Periodic Maintenance: S4.0FT, 4.5FT, 5.5FT, S5.5FTS (J004) H4.0FT5/FT6 H4.5FTS5, H4.5FT6 H5.0-5.5FT (U005)

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com
PERIODIC
MAINTENANCE
S4.0FT, 4.5FT, 5.5FT, S5.5FTS [J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
[U005]
PART NO. 4128429 8000 SRM 1902

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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
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Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Serial Number Data ............................................................................................................................................1
How to Move Disabled Lift Truck ...................................................................................................................... 2
How to Tow Lift Truck ................................................................................................................................... 2
How to Put Lift Truck on Blocks ........................................................................................................................4
How to Raise Drive Tires ............................................................................................................................... 4
How to Raise Steering Tires ...........................................................................................................................4
How to Clean a Lift Truck .................................................................................................................................. 6
Maintenance Schedule ............................................................................................................................................ 6
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 26
How to Make Checks With Engine Stopped ....................................................................................................26
Tires and Wheels .......................................................................................................................................... 26
Safety Labels .................................................................................................................................................26
Mast, Carriage, Lift Chains, Header Hoses, Attachment .......................................................................... 26
Operator Restraint System .......................................................................................................................... 27
Emergency Locking Retractor (ELR) ...................................................................................................... 27
Adjust Seat - Full Suspension ................................................................................................................. 29
Adjust Seat - Internal Suspension .......................................................................................................... 30
Hood and Seat Latches .................................................................................................................................30
Engine Compartment ................................................................................................................................... 30
Paper Application ......................................................................................................................................... 30
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................... 31
Hydraulic Hoses ............................................................................................................................................31
Coolant Hoses ............................................................................................................................................... 32
Steering Column Gas Cylinder .................................................................................................................... 32
Transmission .................................................................................................................................................32
Hydraulic System Oil ................................................................................................................................... 32
Engine Oil ..................................................................................................................................................... 33
Air Filter ....................................................................................................................................................... 36
Forks ..............................................................................................................................................................36
Remove ......................................................................................................................................................36
Inspect .......................................................................................................................................................37
Install ........................................................................................................................................................38
Adjust ........................................................................................................................................................38
Integral Sideshift Carriage .......................................................................................................................... 38
How to Make Checks With Engine Running ...................................................................................................39
Indicator Lights, Horn, Fuses, and Relays ..................................................................................................39
Service Brakes .............................................................................................................................................. 41
Brake Oil Level .........................................................................................................................................41
Operation, Check ......................................................................................................................................42
Parking Brake ...............................................................................................................................................42
Engine Oil Pressure ......................................................................................................................................42
Cooling System ............................................................................................................................................. 42
Steering System ............................................................................................................................................43
Control Levers and Pedals ........................................................................................................................... 44
Fuel/Water Separator Filter, Kubota Diesel Engine .................................................................................. 44
Lift System, Operate .................................................................................................................................... 44
Air Filter ....................................................................................................................................................... 44
First Service After First 100 Hours of Operation ................................................................................................45
Kubota Diesel Engine Oil and Oil Filter ......................................................................................................... 45
©2016 HYSTER COMPANY i

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Table of Contents
TABLE OF CONTENTS (Continued)

Kubota 3.8L LPG Engine Oil and Oil Filter ....................................................................................................46
Maintenance Procedures Every 500 Hours or 1 Year ......................................................................................... 46
Hydraulic System Oil ........................................................................................................................................46
Hydraulic Tank Breather ................................................................................................................................. 46
Inspect ........................................................................................................................................................... 46
Battery ...............................................................................................................................................................47
Kubota 3.8L Diesel Engine Oil and Oil Filter .................................................................................................47
Kubota 3.8L LPG Engine Oil and Oil Filter ....................................................................................................48
Fuel/Water Separator Filter Replacement, Kubota 3.8L Engine ...................................................................49
Remove .......................................................................................................................................................... 49
Install ............................................................................................................................................................ 49
Priming the Fuel System (Kubota 3.8L Engine) .............................................................................................50
Fuel/Water Separator Filter Replacement, Kubota 3.6L Engine ...................................................................51
Remove .......................................................................................................................................................... 51
Install ............................................................................................................................................................ 51
Priming the Fuel System (Kubota 3.6L Engine) .............................................................................................52
Drain Tar From LPG Converter .......................................................................................................................52
Drive Belt .......................................................................................................................................................... 53
Kubota Diesel Engine ...................................................................................................................................53
Fan and Alternator Drive Belt ................................................................................................................ 53
Kubota LPG Engine ......................................................................................................................................54
Fan and Alternator Drive Belt ................................................................................................................ 54
Clean Debris From Radiator Core ................................................................................................................... 56
Transmission Oil Level .....................................................................................................................................56
Wet Brake Center Body Oil Level Check (Dana Drive Axle) ......................................................................... 57
Wet Brake Oil Level Check (NMHG Drive Axle) ............................................................................................ 58
Forks .................................................................................................................................................................. 59
Mast Lubrication ...............................................................................................................................................59
Header Hose Checks ......................................................................................................................................... 61
Lift Chain Lubrication ......................................................................................................................................61
Tilt Cylinder Lubrication ..................................................................................................................................61
Master Brake Cylinder Rod End Pin Lubrication ...........................................................................................63
Manual Hydraulic Levers Lubrication ............................................................................................................ 64
Brake Oil ........................................................................................................................................................... 64
Tie Rod Lubrication .......................................................................................................................................... 65
Parking Brake Adjustment .............................................................................................................................. 66
Maintenance Procedures Every 1000 Hours or 1 Year ....................................................................................... 66
Valve Clearance, Check and Adjust, Kubota 3.6L Engine ............................................................................. 66
Valve Clearance, Check and Adjust for Kubota 3.8L Diesel Engine ............................................................. 66
Valve Clearance, Check and Adjust for Kubota 3.8L LPG Engine ................................................................ 67
Ignition System ................................................................................................................................................. 67
Standard Spark Plugs, Kubota 3.8L LPG Engine ...................................................................................... 67
LPG Fuel Filter Element Replace, Kubota 3.8L LPG Engine ........................................................................67
Remove .......................................................................................................................................................... 67
Install ............................................................................................................................................................ 68
In-Line Strainer Replacement, Kubota Diesel Engine ................................................................................... 68
Remove .......................................................................................................................................................... 68
Install ............................................................................................................................................................ 68
Lift Chains Wear Check ................................................................................................................................... 70
Lift Chain Lubrication ......................................................................................................................................70
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Table of Contents

Integral Sideshift Carriage, Check Sliding Surfaces ...................................................................................... 70
Steering Axle (Spindle Bearings) ..................................................................................................................... 71
Control Levers and Pedals ................................................................................................................................72
Parking Brake Lever Lubrication, Dana Wet Brake Axle ..............................................................................72
Normal Operating Environment ..................................................................................................................72
Heavy Duty or Contaminated Environment ............................................................................................... 73
Remove ......................................................................................................................................................73
Clean and Inspect .....................................................................................................................................74
Install ........................................................................................................................................................74
Inspect Engine Electrical System, Connectors ................................................................................................75
Crankcase Breather Element, Kubota 3.8L Diesel Engine ............................................................................ 75
Remove .......................................................................................................................................................... 75
Clean and Inspect ......................................................................................................................................... 75
Install ............................................................................................................................................................ 76
Maintenance Procedures Every 2000 Hours or Annually ...................................................................................76
Hydraulic System ..............................................................................................................................................76
Hydraulic Filter, Replace ............................................................................................................................. 76
Hydraulic Tank Breather, Replace ..............................................................................................................77
Cooling System, Kubota Diesel Engines ..........................................................................................................78
Air Filter ............................................................................................................................................................78
Fuel Injector, Kubota 3.8L Engine ...................................................................................................................80
Fuel Injector, Kubota 3.6L Engine ...................................................................................................................80
Long-Life Spark Plugs, Kubota 3.8L LPG Engine .......................................................................................... 80
Remove .......................................................................................................................................................... 80
Install ............................................................................................................................................................ 81
Forks .................................................................................................................................................................. 81
Transmission Oil and Filter, Replace .............................................................................................................. 81
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) .......................... 83
Wet Brake Center Section Oil Change (Dana Drive Axle) ............................................................................. 85
Remove .......................................................................................................................................................... 85
Install ............................................................................................................................................................ 85
Wet Brake Oil Change (NMHG Drive Axle) ....................................................................................................86
Brake Oil (Master Cylinder), Change ..............................................................................................................87
Check Throttle Shaft for Sticking .................................................................................................................... 88
Inspect Exhaust Manifold and Piping for Leaks .............................................................................................88
Wheel Bearings ................................................................................................................................................. 88
Steer Wheels, Lubrication ............................................................................................................................88
Maintenance Procedures Every 4000 Hours or 2 Years ......................................................................................88
Hydraulic Oil, Replace ......................................................................................................................................88
Weld Inspection .................................................................................................................................................90
Safety Procedures When Working Near Mast .....................................................................................................93
Fuel Filter Water Removal ................................................................................................................................... 95
Kubota Diesel Engine ....................................................................................................................................... 95
3.8L Diesel Engine ........................................................................................................................................95
3.6L Diesel Engine ........................................................................................................................................96
Hood Latch Check ................................................................................................................................................. 97
Lift Chain Adjustments ........................................................................................................................................ 98
Jump-Starting the Lift Truck .............................................................................................................................100
Jump-Starting Using a Battery Charger .......................................................................................................100
Jump-Starting a Lift Truck Using Another Lift Truck ................................................................................ 100
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Table of Contents

Welding Repairs .................................................................................................................................................. 100
Overhead Guard Changes ...................................................................................................................................101
Wheel and Tire Replacement ..............................................................................................................................101
General ............................................................................................................................................................ 101
Pneumatic Tire With Tube, Repair ( Series) H.............................................................................................. 101
Remove Wheels From Lift Truck ............................................................................................................... 101
Remove Tire From Wheel ...........................................................................................................................102
Remove Tire From Two-Piece Wheel .................................................................................................... 102
Remove Tire From Three- and Four-Piece Wheels ...............................................................................103
Install Wheel in Tire ...................................................................................................................................104
Install Three-Piece or Four-Piece Wheel in Tire .................................................................................. 105
Install Tire on Two-Piece Wheel ............................................................................................................106
Install Two-Piece Wheel in Tire ............................................................................................................ 107
Add Air to Pneumatic Tires With Tube ......................................................................................................... 108
Install the Wheels .......................................................................................................................................108
Dual Drive Wheels, Install .........................................................................................................................108
Pneumatic Tubeless Tire, Repair ( Series) H................................................................................................. 109
Remove Wheels From Lift Truck ............................................................................................................... 109
Remove Tire From Wheel ...................................................................................................................... 110
Install Tire on Wheel ..............................................................................................................................112
Add Air to Pneumatic Tubeless Tire ..............................................................................................................114
Install the Wheels .......................................................................................................................................115
Solid Rubber Tire on Pneumatic Wheel, Change ( Series) H........................................................................ 115
Remove Tire From Wheel ...........................................................................................................................116
Install Tire on Wheel ..................................................................................................................................118
Solid Rubber Tire, Change ( Series) S............................................................................................................ 120
Remove and Install Tire on Wheel ............................................................................................................ 120
Snap-On-Tire, Change .................................................................................................................................... 121
Remove Snap-On-Tire, Solid Tire From Wheel ........................................................................................ 122
Install Snap-On-Tire, Solid Tire on Wheel ................................................................................................123
Adhesives and Sealants ...................................................................................................................................... 124
This section is for the following models:
S4.0FT, 4.5FT, 5.5FT, S5.5FTS [J004];

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT [U005]
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8000 SRM 1902 General
General
• The lift truck is used more than eight hours
WARNING per day.
DO NOT make repairs or adjustments unless you • The lift truck must work in dirty operating
have both authorization and training. Repairs and conditions.
adjustments that are not correct can make a
dangerous operating condition. • Poor ground conditions.
• Intensive usage at high performance levels
or other abnormal conditions will require
WARNING more frequent servicing.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair Your dealer for Hyster lift trucks has equipment
is necessary, put a DO NOT OPERATE tag in the and trained service personnel to do a complete
operator's area. Remove the key from the key program of inspection, lubrication, and
switch. maintenance. A regular program of inspection,
lubrication, and maintenance will help your lift
truck provide more efficient performance and
CAUTION
operate for a longer period of time.
Disposal of lubricants and fluids must meet local
environmental regulations. Some users have service personnel and equipment
to do inspection, lubrication, and maintenance
This section contains a Maintenance Schedule and shown in Maintenance Schedule. Service Manuals
instructions for maintenance and inspection. are available from your dealer for Hyster lift trucks
to help users who do their own maintenance.
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance of your lift
truck. The service intervals are provided in both
SERIAL NUMBER DATA
operating hours recorded on lift truck hourmeter
The serial number for lift truck is on Nameplate. It
and in calendar time. The recommendation is to
is also on right side of frame, under floor plate.
use interval that comes first.
The recommendations for time intervals provided is

for eight hours of operation per day. The time
intervals must be decreased from recommendations
in Maintenance Schedule for following conditions:
1
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General 8000 SRM 1902
HOW TO MOVE DISABLED LIFT TRUCK weight center of the disabled lift truck on load
center of the forks. Be careful to not damage the
How to Tow Lift Truck underside of the lift truck.
1. The towed lift truck must have an operator.

WARNING
2. Tow truck slowly.
Use extra caution when towing a lift truck if any of
the following conditions exist: 3. Using a lift truck or a lifting device that could
• Brakes do not operate correctly. be attached to mast (I.E. come-a-long), raise
carriage and forks approximately 30 cm (12 in.)
• Steering does not operate correctly.
from surface. Install chain around a mast
• Tires are damaged. crossmember and carriage to prevent carriage
• Traction conditions are bad. and mast channels from moving.
• The lift truck must be towed on a slope. 4. If another lift truck is used to tow disabled lift
truck, that lift truck must have an equal or
If the engine cannot run, there is no power
larger capacity than disabled lift truck. Install
available for the hydraulic steering system and
approximately 1/2 of a capacity load on forks of
the service brakes. This condition can make the
lift truck that is being used to tow disabled lift
lift truck difficult to steer and stop. If the lift truck
truck. This 1/2 capacity load will increase
uses power from the engine to help apply the
traction of lift truck. Keep load as low as
brakes, the application of the brakes will be more
possible.
difficult. Poor traction can cause the disabled lift
truck or towing vehicle to slide. A slope will also 5. If lift trucks are equipped with a leaded
make the lift truck more difficult to stop. counterweight without a tow pin, use a towing
link made of steel that fastens to the two center
Never lift and move a disabled lift truck unless the
grill bars of both lift trucks. See Figure 1.
disabled lift truck MUST be moved and cannot be
Slowly and carefully remove the slack out of the
towed. A lift truck used to move a disabled lift
towing link.
truck MUST have a capacity rating equal to or
greater than the weight of the disabled lift truck. 6. If lift trucks are equipped with a tow pin in
The capacity of the lift truck used to move a counterweight (standard counterweight), use a
disabled lift truck must have a load center equal towing link made of steel that fastens to tow
to half the width of the disabled lift truck. See the pins in counterweights of both lift trucks. See
Nameplate of the disabled lift truck for the Figure 1. Slowly and carefully remove slack out
approximate total weight. The forks must extend of towing link.
the full width of the disabled lift truck. Put the
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A. COUNTERWEIGHT WITHOUT TOW PIN B. COUNTERWEIGHT WITH TOW PIN

(LEADED COUNTERWEIGHT) (STANDARD COUNTERWEIGHT)
1. TOWING LINK 3. TOW PIN
2. CENTER GRILL BARS
Figure 1. Tow Pin
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HOW TO PUT LIFT TRUCK ON BLOCKS 1. Put blocks on each side (front and back) of
steering tires to prevent movement of lift truck.
How to Raise Drive Tires See Figure 2.
2. Put mast in vertical position. Put a block under

WARNING each outer mast channel.
The lift truck must be put on blocks for some
3. Tilt mast fully forward until drive tires are
types of maintenance and repair. The removal of
raised from surface.
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine, 4. Put additional blocks under frame behind drive
transmission, and counterweight. When the lift tires.
truck is put on blocks, put additional blocks in the
following positions to maintain stability: 5. If hydraulic system will not operate, use a
• Before removing the mast and drive axle, hydraulic jack under side of frame near front.
put blocks under the counterweight so the Make sure jack has a capacity equal to at least
lift truck cannot fall backward. half weight of lift truck. See Nameplate.
• Before removing the counterweight, put How to Raise Steering Tires

blocks under the mast assembly so the lift
truck cannot fall forward. NOTE: Some lift trucks are equipped with lifting
eyes for purpose of lifting entire lift truck. If lift
The surface must be solid, even, and level when truck is equipped with this type of lifting eyes, lift
the lift truck is put on blocks. Make sure any truck can be lifted and blocks installed.
blocks used to support the lift truck are solid,
one-piece units. 1. Apply parking brake. Put blocks on both sides
(front and back) of drive tires to prevent
movement of lift truck. See Figure 2.
CAUTION
These lift trucks are equipped with cowl lifting 2. Use hydraulic jack to raise steering tires. Make
eyes. The cowl lifting eyes are to be used to lift sure jack has a capacity of at least 2/3 of total
the front of the lift truck only. Lifting more than weight of lift truck as shown on nameplate.
the front of the lift truck with the cowl lifting eyes
will damage the cowl section. 3. Put jack under steering axle or frame to raise
lift truck. Put blocks under frame to support lift
truck.
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1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
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HOW TO CLEAN A LIFT TRUCK 4. Lightly spray a non-corrosive cleaning agent

onto areas to be cleaned. This will help loosen
grime, so close contact direct spraying will not
WARNING be necessary.
Engine, exhaust system components and other
components are hot to the touch. Be sure lift 5. Be sure to avoid directing spray into electrical
truck components are cool before starting panel compartment. Ensure overspray does not
inspection and cleaning, or personal injury may come in contact with electrical components; do
occur. not spray water directly at electrical
components, wiring connectors or electrical
enclosures. Even sealed connectors may allow
WARNING water egress under pressure or if connector is
Compressed air can move particles so that they damaged.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is 6. Avoid spraying in areas containing electrical
away from all personnel. Wear protective goggles components such as:
or a face shield to prevent injury to the eyes. • Floor Plates
• Battery Compartment
CAUTION • Dash/cowl assembly
Units may be washed with a non-heated pressure • Armrests with electrical components
washer. Steam cleaning is not recommended in
most instances, as condensation may form in 7. Clean battery compartment by using a clean
electrical components causing damage or erratic cloth to wash battery with water. Dry with
behavior. compressed air. Care should be taken to keep
moisture at a minimum as some units have a
NOTE: Lift trucks used in paper applications may traction or hydraulic motor directly below
need cleaning beyond what is described here. battery compartment.
Please refer to Paper Application section in
applicable Operating Manual and to available 8. DO NOT pressure wash battery. Do not use hot
Service Gram/Bulletin for more detail. water. For cleaning traction batteries, refer to
Battery section of Service Manual.
If it becomes necessary to clean fork lift, follow
guidelines listed below. 9. DO NOT pressure wash lift chains, sheaves or
load rollers in mast assembly. Refer to Chains,
1. Assure truck components are cool before Sheaves and Load Rollers maintenance section
starting cleaning procedure. in Service Manual for proper cleaning
procedures.
2. Disconnect battery. If an electric truck, remove
traction battery. 10. After cleaning, immediately start and run lift
truck to dry out components.
3. Remove accumulated debris using a
compressed air line and nozzle.
Maintenance Schedule
NOTE:
The 500-hour and 1000-hour/1 year maintenance services are performed either at the specified hours or at 1
year, whichever occurs first.
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8000 SRM 1902 Maintenance Schedule
Figure 3. Maintenance and Lubrication Points, Kubota 3.6L Diesel Trucks (NMHG Wet Brake Drive Axle
Shown), for Lift Truck Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H50.-5.5FT (U005)
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Maintenance Schedule 8000 SRM 1902
Figure 4. Maintenance and Lubrication Points, Kubota 3.8L Diesel Trucks (NMHG Wet Brake Drive Axle
8
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Figure 5. Maintenance and Lubrication Points, Kubota 3.8L LPG Trucks (NMHG Wet Brake Drive Axle
9
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Table 1. Maintenance Schedule, Lift Truck Model S4.0-5.5FT, S5.5FTS (J004)

Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 4000 hr/ Procedure or Specification
No. 1 day 1 yr 1 yr hr/ 2 yr Quantity
1 yr
29 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as Necessary See Parts Manual
30, Mast, Carriage, X Check Condition and See Parts Manual
33 Header Hoses, Lift Lubrication
Chains, Attachment
Seat Belt, Hip X Check Condition and
Restraints, and Operation
Seat Rails
Hood and Seat X Check Condition and
Latches Operation
Engine X Remove Combustible
Compartment Materials
See NOTE 5.
Paper Application: X Check Condition
Engine Clean as Required
Compartment; Replace as Required
Truck Components; See NOTE 8.
Exhaust Wraps;
Radiator; Radiator
Screen, if equipped;
Belly Pan, if
equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition. See Parts Manual
15 Coolant Hoses X Check Condition. See Parts Manual
19 Fuel Tank CIL 15.1 to 20.4 kg (33.5 LPG - HD 5,
LPG to 45.0 lb) Full HD 10
Horn, Lights, X Check Operation.

Alarms, Fuses,
and Relays
1 Service Brakes X Check Operation.
28 Parking Brake X Check Operation.
Steering Controls X Check Condition and
and Steering Operation.
Column Gas
Cylinder
4 Transmission X Check for Leaks. John Deere JDM J20C
Check Operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
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Table 1. Maintenance Schedule, Lift Truck Model S4.0-5.5FT, S5.5FTS (J004) (Continued)
1 yr
8 Hydraulic Oil X X C Initial Fill ISO VG 46 Hydraulic Oil
Dual 81.5 liter (86.1 qt) -15°C (5°F) and Above
Hydraulic Drain and Refill
Tanks 77.7 liter (82.1 qt)
Dipstick
47.1 liter (49.8 qt)
See NOTE 2,
NOTE 3, and
NOTE 17.
7 Hydraulic Oil Filter C 1 Filter. See Parts Manual
See NOTE 17.
12 Hydraulic Tank X C Inspect and Replace See Parts Manual
Breather as Required
See NOTE 5.
10 Battery and Cable X Clean.
Terminals
11 Engine Oil X C 12.2 liter (12.9 qt) SAE 10W-30
CIL Every See NOTE 4 and API SL
6 mos NOTE 5. ILSAC GF3
MINIMUM
23 Engine Oil Filter C 1 Filter See Parts Manual
Every See NOTE 4 and
6 mos NOTE 5.
22 Air Filter (with CIL C 1 Filter See Parts Manual
premium See NOTE 5,
monitoring) NOTE 6, and
NOTE 12.
22 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
Engine Oil Pressure CIL Check Oil Pressure Kubota Engine
50 kPa (7 psi) Minimum
18 Drive Belt X Check for Wear and
Damage.
No Adjustment
Needed.
See NOTE 5.
20 LPG Converter X See NOTE 5.
Engine Idle Speed X See NOTE 5. 800 ±25 rpm
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1 yr
Engine Governed X See NOTE 5. 2400 ±25 rpm
Speed
9 Valve Adjustment X Adjust as Required. 0.18 to 0.22 mm
(0.0071 to 0.086 in.)
Cold Exhaust 0.18 to
0.22 mm (0.0071 to
0.086 in.)
Intake
21 Fuel Filter, LPG C 1 Filter See Parts Manual
24 Spark Plugs, C 4 Plugs See Parts Manual
Standard See NOTE 9.
24 Spark Plugs, Long- C 4 Plugs See Parts Manual
life See NOTE 9
16, Cooling System X C 11 liter (11.6 qt) See NOTE 14.
17 CIL
Clean Debris From X See NOTE 5.
Radiator Core
26, 6 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
31 Forks X X X Check Condition
31 Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
Lift System, X Check Operation
Operate
32 Mast L Lubricate as Required Multipurpose Grease
Sliding See NOTE 10 and See NOTE 7.
Surfaces NOTE 11.
and Load
Roller
Surfaces
32 Header Hoses X Check Condition
33 Lift Chains X Check Condition/ SAE 30W
Lube if Necessary. Engine Oil
See NOTE 11
33 Lift Chains L L, X Check for Wear SAE 30W
Lube as Required Engine Oil
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
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1 yr
Mast X L X Lube as Required Multipurpose Grease
Integral Side 8 Fittings See NOTE 7.
Shift 4 Bearing Strips 2.0 mm (0.08 in.)
Carriage Check Bearings For Minimum Thickness.
Sliding Wear.
Surfaces
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 7.
Brake Master L SAE 10W-30
Cylinder Rod API SM
End Pin ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
27 Brake Oil CIL X C 0.35 liter (0.74 pt) Dexron® III from Sealed
Master Container
Cylinder
14 Steering Axle L 4 Fittings Multipurpose Grease
Spindle See NOTE 7.
Bearings
Tie Rods See NOTE 7.
13 Wheel Bearings L Check Grease. Multipurpose Grease

Steer See NOTE 7.
Wheels
3 Pedals, Levers, Seat L Lubricate as Use Silicone Spray
Rails, Cables, Necessary Hyster Part No. 328388
Hinges, Linkages,
Hood Latch
28 Parking Brake X Adjust as Necessary. Must Hold a Full
Adjustment Capacity Load on a 15%
Grade.
28 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Hyster Part Number
328388)
5 Transmission Oil X C 20.0 liter (21.0 qt) John Deere
S4.0FT, S4.5FT, JDM J20C
S5.5FT, S5.5FTS
(J004)
13
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1 yr
2 NMHG Drive Axle X C 9.4 liter (9.9 qt) John Deere
Planetary Carrier JDM J20C
Housing Oil
S4.0FT, S4.5FT,
S5.5FT, S5.5FTS
(J004)
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel
Lines, and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure Lock-
Off Closing
Check X
Air Induction
System for Leaks
Check X
Manifold for
Vacuum Leaks
Check X
Throttle Shaft for
Sticking
25 Inspect X
Exhaust Manifolds
and Piping for
Leaks
Inspect X
Catalyst Inlet
and Outlet
Inspect Muffler X Replace as Required
Inlet and Outlet
Mast and Carriage X Inspect - See Dye Penetrant Test:
with Paper Roll Specification Inspect after an impact
Clamp likely to cause damage.
Also, in large diameter
paper-roll production
applications, inspect at
first 4000 hours with
subsequent inspection at
2000-hour intervals. At
your request your Yale
dealer will advise you of
the appropriate service
intervals base on an
application survey.
14
HeavyManuals.com
1 yr
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.
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
involving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your 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: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: 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. Used compressed air and
steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000SRM1903.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate if dry or at first sign of visible surface rust.
NOTE 12: 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 13: Valve lash adjustments must be performed at 1000-hour/1-year intervals, whichever comes first.
NOTE 14: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled water or deionized water.
NOTE 15: Change every 1500 hours. Use hourly interval only.
NOTE 16: Fluid service quantity will be 1.0 liter (1.0 qt) less than fluid capacity listed.
NOTE 17: Hydraulic oil sampling and analysis is a recommended practice. See for oil cleanliness and water content
guidelines. For lift trucks operating in heavy duty applications or highly contaminated environments, take oil samples
every 500 hours. Normal Operating conditions may allow for less frequent oil sampling. Oil sampling should be done just
prior to all oil and filter changes.
15
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Table 2. Maintenance Schedule, Lift Truck Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (U005)
1 yr
25 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as Necessary See Parts Manual
27, Mast, Carriage, X Check Condition and See Parts Manual
28, 29 Header Hoses, Lift Lubrication
Chains, Attachment
Seat Belt, Hip X Check Condition and
Restraints, and Seat Operation
Rails
Hood and Seat X Check Condition and
Latches Operation
Engine X Remove Combustible
Compartment Materials
See NOTE 5.
Paper Application: X Check Condition
Engine Clean as Required
Compartment; Truck Replace as Required
Components; See NOTE 8.
Exhaust Wraps;
Radiator; Radiator
Screen, if equipped;
Belly Pan, if
equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition. See Parts Manual
13 Coolant Hoses X Check Condition. See Parts Manual
16 Fuel Tank CIL 15.1 to 20.4 kg (33.5 LPG - HD 5,
LPG to 45.0 lb) Full HD 10
16 Fuel Tank (Short CIL 79 liter (20.8 gal) See Table 3.

Wheel Base)
Kubota 3.6L
Diesel Engine
16 Fuel Tank (Long CIL 100.3 liter (26.5 gal) See Table 3.
Wheel Base)
Kubota 3.6L
Diesel Engine
16
HeavyManuals.com
Table 2. Maintenance Schedule, Lift Truck Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(U005) (Continued)
1 yr
16 Fuel Tank (Short CIL 79 liter (20.8 gal) See Table 3.
Wheel Base)
Kubota 3.8L
Diesel Engine
16 Fuel Tank (Long CIL 100.3 liter (26.5 gal) See Table 3.
Wheel Base)
Kubota 3.8L
Diesel Engine
Horn, Lights, X Check Operation.
Alarms, Fuses,
and Relays
1 Service Brakes X Check Operation.
23 Parking Brake X Check Operation.
Steering Controls X Check Condition and
and Steering Operation.
Column Gas
Cylinder
22 Transmission X Check for Leaks. John Deere JDM
Check Operation. J20C
22 Transmission X Perform Automatic See Calibration
Clutch Calibration. Procedures
8000SRM1134 for
Calibration
Procedures
3 Hydraulic Oil (Short X C 62.0 liter (65.5 qt) ISO VG 46
Wheel Base) See NOTE 2, NOTE 3 Hydraulic Oil
and NOTE 20. -15°C (5°F) and
Above
3 Hydraulic Oil (Long X C 78 liter (82.4 qt) ISO VG 46
Wheel Base) See NOTE 2, Hydraulic Oil
NOTE 3, and -15°C (5°F) and
NOTE 20. Above
6 Hydraulic Oil Filter C 1 Filter. See See Parts Manual.
NOTE 20.
10 Hydraulic Tank X C Inspect and Replace as See Parts Manual.
Breather Required
See NOTE 5.
17
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(U005) (Continued)
1 yr
8 Battery and Cable X Clean.
Terminals
9 Engine Oil X C 13.2 liter (13. qt) See Table 3.
Kubota 3.8L CIL See NOTE 4, and
Diesel Engine NOTE 5.
19 Engine Oil Filter C 1 Filter See Parts Manual.

Kubota 3.8L See NOTE 4 and
9 Engine Oil X C 13.2 liter (13. qt) See Table 3.

Kubota 3.6L CIL See NOTE 4 and

9 Engine Oil X C 12.2 liter (12.9 qt) SAE 10W-30

Kubota 3.8L CIL See NOTE 4 and API SL
LPG Engine NOTE 5. ILSAC GF-3
MINIMUM
LPG Engine NOTE 5.
18 Air Filter (with CIL C 1 Filter See Parts Manual

premium See NOTE 5,
monitoring) NOTE 6, and
NOTE 12.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
Engine Oil Pressure CIL Check Oil Pressure Kubota 3.8L Engine
50 kPa (7 psi)
Minimum
15 Drive Belt X Check for Wear and
Kubota Damage.
Engine Adjustment As
Needed.
See NOTE 5.
18
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(U005) (Continued)
1 yr
33 LPG Converter X Drain Tar
Kubota 3.8L See NOTE 5.
LPG Engine
Engine Idle Speed X Coolant Temperature 800 ±25 rpm
(Hot Greater than
Engine) 15°C (59°F)
Kubota 3.8L
Diesel Engine
Engine Governed X 2200 ±25 rpm
Speed (No Load)
Kubota 3.8L
Diesel Engine
Engine Idle Speed X Coolant Temperature 850 ±25 rpm
(Hot Greater than
Engine) 15°C (59°F)
Kubota 3.6L
Diesel Engine
Engine Governed X 2400 ±25 rpm
Speed (No Load)
Kubota 3.6L
Diesel Engine
Engine Idle Speed X TBD
(Hot
Engine)
Kubota 3.8L
LPG Engine
Engine Governed X TBD
Speed (No Load)
Kubota 3.8L
LPG Engine
39 Crankcase Breather C See NOTE 17.
Element
Kubota 3.8L
Diesel Engine
19
HeavyManuals.com
(U005) (Continued)
1 yr
4 Valve Adjustment X Adjust as Required. 0.23 to 0.27 mm
Kubota (0.009 to 0.011 in.)
Engines Cold Exhaust 0.23 to
0.27 mm (0.009 to
0.011 in.)
Intake
17 Fuel Filter, LPG C 1 Filter See Parts Manual
Kubota
Engine
17 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain Water from
Kubota 3.8L Filter as Required
Diesel
Engines
17 Fuel Water X C 1 Filter See Parts Manual
Separator Filter Drain Water from
Kubota 3.6L Filter as Required
Diesel
Engines
36 In-Line Fuel C 1 Filter See Parts Manual
Strainer
Kubota
Diesel Engine
20 Fuel Injectors X Check and Replace if
Kubota Required
Diesel Engine 4 Injectors
5 Spark Plugs, C Change Spark Plugs See Parts Manual

Standard 4 Plugs See NOTE 9
Kubota 3.8L
LPG Engine
5 Spark Plugs, Long- C Change Spark Plugs See Parts Manual
life 4 Plugs See NOTE 9
Kubota 3.8L
LPG Engine
20
HeavyManuals.com
(U005) (Continued)
1 yr
12, 14 Cooling System X C 11.0 liter (11.6 qt) See NOTE 15.
Kubota CIL
Diesel Engine
12, 14 Cooling System X C 11.0 liter (11.6 qt)
Kubota LPG CIL
Engine
Clean Debris From X See NOTE 5.
Radiator Core
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check Condition
26 Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
Lift System, Operate X Check Operation
27 Mast L Lubricate as Required Multipurpose Grease
Sliding See NOTE 10 and See NOTE 7.
Surfaces NOTE 11.
and Load
Roller
Surfaces
27 Header Hoses X Check Condition
28 Lift Chains X Check Condition/ Lube SAE 30W
if Necessary. Engine Oil
See NOTE 11.
28 Lift Chains L L, X Check for Wear SAE 30W
Lube as Required Engine Oil
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
21
HeavyManuals.com
(U005) (Continued)
1 yr
Mast X L X Lube as Required Multipurpose Grease
Integral Side 8 Fittings See NOTE 7.
Shift 4 Bearing Strips 2.0 mm (0.08 in.)
Carriage Check Bearings For Minimum Thickness.
Sliding Wear.
Surfaces
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 7.
Brake Master L SAE 10W-30
Cylinder Rod API SM
End Pin ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
24 Brake Oil CIL X C 0.35 liter (0.74 pt) Dexron® III from
Master Sealed Container
Cylinder
Spindle See NOTE 7.
Bearings
Tie Rods See NOTE 7.
34 Wheel Bearings L Check Grease. Multipurpose Grease

Steer Wheels See NOTE 7.
2 Pedals, Levers, Seat L Lubricate as Use Silicone Spray

Rails, Cables, Necessary Hyster Part No.
Hinges, Linkages, 328388
Hood Latch
23 Parking Brake X X Adjust as Necessary. Must Hold a Full
Adjustment Capacity Load on a
15% Grade.
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Hyster Part Number
328388)
30 Transmission And X C Change Oil John Deere
Planetary Carrier 31.3 liter (32.9 qt) JDM J20C
Housing Oil
Dana Drive
Axle
22
HeavyManuals.com
(U005) (Continued)
1 yr
38 Center Section Oil X C Change Oil SAE 80W-90
Dana Drive 2.0 liter (2.1 qt)
Axle
37 Parking Brake X Check and Lubricate Normal Operating
Levers (Dana Wet as Necessary Environment: Spray
Brake Axle) Lubricant Heavy
Duty or
Contaminated
Environment:
Multipurpose Grease
See NOTE 7.
7 Transmission Oil X C 20.0 liter (21.0 qt) John Deere JDM
NMHG Drive J20C
Axle
30 Wet Brake Axle X C 10.3 liter (10.9 qt) John Deere
Drive Axle Oil JDM J20C
NMHG Drive See NOTE 19.
Axle
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel Lines,
and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure Lock-Off
Closing
Check X
Air Induction
System for Leaks
Check X
Manifold for Vacuum
Leaks
Check X
Throttle Shaft for
Sticking
Check X
Injectors and Rails
for leaks
32 Inspect X
Exhaust Manifolds
and Piping for Leaks
23
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(U005) (Continued)
1 yr
Inspect X
Catalyst Inlet
and Outlet
Inspect Muffler Inlet X Replace as Required
and Outlet
Mast and Carriage X Replace as Required. Dye Penetrant Test:
with Paper Roll Inspect after an
Clamp impact likely to
cause damage. Also,
in large diameter
paper-roll production
applications, inspect
at first 4000 hours
with subsequent
inspection at 2000-
hour intervals. At
your request your
Hyster dealer will
advise you of the
appropriate service
intervals based on an
application survey.
35 Diesel Particulate X Service See NOTE 18.
Filter
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.
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
involving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your 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: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: 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. Used compressed air and
steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000SRM1903.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate if dry or at first sign of visible surface rust.
NOTE 12: 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.
24
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(U005) (Continued)
1 yr
NOTE 13: Initial valve lash adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at 2000-
hour/2-year intervals, whichever comes first.
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.
NOTE 16: In large diameter paper-roll production applications, inspect at first 4000 hours with subsequent inspection at
2000-hour intervals. At your request your dealer will advise you of the appropriate service intervals based on an
application survey.
NOTE 17: Change every 1500 hours. Use hourly interval only.
NOTE 18: Service Diesel Particulate Filter (DPF) every 3000 hours. See dealer. Use hour interval only.
NOTE 19: Quantity shown for factory or rebuild. Service will be one liter less, 9.3 liter (9.8 qt).
NOTE 20: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures
1900SRM1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or
highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less
frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
Table 3. Diesel Fuel and Engine Oil
Engine Oil Specification by Diesel Fuel Type

Engine Diesel Fuel Type Engine Oil Viscosity based
WWFC Diesel WWFC Diesel WWFC Diesel Category 4 on ambient temperature
Category 1 Category 2 ASTM D975 NO.2 D S15
500ppm <Sul- 15ppm<Sul- Sulfur<15ppm
fur<5000ppm fur<500ppm
3.6L T3 API CF API CF or bet- API CF or better -15°C (5°F) and above
ter 15W-40 -25°C (-13°F) and
3.8L W/DPF NA API CJ-4 above 10W30 Below
-25°C (-13°F) 5W-30
25
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Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1902
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE not normal. Clean any oil or fuel spills. Ensure all
STOPPED surfaces are free of oils, lubricants, fuel, and or-
ganic dust or fibers (paper, wood, cotton, agricul-
tural grass/grain, etc.).
WARNING
DO NOT operate a lift truck that needs repairs. Re- Tires and Wheels
port the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the op- Check tires for damage. See Figure 6. Check tread
erator's area. If the lift truck is equipped with a and remove any objects that will cause damage.
key switch, remove the key from the key switch. Check for bent or damaged rims. Check for loose or
missing hardware. Remove any wire, strapping, or
Put lift truck on a level surface. Lower carriage and other material that is wrapped around axle.
forks, stop engine, and apply parking brake. Open
hood and check for leaks and conditions that are
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE
Figure 6. Tire Check
Safety Labels Mast, Carriage, Lift Chains, Header Hoses,

Attachment
WARNING
Safety labels are installed on the lift truck to give WARNING
information about operation and possible haz- Lower the lift mechanism completely. Never allow
ards. It is important that all safety labels are in- any person under a raised carriage. DO NOT put
stalled on the lift truck and can be read. any part of your body in or through the lift mecha-
nism unless all parts of the mast are completely
Check that all safety labels are installed in correct lowered and the engine is STOPPED. DO NOT try
location on lift truck. See Parts Manual, Model to correct the alignment of the fork tips by bend-
Description section in Operating Manual or ing the forks or adding shims. Never repair dam-
Frame 0100SRM1891 for correct location of safety aged forks by heating or welding. Forks are made
labels. See Parts Manual for part numbers of of special steel using special procedures. If either
safety labels. fork is damaged, replace the forks as a set.
26
HeavyManuals.com
8000 SRM 1902 Maintenance Procedures Every 8 Hours or Daily
DO NOT operate fork lift without lateral fork stops

in place. Forks may disengage from fork carriage.
1. Inspect welds on mast and carriage for cracks.

Make sure that capscrews and nuts are tight.
2. Inspect carriage to be sure fork stops are in

place. Fork stops prevent forks from laterally
disengaging from carriage.
3. Inspect channels for wear in areas where roll-

ers travel. Inspect the rollers for wear or dam-
age.
4. Inspect load backrest extension for cracks and

damage.
5. If lift truck is equipped with an integral side-

shift carriage or attachment, inspect parts for
cracks and wear. Make sure parts that fasten
integral sideshift carriage or attachment to car- 1. WORN PIN 5. LOOSE LEAVES
riage are in good condition. 2. CRACKS 6. TURNED PIN
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
6. Visually inspect hoses/fittings for hydraulic
leaks; hose cover for cuts, cracks or exposed re- Figure 7. Lift Chain Check
inforcement; defective/broken clamping devices
or sheaves; proper tracking during operation.
Adjust/repair/replace hose/components as nec-
essary. See Mast Repairs, 2- and 3-Stage
Operator Restraint System
Masts (S/N A513, A514, A613, A614, A702,
The seat belt, hip restraint, seat, hood, and hood
A703, A704, A705, A706, A707, A751, A752,
latch are all part of operator restraint system. See
B513, B514, B586, B587, B588, B589, B590,
Figure 8. Each item must be checked to make sure
B591, B749, B750, B751, B752, B753, B754)
it is fastened correctly, functions correctly, and is in
4000SRM1250 for quick disconnect procedures.
good condition.
7. Check that lift chains are correctly lubricated.
Use SAE 30W engine oil as necessary to lubri- Emergency Locking Retractor (ELR)
cate lift chains.
NOTE: Lift trucks produced after November 2005
8. Inspect lift chains for cracks or broken links, are equipped with Emergency Locking Retractor
and worn or turned pins. See Figure 7. (ELR) style seat belt.
9. Inspect chain anchors and pins for cracks and When ELR style seat belt is properly buckled
damage. across operator, the belt will permit slight operator
repositioning without activating locking mecha-
10. Make sure lift chains are adjusted so that they
nism. If truck tips, travels off a dock, or comes to a
have equal tension. Adjustments or replace-
sudden stop, locking mechanism will be activated
ment of lift chains must be done by au-
and hold operator's lower torso in seat.
thorized personnel.
27
HeavyManuals.com
A seat belt that is damaged, worn, or does not oper- • With hood closed and in locked position, pull
ate properly will not give protection when it is nee- seat belt with a sudden jerk. Make sure the
ded. The end of belt must fasten correctly in latch. seat belt will not pull from retractor assem-
The seat belt must be in good condition. Replace bly. If seat belt can be pulled from retractor,
seat belt if damage or wear is seen. See Figure 8. when it is pulled with a sudden jerk, replace
seat belt assembly.
NOTE: The following seat belt operation checks • With hood in open position, make sure seat
must be performed three times before replacing belt will not pull from retractor assembly. If
seat belt assembly. seat belt can be pulled from retractor, with
hood in open position, replace seat belt as-
• With hood closed and in locked position, pull sembly.
seat belt slowly from retractor assembly.
Make sure seat belt pulls out and retracts
smoothly. If seat belt cannot be pulled from
retractor assembly or belt will not retract, re-
place seat belt assembly.
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 8. Hood and Seat Check
28
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Adjust Seat - Full Suspension NOTE: It is important to adjust weight setting for
each operator.
Seat Position Adjustment (Swivel Seat)
NOTE: The seat is designed for maximum weight
• The seat swivels 12 degrees to the right to al- of 135 kg (298 lb).
low operator a more ergonomic position when
driving in reverse. • The target is for "ride indicator" to fall be-
• The seat swivels 5 degrees to the left to allow tween arrows when operator sits upright in
an easier exit of truck. seat with feet positioned on pedals. This en-
• The neutral position is shown in Figure 9. sures that operator is set at midpoint of
80 mm (3.15 in.) suspension.
Seat Adjustment for Operator Weight. • The handle can be turned as shown to in-
crease or decrease weight resistance, pull
handle out before turning. As handle is
CAUTION turned "stiffness" of suspension can be felt to
A major cause for high Whole Body Vibration is increase or decrease on which way handle is
caused by the operator not adjusting the seat to turned.
his/her weight.
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 9. Seat Adjustment
29
HeavyManuals.com
Adjust Seat - Internal Suspension Engine Compartment
Seat Position Adjustment (Swivel Seat) Check for presence of any combustible material
• The seat swivels 10.5 degrees to the right to such as paper, leaves, etc. Remove any combustible
allow operator a more ergonomic position materials.
when driving in reverse.
Paper Application
• The seat swivels 5 degrees to the left to allow
an easier exit of truck.
Vehicles used in paper applications require regular
• The neutral position is shown in Figure 9. inspection and cleaning to minimize risk of fire.
This should be done at least once every 8 hours or
Seat Adjustment for Operator Weight. more frequently depending upon operating environ-
ment. The paper application option will help limit
contact of paper or tissue scraps to hot surfaces un-
CAUTION der hood, but frequent maintenance is required.
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight. WARNING
Engine and exhaust system components are hot
NOTE: It is important to adjust weight setting for to touch. Be sure lift truck components are cool
each operator. before starting inspection and cleaning or per-
sonal injury may occur.
NOTE: The seat is designed for maximum weight
of 135 kg (298 lb).
Ensure truck engine cools properly by allowing it to
idle for several minutes. Shutting truck down while
• The target is for "ride indicator" to fall be-
hot will not allow engine to cool quickly due to loss
tween arrows when operator sits upright in
of coolant circulation. The heat trapped under hood
seat with feet positioned on pedals. This en-
may actually increase engine temperature because
sures that operator is set at midpoint of
of no heat transfer through radiator. With engine
40 mm (1.57 in.) suspension.
off and lift truck components cooled, check and
• The weight adjustment knob can be turned clean radiator and if equipped, radiator screen.
left or right to increase or decrease weight Check engine manifold, exhaust pipes, muffler and
resistance. As weight adjustment knob is catalytic converter for paper scraps. Clean as re-
turned "stiffness" of suspension can be felt to quired. Check and clean engine compartment com-
increase or decrease on which way weight ponents, transmission, fan shroud, belly pan if
adjustment knob is turned. equipped, and inside frame ledges to avoid paper,
dust and oil accumulation. Check axle and cowl
Hood and Seat Latches openings for paper buildup and bailing wire. Re-
move any debris.
Make sure seat rails and latch striker are not loose.
The seat rails must lock tightly in position, but
move freely when unlocked. See Figure 8. The seat
rails must be correctly fastened to hood and hood
fastened to hinges on frame. Try to lift hood to
make sure it is fastened correctly and will not
move. If adjustment is required, go to Hood Latch
Check.
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Check condition of exhaust wraps for wear, proper

WARNING fit, contamination with oil or antifreeze, gaps in
Compressed air can move particles so that they coverage, failed fasteners and replace as necessary.
cause injury to the user or to other personnel. DO NOT reuse wraps if they have been removed for
Make sure that the path of the compressed air is some other service operation.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. Fuel, Oil, and Coolant Leaks, Check
CAUTION WARNING
Air pressure, nozzle or extension tube may cause All fuels are very flammable and can burn or
damage to exhaust wraps and radiator fins. As- cause an explosion. DO NOT use an open flame to
sure that air pressure, nozzle or extension tube check the fuel level or to check for leaks in the
does not damage exhaust wraps or radiator fins. fuel system. If there is a leak in the fuel system,
extra care must be used during the repair. DO
Paper removal can generally be accomplished using NOT operate the lift truck until a leak is repaired.
a compressed air line and nozzle. An extension may
be helpful to access hard to reach places. Remove Make a visual check for leaks on and under lift
floor plates and side covers for better access to en- truck. If possible, find and report leak to mainte-
gine compartment. Open or removed belly pan, if nance for repair. Leaks often indicate a need for re-
equipped. Clean components with compressed air. pair of damaged or worn components. Leaks in LPG
Take care to maintain integrity of exhaust wraps fuel system are usually not visible unless ice is
when cleaning with compressed air and use caution present. There is however, usually a strong odor.
to not force debris into openings. Check condition of Fuel leaks MUST be repaired IMMEDIATELY.
exhaust wraps for wear, proper fit, contamination
with oil or antifreeze, gaps in coverage, failed fas- Check fuel system for leaks and condition of parts.
teners and replace as necessary. DO NOT reuse When fuel is added to lift truck, see section HOW
wraps if they have been removed for some other TO ADD FUEL TO THE LIFT TRUCK in Oper-
service operation. ating Manual.
Also check condition of radiator or heater hoses

WARNING that are not leaking. Soft or cracked hoses need to
Be careful when cleaning with steam. Steam can be replaced before a major leak occurs.
cause serious burns. Wear protective clothing,
gloves, and eye protection. Never expose your Hydraulic Hoses
skin to steam.
Check condition of hydraulic hoses for serviceabil-
If compressed air did not adequately remove debris, ity by inspecting for cracks or other obvious dam-
steam clean to remove any persistent accumulation age. Check to insure that hydraulic hoses are not
of material or oil. Protect electrical components leaking. If any hose is leaking, report it to mainte-
from moisture when steam cleaning. DO NOT nance for repair.
spray exhaust wraps directly with high pressure
steam. Allow lift truck to air dry before returning to
work in a contaminated environment. Paper dust
and scraps will adhere to wet surfaces.
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Coolant Hoses Transmission
Check condition of coolant hoses for serviceability Check transmission for leaks and damaged or loose
by inspecting for cracks or other obvious damage. components. Heavy-duty or high temperature oper-
Check to insure that coolant hoses are not leaking. ations can require more frequent checks.
If any hose is leaking, report it to maintenance for
repair. Hydraulic System Oil
Steering Column Gas Cylinder

WARNING
Make sure gas cylinder for steering column oper- At operating temperature, the hydraulic oil is HOT.
ates correctly. The cylinder must NOT allow col- DO NOT permit the hot oil to touch the skin and
umn to move unless tilt lever is released. See Fig- cause a burn.
ure 10.
CAUTION
DO NOT permit dirt to enter the hydraulic system
when the oil level is checked or the filter is
changed.
Never operate the hydraulic pump without oil in

the hydraulic system. The operation of the hy-
draulic pump without oil will damage the pump.
After engine has stopped, wait one minute before

checking oil level. Keep hydraulic oil at correct
level as indicated on dipstick. Use correct oil as
shown in Maintenance Schedule.
Check hydraulic system for leaks and damaged or

loose components. Heavy-duty or high-temperature
operations can require more frequent checks.
1. TILT LEVER 2. GAS CYLINDER
Figure 10. Steering Column Gas Cylinder and Tilt
Lever
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Engine Oil
WARNING
At operating temperature, the engine oil is HOT.
DO NOT permit the hot oil to touch the skin and
cause a burn.
CAUTION
DO NOT permit dirt to enter the engine when the
oil level is checked or the filter is changed.
Never operate the engine without oil. The opera-

tion of the engine without oil will damage the en-
gine.
After engine has stopped, wait one minute before

checking oil level. Keep oil at correct level as indi-
cated on dipstick. Use correct oil as shown in Main-
tenance Schedule.
1. BATTERY AND CABLES
See Figure 11 for lift trucks equipped with Kubota 2. AUXILIARY COOLANT RESERVOIR
3.8L LPG engines. 3. DIPSTICK
4. RADIATOR CAP
5. DRIVE BELT
See Figure 12 for lift trucks equipped with Kubota 6. ENGINE OIL FILL
3.8L diesel engines. 7. LPG CONVERTER
8. AIR FILTER
See Figure 13 for lift trucks equipped with Kubota 9. ENGINE OIL FILTER
10. SPARK PLUGS
3.6L diesel engines.
Figure 11. Kubota 3.8L LPG Engine Maintenance
Points
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A. TOP VIEW B. LEFT HAND SIDE SHOWN

1. BATTERY 7. FUEL INJECTION PUMP
2. AUXILIARY COOLANT RESERVOIR 8. ENGINE OIL FILL CAP
3. RADIATOR CAP 9. IN-LINE FUEL STRAINER
4. WATER SEPARATOR 10. DIPSTICK ENGINE OIL
5. AIR FILTER 11. FUEL INJECTOR
6. FUEL FILTER 12. DRIVE BELT
Figure 12. Kubota 3.8L Diesel Engine Maintenance Points
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A. TOP VIEW B. LEFT HAND SIDE SHOWN

1. BATTERY 7. ENGINE OIL FILL CAP
2. AUXILIARY COOLANT RESERVOIR 8. IN-LINE FUEL STRAINER
3. RADIATOR CAP 9. DIPSTICK ENGINE OIL
4. WATER SEPARATOR 10. FUEL INJECTOR
5. AIR FILTER 11. DRIVE BELT
6. FUEL INJECTION PUMP
Figure 13. Kubota 3.6L Diesel Engine Maintenance Points
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Air Filter 1. A fork can be removed from carriage for re-

placement of fork or other maintenance. Lift
The air filter canister should not be opened until an lock pin and slide a hook fork to fork removal
air filter element replacement is required. An air notch on carriage. See Figure 14 and Figure 15.
filter element replacement is required when one of Lower fork onto blocks so that bottom hook of
the following occurs: fork moves through fork removal notch. See
Figure 15. Lower carriage further so that top
• The optional air flow restriction indicator
hook of fork is disengaged from top carriage
light on dash illuminates
bar. Move carriage away from fork, or use a lift-
• If equipped, manual air flow indicator is red ing device to move fork away from carriage.
• The specified number of hours has passed
since the last filter element replacement
DO NOT operate lift truck until air filter element

has been replaced.
Forks
NOTE: Forks must be removed or installed by
trained personnel only.
The identification of a fork describes how fork is

connected to carriage. These lift trucks have hook
forks.
Remove
WARNING
DO NOT try to move a fork without a lifting device.
Each hook fork for these lift trucks can weigh 45 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
to 115 kg (99 to 253 lb).
Figure 14. Hook Fork Removal
NOTE: Forks are to be replaced only in sets and
not individually.
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Inspect
1. Inspect forks for cracks and wear. Check that
fork tips are aligned as shown in Figure 15.
Check that bottom of fork is not worn. See Fig-
ure 15, item 4.
2. Replace any damaged or broken parts that are

used to keep forks locked in position.
Fork Tip Alignment

Length of Forks 3% Dimension
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
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 15. Forks Check
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Install Integral Sideshift Carriage
Move fork and carriage so that top hook on fork can Check for cracks, wear and damage. If damaged,
engage upper carriage bar. Raise carriage to move see for repair procedures. If necessary, lubricate
lower hook through fork removal notch. Slide fork sliding surfaces at grease fittings with multipur-
on carriage so that both upper and lower hooks en- pose grease shown in Maintenance Schedule. See
gage carriage. Engage lock pin with a notch in up- Figure 17.
per carriage bar.
Adjust
NOTE: During adjustment of forks, heel of forks
should not be touching ground.
The forks are connected to carriage by hooks and

lock pins. See Figure 14 and Figure 16. The lock
pins are installed through top fork hooks and fit
into slots in top carriage bar. If pin does not remain
engaged in carriage slot, replace with new pin. Ad-
just forks as far apart as possible for maximum
support of load. Hook forks will slide along carriage
bars to adjust for load to be lifted. Raise lock pin in
each fork to slide fork on carriage bar. Make sure
lock pin is engaged in carriage bar to lock fork in 1. CAPSCREWS
position after width adjustment is made. 2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
8. SNAP RING
9. ROD SCRAPER
10. ROD BUSHINGS
11. SEAL
12. FIXED FRAME
Figure 17. Integral Sideshift Carriage
1. FORK
2. LOCK PIN
3. SPRING
4. WASHER
5. WEDGE
6. KNOB
7. LOCK PIN ASSEMBLY
Figure 16. Fork Lock Pin Assembly
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HOW TO MAKE CHECKS WITH ENGINE Indicator Lights, Horn, Fuses, and Relays
RUNNING
If lift truck is equipped with a key switch, turn key
to ON position. If lift truck is equipped with a
WARNING Power ON/OFF button, press button to turn sys-
DO NOT operate a lift truck that needs repairs. Re- tem power on. All warning light and indicator
port the need for repair immediately. If repair is lights will light up for two seconds (start check)
necessary, put a DO NOT OPERATE tag in the op- when system power is turned ON. See Figure 18.
erator's area. If lift truck is equipped with a key Check all indicator lights for correct operation as
switch, remove the key. described in Operating Manual. Check operation
of horn. Start engine by turning key switch to
Start position, if truck is equipped with a key
WARNING switch, or press engine start button, if lift truck is
FASTEN YOUR SEAT BELT! The seat belt is in- equipped with this button. If any indicator lights do
stalled to help the operator stay on the truck if the not operate correctly, check fuses. The fuses are lo-
lift truck tips over. IT CAN ONLY HELP IF IT IS cated in Power Distribution Module (PDM) which is
FASTENED. under hood next to the battery on right side. See
Figure 19.
Make sure that area around lift truck is clear be-
fore starting engine or making any checks of opera-
tion. Be careful when making checks. If lift truck is
stationary during a check, apply parking brake and
put transmission in NEUTRAL. Make checks care-
fully.
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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
14 Indicator Light, 1st Gear Locking ( Transmissions)
15 Indicator Light, Water Separator (Kubota 3.8L Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 18. Warning and Indicator Lights
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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) 20. SEMICONDUCTOR TRANSZORB
Figure 19. PDM Showing Fuses and Relays
Service Brakes Loss of oil from the brake oil reservoir indicates a
leak. Repair the brake system before using the lift
Brake Oil Level truck. Replace the brake oil in the system if there
is dirt or water in the system.
WARNING DO NOT use "DOT" fluid, only use Dexron III oil
Small amounts of water in the brake system can from sealed container to prevent possible damage
cause reduced braking performance if the water to the brake system. Failure to observe the above
reaches the brake cylinder areas. DO NOT allow Warning could result in death or serious injury.
water entry. Ensure that the sealed reservoir lid is
properly replaced. There is an indicator light on Display Switch Clus-
ter for brake oil. The red light is ON when key
The brake system has a boosted master cylinder, switch is in START position or Power ON/OFF
braking will be more difficult if the engine is not button is pressed, and must go OFF when engine is
running. running. If light is on when engine is running,
brake oil in reservoir is too low.
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Operation, Check Engine Oil Pressure
Check operation of service brakes. Push on inching/ NOTE: The engine will enter shutdown mode after
brake pedal. The service brakes must be applied be- a warning buzzer sounds and a 30 second count-
fore inching/brake pedal reaches floor plate. The down, if engine oil pressure is less than
pedal must stop firmly and must not move slowly 34.5 kPa (5 psi) on lift trucks with a GM 4.3L en-
down after brakes are applied. The service brakes gine and powertrain protection system. Lift trucks
must apply equally to both drive wheels. The serv- equipped with a Kubota diesel engine and power-
ice brakes must not pull lift truck to either side of train protection system will enter shutdown mode
direction of travel when they are applied. The serv- when engine oil pressure is less than 50 kPa (7 psi).
ice brakes are automatically adjusted when trans- See Engine Shutdown procedures in Operating
mission is in reverse and lift truck is moving and Manual.
brakes are firmly applied. Full application of in-
ching/brake pedal applies service brakes and puts There is an indicator light for engine oil pressure
transmission in NEUTRAL. on Display Switch Cluster. During normal opera-
tion, red indicator light will illuminate when key
Lift trucks with a MONOTROL ® pedal. When switch is turned to ON, if truck is equipped with a
inching/brake pedal is fully applied, a switch in key switch, or when power ON/OFF button is
starting circuit is closed so that engine can be star- pressed, if truck is equipped with a keyless option,
ted. and will stay illuminated until correct oil pressure
is obtained, at which time light will go off.
Parking Brake
If light continues to stay on when engine is run-
ning, engine oil pressure is low. Stop engine and
There is an indicator icon on display panel for park-
check oil level. DO NOT restart engine until low
ing brake. This icon is illuminated as describe in
pressure condition has been corrected.
Operating Manual. There is a sensor in seat that
actuates an audible alarm. If operator leaves seat,
See Figure 11 for lift trucks equipped with Kubota
with system power OFF, without applying parking
3.8L LPG engines.
brake, the alarm will sound for 10 seconds until
parking brake is applied or operator sits back on
seat. If system power is ON or engine is running,
and operator leaves seat, without applying parking
brake, the alarm will sound continuously until
parking brake is applied or operator sits back on
seat.
Make sure service brakes operate correctly before Cooling System

checking operation of parking brake. Check opera-
tion of parking brake. The parking brake, when in WARNING
good condition and correctly adjusted, will hold a DO NOT remove the radiator cap from the radiator
lift truck with a full capacity load on a 15% grade [a when the engine is hot. When the radiator cap is
slope that increases 1.5 meters in 10 meters (1.5 removed, the pressure is released from the sys-
feet increase in 10 feet)]. If parking brake requires tem. If the system is hot, the steam and boiling
adjustment, notify service personnel. coolant can cause burns.
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NOTE: Lift trucks equipped with a Kubota diesel

engine will enter shutdown mode when coolant
temperature reaches 114°C (238°F) or above on lift
trucks with powertrain protection system. See En-
gine Shutdown procedures in Operating Man-
ual.
There is an indicator light on the Display Switch

Cluster for coolant temperature. The red light is on
when key switch is in START position or Power
ON/OFF button is pressed, and must go off when
engine is running. If light is on when engine is run-
ning, coolant and engine are too hot. Stop engine
and check coolant level in coolant recovery reser-
voir.
Make sure coolant level is between ADD and

FULL marks on auxiliary coolant reservoir. See
Figure 20. The coolant will expand as it is heated
and level in auxiliary coolant reservoir will in-
crease.
1. FILL CAP 3. FULL COLD MARK
2. FULL HOT MARK 4. ADD COLD MARK
CAUTION Figure 20. Auxiliary Coolant Reservoir
Additives may damage the cooling system. Before
using additives, contact your local dealer.
Steering System
If coolant is added, see Maintenance Schedule for
correct solution.
WARNING
The lift truck has hydraulic power steering. The
WARNING steering can be difficult if the engine is not run-
Compressed air can move particles so that they ning.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is Make sure steering system operates smoothly and
away from all personnel. Wear protective goggles provides good steering control. Make sure steering
or a face shield to prevent injury to the eyes. column can be adjusted and gas cylinder function is
correct.
Check radiator fins. Clean radiator with com-
pressed air or water as needed. Check for and re-
move any debris on radiator core. If indicator light
turns on again after restarting, shut down lift truck
and do not operate lift truck until problem is cor-
rected.
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Control Levers and Pedals Perform following checks and inspections:
Check that control levers for transmission, mast, 1. Check for leaks in hydraulic system. Check con-
and attachment operate as described in Operating dition of hydraulic hoses and tubes.
Manual. Check that pedals operate correctly as de-
scribed in Operating Manual. NOTE: Some parts of mast move at different
speeds during raising and lowering.
Fuel/Water Separator Filter, Kubota Diesel 2. Slowly raise and lower mast several times with-
Engine out a load. Raise mast to its full height at least
once. The mast components must raise and
On Kubota 3.8L diesel engine, this amber light (see lower smoothly in correct sequence. Hose must
Figure 18) will illuminate if sensor on fuel/water track properly during operation.
separator filter indicates that water must be
drained from filter. See Figure 12. 3. The inner weldments and carriage must lower
completely.
Check Kubota 3.6L fuel/water separator filter daily
for water accumulation. See Figure 13. 4. Raise mast 1 m (3 ft) with a capacity load. The
inner weldments and carriage must raise
See section Fuel Filter Water Removal for proce- smoothly. Lower mast. All moving components
dures to drain water and change filter. must lower smoothly.
5. Lower load to approximately 0.3 m (1 ft). Tilt

Lift System, Operate mast forward and backward. The mast must
tilt smoothly and both tilt cylinders must stop
WARNING evenly.
When working on or near the mast, see Safety 6. Check that controls for attachment operate
Procedures When Working Near Mast at the end functions of attachment. See symbols by each of
of this section. controls. Make sure all of hydraulic lines are
Lower the lift mechanism completely. Never allow connected correctly and do not leak.
any person under a raised carriage. DO NOT put
any part of your body in or through the lift mecha- Air Filter
nism unless all parts of the mast are completely
lowered and the engine is STOPPED. There is an indicator light on the Display Switch
Cluster (see Figure 21) for the air filter. The amber
If the mast cannot be lowered, use chains on the light is ON when the key switch is in the START
mast weldments and carriage so that they cannot position or the Power ON/OFF button is pressed,
move. Make sure the moving parts are attached to and must go OFF when the engine is running. If
a part that does not move. the light is ON when the engine is running, there is
a restriction in the air filter. Turn engine off and
DO NOT try to find hydraulic leaks by putting remove restriction from air filter. See Figure 21.
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by the
pressure.
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Legend for Figure 21
1. AIR FILTER COVER

2. RESTRICTION INDICATOR PORT
3. AIR OUTLET
4. DUST DISCHARGE VALVE
5. AIR INLET
6. COVER LATCHES
Figure 21. Air Filter
First Service After First 100 Hours of Operation

KUBOTA DIESEL ENGINE OIL AND OIL
FILTER
Change engine oil and oil filter. See Figure 22. 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.
NOTE: KUBOTA 3.8L DIESEL SHOWN, 3.6L SIMI-

LAR.
1. OIL FILTER 2. DRAIN PLUG
Figure 22. Engine Oil Filter Change, Kubota Diesel
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First Service After First 100 Hours of Operation 8000 SRM 1902
KUBOTA 3.8L LPG ENGINE OIL AND OIL

FILTER
Change engine oil and oil filter. See Figure 23 . 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.
1. OIL FILTER 3. ENGINE OIL DIP-

2. DRAIN PLUG STICK
Figure 23. Engine Oil Filter Change, Kubota 3.8L

LPG
Maintenance Procedures Every 500 Hours or 1 Year

NOTE: Perform Maintenance Procedures Every 8
Hours or Daily prior to performing procedures in CAUTION
this section. Additives may damage the hydraulic system. Be-
fore using additives, contact your local dealer.
HYDRAULIC SYSTEM OIL
Check hydraulic oil level when oil is at operating
temperature with mast in a vertical position, car-
WARNING
riage lowered, and engine stopped. See Figure 35.
At operating temperature, the hydraulic oil is HOT. Add hydraulic oil only as needed. If hydraulic oil is
DO NOT permit the hot oil to touch the skin and above FULL level, hydraulic oil will leak from
cause a burn. breather during operation. The oil level indicated
by dipstick is most accurate when oil temperature
CAUTION is 53 to 93°C (130 to 200°F).
when the oil level is checked or the filter is HYDRAULIC TANK BREATHER
changed.
Inspect
the hydraulic system. The operation of the hy- NOTE: When inspecting breather, do not remove it.
draulic pump without oil will damage the pump. The breather element is a non serviceable part. If it
is damaged, replace with a new breather element.
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8000 SRM 1902 Maintenance Procedures Every 500 Hours or 1 Year
1. Raise hood and remove right rear side panel. BATTERY

See Figure 24.
WARNING
WARNING The acid in the electrolyte can cause injury. If the
Compressed air can move particles so that they electrolyte is spilled, use water to flush the area.
cause injury to the user or to other personnel. Use a solution of sodium bicarbonate (soda) to
Make sure that the path of the compressed air is make the acid neutral. Acid in the eyes must be
away from all personnel. Wear protective goggles flushed with water immediately. Wear eye protec-
or a face shield to prevent injury to the eyes. tion.
CAUTION WARNING
Direct air pressure on the filter element can cause Batteries generate explosive fumes. Keep the
damage. Direct air pressure away from filter ele- vents in the caps clean. Keep sparks or open
ment. flame away from the battery area. DO NOT make
sparks from the battery connections. Disconnect
2. Using compressed air, remove any dirt and deb- the battery ground cable when doing mainte-
ris in frame cavity around breather. See Fig- nance.
ure 24.
3. If necessary, unscrew and replace breather if oil Disconnect negative and positive terminals of bat-
has accumulated in cavity or on breather, or if tery. Using a damp cloth clean case of battery. If
dirt has accumulated at breather passages at terminals are corroded, clean terminals with a wire
bottom of breather brush. Connect negative and positive cables to their
respective terminals.
4. Install right rear side panel and close hood. See
Figure 24. KUBOTA 3.8L DIESEL ENGINE OIL AND
OIL FILTER
NOTE: Change oil and oil filter for engine at first
100 hours of operation on new lift trucks.
Change engine oil and engine oil filter. See Fig-

ure 25. Use correct oil according to Maintenance
Schedule. Apply clean oil to gasket of new filter. In-
stall new filter. Turn filter until gasket touches,
then tighten 1/2 to 3/4 turn with your hand. Start
engine. Check area around oil filter for leaks.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 24. Hydraulic Tank Breather
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Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1902
Change engine oil and engine oil filter. See Fig-

ure 26. Use correct oil according to Maintenance
Schedule. Apply clean oil to gasket of new filter. In-
stall new filter. Turn filter until gasket touches,
then tighten 1/2 to 3/4 turn with your hand. Start
engine. Check area around oil filter for leaks.
NOTE: KUBOTA 3.8L DIESEL ENGINE SHOWN,

3.6L SIMILAR.
1. OIL FILTER 2. DRAIN PLUG

1. OIL FILTER
Figure 25. Engine Oil Change Kubota Diesel 2. DRAIN PLUG
3. ENGINE OIL DIPSTICK
KUBOTA 3.8L LPG ENGINE OIL AND OIL Figure 26. Engine Oil Change Kubota LPG
FILTER
NOTE: Change oil and oil filter for engine at first
100 hours of operation on new lift trucks.
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FUEL/WATER SEPARATOR FILTER 7. Drain water until fuel is visible in container.

REPLACEMENT, KUBOTA 3.8L ENGINE 8. Tighten drain valve.
9. Remove and discard fuel filter element.

CAUTION
Disposal of lubricants and fluids must meet local Install
environmental regulations.
1. Clean fuel filter head mounting surface and ap-
Replace fuel filter at specified intervals to prevent ply a small amount of diesel fuel to gasket on
contaminants from adversely affecting diesel fuel new fuel filter element. See Figure 27.
flow.
2. Before installing filter element, fill filter ele-
Remove ment with diesel fuel. This method will aid in
bleeding fuel system.
1. Stop engine and allow it to cool.
2. Disconnect fuel filter sensor connector from fuel CAUTION

filter element. DO NOT overtighten the filter element. Overtight-
ening the filter element may distort the threads.
3. Close fuel supply valve. See Figure 27.
3. Install new fuel filter element until it contacts
4. Connect a hose, suitable for use with diesel fuel filter head mounting surface. Tighten one
fuel, to drain valve and place open end of hose additional turn.
into a container with a capacity of 7.57 to
11.36 liter (2 to 3 gal) 4. Tighten outlet plug. See Figure 28.
5. Loosen outlet plug. See Figure 28. 5. Connect fuel sensor connector to fuel filter ele-
ment.
CAUTION 6. Open fuel supply valve.
Drain the water/fuel into a container and dispose
in accordance with local environmental regula- 7. Prime fuel system. See Priming the Fuel Sys-
tions. tem (Kubota 3.8L Engine).
6. Open drain valve by turning valve counter- 8. Check for fuel leaks.
clockwise approximately 3 1/2 turns until
draining occurs.
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A. RIGHT SIDE VIEW B. FRONT VIEW

1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. FUEL INJECTION PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. COMMON FUEL RAIL 9. FUEL INJECTOR
5. IN-LINE FUEL STRAINER
Figure 27. Kubota 3.8L Engine Fuel System
PRIMING THE FUEL SYSTEM (KUBOTA 4. Tighten outlet plug at top of fuel filter element.
3.8L ENGINE) See Figure 28.
5. Lift truck should now be ready to start.

After fuel filter has been replaced, it is necessary to
prime fuel system before lift truck can be operated.
CAUTION
1. Loosen outlet plug located on top of fuel filter Disposal of lubricants and fluids must meet local
element. See Figure 28. environmental regulations.
2. Rotate ignition key to ON position and allow 6. Wipe up any fuel that may have spilled and dis-
electric fuel pump to cycle. pose of fuel and rags in accordance with local
directives.
3. The electric fuel pump will run approximately 6
to 10 seconds. This process will need to be re-
peated for 60 to 90 seconds (6 to 12 cycles) or
until fuel has been expelled from outlet plug.
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2. Connect a hose, suitable for use with diesel

fuel, to drain valve and place open end of hose
11.36 liter (2 to 3 gal)
3. Loosen vent plug. See Figure 29.
CAUTION
Drain the water/fuel into a container and dispose
in accordance with local environmental regula-
tions.
4. Open drain valve by turning valve counter-

clockwise approximately 3 1/2 turns until
draining occurs. See Figure 29.
5. Drain water until fuel is visible in container.
6. Tighten vent plug and drain valve.
7. Remove and discard fuel filter element.
1. FUEL FILTER ELEMENT Install

2. DRAIN VALVE
3. OUTLET PLUG 1. Clean fuel filter head mounting surface and ap-
4. ELECTRIC FUEL PUMP ply a small amount of diesel fuel to gasket on
new fuel filter element. See Figure 29.
Figure 28. Electric Fuel Pump and Outlet Plug
2. Before installing filter element, fill filter ele-
ment with diesel fuel. This method will aid in
FUEL/WATER SEPARATOR FILTER bleeding fuel system.
REPLACEMENT, KUBOTA 3.6L ENGINE
CAUTION
CAUTION DO NOT overtighten the filter element. Overtight-
ening the filter element may distort the threads.
environmental regulations. 3. Install new fuel filter element until it contacts
fuel filter head mounting surface. Tighten one
Replace fuel filter at specified intervals to prevent additional turn.
contaminants from adversely affecting diesel fuel
flow. 4. Tighten vent plug. See Figure 29.
Remove 5. Prime fuel system. See Priming the Fuel Sys-

tem (Kubota 3.6L Engine).
6. Check for fuel leaks.
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3. Continue pumping until fuel is present at

bleeder valve.
4. Close bleeder valve.
5. Turn key to ON position and start lift truck

normally.
CAUTION
6. Wipe up any fuel that may have spilled and dis-

pose of fuel and rags in accordance with local
directives.
For more details about Priming Procedure, see Ku-

bota Diesel 3.6L Engine 0600SRM1579.
DRAIN TAR FROM LPG CONVERTER

1. Move lift truck to a well ventilated area, and
1. FUEL FILTER ELEMENT ensure no external ignition sources are present.
2. DRAIN VALVE
3. FUEL INJECTION PUMP 2. Start engine.
4. MECHANICAL FUEL PUMP
5. INLINE FUEL STRAINER 3. Close valve on LPG tank.
6. FUEL SENDING UNIT
7. FUEL INJECTOR
8. VENT PLUG 4. When engine runs out of fuel, turn key or key-
less switch to OFF position, and disconnect
Figure 29. Kubota 3.6L Engine Fuel System negative terminal on battery.
PRIMING THE FUEL SYSTEM (KUBOTA CAUTION

A small amount of fuel may remain in the fuel line.
3.6L ENGINE) To prevent the possibility of burns wear gloves
and eye protection. If fuel continues to flow check
After fuel filter has been replaced, it is necessary to
to make sure the LPG tank valve is completely
prime fuel system before lift truck can be operated.
closed.
1. Open bleeder valve located on fuel injection 5. Disconnect inlet line and outlet hose from LPG
pump. converter. See Figure 30.
2. Pump fuel into fuel system using hand primer
pump on fuel filter.
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8. Using mounting bolts and washers, install LPG

converter on mounting bracket.
9. Connect inlet line and outlet hose to LPG con-

verter. If disconnected, connect two cooling ho-
ses.
10. Connect negative terminal on battery.
11. Open valve on LPG tank and check for leaks on

LPG converter using soapy water or a leak de-
tector. If any leaks are found, tighten fittings or
replace hose clamps as applicable.
12. Start engine and recheck for leaks at converter.
DRIVE BELT
Kubota Diesel Engine

1. LPG CONVERTER 4. MOUNTING BOLTS
2. INLET LINE 5. WASHER
3. OUTLET HOSE 6. COOLANT HOSE Fan and Alternator Drive Belt
Figure 30. LPG Converter Removal Check drive belt for wear and damage. See Fig-
ure 31. A few small cracks that run across belt are
acceptable. A belt with cracks that run length of
6. Remove mounting bolts, washers and LPG con- belt or a belt with missing pieces is not acceptable.
verter from mounting bracket. See Figure 32 for drive belt arrangement.
CAUTION
Engine components may be hot. Use gloves when
handling the LPG Converter to prevent the possi-
bility of burns.
CAUTION
Drain the tar into a suitable container and dispose
in accordance with local environmental regula-
tions
7. Rotate LPG converter sightly so that outlet

opening is pointing toward container and allow
tar to drain from LPG converter. If LPG con- Figure 31. Drive Belt Inspection
verter cannot be rotated a sufficient amount to
drain tar, disconnect two cooling hoses.
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Kubota LPG Engine
Fan and Alternator Drive Belt
Check drive belt for wear and damage. See Fig-

ure 33. A few small cracks that run across belt are
acceptable. A belt with cracks that run length of
belt or a belt with missing pieces is not acceptable.
See Figure 34 for drive belt arrangement.
Figure 33. Drive Belt Inspection

NOTE: KUBOTA 3.8L DIESEL ENGINE SHOWN,
3.6L SIMILAR.
1. ALTERNATOR PULLEY
2. CRANKSHAFT PULLEY
3. IDLER PULLEY
4. WATER PUMP PULLEY
5. COOLING FAN PULLEY
Figure 32. Kubota Diesel Engine Drive Belt
Arrangement
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A. LIFT TRUCKS NOT EQUIPPED WITH HYDRAULIC FAN UNIT

B. LIFT TRUCKS EQUIPPED WITH HYDRAULIC FAN UNIT
1. ALTERNATOR PULLEY 4. WATER PUMP PULLEY
2. CRANKSHAFT PULLEY 5. COOLING FAN PULLEY
3. IDLER PULLEY
Figure 34. Kubota Diesel Engine Drive Belt Arrangement
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CLEAN DEBRIS FROM RADIATOR CORE

CAUTION
Check radiator core for restrictions and remove ma- DO NOT permit dirt to enter the transmission
terial causing radiator core to be plugged or restric- when the oil level is checked or the filter is
ted. changed.
NOTE: Transmission oil temperature should be at

WARNING least 50°C (120°F) when checking oil level.
Compressed air can move particles so that they
cause injury to the user or to other personnel. If engine has been running, engine must be shut
Make sure that the path of the compressed air is down for one minute or longer prior to checking oil
away from all personnel. Wear protective goggles level (see Figure 35). If transmission oil is low, add
or a face shield to prevent injury to the eyes. oil to transmission at dipstick tube at correct level
as indicated on dipstick. Use correct oil as shown in
Clean with compressed air, adjusted to a maximum Maintenance Schedule.
output of 103 kPa (15 psi), and blow debris from
core and fan shroud.
TRANSMISSION OIL LEVEL
WARNING
At operating temperature, the transmission oil is
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn.
1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 35. Transmission and Hydraulic Oil Check
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WET BRAKE CENTER BODY OIL LEVEL

CHECK (DANA DRIVE AXLE)
WARNING
At operating temperature, the center section oil is
and cause a burn.
CAUTION
DO NOT permit dirt to enter the center body when
the oil level is checked. Dirt will contaminate the
oil and cause damage to the center body of the
axle.
1. Remove center body fill/level plug. See Fig-

ure 36.
2. Visually check oil level. If necessary, add oil at

fill/level port until oil/fill level port has over-
flowed. The correct oil is shown in Maintenance
Schedule.
3. Install center body oil/level fill level plug and

tighten to 30 to 50 N•m (22 to 37 lbf ft).
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
Figure 36. Wet Brake Drive Axle Drain and Fill/

Level Plug Location for Dana Drive Axles
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WET BRAKE OIL LEVEL CHECK (NMHG 1. Remove fill/level plug. See Figure 37.
DRIVE AXLE) 2. Visually check oil level. If necessary, add oil at
fill/level port until oil level is 10 mm (0.39 in.)
WARNING from bottom of fill/level port. The correct oil is
At operating temperature, the center section oil is shown in Maintenance Schedule.
HOT. DO NOT permit the hot oil to touch the skin 3. Install fill/level plug and tighten to 50 to
and cause a burn. 55 N•m (37 to 41 lbf ft).
CAUTION
DO NOT permit dirt to enter the center body when
the oil level is checked. Dirt will contaminate the
oil and cause damage to the center body of the
axle.
A. TOP VIEW SHOWN B. BOTTOM VIEW SHOWN

1. SERVICE BRAKE PORT 4. FILL/LEVEL PLUG
2. FILL PLUG 5. BRAKE BLEEDER VALVE
3. OIL BREATHER 6. DRAIN PLUG
Figure 37. Wet Brake Drive Axle Drain and Fill/Level Plug Location for NMHG Drive Axles
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FORKS NOTE: When lubricating mast mounting/pivot

pins, load must be removed from normal contact
surface to allow grease to properly lubricate normal
WARNING contact surfaces of mast bushings.
Never repair damaged forks. DO NOT heat, weld,
or bend the forks. Forks are made of special steel 2. Raise carriage about 61 cm (2 ft), and tilt mast
using special methods. Replace damaged forks as fully back. Place blocks under outer mast chan-
a complete set. nels to within 13 mm (0.5 in.) of channels. See
Figure 39.
Measure thickness of forks with a fork arm caliper
3. Tilt mast fully forward. See Figure 39.
(Hyster P/N 3020387) at a vertical section where
there is no wear. This thickness is dimension X.
Now measure thickness at heel of fork (see Fig-
ure 15). If thickness of heel is not greater than 90%
of dimension X, replace fork.
MAST LUBRICATION
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this sec-
tion.
NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller surfa-

ces along full length of channels as shown in
Figure 38.
A. MAST TILTED FULLY BACK

A. UPPER LOAD ROLLERS B. MAST TILTED FORWARD
B. LOWER LOAD ROLLERS
1. BLOCK
1. LUBRICATE STRIP BEARING SURFACES 2. MAST
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER Figure 39. Blocking the Mast
Figure 38. Mast Lubrication
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4. Lubricate mast pivot bushings at grease fit- 6. If a sideshift carriage is installed, lubricate
tings on outer mast. See Figure 40. Use multi- sliding surfaces at grease fittings with multi-
purpose grease shown in Maintenance Sched- purpose grease shown in Maintenance Sched-
ule. ule. See Figure 41.
1. CAPSCREWS
2. LOWER HOOK
3. APRON
1. OUTER MAST 4. LOWER BEARING STRIPS
2. MAST PIVOT BUSHING 5. UPPER BEARING STRIPS
3. LUBRICATION FITTING 6. GREASE FITTINGS
4. PIVOT PIN 7. CYLINDER ROD
8. SNAP RING
Figure 40. Pivot Pin Lubrication 9. ROD SCRAPER
10. ROD BUSHING
11. SEAL
5. Tilt mast fully back. Remove blocks from under 12. FIXED FRAME
channels. Figure 41. Integral Sideshift Carriage
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HEADER HOSE CHECKS NOTE: The 500 Hour/1 year Lift Chain Lubrication
should not be performed in combination with 1000
Daily inspection plus; kinked, crushed flattened or Hour/1 year Lift Chain Lubrication.
twisted hose; hard, stiff or charred hose; hose fit-
ting slippage; proper hose tensioning. Adjust/ Lubricate lift chains with SAE 30W engine oil. The
repair/replace hose/components as necessary. See best procedure is to remove chains from lift truck
Mast Repairs, 2- and 3-Stage Masts (S/N A513, and soak them in engine oil. Be sure to clean any
A514, A613, A614, A702, A703, A704, A705, dirt or grease from chains before lubricating. DO
A706, A707, A751, A752, B513, B514, B586, NOT USE STEAM TO CLEAN THE LIFT
B587, B588, B589, B590, B591, B749, B750, CHAINS.
B751, B752, B753, B754) 4000SRM1250.
TILT CYLINDER LUBRICATION
LIFT CHAIN LUBRICATION
NOTE: The floor plate must be removed in order to
lubricate rear tilt cylinder lubrication fittings.
WARNING
When working on or near the mast, see Safety Lubricate tilt cylinder ends. Use multipurpose
Procedures When Working Near Mast in this sec- grease shown in Maintenance Schedule. There are
tion. four lubrication fittings. See Figure 42.
DO NOT repair worn or damaged lift chains. If a

lift chain is worn or damaged, both lift chains
must be replaced.
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NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.
1. CAPSCREW 4. LUBRICATION FITTING

2. RETAINER 5. TILT SPACER
3. ANCHOR PIN
Figure 42. Tilt Cylinder Lubrication
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MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION
Lubricate master brake cylinder rod end pin. Use

engine oil shown in Maintenance Schedule. See
Figure 43.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 43. Master Brake Cylinder Rod End Pin

Lubrication
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MANUAL HYDRAULIC LEVERS Replace the brake oil in the system if there is dirt
LUBRICATION or water in the system.
Lubricate bushings for manual hydraulic levers. CAUTION

Use spray lubricant as listed in Maintenance
DO NOT use "DOT" fluid, only use Dexron III oil
Schedule. See Figure 44.
from sealed container to prevent possible damage
to the brake system.
Remove dash board from the cowl. The brake oil

reservoir is located on cowl, at master cylinder. See
Figure 45. Add brake oil, as necessary. Use brake
oil shown in Maintenance Schedule.
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 44. Manual Hydraulic Levers Lubrication 1. RESERVOIR CAP

2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
4. COWL
BRAKE OIL 5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING
7. LOWER BRAKE OIL SUPPLY HOSE
WARNING 8. NIPPLE
Small amounts of water in the brake system can 9. MASTER CYLINDER
cause reduced braking performance if the water 10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
reaches the wheel cylinder areas. DO NOT allow 12. CYLINDRICAL BLOCK MOUNTING BRACKET
water entry. Ensure that the sealed reservoir lid is CAPSCREW
properly replaced.
Figure 45. Brake Oil Reservoir
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TIE ROD LUBRICATION
Lubricate tie rods. Use multipurpose grease shown

in Maintenance Schedule. There is one lubrication
fittings on each tie rod. See Figure 46 or Figure 47.
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE BEARINGS)
Figure 47. Tie Rod Lubrication, Lift Truck Model

S4.0-5.5FT, S5.5FTS (J004)
1. LUBRICATION FITTING (TIE ROD)

2. LUBRICATION FITTING (SPINDLE)
3. STEERING AXLE
Figure 46. Tie Rod Lubrication, Lift Truck Model
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(U005)
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PARKING BRAKE ADJUSTMENT
Make sure service brakes are adjusted and opera-

tion of automatic adjuster mechanism is correct be-
fore parking brake is adjusted.
Lift trucks with a pedal. The switch energizes

seat warning circuit when hand lever is released.
This switch puts transmission in NEUTRAL by de-
energizing direction solenoid. There is also a switch
on left-hand side of bracket. This switch prevents
engine from starting unless parking brake is ap-
plied.
NOTE: Make sure parking brake is released before

making adjustment.
1. Turn adjustment knob to raise equalized link

and tighten parking brake cables shown in Fig-
ure 48. DO NOT tighten adjustment so that
brake is applied when lever is released. The
lever for parking brake has a lock. Use your
thumb or finger to release lock on lever when
parking brake is released.
1. LOCK BUTTON RELEASE
2. For burnished brakes, test operation of parking 2. OFF POSITION
brake. The lift truck with a capacity load must 3. ON POSITION
not move when parking brake is applied on a 15 4. ADJUSTMENT KNOB
percent grade [a slope that increases 1.5 m in
10 m (1.5 ft in 10 ft)]. Figure 48. Parking Brake
Maintenance Procedures Every 1000 Hours or 1 Year

NOTE: Perform Maintenance Procedures Every 8 VALVE CLEARANCE, CHECK AND
Hours or Daily and Maintenance Procedures Every ADJUST FOR KUBOTA 3.8L DIESEL
500 Hours or 1 Year checks prior to performing pro-
cedures in this section.
ENGINE
VALVE CLEARANCE, CHECK AND The Kubota 3.8L engine requires valve clearance
adjustments during normal service. See Mainte-
ADJUST, KUBOTA 3.6L ENGINE nance Schedule for valve clearances.
The Kubota 3.6L engine requires valve clearance
For valve clearance procedure see section:
adjustments during normal service. See Mainte-
nance Schedule for valve clearances. • Kubota Diesel 3.8L Engines
0600SRM1557
For valve clearance procedure see section:
• Kubota Diesel 3.6L Engine 0600SRM1579
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VALVE CLEARANCE, CHECK AND 2. Disconnect negative battery cable.

ADJUST FOR KUBOTA 3.8L LPG ENGINE
WARNING
The Kubota 3.8L engine requires valve clearance A small amount of fuel may still be present in the
adjustments during normal service. See Mainte- fuel line. Use gloves to prevent burns and wear
nance Schedule for valve clearances. eye protection. If liquid fuel continues to flow
from the connections when loosened, check to
For valve clearance procedure see section: make sure the manual valve is fully closed.
• Kubota 3.8L LPG SI Engine
0600SRM1893 3. Remove bolt and seal washer retaining top sec-
tion of fuel filter housing. Discard seal washer.
IGNITION SYSTEM See Figure 49.
Standard Spark Plugs, Kubota 3.8L LPG

Engine
The Kubota 3.8L LPG engine have an electronic

control unit (ECU) that controls ignition timing.
There are no adjustments. Change standard spark
plugs every 1000 hours. The correct spark plug gap
is 0.7 to 0.8 mm (0.028 to 0.032 in.).
1. Disconnect ignition coil.
2. Remove spark plug.
NOTE: When installing spark plugs, insert ignition

coil inside the plug terminal firmly. Make sure the
wiring and ignition coil are correctly connected.
3. Install new standard spark plug.
4. Tighten spark plug to 24.5 to 29.4 N•m (18.1 to 1. BOLT

21.6 lbf ft). 2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION
5. Repeat Step 1 through Step 4 for remaining 4. FUEL FILTER
spark plugs. 5. FUEL FILTER O-RING
6. HOUSING O-RING
LPG FUEL FILTER ELEMENT REPLACE, 7. FUEL FILTER HOUSING BOTTOM SECTION
KUBOTA 3.8L LPG ENGINE Figure 49. Fuel Filter Removal and Installation,
Kubota 3.8L LPG Engine
Remove
4. Remove top section of fuel filter housing.

WARNING
LPG can cause an explosion. DO NOT permit any 5. Remove and discard housing O-ring.
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.
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Install Replace fuel strainer at specified intervals to pre-

vent contaminants from adversely affecting diesel
1. Clean and inspect fuel filter housing for con- fuel flow.
tamination or damage.
Remove
2. Install new fuel filter and fuel filter O-ring. See
Figure 49. 1. Stop engine and allow it to cool.
3. Install new housing O-ring.
CAUTION
4. Install top section of fuel filter housing.
Drain the fuel into a container and dispose in ac-
5. Install bolt and new seal washer. Tighten bolt cordance with local environmental regulations.
to 13 N•m (115 lbf in).
2. Loosen clamps and disconnect two fuel lines
NOTE: Opening fuel valve too quickly can cause in- from in-line fuel strainer. Remove and discard
ternal excessive flow valve to close, restricting flow in-line fuel strainer. See Figure 50.
of fuel. If this happens, close fuel valve, wait a few
seconds, and then slowly open fuel valve again. Install
This will reset excess fuel valve.
1. Install in-line fuel strainer by connecting two
6. Slowly open fuel valve on tank. fuel lines and tighten clamps. Torque fuel line
clamps to 1.0 to 1.7 N•m (9 to 15 lbf in). See
7. Turn key to ON position and back to OFF posi- Figure 50.
tion to pressurize fuel system. Check for leaks.
2. Check for fuel leaks.
8. Check for leaks at connections by using soapy
solution or electronic leak detector. If leaks are
detected, make proper repairs.
IN-LINE STRAINER REPLACEMENT,

KUBOTA DIESEL ENGINE
CAUTION
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NOTE: KUBOTA 3.8L DIESEL ENGINE SHOWN, 3.6L SIMILAR.
A. RIGHT SIDE VIEW B. FRONT VIEW

5. IN-LINE FUEL STRAINER
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LIFT CHAINS WEAR CHECK LIFT CHAIN LUBRICATION
If a section of chain is 3% longer than a similar sec-

tion of new chain, chain is worn and must be re- WARNING
placed. Measure chain for wear where it moves over Cleaning solvents can be flammable and toxic and
sheaves. Using a chain scale, (Hyster P/N 871796) can cause skin irritation. When using cleaning
check lift chains as shown in Figure 51. solvents, always follow the recommendations of
the manufacturer.
Compressed air can move particles so they cause

injury to the user or to other personnel. Make sure
that the path of the compressed air is away from
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
Remove lift chains. Clean lift chains by soaking

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 chains when they are clean.
Lubricate lift chains by soaking them in 30W en-

gine oil for at least 30 minutes. Remove chains
from oil. Hang chains for one hour so excess oil will
drain from chains.
INTEGRAL SIDESHIFT CARRIAGE,

CHECK SLIDING SURFACES
Pitch Wear Limit 1. Check sideshift carriage sliding surfaces, and if
Total Length of
(The Maximum necessary lubricate sliding surface at grease fit-
20 Links (Pitch)
Length of 20 tings with multipurpose grease shown in Main-
of New Chain
Links) tenance Schedule. See Figure 52.
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
1. CHAIN WEAR SCALE
Figure 51. Lift Chains Check
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STEERING AXLE (SPINDLE BEARINGS)
Lubricate spindle bearings on steering axle. There

are four lubrication fittings, two on each side of
steering axle. See Figure 53 and Figure 54. Use
multipurpose grease as shown in Maintenance
Schedule.
1. CAPSCREWS
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
8. SNAP RING
9. ROD SCRAPER
10. ROD BUSHING
11. SEAL
12. FIXED FRAME
Figure 52. Integral Sideshift Carriage
2. Clean bearing strip areas. Inspect sideshift

bearing strips for wear as follows:
a. Remove upper bearing strips from cylinder 1. LUBRICATION FITTING (TIE ROD)
body. If either upper bearing strip is worn to 2. LUBRICATION FITTING (SPINDLE BEARINGS)
less than 2.0 mm (0.08 in.) thickness, replace 3. STEERING AXLE
all upper bearing strips by driving upper
Figure 53. Lubricate Spindle Bearings, Lift Truck
bearing strips from cylinder body. See Fig-
Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
ure 52. Install new upper bearing strips onto
H5.0-5.5FT (U005)
cylinder body. See Parts Manual.
b. Remove lower bearing strips from carriage

apron. If either lower bearing strip is worn to
less than 2.0 mm (0.08 in.) thickness, replace
all lower bearing strips by prying lower bear-
ing strips from carriage apron. See Fig-
ure 52. Install new lower bearing strips onto
carriage apron. See Parts Manual.
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4. If lever(s) move freely and lift truck operates in

a normal operating environment, go to Normal
Operating Environment. If lever(s) do not move
or if lift truck operates in a heavy duty or con-
taminated environment, go to Heavy Duty or
Contaminated Environment.
Normal Operating Environment

1. Clean area around parking brake lever and
thrust bushing to remove dirt and debris. See
Figure 55.
2. Remove socket head screw and spacer from

parking brake lever. See Figure 55.
3. Lift parking brake lever approximately 1 mm (.

040 in.) up from thrust lever and away from
drive axle housing. See Figure 55.
4. Use spray grease, shown in Maintenance

1. STEERING AXLE Schedule, with an extension tube and insert
2. LUBRICATION FITTING (TIE ROD) tube in space between parking brake lever and
3. LUBRICATION FITTING (SPINDLE BEARINGS) thrust lever.
Figure 54. Lubricate Spindle Bearings, Lift Truck
5. Spray a generous amount of grease in space be-
Model S4.0-5.5FT, S5.5FTS (J004)
tween parking brake lever and thrust lever. See
Figure 55.
CONTROL LEVERS AND PEDALS
6. Wait a few minutes to allow solvent to evapo-
Lubricate linkages, pedal shafts, control cables rate. Once solvent has evaporated, spray the
(throttle, hood, parking brake), and seat rails. Use area a second time.
a silicone spray lubricant (Hyster Part No. 328388).
7. After second application of grease has evapora-
ted, check parking brake lever for free move-
PARKING BRAKE LEVER LUBRICATION, ment.
DANA WET BRAKE AXLE
8. Install the spacer and socket head screw onto
Before lubricating the parking brake levers on the parking brake lever. Tighten socket head screw
wet brake axle, perform the following: to 21 to 30 N•m (15 to 22 lbf ft).
1. Block lift truck wheels to prevent lift truck 9. Adjust the parking brake lever(s) using parking
from moving when parking brake is released. brake adjustment screw (see Figure 55). See
Drive Axle and Differential Assembly Re-
2. Have one person sit in the lift truck seat and pair (Wet Brake) 1400SRM1246 for proce-
apply the service brake and release the parking dures.
brake.
10. After adjusting parking brake lever(s), adjust
3. Have another person observe the parking brake parking brake. See Maintenance Procedures
lever(s) on top of the drive axle while the other Every 500 Hours or 1 Year for procedures.
person turns the parking brake adjustment
knob counterclockwise. See Figure 48. The
spring on the cable(s) should have enough force
to cause the lever(s) to move forward as the
parking brake adjustment cable is slackened.
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1. SOCKET HEAD SCREW

2. SPACER
3. PARKING BRAKE LEVER
4. THRUST LEVER
5. THRUST BUSHING
6. PARKING BRAKE LEVER ADJUSTMENT SCREW
Figure 55. Lubricate Parking Brake Lever, Normal Operating Environment
Heavy Duty or Contaminated Environment
Remove
1. Clean area around parking brake lever and
thrust bushing to remove dirt and debris. See
Figure 55.
2. Remove parking brake cable from parking

brake lever.
3. Remove socket head screw securing parking

brake lever to thrust lever. See Figure 55.
NOTE: Mark parking brake lever in relation to the

thrust lever to help install parking brake lever in NOTE: CIRCLE INDICATES WHERE TO MARK
correct position during installation. See Figure 56. PARKING BRAKE LEVER.
4. Remove spacer and parking brake lever from 1. SPACER

2. SOCKET HEAD SCREW
thrust lever.
Figure 56. Remove Parking Brake Lever
5. Remove socket head screws and thrust bushing
from drive axle. See Figure 57.
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1. SOCKET HEAD SCREW 1. THRUST LEVER

2. THRUST BUSHING 2. APPLY MULTIPURPOSE GREASE HERE
3. THRUST LEVER 3. COVER OPENINGS AND EDGES
Figure 57. Remove Thrust Bushing Figure 59. Inspect and Clean Thrust Lever
6. Remove O-rings from inside and outside of

Install
thrust bushing. See Figure 58.
1. Apply thin coat of multipurpose grease (see
Maintenance Schedule) to thrust lever from the
bottom of the spline down to where the O-ring
contacts the thrust lever when the thrust bush-
ing is installed. See Figure 59.
2. Lubricate new O-ring (inside) with lithium

based grease and install the O-ring inside the
bore on the thrust bushing. See Figure 58.
3. Pack area above the O-ring, inside the bore,

with multipurpose grease, as shown in the
Maintenance Schedule, prior to installing
thrust bushing onto thrust lever. See Figure 58.
4. Lubricate new O-ring (outside) with lithium

1. O-RING (OUTSIDE)
2. O-RING (INSIDE) based grease and install the O-ring on outside
3. BORE (APPLY GREASE HERE) of thrust bushing. See Figure 58.
4. THRUST BUSHING
5. Apply Loctite® 242 to socket head screws and
Figure 58. Remove O-Rings From Thrust Bushing
install thrust bushing to drive axle. Tighten
socket head screws to 21 to 30 N•m (15 to
Clean and Inspect 22 lbf ft). See Figure 57.
1. Inspect inside bore of thrust bushing. Remove 6. Install parking brake lever in same position as
any rust or debris. See Figure 58. noted during Remove procedure. See Figure 56.
NOTE: Before removing rust and debris from 7. Install spacer and socket head screw and secure
thrust lever, cover the opening in the top of the parking brake lever to thrust lever. Tighten
drive axle, as well as the edges, so that rust and socket head screws to 21 to 30 N•m (15 to
debris do not get into the drive axle trumpet arms. 22 lbf ft). See Figure 55.
2. Inspect thrust lever and remove any rust or 8. Attach parking brake cable to parking brake
debris as necessary. See Figure 59. lever.
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9. Adjust the parking brake lever(s) using parking

brake adjustment screw (see Figure 55). See
Drive Axle and Differential Assembly Re-
pair (Wet Brake) 1400SRM1246 for proce-
dures.
10. After adjusting parking brake lever(s), adjust

parking brake. See Maintenance Procedures
Every 500 Hours or 1 Year for procedures.
INSPECT ENGINE ELECTRICAL SYSTEM,

CONNECTORS
When inspecting electrical system, check following:
• Check and clean battery connection. Ensure

that connections are tight.
• Check battery for damage or cracks to case.
Replace if necessary.
1. DRAIN HOSES
• Check positive and negative cables for corro- 2. TOP SECTION
sion, rubbing, and chaffing. Tighten connec- 3. O-RING
tions at both ends. 4. CRANKCASE BREATHER ELEMENT
5. CRANKCASE BREATHER HOUSING
• Check engine wire harness for rubbing,
chaffing, pinching, and cracks or breaks in Figure 60. Crankcase Breather
wiring.
• Check engine harness connectors. Check to
ensure connectors are fitted and locked by 3. Remove and discard O-ring from top section.
pushing connectors together. Pull on connec- See Figure 60.
tor halves to make sure they are locked.
4. Remove and discard breather element. See Fig-
• Check ignition coil wire and spark plug wires ure 60.
for hardening, cracking, arching, chaffing,
separation, split boot covers, and proper fit. Clean and Inspect
Replace spark plugs at recommended inter-
val as shown in Maintenance Schedule.
• Check that all electrical components are se- CAUTION
curely mounted and retained to engine or A small amount of oil may be present in the
chassis. breather element housing. Use gloves to prevent
skin irritation and wear eye protection.
• Check MIL, charging, and oil pressure lights
for operation by starting engine and checking
that light illuminates before turning out. CAUTION
CRANKCASE BREATHER ELEMENT, environmental regulations.
KUBOTA 3.8L DIESEL ENGINE
Clean and inspect crankcase breather element
Remove housing for cracks and leaks. If necessary see
Parts Manual for replacement parts.
Inspect hoses for wear and cracks. Replace if neces-
2. Remove top section of breather element hous- sary. See Parts Manual.
ing. See Figure 60.
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Install 3. Install breather element housing top section to

breather housing. See Figure 60.
1. Install new breather element into breather ele-
ment housing. See Figure 60. 4. Start engine and check for leaks.
2. Install new O-ring on top section of breather el-

ement. See Figure 60.
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform 8-hour, 500-hour, and 1000-hour NOTE: Have container large enough to hold filter
checks prior to performing procedures in this sec- element and allow for final hydraulic oil draining.
tion.
2. Remove hydraulic filter element and O-ring
HYDRAULIC SYSTEM from bowl and place into container. Cover head
to prevent any foreign materials from getting
Hydraulic Filter, Replace into hydraulic tank.
3. Lubricate new O-ring with hydraulic oil and in-

WARNING stall it on bottom of new filter element. Install
At operating temperature, the hydraulic oil is HOT. new filter element into bowl.
DO NOT permit the hot oil to touch the skin and
4. Inspect gasket for damage. If damaged, replace.
cause a burn.
5. Lubricate gasket with hydraulic oil and seat it
on filter lid and install spring and lid onto
CAUTION
head. Tighten lid to 15 N•m (132.8 lbf in).
changed. Dirt can cause damage to the compo- CAUTION
nents of the hydraulic system. Additives may damage the hydraulic system. Be-
fore using additives, contact your local dealer.
the hydraulic system. The operation of the hy- 6. Start truck, and allow it to run for 30 seconds.
draulic pump without oil will damage the pump. Check for leaks. Stop engine and check hy-
draulic oil level. Add oil, if necessary. Use hy-
draulic oil shown in Maintenance Schedule. To
CAUTION
change hydraulic oil, see Hydraulic Oil, Re-
Disposal of lubricants and fluids must meet local place.
1. Put lift truck on a level surface and lower car-

riage. Unscrew and remove filter lid, gasket,
and spring from head. See Figure 61. Lift hy-
draulic filter element enough to allow hydraulic
oil to drain.
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8000 SRM 1902 Maintenance Procedures Every 2000 Hours or Annually
Hydraulic Tank Breather, Replace

1. Raise hood and remove right rear side panel.
See Figure 62.
1. HOOD/SEAT ASSEMBLY
2. RIGHT REAR SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 62. Hydraulic Tank Breather
2. Unscrew and remove old hydraulic tank

breather, and replace with new hydraulic tank
breather.
3. Install right rear side panel and close hood. See

Figure 62.
1. LID 6. FITTING
2. SPRING 7. QUAD RING
3. O-RING 8. FILTER ELEMENT
4. CAPSCREW 9. BOWL
5. HEAD
Figure 61. Hydraulic Filter
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Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1902
COOLING SYSTEM, KUBOTA DIESEL 4. Close drain valve. Fill cooling system with a
ENGINES solution of ethylene glycol boron-free antifreeze.
See Maintenance Schedule for correct solution.
1. Put lift truck on a level surface. Stop engine. Fill auxiliary reservoir to a level between ADD
Place a container with a minimum capacity of and FULL marks on reservoir.
15.1 liter (15.9 qt) under radiator drain valve
which could be located on either lower left or 5. Install radiator cap. Start engine. Check for
right side of radiator on engine side of radiator. leaks. Add coolant to auxiliary coolant reservoir
as needed. Coolant level should be between
ADD and FULL marks on reservoir.
WARNING
DO NOT remove the radiator cap from the radiator AIR FILTER
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys- The air filter canister should not be opened until an
tem. If the system is hot, the steam and boiling air filter element replacement is required. An air
coolant can cause burns. DO NOT remove the filter element replacement is required when one of
cover for the radiator when the engine is running. following occurs:
• The optional air flow restriction indicator
light on dash illuminates.
CAUTION
Disposal of lubricants and fluids must meet local • The optional manual air flow indicator but-
environmental regulations. ton pops up.
• The specified number of hours has passed
2. Open drain valve and remove radiator cap. since last filter element replacement.
Drain coolant into container. Flush cooling sys-
tem. Check hoses for damage. Replace with new
hoses, as needed. CAUTION
DO NOT allow dirt to enter the engine air intake
3. Disconnect hose leading from auxiliary reser-
when replacing the air filter element. A small
voir to fitting at top of radiator under radiator
amount of dirt could cause engine damage.
cap, and drain reservoir into same container
used for radiator coolant. Check reservoir for 1. Shut off engine. Never open air filter canister
contaminants and flush, as necessary. Connect or remove filter element with engine running.
hose back on fitting at top of radiator.
2. Unlatch and remove cover. To remove filter ele-
ment, press and rotate filter element counter-
CAUTION clockwise about 1/8 turn until filter element is
Additives may damage the cooling system. Before free. To assist removal, gently move end back
using additives, contact your local dealer. and forth to help break seal. See Figure 63.
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NOTE: ILLUSTRATION USED FOR REFERENCE ONLY.
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 63. Air Filter
3. Gently pull filter element from canister. Avoid If your air filter assembly is equipped with a sec-
dislodging contaminants from element or ondary element in place of liner assembly, re-
knocking it against canister. place secondary element with every 2 to 3 pri-
mary element replacements.
4. With a clean, soft rag, clean inside surface of
canister. Remove liner assembly to make clean- 7. Inspect new filter element for voids, cuts, tears
ing easier. Clean well around locking tabs that or indentations in urethane-sealing surfaces.
retain element. Clean tabs make new filter ele- DO NOT use if damage is detected.
ment installation easier. Be careful not to
knock any contaminants into outlet tube to en-
gine. CAUTION
The element must be properly installed to ensure
5. Inspect liner and O-ring assembly for damage. adequate engine protection. An improperly instal-
If damaged, replace liner and O-ring assembly. led element may allow dirt and dust to enter and
damage the engine.
6. Install liner assembly into canister by pushing
in. Make sure liner assembly is properly seated
in canister. It will fit snugly into and be cen-
tered in canister.
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NOTE: Proper element installation is required to NOTE: DO NOT use latches to pull cover down
allow cover to be installed correctly. Never reinstall against canister. If cover does not fit completely
a used element. Never install a damaged element. against canister with no gaps, element is not instal-
Always use a Hyster-approved filter element. led correctly.
8. Install new filter element into canister. Press 10. Fasten latches to secure cover to canister. Make
and rotate filter element 1/8 turn clockwise un- sure latches penetrate slots in both canister
til fully engaged in canister. See Figure 64. and cover.
11. Inspect entire air intake system for leaks. In-

spect all clamps for tightness and tighten if
necessary. Inspect all hoses for damage. Re-
place damaged hoses. Inspect dust evacuation
valve for damage. If damaged, replace dust
evacuation valve.
FUEL INJECTOR, KUBOTA 3.8L ENGINE
For removal and cleaning instructions for lift

trucks equipped with Kubota 3.8L diesel engine,
contact your local dealer or see Kubota Diesel
3.8L Engines 0600SRM1557.
1. PUSH IN 2. TWIST TO LOCK
FUEL INJECTOR, KUBOTA 3.6L ENGINE
Figure 64. Air Filter Label
For removal and cleaning instructions for lift
trucks equipped with Kubota 3.6L diesel engine,
contact your local dealer or see Kubota Diesel
CAUTION 3.6L Engine 0600SRM1579.
During cover installation, DO NOT force the cover
on the canister. To do so will result in damage to LONG-LIFE SPARK PLUGS, KUBOTA
the filter element, cover, and possibly the canis-
3.8L LPG ENGINE
ter.
NOTE: If filter element is properly installed, cover Remove

will fit easily into canister with no gap between
cover and canister. If cover does not fit easily, filter 1. Remove capscrew from ignition coil. See Fig-
element is not installed properly. Do not use a ure 65.
cover that is bent, damaged, or missing latches. 2. Remove ignition coil from cylinder head.
9. Install cover into canister and ensure INLET 3. Remove spark plug from ignition coil flange.
arrow is in line with canister inlet.
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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.
TRANSMISSION OIL AND FILTER,

REPLACE
WARNING
At operating temperature, the transmission oil is
and cause a burn.
CAUTION
DO NOT permit dirt to enter the transmission
1. CAPSCREW
2. IGNITION COIL when the oil level is checked or the filter is
3. SPARK PLUG changed. Dirt can cause damage to the transmis-
4. IGNITION COIL FLANGE sion components.
5. CYLINDER HEAD
Figure 65. Spark Plug Change CAUTION

4. Repeat Step 1 through Step 3 for remaining
spark plugs. NOTE: Change transmission oil filter at first 500
hours of operation on new lift trucks. Before remov-
Install ing oil filter, make a hole at top of filter and allow
five minutes for oil to drain down into transmis-
1. Install spark plug into ignition coil flange. See sion. This will reduce oil that will run out of filter
Figure 65. and onto transmission when filter is removed.
2. Install ignition coil onto cylinder head. NOTE: The drain plug for transmission is on lower
right side of cover of transmission, toward rear of
3. Instal capscrew into ignition coil.
lift truck.
4. Repeat Step 1 through Step 3 for remaining
1. Remove drain plug, spring, and screen. Drain
spark plugs.
oil into a container. See Figure 66.
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the path of the compressed air is away from all
personnel. Wear protective goggles or a face
2. Clean screen with cleaning solvent, and dry

with compressed air, adjusted to a maximum
output of 103 kPa (15 psi).
3. When oil has drained, first install screen, then

spring, and drain plug. See Figure 66.
4. Remove and discard transmission breather. In-

stall new transmission breather and hand
tighten.
5. Remove and discard old oil filter. Apply clean

oil to gasket of new filter. Install new filter and
hand tighten. See Figure 66.
6. Add oil to transmission at dipstick tube. The

correct oil is shown in Maintenance Schedule.

NOTE: ALL MAJOR COMPONENTS AND FRAME least 50°C (120°F) when checking oil level.
COMPONENTS REMOVED FOR SAKE OF
CLARITY. 7. Start and run engine for approximately five mi-
nutes after fill to allow oil to lubricate parts
1. TRANSMISSION within transmission and wet brake portion of
2. TRANSMISSION DRAIN PLUG drive axle center section. With truck in ON po-
3. SPRING
4. SCREEN sition, see Maintenance Schedule to add addi-
5. TRANSMISSION OIL FILTER tional oil at transmission dipstick tube that will
6. TRANSMISSION DIPSTICK need to be added to properly fill wet brake por-
7. TRANSMISSION BREATHER tion of drive axle center section and transmis-
sion.
Figure 66. Transmission Oil Change
least 50°C (120°F) when checking oil level.
WARNING 8. Turn key to OFF position and check for leaks
Cleaning solvents can be flammable and toxic and and check oil level. If necessary, top off oil.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
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TRANSMISSION AND WET BRAKE

PLANETARY CARRIER HOUSING OIL
CHANGE (DANA DRIVE AXLE)
WARNING
The oil used for the wet brake planetary carrier
housing or transmission should not be contami-
nated. If either the wet brake planetary carrier
housing and/or transmission oil becomes conta-
minated, the oil must be drained and replaced
with new oil.
WARNING
At operating temperature, the transmission and
wet brake planetary carrier housing oil is HOT. DO
NOT permit the hot oil to touch the skin and cause
a burn.
CAUTION
DO NOT permit dirt to enter the transmission or
wet brake planetary carrier housing when the oil NOTE: ALL MAJOR COMPONENTS AND FRAME
level is checked or the filter is changed. Dirt will COMPONENTS REMOVED FOR SAKE OF
contaminate the oil and cause damage to the CLARITY.
transmission and wet brake planetary carrier
housing components. 1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
3. SPRING
CAUTION 4. SCREEN
5. TRANSMISSION OIL FILTER
Disposal of lubricants and fluids must meet local 6. TRANSMISSION DIPSTICK
environmental regulations. 7. TRANSMISSION BREATHER
NOTE: Change transmission oil filter at first 500 Figure 67. Transmission Oil Change
hours of operation on new lift trucks. Before remov-
ing oil filter, make a hole at top of filter and allow
five minutes for oil to drain down into transmis- 2. Remove planetary carrier housing drain plug
sion. This will reduce oil that will run out of filter and fill/level plug. Drain oil into a suitable con-
and onto transmission when filter is removed. See tainer. When oil is completely drained, reinstall
Figure 67. drain plug and fill/level plug. Tighten to 30 to
50 N•m (22 to 37 lbf ft). See Figure 68.
1. The drain plug for transmission is on lower
right side of cover of transmission, toward rear
of lift truck. Remove drain plug, spring, and
screen. Drain oil into a container. See Fig-
ure 67.
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WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.

the path of the compressed air is away from all
personnel. Wear protective goggles or a face
3. Clean screen with cleaning solvent, and dry

with compressed air, adjusted to a maximum
output of 103 kPa (15 psi).
4. When oil has drained, first install screen, then

spring, and drain plug. See Figure 67.
5. Remove and discard transmission breather. In-

stall new transmission breather and hand
tighten.
6. Remove and discard old oil filter. Apply clean

oil to gasket of new filter. Install new filter and
hand tighten. See Figure 67.
7. Add oil to transmission at dipstick tube. The

correct oil is shown in Maintenance Schedule.
8. Start and run engine for approximately five mi-

A. REAR VIEW SHOWN nutes after fill to allow oil to lubricate parts
B. FRONT VIEW SHOWN within transmission and wet brake planetary
carrier housings. With truck in ON position,
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS see Maintenance Schedule to add additional oil
2. PLANETARY CARRIER HOUSING DRAIN at transmission dipstick tube that will need to
PLUGS be added to properly fill planetary carrier hous-
3. CENTER BODY FILL/LEVEL PLUG ings and transmission. See Figure 68.
4. CENTER BODY DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH) NOTE: Transmission oil temperature should be at
6. PLANETARY CARRIER HOUSING (LH) least 50°C (120°F) when checking oil level.
7. CENTER BODY
Figure 68. Wet Brake Drive Axle Drain and Fill/ 9. Turn key to OFF position and check for leaks
Level Plug Location for Dana Drive Axles and check oil level.
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WET BRAKE CENTER SECTION OIL

CHANGE (DANA DRIVE AXLE) CAUTION
Before adding oil, ensure the truck is parked and
Remove on level ground.
1. Remove center body fill/level plug. Removing 2. Add oil at fill/level port for center body until oil/
fill/level plug will allow oil to drain at a faster fill level port has overflowed. The correct oil is
rate. See Figure 68. shown in Maintenance Schedule and in Fig-
ure 69.
2. Place and empty container under center body
drain plug. 3. Install oil fill/level plug. Tighten to 30 to
50 N•m (22 to 37 lbf ft).
3. Remove center body drain plug, and wait until
oil has drained completely.
Install
1. Install drain plug for center body. Tighten to 30
to 50 N•m (22 to 37 lbf ft). See Figure 68.
A. RIGHT PLANETARY CARRIER HOUSING - USE JDM J20C

B. LEFT PLANETARY CARRIER HOUSING - USE JDM J20C
C. CENTER BODY - USE SAE 80W/90
1. PLANETARY FILL/LEVEL PLUGS 5. RIGHT PLANETARY CARRIER HOUSING
2. PLANETARY DRAIN PLUGS 6. LEFT PLANETARY CARRIER HOUSING
3. CENTER BODY FILL/LEVEL PLUG 7. CENTER BODY
4. CENTER BODY DRAIN PLUG
Figure 69. Oil Application Diagram for Dana Drive Axles
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WET BRAKE OIL CHANGE (NMHG DRIVE

AXLE) CAUTION
DO NOT permit dirt to enter the wet brake drive
axle when the oil level is checked or the filter is
WARNING changed. Dirt will contaminate the oil and cause
The oil used for the wet brake drive axle should damage to the wet brake drive axle components.
not be contaminated. If oil becomes contamina-
ted, the oil must be drained and replaced with new
oil. CAUTION
WARNING
At operating temperature, the wet brake drive axle 1. Remove three drain plugs on bottom of drive
oil is HOT. DO NOT permit the hot oil to touch the axle. See Figure 70.
skin and cause a burn.
A. TOP VIEW SHOWN B. BOTTOM VIEW SHOWN

1. SERVICE BRAKE PORT 4. FILL/LEVEL PLUG
2. FILL PLUG 5. BRAKE BLEEDER VALVE
3. OIL BREATHER 6. DRAIN PLUG
Figure 70. Wet Brake Drive Axle Drain and Fill/Level Plug Location for NMHG Drive Axles
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2. Drain oil into a suitable container. When oil is

completely drained, reinstall drain plugs and
tighten to 50 to 55 N•m (37 to 41 lbf ft).
3. Remove fill/ level plug and two fill plugs located

on top of drive axle. See Figure 70.
4. Add half amount of oil, specified in Mainte-

nance Schedule, to one fill port and other half
to second fill port.
5. Check oil level of drive axle at fill/level port.

Add oil to either fill port until drive axle oil
level is 10 mm (0.39 in.) below fill/level port.
6. Install fill/level plug and tighten to 50 to

55 N•m (37 to 41 lbf ft).
7. Install two fill plugs and tighten 50 to

55 N•m (37 to 41 lbf ft).
BRAKE OIL (MASTER CYLINDER),

CHANGE
1. Remove dashboard from cowl.
CAUTION 1. RESERVOIR CAP

Disposal of lubricants and fluids must meet local 2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
environmental regulations. 4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
2. Remove brake oil reservoir from bracket on 6. CYLINDRICAL BLOCK OUTLET FITTING
cowl. See Figure 71. 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 71. Brake Oil Change
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INSPECT EXHAUST MANIFOLD AND

WARNING
PIPING FOR LEAKS
Small amounts of water in the brake system can
cause reduced braking performance. DO NOT al- To check exhaust manifold and piping for leaks,
low water entry. Ensure that the sealed reservoir perform following:
lid is properly replaced.
• Check exhaust manifold at cylinder head for
CAUTION leaks. Ensure that all bolts and shields are
in place.
DO NOT use "DOT" fluid, only use Dexron III oil
from a sealed container to prevent possible dam- • Check exhaust pipe fasteners to manifold for
age to the brake system. leaks to ensure they are tight. Repair if nec-
essary.
3. Remove brake oil reservoir cover and cylindri-
• Check all exhaust pipe extension connectors
cal block drain plug. Pour oil into a suitable
for leaks and tighten, if necessary.
container with a 0.35 liter (0.74 pt) minimum
capacity. Install cylindrical block drain plug. • Visually inspect converter for correct muffler
Refill reservoir with clean oil from a sealed con- mounting and tail pipe mounting.
tainer and install cover on reservoir. The cor- • Check for any leaks at inlet and outlet of
rect oil is shown in Maintenance Schedule. converter.
4. Install reservoir into bracket located on cowl.
WHEEL BEARINGS
CHECK THROTTLE SHAFT FOR
STICKING Steer Wheels, Lubrication
Lubricate wheel bearings in hubs for steer wheels

Check Throttle body return action to ensure throt-
with multipurpose grease as shown in Maintenance
tle shaft is not sticking. Repair if necessary.
Schedule. See Steering Axle 1600SRM1896 for
procedures.
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform 8-hour, 500-hour, 1000-hour, and Never operate the hydraulic pump without oil in
2000-hour checks prior to performing procedures in the hydraulic system. The operation of the hy-
this section. draulic pump without oil will damage the pump.
HYDRAULIC OIL, REPLACE

CAUTION
WARNING environmental regulations.
At operating temperature the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and NOTE: Heavy-duty or contaminated applications
cause a burn. will require hydraulic oil change at 2000 hours.
NOTE: Replace hydraulic oil filter at same time oil

CAUTION is changed.
1. Replace hydraulic oil as described below:
changed. Dirt can cause damage to the compo-
nents of the hydraulic system.
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8000 SRM 1902 Maintenance Procedures Every 4000 Hours or 2 Years
a. Place a container with a minimum capacity

of 62 liter (65.5 qt) for short wheel base lift CAUTION
trucks or 78 liter (82.4 qt) for long wheel Additives may damage the hydraulic system. Be-
base lift trucks, under drain plug at bottom fore using additives, contact your local Hyster
of hydraulic tank. To drain oil, remove drain dealer.
plug from bottom of hydraulic tank. See Fig-
ure 72 or Figure 73. 2. Fill hydraulic tank with oil specified in Mainte-
nance Schedule.
b. When tank is empty, inspect inside of tank
for any foreign matter or possible fungus. If 3. When oil level is correct, operate system and
necessary, clean inside of tank in accordance check for leaks.
with instructions found in section Frame
0100SRM1891.
c. When either inspection or cleaning of tank is

completed, install drain plug in bottom of hy-
draulic tank. Tighten drain plug to
38 N•m (28 lbf ft).
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 72. Hydraulic Oil Change for Lift Trucks with Single Hydraulic Tank
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Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1902
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 73. Hydraulic Oil Change for Lift Trucks with Dual Hydraulic Tanks
WELD INSPECTION NOTE: Dye penetrant checks are made in a three-

step process using a cleaner, penetrant, and devel-
Initial inspection is suggested at 4000 hours, with oper. Follow manufacturers instructions for clean-
subsequent inspections at 2000 hour intervals. Re- ing the area to be inspected, then applying pene-
moval of carriage from mast is not required, but trant and developer. If a crack is present, it will
recommended, to perform inspection. Removal of show up as a well-defined maroon/red line as the
attachment is recommended for access to carriage. dye penetrant is drawn out into the white devel-
oper coating.
NOTE: Visual inspection supported by dye pene-
trant application is recommended with focus on
areas defined below.
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8000 SRM 1902 Maintenance Procedures Every 4000 Hours or 2 Years
Contact your local Hyster dealer for instructions if a. Welded joints of lower crossmember of
a crack is detected. mast outer channel and related gussets.
See Figure 75.
1. Carriage inspection: welded joints between cast b. Welded joints around tilt anchor and in-
insert and top and vertical carriage bars. See termediate cross member. See Figure 75.
Figure 74.
c. Right side rail of outer mast channel in
NOTE: The welded boss for tilt lock option is typi- area of welded boss for optional tilt lock
cally located on right side of mast channel above rod. See Figure 75.
tilt anchor bracket.
2. Mast Inspection:
A. FRONT VIEW B. REAR VIEW

1. WELDS
Figure 74. Carriage Bar Welds for Inspection
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Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1902
A. TYPICAL "XM" MAST C. WELDED BOSS FOR TILT LOCK OPTION

B. TYPICAL "FT" MAST
1. WELDS
Figure 75. Mast Welds for Inspection
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8000 SRM 1902 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast

The following procedures must be used when in- OR
specting or working near the mast. Additional pre-
cautions and procedures can be required when re- 2. If parts of the mast must be in a raised posi-
pairing or removing the mast. See the correct Serv- tion, install a safety chain to restrain the mov-
ice Manual section for the specific mast being re- ing parts of the mast. Connect moving parts to
paired. a part that does not move. Follow these proce-
dures:
WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances be- b. Raise mast to align bottom crossmember of
tween parts are small. Serious injury or death can weldment that moves in outer weldment
result if part of the body is hit by parts of the mast with a crossmember on outer weldment. On
or the carriage. the two-stage and free-lift mast, the moving
part is the inner weldment. On the three-
• Never put any part of the body into or under
stage mast, it is the intermediate weldment.
the mast or carriage unless all parts of the
See Figure 76.
mast are completely lowered or a safety
chain is installed. Also make sure that the c. Use a 3/8-in. minimum safety chain with a
power is off and the key is removed. Put a hook to fasten the crossmembers together so
DO NOT OPERATE tag in the operator's the movable member cannot lower. Put the
compartment. hook on the back side of the mast. Make sure
• Be careful of the forks. When the mast is the hook is completely engaged with a link in
raised, the forks can be at a height to cause the chain. Make sure the safety chain does
an injury. not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
• DO NOT climb on the mast or lift truck at
any time. Use a ladder or personnel lift to d. Lower the mast until there is tension in the
work on the mast. safety chain and the free-lift cylinder (free-
• DO NOT use blocks to support the mast lift, three-stage, and four-stage masts only)
weldments nor to restrain their movement. is completely retracted. If running, stop en-
• Mast repairs require disassembly and re- gine. Apply parking brake. Install a DO
moval of parts and can require removal of NOT REMOVE tag on the safety chain(s).
the mast or carriage. Follow the repair pro- e. Install another safety chain (3/8-in. mini-
cedures in the correct Service Manual for mum) between the top or bottom crossmem-
the mast. ber of the carriage and a crossmember on the
NOTE: If there is no power to lower the mast on lift outer weldment.
trucks equipped with Electronic Hydraulic System, 3. Apply parking brake. After lowering or re-
there is an emergency load lowering valve located straining the mast, shut off power and remove
on the hoist/lower valve section of the main control key. Put a DO NOT OPERATE tag in the op-
valve. See the Operating Manual for the proce- erator's compartment.
dures to lower a load using the emergency load low-
ering valve.
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 low-
ered.
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Safety Procedures When Working Near Mast 8000 SRM 1902
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
Figure 76. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
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8000 SRM 1902 Safety Procedures When Working Near Mast
Fuel Filter Water Removal

KUBOTA DIESEL ENGINE
3.8L Diesel Engine

1. Shut off the engine.
2. Close fuel supply valve. See Figure 78.

11.36 liter (2 to 3 gal).
4. Loosen outlet plug. See Figure 77.
1. FUEL FILTER ELEMENT

2. DRAIN VALVE
3. OUTLET PLUG
4. ELECTRIC FUEL PUMP
Figure 77. Engine Fuel Filter Drain Valve Location
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Fuel Filter Water Removal 8000 SRM 1902
A. RIGHT SIDE VIEW B. REAR VIEW

5. INLINE FUEL STRAINER
Figure 78. Kubota 3.8L Fuel System
7. Close the drain valve by lifting and turning

CAUTION clockwise until it is hand-tight.
Drain water/fuel into a container and dispose in
accordance with local environmental regulations. 8. Open fuel supply valve. See Figure 77.
NOTE: The drain valve is located on the bottom of 9. CIL should be off and truck should be ready to
fuel filter element. start.
5. Turn the drain valve counterclockwise ap- 3.6L Diesel Engine

proximately 3 1/2 turns. Drain fuel filter until
clear fuel is visible in container. 1. Shut off the engine.
6. Tighten outlet plug. See Figure 77. 2. Open vent plug. See Figure 79.
CAUTION
DO NOT overtighten when closing the drain valve.
Overtightening can damage the threads.
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8000 SRM 1902 Fuel Filter Water Removal

11.36 liter (2 to 3 gal).
CAUTION
Drain water/fuel into a container and dispose in
accordance with local environmental regulations.
NOTE: The drain valve is located on the bottom of

fuel filter element.
4. Turn the drain valve counterclockwise ap-

proximately 3 1/2 turns. Drain fuel filter until
clear fuel is visible in container.
5. Close vent plug. See Figure 79.
CAUTION
DO NOT overtighten when closing the drain valve.
Overtightening can damage the threads.
1. FUEL FILTER ELEMENT
2. DRAIN VALVE 6. Close the drain valve by lifting and turning
3. FUEL INJECTION PUMP clockwise until it is hand-tight.
4. MECHANICAL FUEL PUMP
5. INLINE FUEL STRAINER 7. Truck should be ready to start.
6. FUEL SENDING UNIT
7. FUEL INJECTOR
8. VENT PLUG
Hood Latch Check

3. Carefully close hood to fully-closed position.
WARNING The hood latch has two positions. The hood
The hood, hood latch, and latch striker must be latch is 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 cen-
1. Install hood latch on frame of hood. Tighten ter of hood latch. Open hood and tighten cap-
capscrews so that hood latch can still move screws for latch.
when hood is closed. See Figure 80.
5. Check operation of hood latch. Have an opera-
2. Install latch striker in highest slot position. tor sit in the seat. Make sure hood is fully
Check that latch striker is in center of jaws of closed (two clicks). Also check that hood touches
hood latch when hood closes. rubber bumper. If necessary, repeat Step 4.
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Hood Latch Check 8000 SRM 1902
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME
Figure 80. Hood Latch Check
Lift Chain Adjustments

DO NOT try to find hydraulic leaks by putting your
WARNING hand on hydraulic components under pressure.
When working on or near the mast, see Safety Hydraulic oil can be injected into the body by the
Procedures When Working Near Mast in this sec- pressure.
tion.
During test procedures for the hydraulic system,
Never allow anyone under a raised carriage. DO fasten the load to the carriage with chains to pre-
NOT put any part of your body in or through the vent it from falling. Keep all personnel away from
lift mechanism unless all parts of the mast are the lift truck during the tests.
completely lowered and the engine is STOPPED.
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8000 SRM 1902 Lift Chain Adjustments
When lift chains are correctly adjusted: 3. Adjust chain anchors which support carriage
• Tension will be the same on each chain of until the bottom of lower carriage bar is above
chain set. Check tension by pushing on both the floor level as shown in Table 4. See Fig-
chains at the same time. ure 82.
• Chain length will be correct.

• Chains must travel freely through complete
cycle.
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 car-

riage until bottom of the fork heel is 12
+3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above floor
level. See Figure 81.
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER CAR-
RIAGE BAR
Figure 82. Lift Chain Adjustment Without Forks

Installed
In Table 4, the masts are divided by class. Each

class is determined by the lifting capability of
the lift cylinders. The Class II mast would have
the lift capability of 2.5-3.5 tons, Class III has
the lift capability of 3.5-4.0 tons, and Class IV
has the lift capability of 4.0-7.0 tons.
Table 4. Carriage Chain Adjustment, Forks Not In-

stalled
1. MAST
2. CARRIAGE 82.5 ±3 mm
Class II and Class III
3. FORK (3.25 ±0.12 in.)
4. HEEL OF FORK IS 12 +3.0/−6.0 mm (0.47
+0.12/−0.24 in.) ABOVE THE FLOOR LEVEL. 133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
Figure 81. Lift Chain Adjustments With Forks
Installed
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Jump-Starting the Lift Truck 8000 SRM 1902
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 tow- To prevent possible arcing between the two lift
ing the lift truck. Damage to the hydraulic system trucks, make sure that the lift trucks are not
can occur if engine is started by pushing or tow- touching.
ing lift truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these pro- DO NOT try to start the engine by pushing or tow-
cedures carefully when connecting the jumper ca- ing the lift truck. Damage to the hydraulic system
bles. can occur if engine is started by pushing or tow-
ing lift truck.
1. Disconnect the negative battery terminal of the
1. Always connect positive jumper cable to posi-
lift truck being started.
tive terminal of discharged battery and nega-
2. Always connect positive jumper cable to positive jumper cable to negative terminal.
tive terminal of discharged battery and nega-
2. Always connect jumper cable, that is the
tive jumper cable to negative terminal.
ground cable, last.
3. Always connect jumper cable, that is the
3. Always connect jumper cables to discharged lift
ground cable, last.
truck battery before connecting them to the
4. Always connect jumper cables to discharged fully-charged lift truck battery.
battery before connecting them to booster bat-
tery.
Welding Repairs
Forklift frames and components may be painted
WARNING with a catalyzed paint such as polyurethane or a
Welding can cause a fire or an explosion. Always two-part primer. Welding, burning, or other heat
follow the instructions in the Frame section if a sufficient to cause thermal decomposition of the
fuel or hydraulic tank must be welded. Make sure paint may release isocyanates. These chemicals
there is no fuel, oil, or grease near the weld area. are allergic sensitizers to the skin and respiratory
Make sure there is good ventilation in the area tract and overexposure may occur without odor
where the welding must be done. warning. Should work be performed, utilize good
industrial hygiene practices including removal of
DO NOT heat, weld, or bend forks. Forks are made all paint (prime and finish coats) to the metal
of special steel using special methods. The around the area to be welded, local ventilation,
strength of the overhead guard can be reduced by and/or supplied-air respiratory protection.
welding or heating. Get information from your
dealer for Hyster lift trucks before welding on a
mast.
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8000 SRM 1902 Welding Repairs
Some repairs require welding. If an acetylene or arc

CAUTION welder is used, make sure procedures in previous
When an arc welder is used, always disconnect WARNING and CAUTION are done.
the ground cable from the battery in the lift truck.
This action will prevent damage to the alternator
or the battery.
Connect the ground clamp for the arc welder as

close as possible to the weld area. This action will
prevent damage to a bearing from the large cur-
rent from the welder.
Overhead Guard Changes

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

GENERAL matic tire. Changes to the parts of the rim can
cause a failure of the wheel and cause an acci-
The H series lift trucks have pneumatic tires or dent.
solid rubber tires that look like pneumatic tires.
These variations in tires also cause a variation in WARNING
the types of wheels and the disassembly and as-
The type of tire and the tire pressure (pneumatic
sembly procedures. See Pneumatic Tire With Tube,
tires) are shown on the Nameplate. Make sure the
Repair (H Series).
Nameplate is correct for the type of tires on the lift
truck. If the truck is equipped with bias-ply tires,
The S series lift trucks have solid rubber tires (of-
the ply rating listed on the Nameplate is the mini-
ten called cushion tires) that are pressed onto the
mum ply rating that must be installed. Tires with
rim. See Solid Rubber Tire, Change (S Series).
ply rating greater than or equal to the Nameplate
listed ply rating may be acceptable. Check with
PNEUMATIC TIRE WITH TUBE, REPAIR (H your dealer whether a specific bias-ply tire is ap-
SERIES) proved for use on Hyster trucks.
Remove Wheels From Lift Truck

WARNING
Wheels must be changed and tires repaired by
WARNING trained personnel only.
A solid rubber tire that is the same shape as a
pneumatic tire can be installed on a three-piece or Deflate tire completely before removing the wheel
four-piece wheel for a pneumatic tire. DO NOT from the lift truck. If dual wheels are used, deflate
make changes in the parts of the rim if this type of both tires. Air pressure in the tires can cause the
solid rubber tire is installed instead of a pneu- tire and rim parts to explode, causing serious in-
jury or death.
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Wheel and Tire Replacement 8000 SRM 1902
Always wear safety glasses. 1. Put lift truck on blocks as described in How to
Put Lift Truck on Blocks at the beginning of
Never loosen the nuts that hold the inner and this section.
outer wheel halves together when there is air
pressure in the tire. 2. Remove air from tire. Remove valve core to
make sure all air is out of inner tube. Push a
Lift truck tires and wheels are heavy. Use caution wire through valve stem to make sure valve
when removing or installing lift truck tires and stem does not have a restriction.
wheels or personal injury can occur.
3. Remove wheel nuts and remove wheel and tire
from lift truck.
CAUTION
Not all makes of radial tires have sufficient side Remove Tire From Wheel
wall strength for successful use on forklift trucks.
This can affect stability and ride quality. Check NOTE: When you disassemble the wheels, see Fig-
with your dealer whether a specific radial tire is ure 83. There are several types of wheels used on
approved for use on Hyster trucks. this series of lift trucks.
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 83. Types of Pneumatic Wheels
Remove Tire From Two-Piece Wheel
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Always use a tire
inflator with a clip-on chuck when deflating the tire pressure. The tire inflator must be equipped with a
pressure gauge and a hose of at least 3 m (9.8 ft). 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.
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8000 SRM 1902 Wheel and Tire Replacement
STEP 1.
Remove nuts that fasten wheel rims together.
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube
and flap.
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Always use a tire
inflator with a clip-on chuck when deflating the tire pressure. The tire inflator must be equipped with a
pressure gauge and a hose of at least 3 m (9.8 ft). Air pressure in the tires can cause the tire and rim parts
to explode, causing serious injury or death.
cause an injury.
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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.
Install Wheel in Tire • DO NOT use any damaged or repaired

wheel parts.
WARNING • Make sure all parts of the wheel are the cor-
rect parts for that wheel assembly.
Damage to the tire and wheel assembly and injury
or death can occur if you do not do the following • DO NOT mix parts between different types
procedures: or manufacturers of wheels.
• Clean and inspect all parts of the wheel be-
fore installing the tire.
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• DO NOT mix types of tires, type of tire 4. Install new tire flap.
tread, or wheel assemblies of different man-
ufacturers on any one lift truck.
WARNING
DO NOT use a steel hammer on the wheel. Use a DO NOT lubricate tire bead with antifreeze or pe-
rubber, lead, plastic, or brass hammer to put parts troleum-based liquid. Vapors from these liquids
together. Make sure the side ring is in the correct can cause an explosion during inflation or use.
position. The ends of the side ring must not
touch. The clearance at the ends of the lock ring 5. Make sure rim is the correct size for tire. Lubri-
will be approximately 13 to 25 mm (0.5 to 1.0 in.) cate part of wheel that contacts bead and flap.
after it is installed. If the clearance is wrong, the
6. Install the three-piece or four piece wheel in the
wrong part has been used.
tire as shown in Install Three-Piece or Four-
1. Clean and inspect all parts of wheel. Paint any Piece Wheel in Tire.
parts that have rust or corrosion.
2. Install new inner tube in tire. Used tubes and CAUTION

flaps can cause tire failure. Do not use pneumatic-shaped, solid tires on two-
piece bolt together drive wheels. Spinning may
occur.
WARNING
DO NOT lubricate tire bead with antifreeze or pe- 7. Install the two-piece wheel in the tire as shown
troleum-based liquid. Vapors from these liquids in Install Tire on Two-Piece Wheel.
can cause an explosion during inflation or use.
3. Apply a rubber lubricant or a soap solution to

the tire bead and tube.
Install Three-Piece or Four-Piece Wheel in Tire
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following pro-
cedures:
• 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 to-
gether. 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.
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Always use a
tire inflator with a clip-on chuck when deflating the tire pressure. The tire inflator must be equipped with a
pressure gauge and a hose of at least 3 m (9.8 ft) length. Air pressure in the tires can cause the tire and
rim parts to explode causing serious injury or death.
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cause an injury.
STEP 1.
Install inner tube and rubber flap in tire.
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 • Clean and inspect all parts of the wheel be-
WARNING • DO NOT use any damaged or repaired

wheel parts.
Wheels can explode and cause injury or death if
the following procedures are not followed: • Make sure all parts of the wheel are the cor-
rect parts for that wheel assembly.
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• DO NOT mix parts between different types 2. Install new inner tube in tire. Used tubes and
or manufacturers of wheels. flaps can cause tire failure.
• DO NOT mix types of tires, type of tire
tread, or wheel assemblies of different man- WARNING
DO NOT lubricate the tire bead with antifreeze or
DO NOT use a steel hammer on the wheel. Use a petroleum-based liquid. Vapors from these liquids
rubber, lead, plastic, or brass hammer to put parts can cause an explosion during inflation or use.
together. Make sure the side ring is in the correct
3. Apply a rubber lubricant or a soap solution to
tire bead and tube.
touch. The clearance at the ends of the lock ring
will be approximately 13 to 25 mm (0.5 to 1.0 in.) 4. Install new tire flap.
wrong part has been used. 5. Make sure rim is the correct size for tire. Lubri-
cate part of wheel that contacts bead and flap.
CAUTION
DO NOT use pneumatic-shaped solid tires on two-
piece bolt together drive wheels. Spinning may
occur.
1. Clean and inspect all parts of wheel. Paint any

parts that have rust or corrosion.
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).
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ADD AIR TO PNEUMATIC TIRES WITH Install wheel on the hub. Tighten nuts in a cross
TUBE pattern to 610 to 680 N•m (450 to 502 lbf ft) for
drive wheel nuts and steer wheel nuts. If the
wheels are the two-piece rims, make sure nuts that
WARNING fasten rim halves together are toward the hub
Add air pressure to the tires only in a safety cage. when they are installed.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator
to stand away from the safety cage when air pres-
sure is added to the tire.
DO NOT sit or stand by the safety cage. DO NOT

use a hammer to try and correct the position of
the side flange or lock ring when the tire has air
pressure greater than 20 kPa (3 psi).
1. Put tire in a safety cage.
2. Add 20 kPa (3 psi) of air pressure to tire. See

Figure 84.
3. Check that all wheel parts are correctly instal-

led. Hit lock ring lightly to make sure it is in Figure 84. Add Air to Tires
the seat.
4. If installation is correct, add air pressure to tire

Dual Drive Wheels, Install
to the specified pressure. See Nameplate.
5. Check that all wheel parts are correctly instal- WARNING

led. If installation is not correct, remove all air
Lift truck tires and wheels are heavy. Use caution
pressure from tire. Remove valve core to make
when removing and installing lift truck tires and
sure all air pressure has been removed and
then make adjustments. The clearance at the
ends of the lock ring will be approximately 13 NOTE: Some lift trucks have dual drive wheels.
to 25 mm (0.5 to 1.0 in.) when the tire has the The following procedures describe the steps to in-
correct air pressure. stall the dual sets of wheels.
Install the Wheels 1. Install inner wheel on hub. Tighten nuts to 610
to 680 N•m (450 to 500 lbf ft). If two-piece
wheels are installed, make sure the nuts that
WARNING fasten the rim halves together are toward the
Lift truck tires and wheels are heavy. Use caution brake drum when they are installed.
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2. Install the spacer to the axle shaft. Tighten PNEUMATIC TUBELESS TIRE, REPAIR (H
nuts to 98 N•m (72 lbf ft). SERIES)
3. Install the outer wheel on the spacer. Tighten
nuts to 610 to 680 N•m (450 to 500 lbf ft). If the Remove Wheels From Lift Truck
wheels are the two-piece rims, make sure nuts
that fasten rim halves together are toward WARNING
brake drum when they are installed.
4. Install the valve extension bracket and tighten trained personnel only.
the attaching nut to 8 N•m (70 lbf in). Install
Deflate tire completely before removing the wheel
the valve extension hose into the bracket. See
from the lift truck. If dual wheels are used, deflate
Figure 85.
both tires. Air pressure in tires can cause the tire
and rim parts to explode causing serious injury or
death.
Always wear safety glasses.
Never loosen the nuts that hold the inner and

outer wheels halves together when there is air
pressure in the tire.

1. The Tubeless Bead Seal (TBS) enables tubeless

tires to be used on wheel rims that were de-
signed to be used with a tube.
The main component of a TBS is a special rubber

ring that fits inside the tire between the tire
beads to ensure the air tightness of the existing
wheel and the tubeless tire assembly. See Fig-
ure 83.
Put lift truck on blocks as described in How to

Put Lift Truck on Blocks at beginning of this sec-
tion.
2. Remove the valve cap and core to remove all air

1. TIRE
2. DUAL HUB ASSEMBLY from the tire.
3. WHEEL NUT
4. WHEEL 3. Remove the wheel nuts and remove the wheel
5. WHEEL ADAPTER SPACER and tire from the lift truck.
6. VALVE EXTENSION
7. BRACKET
Figure 85. Dual Drive Wheels Installation
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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.
cause injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Fig-
ure 83.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.
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.
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STEP 3.
Remove the loose flange locking ring and the ad-
vance band (four-piece wheel only) using a tire
tool.
STEP 4.
Remove the press and remove the loose flange
locking ring and the advance band (four-piece
wheel only) from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to re-
move it.
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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 proce-
dures:
• 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 to-
gether.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids 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 un-
derside of the TBS.
NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to accommo-
date the needle valve. If the wheel rim width is greater than 152 mm (6 in.), 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 re-
moving 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.
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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 sur-
face. 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
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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

until 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. Re-
move the press from wheel and tire assembly.
ADD AIR TO PNEUMATIC TUBELESS sure all air pressure has been removed and
TIRE then make adjustments. The clearance at the
ends of the lock ring will be approximately 13
to 25 mm (0.5 to 1.0 in.) when the tire has the
WARNING correct air pressure.
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator
to stand away from the safety cage when air pres-
sure is added to the tire.
DO NOT sit or stand by the safety cage.
1. Put tire in a safety cage. See Figure 86.
2. Add air to tire to the recommended air pressure

that is shown on the Nameplate. Install valve
cap to ensure air stays in the tire.
3. Check that all wheel parts are correctly instal-

led. If installation is not correct, remove all air
Figure 86. Add Air to Tires
pressure from tire. Remove valve core to make
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Install the Wheels Always wear safety glasses.

WARNING when removing and installing lift truck tires and
Lift truck tires and wheels are heavy. Use caution wheels or personal injury can occur.
wheels or personal injury can occur. 1. Put lift truck on blocks as described in How to
Put Lift Truck on Blocks at the beginning of
Install wheel on the hub. Tighten nuts in a cross this section.
pattern to 610 to 680 N•m (450 to 502 lbf ft) for 2. Remove wheel nuts and remove wheel and tire
drive wheel nuts and steer wheel nuts. If the from lift truck.
wheels are the two-piece rims, make sure nuts that
fasten rim halves together are toward the hub
when they are installed.
WARNING
NOTE: Some lift trucks have dual drive wheels.

The following procedures describe the steps to in-
stall the dual sets of wheels.
1. Install inner wheel on hub. Tighten nuts to 610

to 680 N•m (450 to 500 lbf ft). If two-piece
wheels are installed, make sure the nuts that
fasten the rim halves together are toward the
brake drum when they are installed. See Fig-
ure 87.
2. Install the spacer to the axle shaft. Tighten

nuts to 98 N•m (72 lbf ft).
3. Install the outer wheel on the spacer. Tighten

nuts to 610 to 680 N•m (450 to 500 lbf ft). If the
wheels are the two-piece rims, make sure nuts 1. TIRE
that fasten rim halves together are toward 2. DUAL HUB ASSEMBLY
3. WHEEL NUT
brake drum when they are installed. 4. WHEEL
5. WHEEL ADAPTER SPACER
4. Install the valve extension bracket and tighten 6. VALVE EXTENSION
the attaching nut to 8 N•m (70 lbf in). Install 7. BRACKET
the valve extension hose into the bracket. See
Figure 87. Figure 87. Dual Drive Wheels Installation
SOLID RUBBER TIRE ON PNEUMATIC

WHEEL, CHANGE (H SERIES)
WARNING
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Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Figure 83. 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.
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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.
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Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 83. 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
or death can occur if you do not do the follow pro-
cedures:
• 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 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
touch. The clearance at the ends of the lock ring
will be approximately 13 to 25 mm (0.5 to 1.0 in.)
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.
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STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to in-
stall tire on wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side
ring, and lock ring in position on wheel rim. In-
stall cage on tire. Use press to push tire onto
wheel rim so side flange and lock ring can be in-
stalled.
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.
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SOLID RUBBER TIRE, CHANGE (S Always wear safety glasses.

SERIES) NOTE: Solid rubber tires made from softer or
harder material can be installed as optional equip-
WARNING ment. The tread on the solid rubber tires can be ei-
The type of solid rubber tire is shown on the ther smooth or it can have lugs. Do not mix types of
Nameplate. Make sure the Nameplate is correct tires or tread on lift truck. See Figure 88.
for the type of tires on the lift truck. The 12,000 lb 1. Raise the lift truck as described in How to Put
capacity solid rubber tired forklift truck must be Lift Truck on Blocks in this manual.
equipped with high-load capacity steering tires.
2. Remove the wheel nuts and remove the wheel
Wheels must be changed and tires repaired by from the lift truck. Lift truck wheels are heavy.
A. STEERING TIRE AND WHEEL C. WIDE TREAD

B. DRIVE TIRES AND WHEELS
1. OUTSIDE OF SOLID RUBBER TIRE 3. OVERHANG
2. WHEEL
Figure 88. Tires and Wheels
Remove and Install Tire on Wheel capacity of the press must be approximately
355 to 1779 kN (80,000 to 400,000 lb). For the
NOTE: Make sure the tires are installed on the tire sizes, see the Nameplate.
wheels so that the outside edges of the tire and
wheel are as shown in Figure 88. Also check the 2. When the drive wheels are installed on the lift
Nameplate of the lift truck for the correct tire size truck, tighten the wheel nuts to 610 to
and tread width. 680 N•m (450 to 502 lbf ft).
1. The correct tools, equipment, and a press ring

must be used for each size of wheel. Use a press
to push the wheel from the rim and tire. The
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3. The steering wheels are fastened to the spindle Always wear safety glasses.
of the steering axle with a large castle nut.
Make sure inner and outer bearings are cor- 1. Put the lift truck on blocks as described in How
rectly lubricated with grease. Install inner to Put Lift Truck on Blocks at the beginning of
bearing assembly and wheel on spindle. Install this section.
outer bearing cone and castle nut. Tighten cas-
NOTE: See Figure 90 when you disassemble the
tle nut up to 203 N•m (150 lbf ft) while rotating
wheels. There are several types of wheels used on
hub in both directions to properly seat the bear-
these series of lift trucks.
ings. Loosen castle nut until wheel hub turns
freely with no end play. Tighten castle nut to 2. Remove the wheel nuts and remove the wheel
34 N•m (25 lbf ft). Install cotter pin in castle and tire from the lift truck. Lift truck tires and
nut. If the cotter pin cannot be installed, loosen wheels are heavy.
the castle nut to the first position where the
cotter pin can be installed. Install caps for bear-
ings.

NOTE: Some lift trucks can have dual drive
wheels. The following procedures describe the steps
to install the dual sets of wheels.
1. See Figure 89. Install inner wheel on hub.

Tighten nuts to 610 to 680 N•m (450 to
502 lbf ft). If two-piece wheels are installed,
make sure the nuts that fasten the rim halves
together are toward the brake drum when they
are installed.
2. Install spacer to axle shaft. Tighten nuts to

98 N•m (72 lbf ft).
1. INNER WHEEL
3. Install outer wheel on spacer. Tighten nuts to 2. ADAPTER ASSEMBLY
610 to 680 N•m (450 to 502 lbf ft). If the wheels 3. OUTER WHEEL
are the two piece rims, make sure the nuts that 4. EXTENSION, AIR VALVE
fasten the rim halves together are toward the
brake drum when they are installed. Figure 89. Dual Drive Wheels Installation
SNAP-ON-TIRE, CHANGE
WARNING
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Figure 90. Snap-On-Tires and Rim Configurations
Remove Snap-On-Tire, Solid Tire From Wheel
WARNING
Keep tire tools in firm contact with the wheel. If
the tool slips, it can move with enough force to
cause serious injury.
STEP 1.
Put a support under the wheel rim. Make sure the
wheel rim is at least 150 to 200 mm (6 to 8 in.)
from the bed of the press.
STEP 2.
Put the cage in position on the tire. Use the press
to push the tire from the wheel rim.
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Install Snap-On-Tire, Solid Tire on Wheel
WARNING
or death can occur if you do not do the follow pro-
cedures:
• 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.
CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.
NOTE: When wheels are disassembled, see Fig-

ure 90. There are several types of wheels used on
this series of lift trucks.
STEP 1.
Lubricate the wheel rim and the inner surface of
the tire with tire lubricant.
STEP 2.
Put the wheel rim on the bed of the press. Put the
tire over the wheel rim. Put the cage in position
on the tire. Use the press to install the tire on the
wheel rim.
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HeavyManuals.com
Adhesives and Sealants 8000 SRM 1902
Adhesives and Sealants
Hyster Loctite®
Description Size
Part No. 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
® ® ®
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.
124
HeavyManuals.com
HeavyManuals.com
TECHNICAL PUBLICATIONS
8000 SRM 1902 1/16 (7/15)(4/15)(3/15)

Periodic Maintenance: S4.0FT, 4.5FT, 5.5FT, S5.5FTS (J004) H4.0FT5/FT6 H4.5FTS5, H4.5FT6 H5.0-5.5FT (U005)

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Periodic Maintenance: S4.0FT, 4.5FT, 5.5FT, S5.5FTS (J004) H4.0FT5/FT6 H4.5FTS5, H4.5FT6 H5.0-5.5FT (U005)

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PART NO. 4128429 8000 SRM 1902

©2016 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

S4.0FT, 4.5FT, 5.5FT, S5.5FTS [J004];

The recommendations for time intervals provided is

1. The towed lift truck must have an operator.

A. COUNTERWEIGHT WITHOUT TOW PIN B. COUNTERWEIGHT WITH TOW PIN

Figure 1. Tow Pin

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

• Before removing the counterweight, put How to Raise Steering Tires

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK 4. Lightly spray a non-corrosive cleaning agent

Table 1. Maintenance Schedule, Lift Truck Model S4.0-5.5FT, S5.5FTS (J004)

Horn, Lights, X Check Operation.

13 Wheel Bearings L Check Grease. Multipurpose Grease

16 Fuel Tank (Short CIL 79 liter (20.8 gal) See Table 3.

19 Engine Oil Filter C 1 Filter See Parts Manual.

9 Engine Oil X C 13.2 liter (13. qt) See Table 3.

19 Engine Oil Filter C 1 Filter See Parts Manual.

9 Engine Oil X C 12.2 liter (12.9 qt) SAE 10W-30

18 Air Filter (with CIL C 1 Filter See Parts Manual

5 Spark Plugs, C Change Spark Plugs See Parts Manual

34 Wheel Bearings L Check Grease. Multipurpose Grease

2 Pedals, Levers, Seat L Lubricate as Use Silicone Spray

Table 3. Diesel Fuel and Engine Oil

Engine Oil Specification by Diesel Fuel Type

Maintenance Procedures Every 8 Hours or Daily

Figure 6. Tire Check

Safety Labels Mast, Carriage, Lift Chains, Header Hoses,

DO NOT operate fork lift without lateral fork stops

1. Inspect welds on mast and carriage for cracks.

2. Inspect carriage to be sure fork stops are in

3. Inspect channels for wear in areas where roll-

4. Inspect load backrest extension for cracks and

5. If lift truck is equipped with an integral side-

1. LATCH STRIKER 7. ARM REST

Figure 8. Hood and Seat Check

1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER

Figure 9. Seat Adjustment

Adjust Seat - Internal Suspension Engine Compartment

Check condition of exhaust wraps for wear, proper

Also check condition of radiator or heater hoses

Coolant Hoses Transmission

Steering Column Gas Cylinder

Never operate the hydraulic pump without oil in

After engine has stopped, wait one minute before

Check hydraulic system for leaks and damaged or

Never operate the engine without oil. The opera-

After engine has stopped, wait one minute before

A. TOP VIEW B. LEFT HAND SIDE SHOWN

Figure 12. Kubota 3.8L Diesel Engine Maintenance Points

A. TOP VIEW B. LEFT HAND SIDE SHOWN

Figure 13. Kubota 3.6L Diesel Engine Maintenance Points

Air Filter 1. A fork can be removed from carriage for re-

DO NOT operate lift truck until air filter element

The identification of a fork describes how fork is

2. Replace any damaged or broken parts that are

Fork Tip Alignment