood closed and in the locked position,
4. HOLE WEAR pull the seat belt slowly from the retractor assem-
bly. Make sure the seat belt pulls out and retracts
Figure 18. Lift Chain Check smoothly. If the seat belt cannot be pulled from the
retractor assembly or the belt will not retract, re-
Operator Restraint System place the seat belt assembly.
The seat belt, hip restraint, seat, hood, and hood • With the hood closed and in the locked position,
latch are all part of the operator restraint system. pull the seat belt with a sudden jerk. Make sure the
See Figure 19. Each item must be checked to make seat belt will not pull from the retractor assembly.
sure it is fastened correctly, functions correctly, and If the seat belt can be pulled from the retractor,
is in good condition. when it is pulled with a sudden jerk, replace the
seat belt assembly.
Automatic Locking Retractor (ALR) • With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly.
NOTE: S2.0-3.5FT (S40-70FT, S55FTS) lift trucks If the seat belt can be pulled from the retractor,
produced before November 2005 are equipped with with the hood in the open position, replace the seat
the ALR type seat belts. belt assembly.
30
NOTE: NON-SWIVEL SEAT SHOWN.

A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR
1. LATCH STRIKER 7. ARM REST
2. HOOD LATCH 8. SEAT BELT
3. FORWARD/BACKWARD ADJUSTMENT 9. SEAT
4. HOOD 10. HIP RESTRAINT
5. OPERATOR WEIGHT ADJUSTMENT 11. HOOD HINGE
6. SEAT RAIL
Figure 19. Hood and Seat Check
Figure 20. Swivel Seat Controls
31
Legend for Figure 20
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR
1. FORWARD/BACKWARD ADJUSTMENT 4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
2. SWIVEL ADJUSTMENT 5. SEAT BELT
3. OPERATOR WEIGHT ADJUSTMENT
Adjust Seat - Full Suspension of the suspension can be felt to increase or decrease
on which way the handle is turned.
Seat Position Adjustment (Standard Seat)
• Fore and aft adjustment - It is recommended that Adjust Seat - Internal Suspension
the seat be adjusted so that the thigh is horizontal
to the ground so that the best ergonomic position Seat Position Adjustment (Swivel Seat)
is achieved, See Figure 19. • The seat swivels 10.5 degrees to the right to allow
the operator a more ergonomic position when driv-
Seat Position Adjustment (Swivel Seat) ing in reverse.
• The seat swivels 12 degrees to the right to allow the • The seat swivels 5 degrees to the left to allow as
operator a more ergonomic position when driving easier exit of the truck.
in reverse. • The neutral position is shown in Figure 22.
• The seat swivels 5 degrees to the left to allow as
easier exit of the truck. Seat Adjustment for Operator Weight
• The neutral position is shown in Figure 21.
CAUTION
Seat Adjustment for Operator Weight
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
CAUTION his/her weight.
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to NOTE: It is important to adjust the weight setting for
his/her weight. each operator.
NOTE: It is important to adjust the weight setting for NOTE: The seat is designed for maximum weight of
each operator. 135 kg (298 lb).
NOTE: The seat is designed for maximum weight of • The target is for the "ride indicator" to fall between
135 kg (298 lb). the arrows when the operator sits upright in the
seat with the feet positioned on the pedals. This
• The target is for the "ride indicator" to fall between ensures that the operator is set at the midpoint of
the arrows when the operator sits upright in the the 40 mm (1.57 in.) suspension.
seat with the feet positioned on the pedals. This • The weight adjustment knob can be turned left or
ensures that the operator is set at the midpoint of right to increase or decrease the weight resistance.
the 80mm suspension. As the weight adjustment knob is turned the "stiff-
• The handle can be turned as shown to increase or ness" of the suspension can be felt to increase or de-
decrease the weight resistance, pull handle out be- crease on which way the weight adjustment knob
fore turning. As the handle is turned the "stiffness" is turned.
32
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 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Figure 21. Seat Adjustment
Figure 22. Seat Adjustment
33

1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Hood and Seat Latches Check axle and cowl openings for paper buildup and
bailing wire. Remove any debris.
Make sure the seat rails and latch striker are not
loose. The seat rails must lock tightly in position,
but move freely when unlocked. See Figure 19 and WARNING
Figure 20. The seat rails must be correctly fastened Compressed air can move particles so that they
to the hood and the hood fastened to the hinges on cause injury to the user or to other personnel.
the frame. Try to lift the hood to make sure it is Make sure that the path of the compressed air
fastened correctly and will not move. If adjustment is away from all personnel. Wear protective
is required, go to Hood Latch Check. goggles or a face shield to prevent injury to the
eyes.
Engine Compartment
Check for the presence of any combustible material CAUTION
such as paper, leaves, etc. Remove any combustible Air pressure, nozzle or extension tube may
materials. cause damage to exhaust wraps and radiator
fins. Assure that air pressure, nozzle or exten-
Paper Application sion tube does not damage exhaust wraps or
radiator fins.
Vehicles used in paper applications require regular
inspection and cleaning to minimize the risk of fire. Paper removal can generally be accomplished using a
This should be done at least once every 8 hours compressed air line and nozzle. An extension may be
or more frequently depending upon operating en- helpful to access hard to reach places. Remove floor
vironment. The paper application option will help plates and side covers for better access to engine com-
limit the contact of paper or tissue scraps to hot partment. Open or removed belly pan, if equipped.
surfaces under the hood, but frequent maintenance Clean components with compressed air. Take care
is required. to maintain the integrity of the exhaust wraps when
cleaning with compressed air and use caution to not
force debris into openings. Check the condition of ex-
WARNING haust wraps for wear, proper fit, contamination with
Engine and exhaust system components are oil or antifreeze, gaps in coverage, failed fasteners
hot to touch. Be sure lift truck components are and replace as necessary. Do not reuse wraps if they
cool before starting inspection and cleaning or have been removed for some other service operation.
personal injury may occur.
Ensure the truck engine cools properly by allowing WARNING

it to idle for several minutes. Shutting the truck Be careful when cleaning with steam. Steam
down while hot will not allow the engine to cool can cause serious burns. Wear protective cloth-
quickly due to the loss of coolant circulation. The ing, gloves, and eye protection. Never expose
heat trapped under the hood may actually increase your skin to steam.
the engine temperature because of no heat transfer
through the radiator. With engine off and lift truck If compressed air did not adequately remove debris,
components cooled, check and clean the radiator and steam clean to remove any persistent accumulation
if equipped, radiator screen. Check engine manifold, of material or oil. Protect electrical components from
exhaust pipes, muffler and catalytic converter for moisture when steam cleaning. Do not spray exhaust
paper scraps. Clean as required. Check and clean wraps directly with high pressure steam. Allow lift
the engine compartment components, transmission, truck to air dry before returning to work in a con-
fan shroud, belly pan if equipped, and inside frame taminated environment. Paper dust and scraps will
ledges to avoid paper, dust and oil accumulation. adhere to wet surfaces.
34
Check the condition of exhaust wraps for wear, column to move unless the tilt lever is released. See
proper fit, contamination with oil or antifreeze, gaps Figure 23.
in coverage, failed fasteners and replace as neces-
sary. Do not reuse wraps if they have been removed
for some other service operation.
Fuel, Oil, and Coolant Leaks, Check
WARNING
All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame
to check the fuel level or to check for leaks in
the fuel system. If there is a leak in the fuel sys-
tem, extra care must be used during the repair.
DO NOT operate the lift truck until a leak is re-
paired.
Make a visual check for leaks on and under the lift

truck. If possible, find and report the leak to main- 1. TILT LEVER 2. GAS CYLINDER
tenance for repair. Leaks often indicate a need for
repair of damaged or worn components. Leaks in the Figure 23. Steering Column Gas Cylinder and
LPG fuel system are usually not visible unless ice Tilt Lever
is present. There is however, usually a strong odor.
Fuel leaks MUST be repaired IMMEDIATELY. Transmission
Check the fuel system for leaks and the condition of Check the transmission for leaks and damaged or
parts. When fuel is added to the lift truck, see the loose components. Heavy-duty or high temperature
section HOW TO ADD FUEL TO THE LIFT TRUCK operations can require more frequent checks.
in the Operating Manual.
Hydraulic System Oil
Also check the condition of the radiator or heater
hoses that are not leaking. Soft or cracked hoses need
to be replaced before a major leak occurs. WARNING
At operating temperature, the hydraulic oil is
Hydraulic Hoses HOT. DO NOT permit the hot oil to touch the
skin and cause a burn.
Check the condition of the hydraulic hoses for ser-
viceability by inspecting for cracks or other obvious
CAUTION
damage. Check to insure that the hydraulic hoses
are not leaking. If any hose is leaking, report it to DO NOT permit dirt to enter the hydraulic sys-
maintenance for repair. tem when the oil level is checked or the filter
is changed.
Coolant Hoses Never operate the hydraulic pump without oil
Check the condition of the coolant hoses for service- in the hydraulic system. The operation of the
ability by inspecting for cracks or other obvious dam- hydraulic pump without oil will damage the
age. Check to insure that the coolant hoses are not pump.
leaking. If any hose is leaking, report it to mainte- After the engine has stopped, wait one minute before
nance for repair. checking the oil level. Keep the hydraulic oil at the
correct level as indicated on the dipstick. Use the
Steering Column Gas Cylinder correct oil as shown in the Maintenance Schedule.
Make sure the gas cylinder for the steering column
Check the hydraulic system for leaks and damaged or
operates correctly. The cylinder must NOT allow the
loose components. Heavy-duty or high-temperature
operations can require more frequent checks.
35
Engine Oil
After the engine has stopped, wait one minute be-
fore checking the oil level. See Figure 24 Figure 25,
Figure 26 and Figure 27. Keep the oil at the correct
level as indicated on the dipstick. Use the correct oil
as shown in the Maintenance Schedule.
There is an indicator light for the engine oil pressure

on the Display Switch Cluster. During normal opera-
tion, the red indicator light will illuminate when the
key switch is turned to ON, if the truck is equipped
with a key switch, or when the power ON/OFF but-
ton is pressed, if the truck is equipped with a key-
less option, and will stay illuminated until correct oil
pressure is obtained, at which time the light will go
off.
If the light continues to stay on when engine is run-

ning, the engine oil pressure is low. Stop the engine
and check the oil level. See Figure 24, Figure 25, Fig-
ure 26, and Figure 27. Do not restart the engine until
the low pressure condition has been corrected.
1. BATTERY 6. ENGINE OIL

2. AUXILIARY FILTER
COOLANT 7. DIPSTICK ENGINE
RESERVOIR OIL
3. RADIATOR CAP 8. FUEL FILTER
4. DRIVE BELT 9. FUEL INJECTOR
5. AIR FILTER 10. ENGINE OIL FILL
Figure 24. Yanmar 2.6L and 3.3L Diesel Engine

Maintenance Points

A. GAS ENGINE B. LPG ENGINE
1. DIPSTICK ENGINE OIL 7. AIR FILTER
2. BATTERY 8. FUEL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. ENGINE OIL FILTER
4. RADIATOR CAP 10. PCV VALVE
5. ENGINE OIL FILL 11. SPARK PLUGS
36
Figure 25. GM Engine Maintenance Points
37
Figure 26. Mazda Engine Maintenance Points (Except 2007 Emission Compliant Engines)
38

A. GAS ENGINE B. LPG ENGINE
39
Figure 27. Mazda Engine Maintenance Points (2007 Emission Compliant Engines Only)
40

A. LPG ENGINE B. GAS ENGINE
6. DRIVE BELT 12. FUEL INJECTORS (GAS ONLY)
Air Filter on the carriage. See Figure 28 and Figure 29. Lower
the fork onto blocks so that the bottom hook of the
The air filter canister should not be opened until an fork moves through the fork removal notch. See Fig-
air filter element replacement is required. An air ure 29. Lower the carriage further so that the top
filter element replacement is required when one of hook of the fork is disengaged from the top carriage
the following occurs: bar. Move the carriage away from the fork, or use
• The optional air flow restriction indicator light on a lifting device to move the fork away from the car-
the dash illuminates riage.
• If equipped, the manual air flow indicator is red
• The specified number of hours has passed since the
last filter element replacement
Do not operate the lift truck until the air filter ele-
ment has been replaced.
Forks
NOTE: Forks must be removed or installed by trained
personnel only.
The identification of a fork describes how the fork is

connected to the carriage. These lift trucks have hook
forks.
1. CARRIAGE BARS 3. BLOCKS
Remove 2. HOOK FORK
WARNING Figure 28. Hook Fork Removal

DO NOT try to move a fork without a lifting
device. Each hook fork for these lift trucks can Inspect
weigh 45 to 115 kg (99 to 253 lb).
1. Inspect the forks for cracks and wear. Check that
NOTE: Forks are to be replaced only in sets and not the fork tips are aligned as shown in Figure 29.
individually. Check that the bottom of the fork is not worn. See
Figure 29, item 4.
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance. Lift the lock 2. Replace any damaged or broken parts that are
pin and slide a hook fork to the fork removal notch used to keep the forks locked in position.
41
Install
Move the fork and carriage so that the top hook on

the fork can engage the upper carriage bar. Raise
the carriage to move the lower hook through the fork
removal notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage. En-
gage the lock pin with a notch in the upper carriage
bar.
Adjust
NOTE: During the adjustment of the forks, the heel

of the forks should not be touching the ground.
The forks are connected to the carriage by hooks and

lock pins. See Figure 28 and Figure 30. The lock
pins are installed through the top fork hooks and fit
into slots in the top carriage bar. If pin does not re-
main engaged in carriage slot, replace with new pin.
Adjust the forks as far apart as possible for maxi-
mum 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
Fork Tip Alignment the carriage bar. Make sure the lock pin is engaged
in the carriage bar to lock the fork in position after
Length of Forks 3% Dimension the width adjustment is made.
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION 1. FORK 5. WEDGE
7. MAXIMUM ANGLE 93° 2. LOCK PIN 6. KNOB
8. FORK REMOVAL NOTCH 3. SPRING 7. LOCK PIN
4. WASHER ASSEMBLY
Figure 29. Forks Check
Figure 30. Fork Lock Pin Assembly
42
HOW TO MAKE CHECKS WITH ENGINE the parking brake and put the transmission in NEU-
RUNNING TRAL. Make the checks carefully.
Indicator Lights, Horn, Fuses, and Relays

WARNING
DO NOT operate a lift truck that needs repairs. If lift truck is equipped with a key switch, turn
Report the need for repair immediately. If re- key to ON position. If lift truck is equipped with a
pair is necessary, put a DO NOT OPERATE tag Power ON/OFF button, press button to turn system
in the operator’s area. If lift truck is equipped power on. All warning light and indicator lights will
with a key switch, remove the key. light up for two seconds (start check) when system
power is turned ON. See Figure 31. Check all in-
WARNING dicator lights for correct operation as described in
the Operating Manual. Check the operation of the
FASTEN YOUR SEAT BELT! The seat belt is in-
horn. Start the engine by turning the key switch to
stalled to help the operator stay on the truck if
the Start position, if truck is equipped with a key
the lift truck tips over. IT CAN ONLY HELP IF
switch, or press the engine start button, if lift truck
IT IS FASTENED.
is equipped with this button. If any indicator lights
Make sure that the area around the lift truck is clear do not operate correctly, check the fuses. The fuses
before starting the engine or making any checks of are located in the Power Distribution Module (PDM)
the operation. Be careful when making the checks. which is under the hood next to the battery on the
If the lift truck is stationary during a check, apply right side. See Figure 32.
43
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking (Duramatch Plus 2™ Transmissions)
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 31. Warning and Indicator Lights
44
NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE)
Figure 32. PDM Showing Fuses and Relays
Service Brakes WARNING

Brake Fluid Level If the brake system has a power assist (or
boosted master cylinder), braking will be more
difficult if the engine is not running.
WARNING
Small amounts of water in the brake system Loss of fluid from the brake fluid reservoir in-
can cause reduced braking performance if the dicates a leak. Repair the brake system before
water reaches the wheel cylinder areas. DO using the lift truck. Replace the brake fluid in
NOT allow water entry. Ensure that the sealed the system if there is dirt or water in the sys-
reservoir lid is properly replaced. tem.
On lift trucks with wet brake drive axles, only There is an indicator light on the Display Switch
use Dexron III oil from sealed container in the Cluster for the brake fluid. The red light is ON
master cylinder. when the key switch is in the START position or
the Power ON/OFF button is pressed, and must go
On lift trucks with dry brake drive axles, only OFF when the engine is running. If the light is on
use SAE J-1703 (DOT 3) brake fluid in the mas-
ter cylinder.
45
when the engine is running, the brake fluid level in

the reservoir is too low.
Operation, Check
Check the operation of the service brakes. Push on

the inching/brake pedal. The service brakes must be
applied before the inching/brake pedal reaches the
floor plate. The pedal must stop firmly and must
not move slowly down after the brakes are applied.
The service brakes must apply equally to both drive
wheels. The service brakes must not pull the lift
truck to either side of the direction of travel when
they are applied. The service brakes are automat-
ically adjusted when the transmission is in reverse
and the lift truck is moving and the brakes are firmly
applied. Full application of the inching/brake pedal
applies the service brakes and puts the transmission
in NEUTRAL.
Lift trucks with a MONOTROL® pedal. When

the inching/brake pedal is fully applied, a switch in
the starting circuit is closed so that the engine can be
started.
Parking Brake 1. LOCK BUTTON RELEASE

2. OFF POSITION
Make sure the service brakes are adjusted and the 3. ON POSITION
operation of the automatic adjuster mechanism is 4. ADJUSTMENT KNOB
correct before the parking brake is adjusted. Figure 33. Parking Brake
Lift trucks with a MONOTROL® pedal. The
switch energizes the seat warning circuit when hand Engine Oil Pressure
lever is released. This switch puts the transmission NOTE: The engine will enter shutdown mode after a
in NEUTRAL by de-energizing the direction sole- warning buzzer sounds and a 30 second countdown,
noid. There is also a switch on the left-hand side of if engine oil pressure is less than 34.5 kPa (5 psi) on
bracket. This switch prevents engine from starting lift trucks with powertrain protection system. Lift
unless parking brake is applied. trucks equipped with a Yanmar diesel engine will en-
NOTE: Make sure parking brake is released before ter the shutdown mode when the engine oil pressure
making adjustment. is less than 49 kPa (7 psi) on lift trucks with power-
train protection system. See the Engine Shutdown
1. Turn the adjustment knob to raise the equalized procedures in the Operating Manual.
link and tighten the parking brake cables shown
in Figure 33. Do not tighten the adjustment so There is an indicator light for the engine oil pressure
that the brake is applied when the lever is re- on the Display Switch Cluster. During normal opera-
leased. The lever for the parking brake has a tion, the red indicator light will illuminate when the
lock. Use your thumb or finger to release the lock key switch is turned to ON, if the truck is equipped
on the lever when the parking brake is released. with a key switch, or when the power ON/OFF but-
ton is pressed, if the truck is equipped with a key-
2. For burnished brakes, test the operation of the less option, and will stay illuminated until correct oil
parking brake. The lift truck with a capacity load pressure is obtained, at which time the light will go
must not move when parking brake is applied on off.
a 15 percent grade [a slope that increases 1.5 m
in 10 m (1.5 ft in 10 ft)]. If the light continues to stay on when engine is run-
ning, the engine oil pressure is low. Stop the engine
46
and check the oil level. See Figure 24 Figure 25, Fig- Make sure that the path of the compressed air
ure 26, and Figure 27. Do not restart the engine until is away from all personnel. Wear protective
the low pressure condition has been corrected. goggles or a face shield to prevent injury to the
eyes.
Cooling System
Check the radiator fins. Clean the radiator with com-
pressed air or water as needed. Check for and re-
WARNING move any debris on the radiator core. If the indicator
DO NOT remove the radiator cap from the radi- light turns on again after restarting, shut down the
ator when the engine is hot. When the radiator lift truck and do not operate the lift truck until the
cap is removed, the pressure is released from problem is corrected.
the system. If the system is hot, the steam and
boiling coolant can cause burns.
NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown,
if coolant temperature reaches 121°C (250°F) or
above on lift trucks with powertrain protection sys-
tem. Lift trucks equipped with a CumminsYanmar
diesel engine will enter the shutdown mode when
the coolant temperature reaches 110°C (230°F) or
above on lift trucks with powertrain protection sys-
tem. See the ENGINE SHUTDOWN procedures in
the Operating Manual.
There is an indicator light on the Display Switch

Cluster for the coolant temperature. The red light
is on when the key switch is in the START position
or the Power ON/OFF button is pressed, and must
go off when the engine is running. If the light is on
when the engine is running, the coolant and engine
are too hot. Stop the engine and check the coolant
level in the coolant recovery reservoir. 1. FILL CAP
2. AUXILIARY COOLANT RESERVOIR
Make sure the coolant level is between the ADD and 3. FULL MARK
FULL marks on the auxiliary coolant reservoir. See 4. ADD MARK
Figure 34. The coolant will expand as it is heated 5. RADIATOR CAP
and the level in the auxiliary coolant reservoir will
increase. Figure 34. Auxiliary Coolant Reservoir
Steering System
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
WARNING
dealer. The lift truck has hydraulic power steering.
The steering can be difficult if the engine is
If coolant is added, see Maintenance Schedule for cor- not running.
rect solution.
Make sure the steering system operates smoothly
and provides good steering control. Make sure the
WARNING steering column can be adjusted and the gas cylinder
Compressed air can move particles so that they function is correct.
47
First Service After First 100 Hours of Operation 8000 SRM 1150
Control Levers and Pedals 1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
Check that the control levers for the transmission,
mast, and attachment operate as described in Oper- NOTE: Some parts of the mast move at different
ating Manual. Check that the pedals operate cor- speeds during raising and lowering.
rectly as described in Operating Manual.
2. Slowly raise and lower the mast several times
Lift System, Operate without a load. Raise the mast to its full height
at least once. The mast components must raise
and lower smoothly in the correct sequence. Hose
WARNING must track properly during operation.
When working on or near the mast, see Safety
Procedures When Working Near Mast at the 3. The inner weldments and the carriage must
end of this section. lower completely.
Lower the lift mechanism completely. Never 4. Raise the mast 1 m (3 ft) with a capacity load.
allow any person under a raised carriage. DO The inner weldments and the carriage must raise
NOT put any part of your body in or through smoothly. Lower the mast. All moving compo-
the lift mechanism unless all parts of the mast nents must lower smoothly.
are completely lowered and the engine is
STOPPED. 5. Lower the load to approximately 0.3 m (1 ft). Tilt
the mast forward and backward. The mast must
If the mast cannot be lowered, use chains on tilt smoothly and both tilt cylinders must stop
the mast weldments and carriage so that they evenly.
cannot move. Make sure the moving parts are
attached to a part that does not move. 6. Check that the controls for the attachment op-
erate the functions of the attachment. See the
DO NOT try to find hydraulic leaks by putting symbols by each of the controls. Make sure all of
hands on pressurized hydraulic components. the hydraulic lines are connected correctly and
Hydraulic oil can be injected into the body by do not leak.
the pressure.
Perform the following checks and inspections:
First Service After First 100 Hours of Operation

MAZDA AND GM ENGINE OIL AND OIL Change engine oil and oil filter. See Figure 35. Ap-
FILTER ply clean oil to gasket of new filter. Install new fil-
ter. Turn filter until gasket touches, then tighten 1/2
NOTE: The engine oil and oil filter must also be to 3/4 turn with your hand. Fill engine with oil as
changed after the first 100 hours of operation for a specified in Maintenance Schedule, until full mark
newly installed engine. reached on the dipstick. Start engine. Check area
around oil filter for leaks, shut engine off and check
oil dipstick, if low add oil.
48
8000 SRM 1150 First Service After First 100 Hours of Operation
NOTE: BOTTOM VIEW OF ENGINE SHOWN.

A. MAZDA B. GM
1. OIL FILTER 2. DRAIN PLUG
Figure 35. Engine Oil Change
YANMAR ENGINE OIL AND OIL FILTER

Change engine oil and oil filter. See Figure 36. Ap-
ply clean oil to gasket of new filter. Install new fil-
ter. Turn filter until gasket touches, then tighten 1/2
to 3/4 turn with your hand. Fill engine with oil as
specified in Maintenance Schedule, until full mark
reached on the dipstick. Start engine. Check area
around oil filter for leaks, shut engine off and check
oil dipstick, if low add oil.

Figure 36. Engine Oil Change Yanmar Diesel
49
Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1150
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform the 8-hour checks prior to performing Change engine oil and engine oil filter. See Fig-
the procedures in this section. ure 37. Use the correct oil according to the Main-
tenance Schedule. Apply clean oil to gasket of new
MAZDA AND GM ENGINE OIL AND OIL filter. Install new filter. Turn filter until gasket
FILTER touches, then tighten 1/2 to 3/4 turn with your hand.
Start engine. Check area around oil filter for leaks.
NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks.

A. MAZDA B. GM
Figure 37. Engine Oil Change
50
8000 SRM 1150 Maintenance Procedures Every 250 Hours or 6 Months
DRIVE BELT GM 2.4L Engine

Mazda 2.0L and 2.2L Engines Fan and Alternator Drive Belt
Fan and Alternator Drive Belt Check the drive belt for the fan and alternator for
wear and damage. See Figure 39. The belt tensioner
Check the drive belt for the fan and alternator for on the GM 2.4L engine is a nonadjustable, self-ten-
wear and damage. sioning device with two positions: tension applied
and tension relieved. Adjustments are not needed.
Check tension by pushing on drive belt to check
deflection. See Figure 38. When pressure is 98 N
(22 lbf), the correct deflection is approximately 7 to
8 mm (0.3 in.). Loosen alternator support bracket to
adjust tension of belt.
1. BELT
2. DRIVE TOOL SLOT
3. SELF-ADJUSTING TENSIONER
Figure 39. GM 2.4L Engine Drive Belt

1. CHECK TENSION HERE
2. ALTERNATOR SUPPORT BRACKET
Figure 38. Drive Belts Check and Adjustment,

Mazda Engines
51
DRAIN TAR FROM LPG REGULATOR

(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES)
NOTE: For 2007 Mazda Emission Compliant Engines
go to Drain Tar From LPG Regulator (2007 Mazda
Emission Compliant Engines Only).
1. Warm engine to operating temperature.
2. Shut fuel valve off and run engine until the en-
gine runs out of fuel and stops.
3. Raise the hood.
4. Remove tar drain screw from regulator. Allow tar

to drain from regulator. When tar has completely
drained, install tar drain screw in regulator. See
Figure 40 and Figure 41.
1. TAR DRAIN SCREW
Figure 41. GM LPG Regulator
DRAIN TAR FROM LPG REGULATOR (2007

MAZDA EMISSION COMPLIANT ENGINES
ONLY)
NOTE: The following procedures are for 2007 Mazda
Emission Compliant Engines Only.
NOTE: Draining the LPG regulator when engine is

warm will help the oils to flow freely from the regu-
lator.
1. Warm engine to operating temperature.
2. Close fuel valve on tank and run engine until it

runs out of fuel and stops. Try to restart engine
2-3 times until it no longer starts.
1. TAR DRAIN SCREW 3. Turn the key to the OFF position.
Figure 40. Mazda LPG Regulator
52
4. Raise hood and disconnect negative battery ca-

ble.
5. Remove the EPR assembly, see LPG Fuel Sys-

tem, Mazda 2.0L and 2.2L Emission Compli-
ant Engines 900 SRM 1326.
6. Remove the retaining pin in the fuel temperature

sensor and remove from the electronic pressure
regulator (EPR). See Figure 42.
7. Using a suitable container, rotate the EPR 90° so

that the outlet fitting is pointing down and drain
the EPR.
8. Inspect and remove any tar or debris from the

secondary chamber.
9. Install fuel temperature sensor and retaining

pin. See Figure 42.
10. Install EPR assembly, see LPG Fuel System,

Mazda 2.0L and 2.2L Emission Compliant
Engines 900 SRM 1326.
1. FUEL TEMPERATURE SENSOR

2. RETAINING PIN
3. ELECTRONIC PRESSURE REGULATOR (EPR)
Figure 42. 2007 Mazda Emission Compliant

EPR Assembly
53

NOTE: Perform the 8-hour and 250-hour checks prior Make sure that the path of the compressed air
to performing the procedures in this section. is away from all personnel. Wear protective
HYDRAULIC SYSTEM OIL eyes.
WARNING CAUTION
At operating temperature, the hydraulic oil is Direct air pressure on the filter element can
HOT. DO NOT permit the hot oil to touch the cause damage. Direct air pressure away from
skin and cause a burn. filter element.
CAUTION 1. Using compressed air, remove any dirt and de-

bris in the frame cavity around the breather. See
DO NOT permit dirt to enter the hydraulic sys-
Figure 43.
tem when the oil level is checked or the filter
is changed. 2. Replace the breather if oil has accumulated in
the cavity or on the breather, or if dirt has accu-
Never operate the hydraulic pump without oil
mulated at the breather passages at the bottom
in the hydraulic system. The operation of the
of the breather.
hydraulic pump without oil will damage the
pump.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
Check the hydraulic oil level when the oil is at operat-

ing temperature with the mast in a vertical position,
the carriage lowered, and the engine stopped. See
Figure 47 and Figure 48. Add hydraulic oil only as
needed. If hydraulic oil is above the FULL level, the
hydraulic oil will leak from the breather during oper-
ation. The oil level indicated by the dipstick is most
accurate when the oil temperature is 53 to 93°C (130
to 200°F).
HYDRAULIC TANK BREATHER

Inspect
1. HOOD/SEAT ASSEMBLY
NOTE: When inspecting the breather, do not remove 2. SIDE PANEL
it. The breather element is a non serviceable part. If 3. HYDRAULIC TANK BREATHER
it is damaged, replace with a new breather element.
Figure 43. Hydraulic Tank Breather
WARNING
54
BATTERY
WARNING
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
the area. Use a solution of sodium bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
Wear eye protection.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. DO NOT NOTE: BOTTOM VIEW OF ENGINE SHOWN.
make sparks from the battery connections.
Disconnect the battery ground cable when 1. OIL FILTER 2. DRAIN PLUG
doing maintenance.
Figure 44. Engine Oil Change Yanmar Diesel
Disconnect the negative and positive terminals of the
battery. Using a damp cloth clean the case of the bat- DRIVE BELT
tery. If the terminals are corroded, clean the termi-
nals with a wire brush. Connect the negative and Yanmar Diesel Engine
positive cables to their respective terminals. Fan and Alternator Drive Belt
YANMAR ENGINE OIL AND OIL FILTER NOTE: The drive belt tension may be checked at any
of the three positions A, B, or C shown in Figure 45
NOTE: Change the oil and oil filter for the engine at which ever is most easily accessible.
the first 100 hours of operation on new lift trucks.
Check the drive belt for the fan and alternator for
Change engine oil and engine oil filter. See Fig- wear and damage. Check tension by pushing on drive
ure 44. Use the correct oil according to the Main- belt with a force of 98 N (22 lbf) to check deflection
tenance Schedule. Apply clean oil to gasket of new at any one of three possible positions. See Figure 45.
filter. Install new filter. Turn filter until gasket Check Table 2 for the correct deflection of the V-belt.
touches, then tighten 1/2 to 3/4 turn with your hand. Loosen alternator support bracket bolt to adjust ten-
Start engine. Check area around oil filter for leaks. sion of belt. See Figure 46. When the tension of
the V-belt is correct, tighten the alternator support
bracket bolt, and check the belt tension again.
Table 2. V-Belt Deflection Table
Used V-Belt Tension New V-Belt Tension

A B C A B C
10-13 mm 7-10 mm 8-13 mm 8-11 mm (0.3125- 5-8 mm (0.1875- 7-11 mm
(0.375-0.5 in.) (0.250-0.375 in.) (0.3125-0.5 in.) 0.4375 in.) 0.3125 in.) (0.250-0.4375 in.)
55
PCV VALVE
Remove the PCV Valve (positive crankcase ventila-
tion valve) from the valve cover. Check the operation
of the PCV Valve by shaking the PCV Valve and lis-
ten for the check ball rattling inside. If the check ball
does not rattle, replace the PCV Valve. See Figure 25,
CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and remove
material causing radiator core to be plugged or re-
stricted.
WARNING
Make sure that the path of the compressed air
is away from all personnel. Wear protective
eyes.
Clean with compressed air, adjusted to a maximum

output of 103 kPa (15 psi), and blow debris from core
and fan shroud.
Figure 45. Yanmar Diesel Engine Drive Belt TRANSMISSION OIL LEVEL
WARNING
At operating temperature, the transmission oil
is HOT. DO NOT permit the hot oil to touch the
CAUTION
DO NOT permit dirt to enter the transmission
when the oil level is checked or the filter is
changed.
NOTE: Transmission oil temperature should be at

least 50°C (120°F) when checking oil level.
If engine has been running, the engine must be shut

down for one minute or longer prior to checking the
oil level. See Figure 47 or Figure 48. If the trans-
mission oil is low, add oil to transmission at the dip-
stick tube at the correct level as indicated on the dip-
stick. Use the correct oil as shown in the Mainte-
1. SUPPORT BRACKET BOLT nance Schedule.
2. ALTERNATOR
3. PRY BAR
Figure 46. Yanmar Diesel Engine Drive Belt

Adjustment
56
NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 47. Transmission and Hydraulic Oil Check
NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 48. Transmission and Hydraulic Oil Check
57
WET BRAKE PLANETARY HOUSING OIL 1. Remove the planetary housing fill/level plugs
LEVEL CHECK and O-rings. See Figure 49.
2. Visually check oil level. If necessary, add oil at

WARNING the right fill/level port for the right planetary
At operating temperature, the transmission housing and at the left fill/level port for the
and wet brake planetary carrier housing oil is left planetary housing until the oil/level port
HOT. DO NOT permit the hot oil to touch the has overflowed. The correct oil is shown in the
skin and cause a burn. Maintenance Schedule or Figure 50.
3. Install the planetary housing fill/level plug and

CAUTION
O-rings and tighten to 40 N•m (29.5 lbf ft).
DO NOT permit dirt to enter the center body
when the oil level is checked. Dirt will contam-
inate the oil and cause damage to the center
body of the axle.
1. RIGHT PLANETARY HOUSING 4. FILL/LEVEL PLUG

2. LEFT PLANETARY HOUSING 5. CENTER SECTION
3. O-RING
Figure 49. Planetary Housings Fill/Level Plugs
58
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY SECTION - USE SAE 80W/90
C. CENTER HOUSING (BRAKE COOLING CHAMBER) - USE JDM J20C
1. OIL FILL/LEVEL PLUG 2. OIL BREATHER 3. COOLING OIL INLET PORT
Figure 50. Oil Application Diagram
FORKS Measure thickness of forks with a fork arm caliper

(Hyster Part No. 3020387) at a vertical section where
WARNING there is no wear. This thickness is dimension X. Now
measure thickness at heel of fork (see Figure 29). If
Never repair damaged forks. DO NOT heat,
the thickness of the heel is not greater than 90% of
weld, or bend the forks. Forks are made of spe-
dimension X, replace fork.
cial steel using special methods. Replace dam-
aged forks as a complete set.
59
MAST LUBRICATION 3. Tilt the mast fully forward. See Figure 52.
4. Lubricate the mast pivot bushings at grease fit-

WARNING tings on outer mast. See Figure 53 and Figure 54.
When working on or near the mast, see Safety Use multipurpose grease shown in the Mainte-
Procedures When Working Near Mast in this nance Schedule.
section.
NOTE: The load rollers and sheaves have sealed bear-

ings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller sur-

faces along full length of channels as shown in
Figure 51.
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 51. 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 A. MAST TILTED FULLY BACK
B. MAST TILTED FORWARD
2. Raise the carriage about 61 cm (2 ft), and tilt the
mast fully back. Place blocks under the outer 1. BLOCK 2. MAST
mast channels to within 13 mm (0.5 in.) of the
Figure 52. Blocking the Mast
channels See Figure 52.
60
1. MAST HANGER BUSHINGS 7. CAPSCREW

2. LUBE FITTINGS 8. NUT
3. MAST BUSHING PLUGS 9. WASHER
4. TILT PIN 10. ROD END BUSHING
5. ROD END 11. TILT CYLINDER ASSEMBLY
6. ANCHOR PIN 12. MAST MOUNTING CAP
Figure 53. Mast Mounting Hanger Lubrication
5. Tilt mast fully back. Remove the blocks from un- grease shown in the Maintenance Schedule. See
der the channels Figure 55.
6. If a sideshift carriage is installed, lubricate slid-

ing surfaces at grease fittings with multipurpose
61
1. OUTER MAST 2. MAST PIVOT BUSHING 3. LUBRICATION FITTING
Figure 54. Pivot Pin Lubrication

1. UPPER BEARING 6. LOWER BEARING
2. LOWER HOOK 7. SHIMS
3. LOAD ROLLER 8. INNER CARRIAGE
4. SNAP RING 9. LUBE FITTING
5. SIDESHIFT 10. OUTER FRAME
CYLINDER
HEADER HOSE CHECKS

Daily inspection plus; kinked, crushed, flattened or
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/re-
place hose/components as necessary. See Mast Re-
pairs, 2-, 3-, and 4-Stage Masts 4000 SRM 1148
for quick disconnect procedures.
Figure 55. Sideshift Carriage
62
LIFT CHAIN LUBRICATION Lubricate lift chains with SAE 30 engine oil. The best
procedure is to remove the chains from the lift truck
WARNING 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.
Procedures When Working Near Mast in this
section.
TILT CYLINDER LUBRICATION
DO NOT repair worn or damaged lift chains. If
NOTE: The floor plate must be removed in order to
a lift chain is worn or damaged, both lift chains
lubricate the rear tilt cylinder lubrication fittings.
must be replaced.
Lubricate the tilt cylinder ends. Use multipurpose
NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
grease shown in the Maintenance Schedule. There
tion should not be performed in combination with the
are four lubrication fittings. See Figure 56.
1000 Hour/6 Months Lift Chain Lubrication.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 3. ANCHOR PIN 5. TILT SPACER
2. RETAINER 4. LUBRICATION FITTING
Figure 56. Tilt Cylinder Lubrication
63
MASTER BRAKE CYLINDER ROD END Legend for Figure 58

PIN LUBRICATION 1. ROD END PIN
2. COTTER PIN (LOCKING)
Lubricate the master brake cylinder rod end pin. Use
engine oil as shown in the Maintenance Schedule.
MANUAL HYDRAULIC LEVERS
See Figure 57 and Figure 58.
LUBRICATION
Lubricate the bushings for the manual hydraulic
levers. Use spray lubricant as listed in the Mainte-
nance Schedule. See Figure 59.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 57. Master Brake Cylinder Rod End Pin

Lubrication (Dry Brake)
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 59. Manual Hydraulic Levers

Lubrication
Figure 58. Master Brake Cylinder Rod End Pin

Lubrication (Wet Brake)
64
BRAKE FLUID Legend for Figure 60

1. BRAKE FLUID RESERVOIR
WARNING 2. MOUNTING BRACKET
Small amounts of water in the brake system 3. COWL
can cause reduced braking performance if the
water reaches the wheel cylinder areas. DO
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced.
On lift trucks with wet brake drive axles, only

use Dexron III oil from sealed container in the
master cylinder.
Replace the brake oil in the system if there is

dirt or water in the system.
On lift trucks with dry brake drive axles, only

use SAE J-1703 (DOT 3) brake fluid in the mas-
ter cylinder.
Remove the dash board from the cowl. The brake

fluid reservoir is located on the cowl, at the master
cylinder. See Figure 60 and Figure 61. Add brake
fluid, as necessary. Use the brake fluid shown in the
Maintenance Schedule.
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 61. Brake Oil Change (Wet Brakes)
Figure 60. Brake Fluid Reservoir (Dry Brakes)
65
TIE ROD LUBRICATION (H40-70FT) 10 mm (0 to 0.40 in.) below the bottom edge of fill
hole. Install fill plug and check for leaks.
Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There are two
lubrication fittings on each tie rod. See Figure 62.
1. AXLE
2. LUBRICATION FITTING
Figure 62. Tie Rod Lubrication
DIFFERENTIAL AND DRIVE AXLE OIL

(DRY BRAKE)
The differential and drive axle use the same oil sup-
ply. The oil level must be between 0 to 10 mm (0 to
0.40 in.) below the bottom edge of fill hole. The fill
hole for checking the oil level is on the front of the
differential housing. Remove fill plug and check fluid 1. DRIVE AXLE
level by sticking a finger into the fill hole to feel if the 2. CHECK/FILL PLUG
fluid level is at the bottom edge of the fill hole. See 3. DRAIN PLUG
Figure 63. If oil is low, add oil shown in the Main-
tenance Schedule until the oil level is between 0 to Figure 63. Drive Axle Fluid Fill

NOTE: Perform the 8-hour, 250-hour, and 500-hour Mazda and Yanmar engines and make adjustments
checks prior to performing the procedures in this sec- as needed. See the Maintenance Schedule for valve
tion. clearances.
VALVE CLEARANCE, CHECK AND Additional engine information is available in the fol-
ADJUST lowing sections:
• GM Engine Repair, GM 2.4 Liter Engine 600
The GM 2.4L engine has hydraulic valve lifters and SRM 1121
does not require valve clearance adjustments dur- • Mazda Engine, 2.0L and 2.2L 600 SRM 1122
ing normal service. Check the valve clearance on
66
IGNITION SYSTEM
GM 2.4L Engine
The GM 2.4L gasoline and LPG engines have an elec-
tronic control unit (ECU) that controls the ignition
timing. There are no adjustments. Change the spark
plugs every 1000 hours. The correct spark plug gap
is 0.8 to 0.9 mm (0.032 to 0.035 in.).
Mazda 2.0L and 2.2L Engines

The Mazda 2.0L and 2.2L engines have an electronic
ignition system. Change the spark plugs and check
the timing every 1000 hours. The correct spark plug
gap is 0.8 ±1 mm (0.032 ±0.04 in.).
The correct timing for the Mazda 2.0L and 2.2L en-
gines is as follows:
• Gasoline = 6° ±1° BTDC at 800 ±25 rpm (Orange
mark)
• LPG = 6° ±1° BTDC at 800 ±25 rpm (Orange mark)
For all Mazda engines except 2007 emission compli-
ant engines, see Electrical System, Mazda 2.0L
and 2.2L 2200 SRM 1143. For 2007 Mazda emission
compliant engines, see Electrical System, Mazda
2.0L and 2.2L Emission Compliant Engines 2200 1. BOLT
2. SEAL WASHER
SRM 1327. 3. FUEL FILTER HOUSING TOP SECTION
4. FUEL FILTER
LPG FUEL FILTER ELEMENT REPLACE, 5. FUEL FILTER O-RING
GM 2.4L ENGINE 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
Remove Figure 64. Fuel Filter Removal and Installation
WARNING 4. Remove top section of fuel filter housing.

LPG can cause an explosion. DO NOT permit 5. Remove and discard housing O-ring.
any sparks or open flames in the work area.
6. Remove fuel filter and fuel filter O-ring.
1. Close fuel valve on tank. Run engine until it
stops. Install
2. Disconnect negative battery cable. 1. Clean and inspect the fuel filter housing for con-
tamination or damage.
WARNING
2. Install the new fuel filter and fuel filter O-ring.
A small amount of fuel may still be present in
See Figure 64.
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues 3. Install new housing O-ring.
to flow from the connections when loosened,
check to make sure the manual valve is fully 4. Install top section of fuel filter housing.
closed.
5. Install bolt and new seal washer. Tighten bolt to
3. Remove the bolt and seal washer retaining the 13 N•m (115 lbf in).
top section of the fuel filter housing. Discard seal
washer. See Figure 64.
67
NOTE: Opening the fuel valve too quickly can cause

the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve,
wait a few seconds, and then slowly open the fuel
valve again. This will reset the excess fuel valve.
6. Slowly open the fuel valve on tank.
7. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.
8. Check for leaks at connections by using soapy

solution or electronic leak detector. If leaks are
detected, make proper repairs.
LPG VAPOR FUEL FILTER REPLACE,

MAZDA ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
1. FILTER BODY
WARNING 2. SPRING
3. O-RING
LPG can cause an explosion. DO NOT permit 4. FILTER ELEMENT
any sparks or open flames in the work area. 5. FILTER COVER
6. CAPSCREW
Remove and install a new LPG vapor fuel filter ele-
ment as follows: Figure 65. Mazda LPG Vapor Fuel Filter
1. Close fuel valve on tank. Run engine until all fuel LPG FUEL FILTER REPLACE, MAZDA 2007
is gone and engine stops. EMISSION COMPLIANT ENGINES ONLY
2. Disconnect negative battery cable. Remove
3. Slowly loosen all hose fittings to filter. Let any
fuel drain from fittings before disassembling fil- WARNING
ter unit. LPG can cause an explosion. DO NOT permit
any sparks or open flames in the work area.
4. Remove capscrews and filter cover.
1. Close fuel valve on tank and run engine until it
5. Remove O-ring, filter element, and spring. Dis- runs out of fuel and stops. Try to restart engine
card spring, filter element, and O-ring. See Fig- 2-3 times until it no longer starts.
ure 65.
2. Disconnect negative battery cable.
6. Install new spring, new filter element, and new
O-ring.
WARNING
7. Install filter cover to filter body with capscrews. A small amount of fuel may still be present in
Tighten hose fittings. the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
NOTE: Leaks are normally indicated by a buildup of to flow from the connections when loosened,
frost around a loose fitting. A leak may also be dis- check to make sure the manual valve is fully
covered by using soapy water. closed.
8. Open fuel valve on LPG tank and check for leaks. 3. Remove the bolt and seal washer from the fuel
If leaks are found, tighten fittings. filter housing top section. Discard seal washer.
See Figure 66.
68
Install
1. Install the new fuel filter and fuel filter O-ring.
See Figure 66.
2. Install new housing O-ring.
3. Install fuel filter housing top section onto fuel

filter housing bottom section.
4. Install bolt and new seal washer. Tighten bolt to

13 N•m (115 lbf in).
NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
1. BOLT* again. This will reset the excess flow valve.
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION* 5. Slowly open the fuel valve on tank.
4. FUEL FILTER
5. FUEL FILTER O-RING 6. Connect the negative battery cable.
6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION* 7. Turn the key to the ON position and back to
8. LOW PRESSURE SWITCH the OFF position to pressurize the fuel system.
*NOT SERVICED SEPARATELY Check for leaks.
Figure 66. Mazda 2007 Emission Compliant 8. Check for leaks at connections by using soapy
Fuel Filter Removal/Installation solution or electron leak detector. If leaks are
detected, make proper repairs.
4. Remove fuel filter housing top section from fuel
filter housing bottom section. GASOLINE FUEL FILTER REPLACEMENT,
MAZDA 2007 EMISSION COMPLIANT
5. Remove and discard housing O-ring.
ENGINES ONLY
6. Remove and discard fuel filter and fuel filter
O-ring. Remove and Replace
1. Raise the hood and disconnect the negative ter-
Clean/Inspect minal of the battery.
1. Clean and inspect the fuel filter housing top sec-
2. Remove and discard the fuel filter. See Figure 67.
tion for contamination or damage. If damaged,
replace the housing. 3. Install the new fuel filter and tighten the clamp
screws to 2.45 to 2.77 N•m (22 to 25 lbf in).
2. Clean and inspect the fuel filter housing bottom
section for contamination or damage. If dam- 4. Connect the negative terminal of the battery and
aged, replace the housing. close the hood.
69
1. SCHRADER VALVE
2. FUEL FILTER
3. FUEL PUMP/SENDER UNIT
Figure 67. Fuel Filter Replacement, Mazda

2007 Emission Compliant Engines Only
FUEL FILTER REPLACEMENT, YANMAR

ENGINE
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
Replace the fuel filter at specified intervals to pre- 1. FUEL FILTER ASSEMBLY
vent contaminants from adversely affecting the 2. FUEL FILTER ELEMENT
diesel fuel flow. 3. FUEL FILTER SENSOR CONNECTOR
4. FUEL FILTER HEAD
NOTE: See Figure 68 for all steps in the following 5. O-RING
6. DRAIN PLUG
procedure 7. FUEL FILTER SENSOR
8. IN-LINE FUEL FILTER
1. Stop the engine and allow it to cool. 9. INLET NIPPLE
2. Close all fuel cocks in the line. Figure 68. Yanmar Fuel Filter Replacement
NOTE: Tag connectors prior to disconnecting to aid 4. Place an approved container under the fuel filter.
in reconnecting.
5. Open the drain plug to drain fuel from the fuel
3. Disconnect fuel filter sensor connector. filter.
70
6. Remove the fuel filter from the fuel filter head. 13. Install the new O-ring on the drain plug, and in-
Wipe up any spilled fuel immediately. stall the drain plug on the new fuel filter element.
Hand tighten only.
7. Remove the drain plug from the fuel filter. Dis-
card the O-ring. 14. Clean the fuel filter head mounting surface and
apply a small amount of diesel fuel to the gasket
8. Remove the fuel filter sensor from the fuel filter on the new fuel filter element.
element and discard the O-ring.
15. Install the new fuel filter element until it con-
9. Remove the in-line fuel filter from the inlet nip- tacts the fuel filter head mounting surface.
ple that goes to the fuel injection pump. See Fig- Tighten one additional turn.
ure 69.
16. Open all the fuel cocks in the fuel line.
17. Reconnect the fuel filter sensor connector.
18. Prime the fuel system. See Priming the Fuel Sys-
tem (Yanmar).
19. Check for fuel leaks.
PRIMING THE FUEL SYSTEM (YANMAR)

1. Place an approved container under the air bleed
port. See Figure 70.
2. Loosen the air bleed port 2 or 3 turns.
CAUTION
NEVER use the starter motor to crank the en-
gine in order to prime the fuel system. This
may cause the starter to overheat and damage
the coils and/or the ring gear.
1. IN-LINE FUEL FILTER
2. FUEL LINE 3. Operate the fuel priming pump (see Figure 70)
3. WATER SEPARATOR/FUEL FILTER until the fuel coming out of the air bleed port is
4. FUEL SUPPLY VALVE free of bubbles.
Figure 69. In-Line Fuel Filter Replacement 4. Tighten the air bleed port.
10. Dispose of the fuel, fuel filters, and O-ring in ac- 5. Wipe up any fuel that may have spilled, and dis-
cordance with local directives. pose of the fuel and rags in accordance with local
directives.
11. Install the new in-line fuel filter into the inlet
nipple.
12. Install the fuel filter sensor assembly in the new

fuel filter using the new O-ring supplied with the
fuel filter.
71
goggles or a face shield to prevent injury to

the eyes.
Remove the lift chains. Clean the lift chains by soak-

ing them in a solvent that has a petroleum base for
at least 30 minutes. Use compressed air, adjusted to
a maximum output of 103 kPa (15 psi), to completely
dry the chains when they are clean.
Lubricate the lift chains by soaking them in 30W en-

gine 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.
1. AIR BLEED PORT

2. FUEL PRIMING PUMP
Figure 70. Priming the Fuel System
LIFT CHAINS WEAR CHECK

If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re- Pitch Wear Limit
Total Length
placed. Measure chain for wear where it moves over (The
of 20 Links
sheaves. Using a chain scale, Hyster P/N 871796 Maximum
(Pitch) of New
check lift chains as shown in Figure 71. Length of 20
Chain
Links)
LIFT CHAIN LUBRICATION 12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
WARNING 15.9 mm 317.5 mm 327.0 mm
Cleaning solvents can be flammable and toxic (0.63 in.) (12.5 in.) (12.9 in.)
and can cause skin irritation. When using 19.1 mm 381.0 mm 392.4 mm
cleaning solvents, always follow the recom- (0.75 in.) (15.0 in.) (15.4 in.)
mendations of the manufacturer. 25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
Compressed air can move particles so they
cause injury to the user or to other personnel. 1. CHAIN WEAR SCALE
Make sure that the path of the compressed air
is away from all personnel. Wear protective Figure 71. Lift Chains Check
72
INTEGRAL SIDESHIFT CARRIAGE, CHECK STEERING AXLE

BEARINGS
Lubricate the spindle bearings on the steering axle.
1. Lower carriage completely and remove forks. There are four lubrication fittings, two on each side of
the steering axle. See Figure 73. Use multipurpose
2. Remove backrest and the lower mounting hooks grease as shown in the Maintenance Schedule.
from sideshift carriage. See Figure 72.
3. Use a lifting device with a capacity of at least

450 kg (1000 lb) to lift outer frame away from
inner carriage.
4. Clean bearing areas. Inspect sideshift bearings

for wear as follows:
a. If either upper bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both up-
per bearings by driving upper bearings out of
carriage bar.
b. If either lower bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both
lower bearings by prying lower bearings from
lower carriage bar.
A. S40-70FT, S55FTS (F187)

B. H40-70FT (L177)
1. STEERING AXLE
2. LUBRICATION FITTING
1. UPPER BEARING 6. LOWER BEARING
2. LOWER HOOK 7. SHIMS
3. LOAD ROLLER 8. INNER CARRIAGE Figure 73. Lubricate Spindle Bearings
4. SNAP RING 9. LUBE FITTING
5. SIDESHIFT 10. OUTER FRAME CONTROL LEVERS AND PEDALS
CYLINDER
Lubricate linkages, pedal shafts, control cables
Figure 72. Integral Sideshift Carriage (throttle, hood, parking brake), and seat rails. Use a
silicone spray lubricant, Hyster Part No. 328388.
73
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1150
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and 5. Remove and discard O-ring from top of bowl. See
1000-hour checks prior to performing the procedures Figure 74.
in this section.
6. Remove and discard quad ring from head. See
HYDRAULIC SYSTEM Figure 74.
Hydraulic Filter, Replace 7. Clean housing and cover plate as necessary.
8. Inspect filter housing, especially sealing sur-

WARNING faces, for damage. Replace if damaged.
At operating temperature, the hydraulic oil is
9. Inspect dipstick plug. Replace O-ring and plug
HOT. DO NOT permit the hot oil to touch the
as necessary.
10. Lubricate sealing surfaces on filter housing and
CAUTION cover plate with clean hydraulic oil.
DO NOT permit dirt to enter the hydraulic sys-
11. Lubricate new quad ring with clean hydraulic oil
tem when the oil level is checked or the filter
and install onto head. See Figure 74.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. 12. Lubricate new O-ring with clean hydraulic oil
and install onto top of bowl. See Figure 74.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the 13. Lubricate new O-ring with clean hydraulic oil
hydraulic pump without oil will damage the and install on bottom of new filter element. See
pump. Figure 74.
14. Install new filter element into bowl as noted dur-

CAUTION ing removal. See Figure 74.
cal environmental regulations. 15. Lubricate new O-ring with clean hydraulic oil
and install on lid. See Figure 74.
1. Put lift truck on a level surface and lower car-
riage. 16. Install spring and lid onto head. See Figure 74.
Hand tighten lid.
2. Unscrew and remove lid and spring from head.
Remove and discard O-ring from lid. See Fig-
ure 74. CAUTION
Additives may damage the hydraulic system.
NOTE: Have container large enough to hold the filter Before using additives, contact your local Hys-
element and allow for final hydraulic oil draining. ter dealer.
NOTE: Note placement of filter element and handle 17. Start the truck, and allow it to run for 30 seconds.
prior to removal to aid in installation. Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
3. Remove filter element and O-ring from bowl and
shown in the Maintenance Schedule. To change
place in container. Cover head to prevent any
the hydraulic oil, see Hydraulic Oil, Replace.
foreign material from getting into the hydraulic
tank. See Figure 74.
4. After filter element has drained, discard filter el-

ement and O-ring.
74
8000 SRM 1150 Maintenance Procedures Every 2000 Hours or Annually
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 75. Hydraulic Tank Breather
AIR FILTER
The air filter canister should not be opened until an
air filter element replacement is required. An air
filter element replacement is required when one of
the following occurs:
• The optional air flow restriction indicator light on
the dash illuminates
• The optional manual air flow indicator button pops
up
• The specified number of hours has passed since the
last filter element replacement
1. O-RING 6. FILTER ELEMENT
2. SPRING 7. BOWL
3. LID 8. DIPSTICK PLUG CAUTION
4. HEAD 9. FILTER HOUSING
5. QUAD RING 10. COVER PLATE DO NOT to allow dirt to enter the engine air
intake when replacing the air filter element. A
Figure 74. Hydraulic Filter small amount of dirt could cause engine dam-
age.
Hydraulic Tank Breather, Replace
1. Shut off the engine. Never open the air filter can-
1. Raise the hood and remove the right rear side ister or remove the filter element with the engine
panel. See Figure 75. running.
2. Unscrew and remove old hydraulic tank 2. Unlatch and remove the cover. To remove filter
breather, and replace with new hydraulic tank element, press and rotate filter element counter-
breather. clockwise about 1/8 turn until the filter element
is free. To assist removal, gently move the end
3. Install right rear side panel and close hood. See
Figure 75.
75
back and forth to help break the seal. See Fig- If your air filter assembly is equipped with a sec-
ure 76. ondary element in place of the liner assembly, re-
place the secondary element with every 2 to 3 pri-
3. Gently pull the filter element from the canister. mary element replacements.
Avoid dislodging contaminants from the element
or knocking it against the canister. 7. Inspect the new filter element for voids, cuts,
tears or indentations in the urethane-sealing
4. With a clean, soft rag, clean the inside surface of surfaces. Do not use if damage is detected.
the canister. Remove the liner assembly to make
cleaning easier. Clean well around the locking
tabs that retain the element. Clean tabs make CAUTION
new filter element installation easier. Be careful The element must be properly installed to en-
not to knock any contaminants into the outlet sure adequate engine protection. An improp-
tube to the engine. erly installed element may allow dirt and dust
to enter and damage the engine.
5. Inspect the liner and O-ring assembly for dam-
age. If damaged, replace the liner and O-ring as- NOTE: Proper element installation is required to al-
sembly. low the cover to be installed correctly. Never reinstall
a used element. Never install a damaged element.
6. Install the liner assembly into the canister by Always use a Hyster-approved filter element.
pushing in. Make sure the liner assembly is
properly seated in the canister. It will fit snugly 8. Install the new filter element into the canister.
into and be centered in the canister. Press and rotate the filter element 1/8 turn clock-
wise until fully engaged in the canister. See Fig-
ure 77.
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 76. Air Filter
76
OXYGEN SENSOR
NOTE: The 2007 Mazda emission compliant engines
are equipped with Pre and Post Catalytic Converter
Oxygen Sensors.
Check that the oxygen sensor electrical connector is

seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair. See
Figure 78. For 2007 Mazda emission compliant en-
gines, see Figure 79.
1. PUSH IN 2. TWIST TO LOCK
Figure 77. Air Filter Label
CAUTION
During cover installation, DO NOT force the
cover on the canister. To do so will result in
damage to the filter element, cover, and possi-
bly the canister.
NOTE: If the filter element is properly installed, the

cover will fit easily into the canister with no gap be-
tween the cover and the canister. If the cover does not
fit easily, the filter element is not installed properly.
Do not use a cover that is bent, damaged, or missing
latches.
9. Install the cover into the canister and ensure the

INLET arrow is in line with the canister inlet.
NOTE: Do not use the latches to pull the cover down

against the canister. If the cover does not fit com-
pletely against the canister with no gaps, the element
is not installed correctly.
10. Fasten the latches to secure the cover to the can-

ister. Make sure the latches penetrate the slots
in both the canister and the cover.
11. Inspect the entire air intake system for leaks.

A. MAZDA EXHAUST SYSTEM
Inspect all clamps for tightness and tighten if B. GM EXHAUST SYSTEM
necessary. Inspect all hoses for damage. Re-
place damaged hoses. Inspect the dust evacua- 1. OXYGEN SENSOR
tion valve for damage. If damaged, replace the 2. EXHAUST PIPE
3. MANIFOLD
dust evacuation valve.
Figure 78. Oxygen Sensor
PCV VALVE
Install a new PCV valve. See Figure 3 through Fig-
ure 8. Also see Figure 25, Figure 26, and Figure 27.
77
1. MUFFLER
2. POST-CATALYTIC CONVERTER OXYGEN SENSOR
3. PRE-CATALYTIC CONVERTER OXYGEN SENSOR
4. EXHAUST PIPE (EXHAUST MANIFOLD TO CATALYTIC CONVERTER)
5. EXHAUST PIPE (CATALYTIC CONVERTER TO MUFFLER)
6. CATALYTIC CONVERTER
Figure 79. Oxygen Sensors for 2007 Mazda Emission Compliant Engines
LPG REGULATOR FUEL FILTER, MAZDA

ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
Remove and Replace
1. Close shutoff valve on tank. Run engine until it
stops.
2. Remove six capscrews, fuel filter cover, and two

filter elements. Discard filter elements. See Fig-
ure 80.
3. Install two new filter elements and six capscrews

on fuel filter cover. Tighten six capscrews to 6.4
to 7.9 N•m (57 to 70 lbf in).
1. FILTER ELEMENTS 3. FUEL FILTER

2. CAPSCREWS COVER
Figure 80. Mazda LPG Regulator Fuel Filter
78
LPG REGULATOR FUEL FILTER, GM 4. Remove and discard the plastic cap, foam filter,
ENGINE paper filter, and rubber washer from the LPG
regulator.
Remove
5. Disconnect the hose from the outlet fitting. Re-
1. Close shutoff valve on tank. Run engine until it move three screws and the outlet fitting from the
stops. LPG regulator. Discard the O-ring.
2. Disconnect the hose from the inlet fitting. 6. Remove and discard the screen from the LPG reg-
ulator.
3. Remove the inlet fitting from the LPG regulator.
Discard the O-ring. See Figure 81. Install
1. Install a new screen in the LPG regulator.
2. Install a new O-ring on the outlet fitting. Using

three screws, install the outlet fitting on the LPG
regulator.
3. Install new rubber washer, paper filter, foam fil-

ter, and plastic cap in the LPG regulator.
4. Install new O-ring on the inlet fitting. Install

inlet fitting into the LPG regulator and connect
hose to the inlet fitting.
5. Open shutoff valve on LPG tank and check for

leaks.
GASOLINE FUEL FILTER

Remove and Replace
1. Raise the hood and disconnect the negative ter-
minal of the battery.
2. Remove and discard the fuel filter. See Figure 82.
1. LPG REGULATOR 6. PAPER FILTER 3. Install the new fuel filter and tighten the clamp
2. INLET FITTING 7. RUBBER WASHER screws to 2.45 to 2.77 N•m (22 to 25 lbf in).
3. O-RING 8. SCREWS
4. PLASTIC CAP 9. OUTLET FITTING 4. Connect the negative terminal of the battery and
5. FOAM FILTER 10. SCREEN
close the hood.
Figure 81. GM LPG Regulator
79
TIMING BELT
Mazda Engines
Change timing belt after 3500 hours of operation.
The cover for the timing belt must be removed for
checks and adjustments. See the section Mazda En-
gine, 2.0L and 2.2L 600 SRM 1122 for more infor-
mation.
GM 2.4L Engine
The cover for the timing belt must be removed for
checks and adjustments. See the section GM Engine
Repair, GM 2.4 Liter Engine 600 SRM 1121 for
more information.
LPG FUEL INJECTOR, MAZDA ENGINES

(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES)
For removal and cleaning instructions, see the sec-
tion LPG Fuel System, Mazda 2.0L and 2.2L En-
gines 900 SRM 1125.
GASOLINE FUEL INJECTOR, MAZDA

ENGINES
tion Gasoline Fuel System, Mazda 2.0L and 2.2L
900 SRM 1127 for all Mazda engines except 2007
emission compliant engines. For 2007 emission com-
pliant engines, see the section Gasoline Fuel Sys-
tem, Mazda 2.0L and 2.2L Emission Compliant
Engines 900 SRM 1325.
LPG FUEL INJECTOR, GM ENGINES

tion LPG Fuel System, GM 2.4L Engine 900 SRM
1124.
GASOLINE FUEL INJECTOR, GM ENGINES

A. MAZDA (EXCEPT 2007 EMISSION COMPLIANT
ENGINES) For removal and cleaning instructions, see the sec-
B. GM 2.4L tion Gasoline Fuel System, GM 2.4L Engine 900
SRM 1126.
1. FUEL FILTER
2. FUEL TANK FUEL INJECTOR, YANMAR ENGINES
3. FUEL PUMP/SENDER UNIT
Figure 82. Fuel Filter Replacement
tion Yanmar Diesel Engines, 2.6L and 3.3L 600
SRM 1205.
80
FORKS
WARNING
Never repair damaged forks. DO NOT heat,
weld, cut, drill, or bend the forks. Forks are
made of special steel using special methods.
Replace damaged forks as a set.
Check heel and attachment points of forks with a

penetrant or by magnetic particle inspection.
INTEGRAL SIDESHIFT CARRIAGE

Bearings, Replace
Replace all four bearings regardless of wear. See the
section, Maintenance Procedures Every 1000 Hours
or 6 Months for the procedure.
TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACE NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF
Iron Transmission Housing CLARITY.
1. TRANSMISSION
WARNING 2. TRANSMISSION DRAIN PLUG
At operating temperature, the transmission oil 3. SPRING
is HOT. DO NOT permit the hot oil to touch the 4. SCREEN
5. TRANSMISSION OIL FILTER
skin and cause a burn. 6. TRANSMISSION DIPSTICK
7. TRANSMISSION BREATHER
CAUTION
Figure 83. Transmission Oil Change
changed. Dirt can cause damage to the trans- WARNING
mission components. Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
CAUTION manufacturer’s recommended safety proce-
Disposal of lubricants and fluids must meet lo- dures.
Compressed air can move particles so they
NOTE: Change the transmission oil filter at the first cause injury to the user or to other personnel.
100 hours of operation on new lift trucks. Before re- Make sure the path of the compressed air is
moving the oil filter, make a hole at the top of the away from all personnel. Wear protective gog-
filter and allow five minutes for the oil to drain down gles or a face shield to prevent injury to the
into the transmission. This will reduce the oil that eyes.
will run out of the filter and onto the transmission
when the filter is removed. 2. Clean screen with cleaning solvent, and dry with
compressed air, adjusted to the maximum output
NOTE: The drain plug for the transmission is on the of 103 kPa (15 psi).
lower right side of the cover of the transmission, to-
ward the rear of the lift truck. 3. When oil has drained, first install screen, then
spring, and transmission drain plug. See Fig-
1. Remove drain plug, spring, and screen. See Fig- ure 83.
ure 83. Drain oil into a container.
81
4. Remove and discard transmission breather. 3. Remove suction screen spring and suction screen.
Install new transmission breather and hand See Figure 84 and Figure 85.
tighten. See Figure 83.
4. Remove flange head capscrews and hydraulic
5. Remove and discard old transmission oil filter. gear pump. See Figure 84 and Figure 85.
Apply clean oil to gasket of new transmission oil
filter. Install new filter and had tighten. See 5. Remove and discard transmission oil filter. See
Figure 83. Figure 84 and Figure 85.
6. Add oil to transmission at the dipstick tube. The 6. Remove and discard transmission breather. See
correct oil is shown in the Maintenance Sched- Figure 84 and Figure 85.
ule.
7. Start and run the engine for approximately 5

minutes after fill to allow oil to lubricate parts
within the transmission.

8. Turn the key to the OFF position, check for leaks,

and check oil level. Top off oil, if necessary.
Aluminum Transmission Housing

Remove
WARNING
CAUTION
changed. Dirt can cause damage to the trans-
mission components.
1. TRANSMISSION
CAUTION 3. TRANSMISSION DIPSTICK
Disposal of lubricants and fluids must meet lo- 4. TRANSMISSION BREATHER
cal environmental regulations. 5. TRANSMISSION DRAIN PLUG
6. SUCTION SCREEN
NOTE: Change the transmission oil filter at the first 7. SUCTION SCREEN SPRING
8. CHARGE PUMP GASKET
100 hours of operation on new lift trucks. 9. CHARGE PUMP
10. WASHER
1. Remove drain plug. See Figure 84 and Fig- 11. CAPSCREW
ure 85. When oil is completely drained, install 12. FLANGE HEAD CAPSCREW
drain plug. 13. HYDRAULIC GEAR PUMP
2. Remove capscrews washers, charge pump, and Figure 84. Transmission Oil Filter Change -
charge pump gasket. Discard gasket. See Fig- Aluminum Gear Drive
ure 84 and Figure 85.
82
Make sure the path of the compressed air is

away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. Clean suction screen spring and suction screen

with cleaning solvent and dry with compressed
air. Inspect spring and screen for damage. Re-
place if damaged.
2. Wipe exterior surfaces of transmission housing,

hydraulic gear pump, and charge pump with sol-
vent soaked clot and dry with a lint-free cloth.
Inspect housing and pumps for damage. Replace
if damaged.
3. Clean metal threaded components with solvent

and dry with compressed air. Clean plastic
threaded components with warm soapy water
and dry with a lint-free cloth. Inspect compo-
nents for damage. Replace if damaged.
Install
1. Install new transmission breather. See Figure 84

and Figure 85.
1. TRANSMISSION 2. Install suction screen and suction screen spring.

2. TRANSMISSION OIL FILTER See Figure 84 and Figure 85.
3. TRANSMISSION DIPSTICK
4. TRANSMISSION BREATHER 3. Using seven washers and seven capscrews install
5. TRANSMISSION DRAIN PLUG
6. SUCTION SCREEN new charge pump gasket and charge pump. See
7. SUCTION SCREEN SPRING Figure 84 and Figure 85. Tighten capscrews to
8. CHARGE PUMP GASKET 19 N•m (168 lbf in).
9. CHARGE PUMP
10. WASHER 4. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of
11. CAPSCREW sealant to either hydraulic gear pump or trans-
12. FLANGE HEAD CAPSCREW mission housing face. Hold pump in the correct
13. HYDRAULIC GEAR PUMP
position on the transmission. Install flange head
Figure 85. Transmission Oil Filter Change - capscrews into pump and transmission housing.
Aluminum Chain Drive See Figure 84 and Figure 85. Tighten capscrews
to 38 N•m (28 lbf ft).
Clean and Inspect
5. Apply clean oil to gasket of new transmission oil
filter and install filter onto transmission. See
WARNING Figure 84 and Figure 85.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 6. Add oil to transmission at dipstick tube. The cor-
cleaning solvents, always follow the solvent rect oil is shown in the Maintenance Schedule.
manufacturer’s recommended safety proce-
dures. 7. Start and run engine for approximately 5 min-
utes after fill to allow oil to lubricate parts within
Compressed air can move particles so they transmission.
83

8. Turn key to OFF position, check for leaks, and

check oil level. Top off oil, if necessary.
TRANSMISSION OIL CHANGE, WET

BRAKE DRIVE AXLE
WARNING
The oil used for the transmission should not be
contaminated. If the transmission oil becomes
contaminated, the oil must be drained and re-
placed with new oil.
WARNING
NOTE: ALL MAJOR COMPONENTS AND FRAME
CAUTION COMPONENTS REMOVED FOR CLARITY.
DO NOT permit dirt to enter the transmission 1. TRANSMISSION
when the oil level is checked or the filter is 2. TRANSMISSION DRAIN PLUG
changed. Dirt will contaminate the oil and 3. SPRING
cause damage to the transmission and wet 4. SCREEN
brake planetary carrier housing components. 5. TRANSMISSION OIL FILTER
CAUTION
Figure 86. Transmission Oil Change - Iron
Disposal of lubricants and fluids must meet lo- Housing
NOTE: Perform Step 2 through Step 7 for lift trucks
NOTE: Change the transmission oil filter at the first equipped with an aluminum transmission housing.
500 hours of operation on new lift trucks.
2. Place a container under transmission. Remove
NOTE: Perform Step 1 for lift trucks equipped with transmission drain plug. See Figure 87 and Fig-
an iron transmission housing. ure 88. When oil is completely drained, install
NOTE: Before removing the oil filter from iron trans- transmission drain plug.
mission housing, make a hole at the top of the filter 3. Remove capscrews, washers, charge pump, and
and allow five minutes for the oil to drain down into charge pump gasket. Discard gasket. See Fig-
the transmission. This will reduce the oil that will ure 87 and Figure 88.
run out of the filter and onto the transmission when
the filter is removed. 4. Remove suction screen spring and suction screen.
1. The drain plug for the transmission is on the
lower right side of the cover of the transmission, 5. Remove flange head capscrews and hydraulic
toward the rear of the lift truck. Place a con- gear pump. See Figure 87 and Figure 88.
tainer under right side of transmission. Remove
drain plug, spring, and screen. See Figure 86. 6. Remove and discard transmission oil filter. See
Drain oil into a container. When oil is completely Figure 87 and Figure 88.
drained, install drain plug.
7. Remove and discard transmission breather. See
84
d. Drain oil into container. When oil has com-

pletely drained, install new O-ring on drain
plug then install drain plug in housing.
Tighten drain plug to40 N•m (29.5 lbf ft)
1. TRANSMISSION
5. TRANSMISSION DRAIN PLUG
6. SUCTION SCREEN
7. SUCTION SCREEN SPRING 1. TRANSMISSION
8. CHARGE PUMP GASKET 2. TRANSMISSION OIL FILTER
9. CHARGE PUMP 3. TRANSMISSION DIPSTICK
10. WASHER 4. TRANSMISSION BREATHER
11. CAPSCREW 5. TRANSMISSION DRAIN PLUG
12. FLANGE HEAD CAPSCREW 6. SUCTION SCREEN
13. HYDRAULIC GEAR PUMP 7. SUCTION SCREEN SPRING
8. CHARGE PUMP GASKET
Figure 87. Transmission Oil Change - 9. CHARGE PUMP
10. WASHER
Aluminum Housing (Prior to January, 2011) 11. CAPSCREW
12. FLANGE HEAD CAPSCREW
8. Drain oil from left planetary housing as de- 13. HYDRAULIC GEAR PUMP
scribed below:
a. Place container under left planetary housing. Figure 88. Transmission Oil Change -
b. Remove drain plug from housing. See Fig- Aluminum Housing Figure (After January,
ure 90. Remove and discard O-ring from 2011)
drain plug.
c. Remove fill/level plug from housing. Re-
moving fill/level plug allows oil to drain at a
faster rate. See Figure 89.
85
15. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of

WARNING sealant to either hydraulic gear pump or trans-
Cleaning solvents can be flammable and toxic mission housing face. Hold pump in the correct
and can cause skin irritation. When using position on the transmission. Install flange head
cleaning solvents, always follow the solvent capscrews into pump and transmission housing.
manufacturer’s recommended safety proce- See Figure 87 and Figure 88. Tighten capscrews
dures. to 38 N•m (28 lbf ft).
Compressed air can move particles so they 16. Apply clean oil to gasket of new transmission oil
cause injury to the user or to other personnel. filter and install filter. See Figure 87 and Fig-
Make sure the path of the compressed air is ure 88.
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the 17. Add transmission oil to transmission at the dip-
eyes. stick tube. The correct oil and volume is shown
in the Maintenance Schedule.
9. Clean screen with cleaning solvent, and dry with
compressed air, adjusted to a maximum output NOTE: Transmission oil temperature should be at
of 103 kPa (15 psi). least 50°C (120°F) when checking oil level.
NOTE: Perform Step 10 and Step 11 for lift trucks 18. Start and run the engine for approximately five
equipped with an iron transmission housing. minutes after fill to allow oil to lubricate parts
within the transmission. Add transmission oil to
10. When oil has drained, first install screen, then transmission at the dipstick tube as needed.
spring, and drain plug.
19. Turn the key to the OFF position and check for
11. Remove and discard old oil filter. Apply clean oil leaks and check oil level.
to gasket of new filter. Install new filter and hand
tighten. WET BRAKE AXLE CENTER SECTION
NOTE: Perform Step 12 through Step 16 for lift
AND PLANETARY HOUSING, OIL CHANGE
trucks equipped with an aluminum transmission 1. Remove the planetary housing fill/level plugs
housing. and O-rings. Discard O-rings. Removing the
fill/level plug will allow the oil to drain at a
12. Install new transmission breather. See Figure 87
faster rate. See Figure 89.
and Figure 88.
2. Place an empty container under the center sec-
13. Install suction screen and suction screen spring.
tion drain plug and under the right and left plan-
etary housing drain plugs.
14. Using seven washers and seven capscrews install
3. Remove drain plugs and wait until oil has
new charge pump gasket and charge pump. See
drained completely. Remove and discard O-rings
Figure 87 and Figure 88. Tighten capscrews to
from drain plugs. See Figure 90.
19 N•m (168 lbf in).
86
1. RIGHT PLANETARY HOUSING 4. FILL/LEVEL PLUG

2. LEFT PLANETARY HOUSING 5. CENTER SECTION (COOLING CHAMBER)
3. O-RING
Figure 89. Planetary Housings Fill/Level Plugs
4. Install new o-rings on drain plugs. Install drain overflowed. The correct oil is shown in the Main-
plugs. Tighten the drain plugs to 40 N•m tenance Schedule or Figure 91.
(29.5 lbf ft).
6. Install new O-ring on planetary fill/level plugs.
Install fill/level plugs.
CAUTION
Before adding oil, ensure the truck is parked 7. The center section (cooling chamber) will fill with
and on level ground. fluid automatically as it circulates through and
back to the transmission.
5. Add oil at the fill/level port for the right and left
planetary housing until the oil/fill level port has
87
1. LEFT PLANETARY HOUSING 4. CENTER SECTION (COOLING CHAMBER)

2. O-RING 5. RIGHT PLANETARY HOUSING
3. DRAIN PLUG
Figure 90. Center Section and Planetary Housings Drain Plugs
88
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY HOUSING - USE SAE 80W/90
C. CENTER SECTION (COOLING HOUSING) - USE JDM J20C
1. OIL FILL/LEVEL PLUG 2. OIL BREATHER 3. COOLING OIL INLET PORT
Figure 91. Oil Application Diagram
BRAKE FLUID (MASTER CYLINDER), On lift trucks with dry brake drive axles, only
CHANGE use SAE J-1703 (DOT 3) brake fluid in the mas-
ter cylinder.
WARNING 1. Remove the dashboard from the cowl.
Small amounts of water in the brake system
can cause reduced braking performance if the
CAUTION
water reaches the wheel cylinder areas. DO
NOT allow water entry. Ensure that the sealed Disposal of lubricants and fluids must meet lo-
reservoir lid is properly replaced. cal environmental regulations.
On lift trucks with wet brake drive axles, only 2. Remove the brake fluid reservoir from the
use Dexron III oil from sealed container in the bracket on the cowl. See Figure 92 and Fig-
master cylinder. ure 93.
89
drain plug. Refill the reservoir with clean oil

from a sealed container and install the cover on
the reservoir. The correct oil is shown in the
Maintenance Schedule.
4. Install the reservoir into the bracket located on

the cowl.
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
1. BRAKE FLUID RESERVOIR 6. CYLINDRICAL BLOCK OUTLET FITTING
2. MOUNTING BRACKET 7. LOWER BRAKE OIL SUPPLY HOSE
3. COWL 8. NIPPLE
9. MASTER CYLINDER
Figure 92. Brake Fluid Change (Dry Brake) 10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
3. Remove the brake oil reservoir cover and cylin- 12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
drical block drain plug. Pour the fluid into a
suitable container with a 0.25 liter (0.53 pt) Figure 93. Brake Oil Change (Wet Brakes)
minimum capacity. Install the cylindrical block
90
BRAKE FLUID (DRY BRAKE), REMOVE DO NOT sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
Perform the following procedure to remove used changes to brake linings must be done in a re-
brake fluid from the remainder of the brake system. stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
1. Ensure that the master cylinder reservoir is
filled with brake fluid. Brake cleaning procedures are as follows:
2. Put one end of a rubber hose on the special fitting
of the wheel cylinder. Put the other end of the CAUTION
hose into a empty container. DO NOT use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
3. Loosen the special fitting at the wheel cylinder
of brake parts. DO NOT permit oil or grease in
one turn so that the used brake fluid can be re-
the brake fluid or on the brake linings.
moved from the brake system. Slowly push the
brake pedal and hold it at the end of its stroke. 1. DO NOT release brake lining dust from brake
Close the special fitting. Release the brake pedal. linings into the air when brake drum is removed.
NOTE: The new brake fluid will be easily recognized, 2. Use a solvent approved for cleaning of brake
as the color will be more clear than the used fluid parts to wet lining dust. Follow the instructions
which will be darker. and cautions of the manufacturer for the use of
the solvent. If a solvent spray is used, do not
4. Repeat Step 1 through Step 3 until there is new
create brake lining dust with the spray.
brake fluid in the container.
3. When the brake lining dust is wet, clean parts.
5. Check the level of the brake fluid in the reser-
Put any cloth or towels in a plastic bag or an
voir for the master cylinder during the procedure.
airtight container while they are still wet. Put
Make sure to keep the brake fluid at the correct
a DANGEROUS FIBERS warning label on the
level.
plastic bag or airtight container.
6. Repeat the procedure for the other wheel cylin-
4. Any cleaning cloths that will be washed must be
der.
cleaned so that fibers are not released into the
air.
SERVICE BRAKES (DRY BRAKE)
Check brake lining and parts of the brake assembly DIFFERENTIAL (DRY BRAKE)
for wear or damage. The minimum acceptable brake
NOTE: Additional information on the differential can
lining thickness is 1.0 mm (0.040 in.). If the brake
be found in the section Drive Axle and Differential
linings are worn thinner than the specification, re-
Assembly Repair 1400 SRM 1132 or Drive Axle
place the brake linings. See the section Brake Sys-
and Differential Assembly Repair, (Dry Brake)
tem 1800 SRM 1135 for the removal and installation
1400 SRM 1214.
procedures of the drive wheels and brake drums. If
the brake linings or brake shoes are worn or dam- 1. Place the lift truck on blocks. See How to Raise
aged, they must be replaced. Brake shoes must be Drive Tires in this manual.
replaced in complete sets. Inspect brake drums for
cracks or damage. Replace any damaged parts. 2. The differential and drive axle use the same oil
supply. Place a container with a minimum capac-
ity of 5 liter (5.3 qt) under the differential. Re-
WARNING
move the drain plug located in the bottom of the
Brake linings can contain dangerous fibers. differential and drain the oil from the differential
Breathing the dust from these brake linings completely. Install the drain plug.
is a cancer or lung disease hazard. DO NOT
create dust! DO NOT clean brake parts with 3. The fill hole is on the front of the differential
compressed air or by brushing. Follow the housing. Add oil shown in the Maintenance
cleaning procedure in this section. When the Schedule until the oil level is at the lower edge of
brake drums are removed, DO NOT create the fill hole. Install fill plug and rotate the drive
dust. wheels in order to get oil pumped into the axle.
91
Remove the fill plug and check the oil level. Add
oil, as necessary. Install the fill plug and check
for leaks. See Figure 94.
1. CRANKSHAFT PULLEY
2. DRIVE BELT
3. ENGRAVE TIMING MARK
Figure 95. Cummins QSB 3.3L TDC Mark
2. Adjust ONLY the valves shown in Figure 96, by

loosening the locknut with a wrench and adjust-
ing the valve clearance using a screwdriver or
Allen wrench.
3. Tighten the lock nut to 24 N•m (212 lbf in) and

measure valve lash.
4. Mark the vibration damper and rotate the crank-

shaft 360 degrees. See Figure 97.
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
Figure 94. Drive Axle Fluid Fill
VALVE CLEARANCE, CHECK AND

ADJUST FOR CUMMINS QSB 3.3L DIESEL
ENGINE
The Cummins QSB 3.3L engine does not require
valve clearance adjustments during normal service.
See the Maintenance Schedule for valve clearances.
Check the valve clearance and make adjustments as 1. EXHAUST VALVE 4. CYLINDER 2
needed. To adjust the valve clearances do the follow- 2. INTAKE VALVE 5. CYLINDER 3
ing: 3. CYLINDER 1 6. CYLINDER 4
1. Align the TDC mark on the crankshaft pulley Figure 96. Cummins Valve Adjustment
with the engraved mark on the block. See Fig-
ure 95.
92
8000 SRM 1150 Maintenance Procedures Every 4000 Hours or 2 Years
5. Perform Step 2 and Step 3 to adjust ONLY the

valves shown in Figure 98. See the Maintenance
Schedule for valve clearances.
1. TIMING PIN
2. VIBRATION DAMPER 1. EXHAUST VALVE 4. CYLINDER 2
2. INTAKE VALVE 5. CYLINDER 3
Figure 97. Cummins Vibration Damper 3. CYLINDER 1 6. CYLINDER 4
Figure 98. Cummins Valve Adjustment
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000- NOTE: Replace the hydraulic oil filter at the same
hour, and 2000-hour checks prior to performing the time the oil is changed.
procedures in this section.
1. Place a container with a minimum capacity of
HYDRAULIC OIL, REPLACE 30.1 liter (32 qt) under the drain plug at the
bottom of the hydraulic tank. To drain the oil,
remove the drain plug from the bottom of the
WARNING hydraulic tank. See Figure 99. When the tank
At operating temperature the hydraulic oil is is empty, inspect the inside of the tank for any
HOT. DO NOT permit the hot oil to touch the foreign matter or possible fungus. If necessary,
skin and cause a burn. clean the inside of the tank in accordance with
the instructions found in the section Frame 100
CAUTION SRM 1120. When either the inspection or the
DO NOT permit dirt to enter the hydraulic sys- cleaning of the tank is completed, install the
tem when the oil level is checked or the filter drain plug in the bottom of the hydraulic tank.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. CAUTION
Never operate the hydraulic pump without oil Additives may damage the hydraulic system.
in the hydraulic system. The operation of the Before using additives, contact your local Hys-
hydraulic pump without oil will damage the ter dealer.
pump. 2. Fill hydraulic tank with oil specified in the Main-
tenance Schedule.
CAUTION
3. When the oil level is correct, operate system and
check for leaks.
NOTE: Heavy-duty or contaminated applications will

require hydraulic oil change at 2000 hours.
93
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1150
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 99. Hydraulic Oil Change
COOLING SYSTEM 2. Open drain valve and remove radiator cap. Drain
coolant into the container. Flush cooling sys-
1. Put lift truck on a level surface. Stop engine. tem. Check hoses for damage. Replace with new
Place a container with a minimum capacity of hoses, as needed.
30.1 liter (32 qt) under the radiator drain valve
which could be located on either the lower left or 3. Disconnect the hose leading from the auxiliary
right side of the radiator on the engine side of the reservoir to fitting at the top of the radiator un-
radiator. der the radiator cap, and drain the reservoir into
the same container used for the radiator coolant.
WARNING Check the reservoir for contaminants and flush,
as necessary. Connect the hose back on the fit-
DO NOT remove the radiator cap from the ra-
ting at the top of the radiator.
diator when the engine is hot. When the radi-
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam CAUTION
and boiling coolant can cause burns. DO NOT Additives may damage the cooling system. Be-
remove the cover for the radiator when the en- fore using additives, contact your local Hyster
gine is running. dealer.
4. Close drain valve. Fill cooling system, use Ethy-

CAUTION lene Glycol Boron-free Antifreeze. Purchase a
Disposal of lubricants and fluids must meet lo- pre-diluted 50/50 solution; or mix 50% concen-
cal environmental regulations. trate with 50% distilled or deionized water. Fill
the auxiliary reservoir to a level between the
ADD and FULL marks on the reservoir.
94
8000 SRM 1150 Safety Procedures When Working Near Mast
5. Install radiator cap. Start engine. Check for as needed. Coolant level should be between the
leaks. Add coolant to auxiliary coolant reservoir ADD and FULL marks on the reservoir.
Safety Procedures When Working Near Mast

The following procedures must be used when inspect- OR
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re- 2. If parts of the mast must be in a raised position,
moving the mast. See the correct Service Manual sec- install a safety chain to restrain the moving parts
tion for the specific mast being repaired. of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances
between parts are small. Serious injury or b. Raise mast to align bottom crossmember
death can result if part of the body is hit by of weldment that moves in outer weldment
parts of the mast or the carriage. with a crossmember on outer weldment.
On the two-stage and free-lift mast, the
• Never put any part of the body into or under moving part is the inner weldment. On
the mast or carriage unless all parts of the the three-stage mast, it is the intermediate
mast are completely lowered or a safety chain weldment. See Figure 100.
is installed. Also make sure that the power is
off and the key is removed. Put a DO NOT OP- c. Use a 3/8-in. minimum safety chain with a
ERATE tag in the operator’s compartment. hook to fasten the crossmembers together so
• Be careful of the forks. When the mast is the movable member cannot lower. Put the
raised, the forks can be at a height to cause hook on the back side of the mast. Make sure
an injury. the hook is completely engaged with a link in
• DO NOT climb on the mast or lift truck at any the chain. Make sure the safety chain does
time. Use a ladder or personnel lift to work not touch lift chains or chain sheaves, tubes,
on the mast. hoses, fittings, or other parts on the mast.
• DO NOT use blocks to support the mast weld- d. Lower the mast until there is tension in the
ments nor to restrain their movement. safety chain and the free-lift cylinder (free-
• Mast repairs require disassembly and re- lift, three-stage, and four-stage masts only)
moval of parts and can require removal of is completely retracted. If running, stop en-
the mast or carriage. Follow the repair pro- gine. Apply parking brake. Install a DO
cedures in the correct Service Manual for NOT REMOVE tag on the safety chain(s).
the mast.
e. Install another safety chain (3/8-in. mini-
NOTE: If there is no power to lower the mast on lift mum) between the top or bottom crossmem-
trucks equipped with Electronic Hydraulic System, ber of the carriage and a crossmember on the
there is an emergency load lowering valve located outer weldment.
on the hoist/lower valve section of the main control
valve. See the Operating Manual for the proce- 3. Apply parking brake. After lowering or restrain-
dures to lower a load using the emergency load lowing the mast, shut off power and remove key. Put
ering valve. a DO NOT OPERATE tag in the operator’s com-
partment.
1. Lower mast and carriage completely. Push lift/
lower control lever forward and make sure there
is no movement in the mast. Make sure all parts
of the mast that move are fully lowered.
95
Safety Procedures When Working Near Mast 8000 SRM 1150
Figure 100. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
96
8000 SRM 1150 Safety Procedures When Working Near Mast

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
97
Hood Latch Check 8000 SRM 1150
Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is
The hood, hood latch, and latch striker must be fully closed after two clicks of the latch.
correctly adjusted for the correct operation of
the operator restraint system. 4. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center
1. Install hood latch on frame of hood. See Fig- of hood latch. Open hood and tighten capscrews
ure 101. Tighten capscrews so that hood latch for latch.
can still move when hood is closed.
5. Check operation of hood latch. Have an operator
2. Install latch striker in highest slot position. sit in the seat. Make sure hood is fully closed
Check that latch striker is in center of jaws of (two clicks). Also check that hood touches rubber
hood latch when hood closes. bumper. If necessary, repeat Step 4.
1. LATCH STRIKER 3. HOOD 5. HOOD LATCH

2. BUMPER 4. HOOD RELEASE HANDLE 6. FRAME
Figure 101. Hood Latch Check
98
8000 SRM 1150 Lift Chain Adjustments
Lift Chain Adjustments

WARNING
Procedures When 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
engine is STOPPED.
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 sys-

1. MAST
tem, fasten the load to the carriage with chains 2. CARRIAGE
to prevent it from falling. Keep all personnel 3. FORK
away from the lift truck during the tests. 4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE THE FLOOR LEVEL.
When lift chains are correctly adjusted:
• Tension will be the same on each chain of chain Figure 102. Lift Chain Adjustments With Forks
set. Check tension by pushing on both chains at Installed
the same time.
• Chain length will be correct.
• Chains must travel freely through complete cycle.
NOTE: When chain adjustments are complete, make

sure the threads on the nuts of the chain anchors
are completely engaged. Make sure all adjustment is
not removed from the chain anchors. Chain anchors
must be able to move on their mounting.
1. When adjusting lift chains on forklift trucks

equipped with the forks installed, go to Step 2.
If forklift truck is equipped with an attachment
without forks, go to Step 3.
NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage 1. MAST

2. CARRIAGE
until bottom of the fork heel is 6 ±3 mm (0.24 3. DISTANCE FROM FLOOR TO LOWER
±0.12 in.) above floor level. See Figure 102. CARRIAGE BAR
3. Adjust chain anchors which support carriage un- Figure 103. Lift Chain Adjustment Without
til the bottom of lower carriage bar is above the Forks Installed
floor level as shown in Table 3. See Figure 103.
99
Jump-Starting the Lift Truck 8000 SRM 1150
In Table 3, the masts are divided by class. Each Table 3. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK
CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by push- touching.
ing or towing lift truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these DO NOT try to start the engine by pushing or
procedures carefully when connecting the jumper towing the lift truck. Damage to the hydraulic
cables: system can occur if engine is started by push-
ing or towing lift truck.
1. Disconnect the negative battery terminal of the
lift truck being started. 1. Always connect positive jumper cable to positive
terminal of discharged battery and negative
2. Always connect positive jumper cable to positive jumper cable to negative terminal.
terminal of discharged battery and negative
jumper cable to negative terminal. 2. Always connect jumper cable, that is the ground
cable, last.
3. Always connect jumper cable, that is the ground
cable, last. 3. Always connect jumper cables to discharged lift
truck battery before connecting them to the fully-
4. Always connect jumper cables to discharged bat- charged lift truck battery.
tery before connecting them to booster battery.
100
8000 SRM 1150 Overhead Guard Changes
Welding Repairs
warning. Should work be performed, utilize
WARNING good industrial hygiene practices including
Welding can cause a fire or an explosion. Al- removal of all paint (prime and finish coats) to
ways follow the instructions in the Frame sec- the metal around the area to be welded, local
tion if a fuel or hydraulic tank must be welded. ventilation, and/or supplied-air respiratory
Make sure there is no fuel, oil, or grease near protection.
the weld area. Make sure there is good venti-
lation in the area where the welding must be
done. CAUTION
When an arc welder is used, always disconnect
DO NOT heat, weld, or bend forks. Forks are the ground cable from the battery in the lift
made of special steel using special methods. truck. This action will prevent damage to the
The strength of the overhead guard can be re- alternator or the battery.
duced by welding or heating. Get information
from your dealer for Hyster lift trucks before Connect the ground clamp for the arc welder as
welding on a mast. close as possible to the weld area. This action
will prevent damage to a bearing from the large
Forklift frames and components may be current from the welder.
painted with a catalyzed paint such as
polyurethane or a two-part primer. Weld- Some repairs require welding. If an acetylene or arc
ing, burning, or other heat sufficient to cause welder is used, make sure procedures in previous
thermal decomposition of the paint may re- WARNING and CAUTION are done.
lease isocyanates. These chemicals are allergic
See the American National Standard Safety in Weld-
sensitizers to the skin and respiratory tract
ing and Cutting, AWS Z 49.1 - 1999.
and overexposure may occur without odor
Overhead Guard Changes

See your dealer for Hyster lift trucks BEFORE
WARNING performing any changes to the overhead
DO NOT weld mounts for lights or accessories guard.
to the legs of the overhead guard. Changes that
are made by welding or by drilling holes that No welding or drilling on legs of overhead guard is
are too big or in the wrong location can reduce permitted as per previous WARNING.
the strength of the overhead guard.
101
Wheel and Tire Replacement 8000 SRM 1150
Wheel and Tire Replacement

GENERAL Wheels must be changed and tires repaired by
trained personnel only.
The S series lift trucks have solid rubber tires (often
called cushion tires) that are pressed onto the rim. Always wear safety glasses.
The H series lift trucks have pneumatic tires or solid
rubber tires that look like pneumatic tires. These 1. Raise lift truck as described in How to Put Lift
variations in tires also cause a variation in the types Truck on Blocks in this manual.
of wheels and the disassembly and assembly proce-
2. Remove wheel nuts and remove wheel from lift
dures.
truck. Lift truck wheels are heavy.
SOLID RUBBER TIRE, CHANGE
Remove and Install Tire on Wheel
(S SERIES)
NOTE: Make sure the tires are installed on the
NOTE: wheels so that the outside edges of the tire and
wheel are as shown in Figure 104. Also, check the
Solid rubber tires made from softer or harder ma-
Nameplate of the lift truck for the correct tire size
terial can be installed as optional equipment. The
and tread width.
tread on the sold rubber tires can be either smooth
or it can have lugs. Do not mix types of tires or tread 1. The correct tools, equipment, and a press ring
on lift truck. See Figure 104. must be used for each size of wheel. Use a press
to push wheel from rim and tire. The capacity of
WARNING the press must be approximately 355 to 1779 kN
The type of solid rubber tire is shown on the (80,000 to 400,000 lbf). For the tire sizes, see the
Nameplate. Make sure the Nameplate is cor- Nameplate.
rect for the type of tires on the lift truck. The
2. When the drive wheels are installed on the lift
7000 lb. capacity solid rubber tired fork lift
truck, tighten wheel nuts to a torque value of 340
must be equipped with high load capacity
to 380 N•m (251 to 280 lbf ft).
steering tires.
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER 2. WHEEL
TIRE 3. OVERHANG
Figure 104. Tires and Wheels for S2.0-3.5FT (S40-70FT, S55FTS) Lift Trucks
102
8000 SRM 1150 Wheel and Tire Replacement
3. The steering wheels are fastened to the spindle of

the steering axle with a large castle nut. Make WARNING
sure inner and outer bearings are correctly lu- Wheels must be changed and tires repaired by
bricated with grease. Install inner bearing as- trained personnel only.
sembly and wheel on spindle. Install outer bear-
ing cone and castle nut. Tighten castle nut up Deflate tire completely before removing the
to 68 N•m (50 lbf ft) while rotating hub in both wheel from the lift truck. If dual wheels are
directions to properly set bearing. Back off nut used, deflate both tires. Air pressure in the
one quarter turn. Tighten castle nut to 3 N•m tires can cause the tire and rim parts to ex-
(27 lbf in). If the cotter pin cannot be installed, plode, causing serious injury or death.
loosen the castle nut to the first position where Always wear safety glasses.
the cotter pin can be installed. Install cap for
bearings. Never loosen the nuts that hold the inner and
outer wheel halves together when there is air
PNEUMATIC TIRE WITH TUBE, REPAIR pressure in the tire.
Remove Wheels From Lift Truck 1. Put lift truck on blocks as described in How to
Put Lift Truck on Blocks at the beginning of this
WARNING section.
A solid rubber tire that is the same shape as 2. Remove air from tire. Remove valve core to make
a pneumatic tire can be installed on a three- sure all air is out of inner tube. Push a wire
piece or four-piece wheel for a pneumatic tire. through valve stem to make sure valve stem does
DO NOT make changes in the parts of the rim if not have a restriction.
this type of solid rubber tire is installed instead
of a pneumatic tire. Changes to the parts of the 3. Remove wheel nuts and remove wheel and tire
rim can cause a failure of the wheel and cause from lift truck. Lift truck tires and wheels are
an accident. heavy.
WARNING Remove Tire From Wheel

The type of tire and the tire pressure (pneu- NOTE: When you disassemble the wheels, see Fig-
matic tires) are shown on the nameplate. Make ure 105. There are several types of wheels used on
sure the nameplate is correct for the type of this series of lift trucks.
tires on the lift truck.
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 105. Types of Pneumatic Wheels
103
Remove Tire From Two-Piece Wheel
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the 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.
104
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
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 other side of wheel rim. Remove
valve stem from wheel.
STEP 4.
Remove wheel from tire.
105
Install Wheel in Tire 1. Clean and inspect all parts of wheel. Paint any
parts that have rust or corrosion.
WARNING 2. Install new inner tube in tire. Used tubes and
Damage to the tire and wheel assembly and in- flaps can cause tire failure.
jury or death can occur if you do not do the fol-
lowing procedures: 3. Apply a rubber lubricant or a soap solution to the
• Clean and inspect all parts of the wheel be- tire bead and tube.
fore installing the tire.
• DO NOT use any damaged or repaired wheel 4. Install new tire flap.
parts.
5. Make sure rim is the correct size for tire. Lubri-
• Make sure all parts of the wheel are the cor-
cate part of wheel that contacts bead and flap.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or
manufacturers of wheels. CAUTION
• DO NOT mix types of tires, type of tire tread, DO NOT use pneumatic-shaped, solid tires on
or wheel assemblies of different manufactur- two-piece bolt together drive wheels. Spinning
ers on any one lift truck. may occur.
DO NOT use a steel hammer on the wheel. Use 6. Install the three-piece or four piece wheel in the
a rubber, lead, plastic, or brass hammer to put tire a shown in Install Three-Piece or Four-Piece
parts together. Make sure the side ring is in the Wheel in Tire.
correct position. The ends of the side ring must
not touch. The clearance at the ends of the lock 7. Install the two-piece wheel in the tire as shown
ring will be approximately 13 to 25 mm (0.5 to in Install Tire on Two-Piece Wheel.
1.0 in.) after it is installed. If the clearance is
wrong, the wrong part has been used.
Install Three-Piece or Four-Piece Wheel in Tire
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause an injury.
STEP 1.
Install inner tube and rubber flap in tire.
106
STEP 2.
Install wheel rim in tire. 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 the correct position on rim. Add air
pressure to tire as described in Install Wheel in Tire.
Install Tire on Two-Piece Wheel parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
WARNING not touch. The clearance at the ends of the lock
ring will be approximately 13 to 25 mm (0.5 to
Wheels can explode and cause injury or death
1.0 in.) after it is installed. If the clearance is
if the following procedures are not followed:
wrong, the wrong part has been used.
• Clean and inspect all parts of the wheel be-
fore installing the tire.
• DO NOT use any damaged or repaired wheel CAUTION
parts. DO NOT use pneumatic-shaped solid tires on
• Make sure all parts of the wheel are the cor- two-piece bolt together drive wheels. Spinning
rect parts for that wheel assembly. may occur.
• DO NOT mix parts between different types or
manufacturers of wheels. 1. Clean and inspect all parts of wheel. Paint any
• DO NOT mix types of tires, type of tire tread, parts that have rust or corrosion.
or wheel assemblies of different manufactur-
ers on any one lift truck. 2. Install new inner tube in tire. Used tubes and
flaps can cause tire failure.
DO NOT use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
107
4. Install new tire flap.

WARNING
DO NOT lubricate the tire bead with antifreeze 5. Make sure rim is the correct size for tire. Lubri-
or petroleum-based liquid. Vapors from these cate part of wheel that contacts bead and flap.
liquids can cause an explosion during inflation
or use.
3. Apply a rubber lubricant or a soap solution to tire

bead and tube.
Install Two-Piece Wheel in Tire
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 (130 lbf ft). Add air pressure to tire (see
nameplate).
ADD AIR TO PNEUMATIC TIRES WITH 2. Add 20 kPa (3 psi) of air pressure to tire. See
TUBE Figure 106.
3. Check that all wheel parts are correctly installed.

WARNING Hit lock ring lightly to make sure it is in the seat.
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before 4. If installation is correct, add air pressure to tire
use. When air pressure is added, use a chuck to the specified pressure.
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit 5. Check that all wheel parts are correctly installed.
the operator to stand away from the safety cage If installation is not correct, remove all air pres-
when air pressure is added to the tire. sure from tire. Remove valve core to make sure
all air pressure has been removed and then make
DO NOT sit or stand by the safety cage. DO adjustments. The clearance at the ends of the
NOT use a hammer to try and correct the po- lock ring will be approximately 13 to 25 mm (0.5
sition of the side flange or lock ring when the to 1.0 in.) when the tire has the correct air pres-
tire has air pressure greater than 20 kPa (3 psi). sure.
1. Put tire in a safety cage.
108
(332 to 369 lbf ft). If the wheels are the two-piece

rims, make sure nuts that fasten rim halves
together are toward brake drum when they are
installed.
4. Install the valve extension bracket and tighten

the attaching nut to 8 N•m (70 lbf in). Install
the valve extension hose into the bracket. See
Figure 107.
Figure 106. Add Air to Tires
Install the Wheels

Install wheel on the hub. Tighten nuts in a cross
pattern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 155 to 175 N•m
(114 to 129 lbf ft) for steer wheel nuts. If the wheels
are the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
they are installed.
Dual Drive Wheels, Install

NOTE: Some lift trucks have dual drive wheels. The
following procedures describe the steps to install the
dual sets of wheels.
1. Install inner wheel on hub. If the wheels are

the two-piece rims, make sure nuts that fasten
1. TIRE
rim halves together are toward brake drum when 2. DUAL HUB ASSEMBLY
they are installed. 3. WHEEL NUT
4. WHEEL
2. Install wheel adapter spacers on the inner wheel 5. WHEEL ADAPTER SPACER
studs and tighten spacers to 100 to 125 N•m (74 6. VALVE EXTENSION
to 92 lbf ft). Install the dual hub assembly and 7. BRACKET
inner wheel nuts on the spacers and tighten the
Figure 107. Dual Drive Wheels Installation
wheel nuts to 450 to 500 N•m (332 to 369 lbf ft).
See Figure 107.
3. Install outer wheel on dual hub assembly.

Tighten nuts to a torque value of 450 to 500 N•m
109
PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be
Remove Wheels From Lift Truck used with a tube.
The main component of a TBS is a special rubber

WARNING
ring that fits inside the tire between the tire beads
Wheels must be changed and tires repaired by to ensure the air tightness of the existing wheel and
trained personnel only. the tubeless tire assembly. See Figure 105.
Deflate tire completely before removing the 1. Put lift truck on blocks as described in How to Put
wheel from the lift truck. If dual wheels are Lift Truck on Blocks at beginning of this section.
used, deflate both tires. Air pressure in tires
can cause the tire and rim parts to explode 2. Remove the valve cap and core to remove all air
causing serious injury or death. from the tire.
Always wear safety glasses. 3. Remove the wheel nuts and remove the wheel
and tire from the lift truck. Lift truck tires and
Never loosen the nuts that hold the inner and wheels are heavy.
outer wheels halves together when there is air
pressure in the tire.
Remove Tire From Wheel
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 105.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.
110
STEP 2.
Put wheel and tire assembly on the press. Position
the feet of the press on the loose flange. Press down
on loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel only)
from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove
it.
111
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liq-
uids can cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubri-
cate tire beads and the inside of the tire, up to the
tire shoulders. Apply lubricant to the entire under-
side of the TBS.
NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve
slot. The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and remov-
ing the lubricated valve several times. If a three- or
four-piece wheel is being used, remove the valve. If
a two-piece wheel is being used, leave valve in valve
hole.
If the TBS has two-valve holes, lubricate the plastic

plug and insert into valve hole that will not be used.
112
STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in the
TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot
in the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
113
STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.
Push down on the press to depress the tire beads un-

til locking ring groove is fully exposed.
STEP 8.
Insert tire tool into the locking ring groove, and a
vise grip on other end. Remove vise grip. Release
the press and check that all component parts are
correctly positioned. Replace the valve core.
STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to ensure all components are correctly sealed. Remove
the press from wheel and tire assembly.
Add Air to Pneumatic Tubeless Tire
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. 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.
1. Put tire in safety cage. See Figure 108.
2. Add air to tire to the recommended air pressure

that is shown on the Nameplate. Install valve Figure 108. Add Air to Tires
cap to ensure air stays in the tire.
114
Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
Install wheel on hub. Tighten nuts in a cross pat-
tern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 155 to 175 N•m WARNING
(114 to 129 lbf ft) for steer wheel nuts. If wheels Wheels must be changed and tires repaired by
are two-piece rims, make sure nuts that fasten rim trained personnel only.
halves together are toward brake drum when they
are installed. Always wear safety glasses.
1. Put lift truck on blocks as described in How to

Put Lift Truck on Blocks at the beginning of this
section.
2. Remove wheel nuts and remove wheel and tire

from lift truck. Lift truck tires and wheels are
heavy.
Remove Wheel From Tire

NOTE: When you disassemble the wheels, see Figure 105. There are several types of wheels used on these
series of lift trucks.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury. Always wear safety glasses.
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.
115
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.
116
Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 105. 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.
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following
procedures.
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not
touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.
Lubricate 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.
117
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 the cage is holding the tire on the wheel rim,
install lock ring. Use a tire tool to make sure lock
ring is in the correct position.
118
8000 SRM 1150 Adhesives and Sealants
Adhesives and Sealants

Loctite®
Hyster Part No. Description Size
Part No.
360387 222 Small Screw Threadlock (Purple) 50 ml
318702* 242 Removable Threadlock (Blue) 10 ml
226414* 271 High Strength Threadlock (Red) 10 ml
318996 277 High Viscosity Threadlock (Red) 50 ml
318650 290 Low Viscosity Threadlock (Green) 0.02 oz
251099 290 Low Viscosity Threadlock (Green) 50 ml
355844* 422 SuperBonder® Adhesive 3 ml
350830 515 Gasket Eliminator (Purple) 6 ml
313022* 515 Gasket Eliminator (Purple) 50 ml
273338* 567 Pipe Sealant with Teflon® 50 ml
318705 595 Super Flex® Silicone 100 ml
318701* 609 Retaining Compound 10 ml
341959 680 Retaining Compound 50 ml
226415 Primer T - Aerosol 6 oz
251979 767 Antiseize Compound 1 lb
360053-10 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
318700 Adhesive and Sealant Kit (Contains one each of *
items)
*Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700.
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.
119
NOTES
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120
TECHNICAL PUBLICATIONS
8000 SRM 1150 12/10 (11/10)(8/10)(2/10)(8/09)(6/09)(7/08)(10/07)(7/07)(3/07)(10/06)(9/06) Printed in U.S.A.

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PERIODIC

PART NO. 1580525 8000 SRM 1150

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2010 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

S40-70FT, S55FTS [F187];

The surface must be solid, even, and level when

1. Put blocks on each side (front and back) of steer-

2. Put mast in vertical position. Put a block under

3. Tilt mast fully forward until drive tires are raised

4. Put additional blocks under frame behind drive

5. If hydraulic system will not operate, use a hy-

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK CAUTION

2. Disconnect the battery. If an electric truck, re- • Dash/cowl assembly

Figure 3. GM 2.4L Gas Trucks (Prior to Jan. 2011)

Figure 4. GM 2.4L LPG Trucks (Prior to Jan. 2011)

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

10 Hydraulic Tank X C Inspect and See Parts Manual

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 17. Tire Check

When the ELR style seat belt is properly buckled

A seat belt that is damaged worn or does not operate

NOTE: The following seat belt operation checks must

NOTE: NON-SWIVEL SEAT SHOWN.

Figure 19. Hood and Seat Check

Figure 20. Swivel Seat Controls

Legend for Figure 20

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

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

Figure 21. Seat Adjustment

Figure 22. Seat Adjustment

Legend for Figure 22

Ensure the truck engine cools properly by allowing WARNING

Fuel, Oil, and Coolant Leaks, Check

Make a visual check for leaks on and under the lift

There is an indicator light for the engine oil pressure

If the light continues to stay on when engine is run-

1. BATTERY 6. ENGINE OIL

Figure 24. Yanmar 2.6L and 3.3L Diesel Engine

Legend for Figure 25

Figure 25. GM Engine Maintenance Points

Legend for Figure 26

Legend for Figure 27

The identification of a fork describes how the fork is

WARNING Figure 28. Hook Fork Removal