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PERIODIC MAINTENANCE

S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS [G004]; H80, 90, 100, 110, 120FT [N005, P005]

PART NO. 1624742

8000 SRM 1248

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR


When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

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

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS
General ................................................................................................................................................................. Serial Number Data ........................................................................................................................................ How to Move Disabled Lift Truck................................................................................................................... How to Tow Lift Truck ................................................................................................................................ How to Put Lift Truck on Blocks .................................................................................................................... How to Raise Drive Tires ............................................................................................................................ How to Raise Steering Tires ....................................................................................................................... How to Clean a Lift Truck............................................................................................................................... Maintenance Schedule....................................................................................................................................... Maintenance Procedures Every 8 Hours or Daily............................................................................................ How to Make Checks With Engine Stopped................................................................................................. Tires and Wheels ....................................................................................................................................... Safety Labels ............................................................................................................................................. Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... Operator Restraint System....................................................................................................................... Emergency Locking Retractor (ELR) ................................................................................................... Adjust Seat - Full Suspension .............................................................................................................. Adjust Seat - Internal Suspension ....................................................................................................... Hood and Seat Latches ............................................................................................................................. Engine Compartment................................................................................................................................ Paper Application ...................................................................................................................................... Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ Hydraulic Hoses ........................................................................................................................................ Coolant Hoses ............................................................................................................................................ Steering Column Gas Cylinder................................................................................................................. Transmission ............................................................................................................................................. Hydraulic System Oil ................................................................................................................................ Engine Oil .................................................................................................................................................. Air Filter .................................................................................................................................................... Forks .......................................................................................................................................................... Remove .................................................................................................................................................. Inspect ................................................................................................................................................... Install..................................................................................................................................................... Adjust..................................................................................................................................................... Integral Sideshift Carriage....................................................................................................................... How to Make Checks With Engine Running................................................................................................ Indicator Lights, Horn, Fuses, and Relays .............................................................................................. Service Brakes ........................................................................................................................................... Brake Oil Level ..................................................................................................................................... Operation, Check .................................................................................................................................. Parking Brake ........................................................................................................................................... Engine Oil Pressure .................................................................................................................................. Cooling System .......................................................................................................................................... Steering System ........................................................................................................................................ Control Levers and Pedals ........................................................................................................................ Lift System, Operate ................................................................................................................................. First Service After First 100 Hours of Operation ............................................................................................ GM 4.3L Engine Oil and Oil Filter ............................................................................................................... Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 1 1 1 1 3 3 3 4 11 21 21 21 22 22 23 23 24 25 26 26 26 27 27 27 27 28 28 28 32 32 32 33 33 34 34 35 35 37 37 38 38 38 39 39 40 40 41 41 41 42 42

2011 HYSTER COMPANY

Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued)


Drive Belt ....................................................................................................................................................... GM 4.3L Engine ........................................................................................................................................ Fan and Alternator Drive Belt ............................................................................................................. Drain Tar From LPG Regulator.................................................................................................................... Drain Tar From LPG Converter ................................................................................................................... Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. Hydraulic System Oil .................................................................................................................................... Hydraulic Tank Breather .............................................................................................................................. Inspect........................................................................................................................................................ Battery ........................................................................................................................................................... Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) .................................................................... Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ............................................................. Controlled Venting .................................................................................................................................... Manual Bleeding ....................................................................................................................................... Drive Belt ....................................................................................................................................................... Cummins 4.5L and QSB 3.3L Diesel Engine........................................................................................... Fan and Alternator Drive Belt ............................................................................................................. Clean Debris From Radiator Core ................................................................................................................ Transmission Oil Level ................................................................................................................................. Wet Brake Center Body Oil Level Check ..................................................................................................... Forks............................................................................................................................................................... Mast Lubrication ........................................................................................................................................... Header Hose Checks...................................................................................................................................... Lift Chain Lubrication .................................................................................................................................. Tilt Cylinder Lubrication .............................................................................................................................. Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... Manual Hydraulic Levers Lubrication ......................................................................................................... Brake Oil ........................................................................................................................................................ Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)........................................................................................................................................ Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) ................................. Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... Valve Clearance, Check and Adjust.............................................................................................................. Ignition System.............................................................................................................................................. GM 4.3L Engine ........................................................................................................................................ LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Lift Chains Wear Check ................................................................................................................................ Lift Chain Lubrication .................................................................................................................................. Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) ...................................................................................................................... 42 42 42 43 43 44 44 44 44 45 45 46 46 46 48 49 49 49 50 50 50 51 51 52 54 54 56 57 57 58 58 59 59 60 60 61 61 61 61 61 61 61 62 62 62 64 64 64 65

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Periodic Maintenance

Table of Contents

TABLE OF CONTENTS (Continued)


Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)............ Control Levers and Pedals ............................................................................................................................ Inspect Engine Electrical System, Connectors ............................................................................................ Maintenance Procedures Every 2000 Hours or Annually ............................................................................... Hydraulic System .......................................................................................................................................... Hydraulic Filter, Replace .......................................................................................................................... Hydraulic Tank Breather, Replace ........................................................................................................... Ignition System; Distributor Cap, Rotor, and Spark Plug Wires ................................................................ Cooling System, GM 4.3L and Cummins 4.5L and QSB 3.3L Engines ...................................................... Air Filter ........................................................................................................................................................ Oxygen Sensor GM 4.3L LPG Engines Equipped with GFI Installed........................................................ LPG Regulator Fuel Filter, GM 4.3L Engines Equipped With GFI Installed............................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Gasoline Fuel Filter....................................................................................................................................... Remove and Replace ................................................................................................................................. LPG Fuel Injector, GM 4.3L Engines Equipped With GFI Installed.......................................................... Gasoline Fuel Injector, GM Engines ............................................................................................................. Fuel Injector, Cummins 4.5L and QSB 3.3L Engine ................................................................................... Forks............................................................................................................................................................... Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... Wet Brake Center Section Oil Change ......................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Brake Oil (Master Cylinder), Change........................................................................................................... Brake Oil (Dry Brake), Remove .................................................................................................................... Service Brakes (Dry Brake) .......................................................................................................................... Differential (Dry Brake) ................................................................................................................................ Test LPG/GAS Regulator Pressure............................................................................................................... Check Throttle Shaft for Sticking................................................................................................................. Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... Hydraulic Oil, Replace .................................................................................................................................. Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... Weld Inspection.............................................................................................................................................. Safety Procedures When Working Near Mast.................................................................................................. Fuel Filter Water Removal ................................................................................................................................ Hood Latch Check .............................................................................................................................................. Lift Chain Adjustments ..................................................................................................................................... Jump-Starting the Lift Truck............................................................................................................................ Jump-Starting Using a Battery Charger ..................................................................................................... Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... Welding Repairs ................................................................................................................................................. Overhead Guard Changes ................................................................................................................................. Wheel and Tire Replacement ............................................................................................................................ General ........................................................................................................................................................... Solid Rubber Tire, Change (S Series) ........................................................................................................... Remove and Install Tire on Wheel ........................................................................................................... Pneumatic Tire With Tube, Repair............................................................................................................... 65 66 66 66 66 66 67 67 68 68 70 71 71 71 71 71 72 72 72 72 72 73 75 75 75 76 77 78 78 79 79 79 79 81 81 82 84 87 89 90 91 92 92 92 93 93 94 94 94 94 95

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Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued)


Remove Wheels From Lift Truck.............................................................................................................. Remove Tire From Wheel ......................................................................................................................... Remove Tire From Two-Piece Wheel ................................................................................................... Remove Tire From Three- and Four-Piece Wheels ............................................................................. Install Wheel in Tire ................................................................................................................................. Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. Install Tire on Two-Piece Wheel ........................................................................................................ Install Two-Piece Wheel in Tire ......................................................................................................... Add Air to Pneumatic Tires With Tube...................................................................................................... Install the Wheels ................................................................................................................................... Dual Drive Wheels, Install ..................................................................................................................... Pneumatic Tubeless Tire, Repair................................................................................................................ Remove Wheels From Lift Truck............................................................................................................ Remove Tire From Wheel ....................................................................................................................... Install Tire on Wheel .............................................................................................................................. Add Air to Pneumatic Tubeless Tire ...................................................................................................... Wheels, Install......................................................................................................................................... Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... Remove Wheel From Tire ....................................................................................................................... Install Tire on Wheel .............................................................................................................................. Adhesives and Sealants ................................................................................................................................... This section is for the following models: S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS [G004]; H80, 90, 100, 110, 120FT [N005, P005] 95 96 96 97 98 99 100 100 101 101 102 103 103 103 105 107 108 108 108 110 112

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8000 SRM 1248

General

General
WARNING
DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can make a dangerous operating condition. shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster lift trucks to help users who do their own maintenance.

SERIAL NUMBER DATA


The serial number for the lift truck is on the nameplate. It is also on the right side of the frame, under the floor plate.

WARNING
DO NOT operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operators area. Remove the key from the key switch.

HOW TO MOVE DISABLED LIFT TRUCK How to Tow Lift Truck WARNING

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. This section contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance of your lift truck. The service intervals are given in both operating hours recorded on the lift truck hourmeter and in calendar time. The recommendation is to use the interval that comes first. The recommendations for the time intervals given for eight hours of operation per day. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: The lift truck is used more than eight hours per day. The lift truck must work in dirty operating conditions. Poor ground conditions. Intensive usage at high performance levels or other abnormal conditions will require more frequent servicing. Your dealer for Hyster lift trucks has the equipment and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A regular program of inspection, lubrication, and maintenance will help your lift truck provide more efficient performance and operate for a longer period of time. Some users have service personnel and equipment to do the inspection, lubrication, and maintenance

Use extra caution when towing a lift truck if any of the following conditions exist: Brakes do not operate correctly. Steering does not operate correctly. Tires are damaged. Traction conditions are bad. The lift truck must be towed on a slope. If the engine cannot run, there is no power available for the hydraulic steering system and the service brakes. This condition can make the lift truck difficult to steer and stop. If the lift truck uses power from the engine to help apply the brakes, the application of the brakes will be more difficult. Poor traction can cause the disabled lift truck or towing vehicle to slide. A slope will also make the lift truck more difficult to stop. Never lift and move a disabled lift truck unless the disabled lift truck MUST be moved and cannot be towed. A lift truck used to move a disabled lift truck MUST have a capacity rating equal to or greater than the weight of the disabled lift truck. The capacity of the lift truck used to move a disabled lift truck must have a load center equal to half the width of the disabled lift truck. See the nameplate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Put the weight center of the disabled lift truck on load center of the forks. Be careful to not damage the underside of the lift truck. 1. The towed lift truck must have an operator. 2. Tow truck slowly.

General 3. Using a lift truck or a lifting device that could be attached to the mast (I.E. come-a-long), raise carriage and forks approximately 30 cm (12 in.) from surface. Install chain around a mast crossmember and the carriage to prevent carriage and mast channels from moving. 4. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. Install approximately 1/2 of a capacity load on forks of lift truck that is being used to tow disabled lift truck. This 1/2 capacity load will increase traction of lift truck. Keep load as low as possible. 5. If lift trucks are equipped with a tow pin in the counterweight (standard counterweight), use a

8000 SRM 1248 towing link made of steel that fastens to the tow pins in the counterweights of both lift trucks. See Figure 1. Slowly and carefully remove the slack out of the towing link. 6. If lift trucks are equipped with a leaded counterweight without a tow pin (see Figure 1), use a towing link made of steel that fastens to the two center grill bars of both lift trucks. Slowly and carefully remove the slack out of the towing link. Lift truck models that are equipped with a leaded counterweight, that are covered in this SRM are S80FTBCS, S100FTBCS, S120FTS, and S120FTPRS (G004).

A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT) B. COUNTERWEIGHT WITH TOW PIN (STANDARD COUNTERWEIGHT) 1. TOWING LINK 2. CENTER GRILL BARS Figure 1. Counterweight Types 3. TOW PIN

8000 SRM 1248

General 2. Put mast in vertical position. Put a block under each outer mast channel. 3. Tilt mast fully forward until drive tires are raised from surface. 4. Put additional blocks under frame behind drive tires. 5. If hydraulic system will not operate, use a hydraulic jack under the side of the frame near the front. Make sure jack has a capacity equal to at least half the weight of the lift truck. See Nameplate.

HOW TO PUT LIFT TRUCK ON BLOCKS How to Raise Drive Tires WARNING
The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine, transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward. The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units.

How to Raise Steering Tires


NOTE: Some lift trucks are equipped with lifting eyes for the purpose of lifting the entire lift truck. If the lift truck is equipped with this type of lifting eyes, the lift truck can be lifted and blocks installed. 1. Apply parking brake. Put blocks on both sides (front and back) of drive tires to prevent movement of lift truck. See Figure 2. 2. Use hydraulic jack to raise steering tires. Make sure jack has a capacity of at least 2/3 of total weight of lift truck as shown on the nameplate. 3. Put jack under steering axle or frame to raise lift truck. Put blocks under frame to support lift truck.

CAUTION
These lift trucks are equipped with cowl lifting eyes. The cowl lifting eyes are to be used to lift the front of the lift truck only. Lifting more than the front of the lift truck with the cowl lifting eyes will damage the cowl section. 1. Put blocks on each side (front and back) of steering tires to prevent movement of lift truck. See Figure 2.

General

8000 SRM 1248

1. DRIVE TIRES

2. STEERING TIRES Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK WARNING


Engine, exhaust system components and other components are hot to the touch. Be sure lift truck components are cool before starting inspection and cleaning, or personal injury may occur.

refer to Paper Application section in the applicable Operating Manual and to available Service Gram/ Bulletin for more detail. If it becomes necessary to clean the fork lift, follow the guidelines listed below. 1. Assure truck components are cool before starting the cleaning procedure. 2. Disconnect the battery. If an electric truck, remove the traction battery. 3. Remove accumulated debris using a compressed air line and nozzle. 4. Lightly spray a non-corrosive cleaning agent onto the areas to be cleaned. This will help loosen grime, so close contact direct spraying will not be necessary. 5. Be sure to avoid directing the spray into electrical panel compartment. Ensure overspray does not come in contact with electrical components; do not spray water directly at electrical components, wiring connectors or electrical enclosures. Even sealed connectors may allow water egress under pressure or if connector is damaged.

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION
Units may be washed with a non-heated pressure washer. Steam cleaning is not recommended in most instances, as condensation may form in electrical components causing damage or erratic behavior. NOTE: Lift trucks used in paper applications may need cleaning beyond what is described here. Please

8000 SRM 1248 6. Avoid spraying in areas containing electrical components such as: Floor Plates Battery Compartment Dash/cowl assembly Armrests with electrical components 7. Clean the battery compartment by using a clean cloth to wash the battery with water. Dry with compressed air. Care should be taken to keep moisture at a minimum as some units have a traction or hydraulic motor directly below the battery compartment.

General 8. DO NOT pressure wash the battery. Do not use hot water. For cleaning traction batteries, refer to the Battery section of the Service Manual. 9. DO NOT pressure wash lift chains, sheaves or load rollers in the mast assembly. Refer to the Chains, Sheaves and Load Rollers maintenance section in the Service Manual for proper cleaning procedures. 10. After cleaning, immediately start and run the lift truck to dry out components.

General

8000 SRM 1248

Figure 3. GM 4.3L LPG Trucks With GFI Installed

8000 SRM 1248

General

Figure 4. GM 4.3L LPG Trucks With PSI Installed

General

8000 SRM 1248

Figure 5. GM 4.3 Gasoline Trucks

8000 SRM 1248

General

Figure 6. Cummins 4.5L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (N005)

General

8000 SRM 1248

Figure 7. Cummins QSB 3.3L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (P005)

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8000 SRM 1248

Maintenance Schedule

Maintenance Schedule
NOTE: The lift trucks shown in Figure 3, Figure 4, and Figure 5 represent SSE 100, 120FT; S80, 100FTBCS; S120FTS, and S120FTPRS (G004) lift trucks. NOTE: The lift trucks shown in Figure 3, Figure 4, Figure 5, Figure 6, and Figure 7 represent H80, 90, 100, 110, 120FT (N005, P005) lift trucks. NOTE: The 250-hour, 500-hour, and 1000-hour/6month maintenance services are performed either at the specified hours or at 6 months whichever occurs first.

Table 1. Maintenance Schedule


Item No. 25 Item Tires and Wheels 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Check Condition Replace as Necessary Check Condition and Lubrication Check Condition and Operation Check Condition and Operation Remove Combustible Materials See NOTE 5. Check Condition Clean as Required Replace as Required See NOTE 8. Specification See Nameplate

Safety Labels 28, 29 Mast, Carriage, Header Hoses, Lift Chains, Attachment Seat Belt, Hip Restraints, and Seat Rails Hood and Seat Latches Engine Compartment

X X

See Parts Manual See Parts Manual

Paper Application: Engine Compartment, Truck Components, Exhaust Wraps, Radiator, Radiator Screen if equipped, Belly Pan if equipped Check for Leaks Fuel, Oil, Water Hydraulic Hoses 13 Coolant Hoses

Check for Leaks See NOTE 1. Check Condition Check Condition See Parts Manual See Parts Manual

X X

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule

8000 SRM 1248

Table 1. Maintenance Schedule (Continued)


Item No. 16 Item Fuel Tank (LPG) 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity CIL Specification

15.1 - 20.4 kg LPG - HD 5, HD 10 (33.5 - 45.0 lb) Full 44.7 liter (11.8 gal) 86 Octane - Gasoline Minimum

16

Fuel Tank GM 4.3L (Gasoline) [S80, 100, 120FT;] S80, 100FTBCS; S120FTS; S120FTPRS (G004) U.S. Only Fuel Tank (Short Wheel Base) GM 4.3L (Gasoline) H80, 90, 100, 110, 120FT (N005, P005) U.S. Only Fuel Tank (Long Wheel Base) GM 4.3L (Gasoline) H80, 90, 100, 110, 120FT (N005, P005) U.S. Only Fuel Tank (Short Wheel Base) Cummins 4.5L and QSB 3.3L (Diesel) H80, 90, 100, 110, 120FT (N005, P005) Fuel Tank (Long Wheel Base) Cummins 4.5L and QSB 3.3L (Diesel) H80, 90, 100, 110, 120FT (N005, P005) Horn, Lights, Alarms, Fuses, and Relays

CIL

16

CIL

79 liter (20.8 gal)

86 Octane Minimum

16

CIL

100.3 liter (26.5 gal)

86 Octane Minimum

16

CIL

79 liter (20.8 gal)

Diesel No. 2

16

CIL

100.3 liter (26.5 gal)

Diesel No. 2

Check Operation Check Operation Check Operation

1 23

Service Brakes Parking Brake

X X

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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8000 SRM 1248

Maintenance Schedule

Table 1. Maintenance Schedule (Continued)


Item No. Item Steering Controls and Steering Column Gas Cylinder 22 22 3 Transmission Transmission Hydraulic Oil GM 4.3L [S80, 100, 120FT]; S80, 100FTBCS, S120FTS; S120FTPRS (G004) Hydraulic Oil (Short Wheel Base) H80, 90, 100, 110, 120FT (N005, P005) Hydraulic Oil (Long Wheel Base) H80, 90, 100, 110, 120FT (N005, P005) Hydraulic Oil Filter Hydraulic Tank Breather X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Check Condition and Operation Check for Leaks Check Operation X C 39.4 liter (41.6 qt) See NOTE 2 and NOTE 3. ISO VG 46 Hydraulic Oil 15C (5F) and Above John Deere JDM J20C Specification

X X X

62.0 liter (65.5 qt) See NOTE 2 and NOTE 3 78.0 liter (82.4 qt) See NOTE 2 and NOTE 3 1 Filter Inspect and Replace as Required See NOTE 5. Clean 4.7 liter (5.0 qt) See NOTE 4 and NOTE 5.

ISO VG 46 Hydraulic Oil 15C (5F) and Above ISO VG 46 Hydraulic Oil 15C (5F) and Above See Parts Manual See Parts Manual

6 10

C C

8 9

Battery and Cable Terminals Engine Oil GM 4.3L Engine (Gasoline/LPG) X CIL C

7C (20F) and Below SAE 5W-20 16C (60F) and Below SAE 5W-30 18C (0F) and Above SAE 10W-30 API SM ILSAC GF4 SAE J2362 See Parts Manual

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Engine Oil Filter GM 4.3L Engine

1 Filter See NOTE 4 and NOTE 5.

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule

8000 SRM 1248

Table 1. Maintenance Schedule (Continued)


Item No. 9 Item Engine Oil Cummins 4.5L Engine (Diesel) 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X CIL C 13.0 liter (13.7 qt) See NOTE 4 and NOTE 5. Specification 0C (32F) and Below SAE 0W-30 25 to 20C ( 13 to 68F) SAE 5W-30 20 to 20C ( 4 to 68F) SAE 10-30 15C (5F) and Above SAE 5W-40 or 15W-40 API CH-4 or CI-4 0C (32F) and Below SAE 0W-30 25 to 20C ( 13 to 68F) SAE 5W-30 20 to 20C ( 4 to 68F) SAE 10-30 15C (5F) and Above SAE 5W-40 or 15W-40 API CH-4 or CI-4 See Parts Manual

Engine Oil Cummins QSB 3.3L Engine (Diesel)

X CIL

7.5 liter (8 qt) See NOTE 4 and NOTE 5.

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Engine Oil Filter Cummins 4.5L and QSB 3.3L (Diesel) Air Filter (with premium monitoring) Air Filter CIL

1 Filter See NOTE 4 and NOTE 5. C 1 Filter See NOTE 5, NOTE 6, and NOTE 12. 1 Filter See NOTE 5, NOTE 6, and NOTE 12.

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See Parts Manual

18

See Parts Manual

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule

Table 1. Maintenance Schedule (Continued)


Item No. Item Engine Oil Pressure 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity CIL Check Oil Pressure Specification GM Engine 207 to 380 kPa (30 to 55 psi) Cummins 4.5L Diesel Engine at High Idle 207 kPa (30 psi) at Low Idle 69 kPa (10 psi) Cummins QSB 3.3L Diesel Engine 49 kPa (7 psi) Minimum

15

Drive Belt GM Engine

Check for Wear and Damage. No Adjustment Needed. See NOTE 5. X Check for Wear and Damage. No Adjustment Needed. See NOTE 5. Drain Tar See NOTE 5. Drain Tar See NOTE 5. 750 25 rpm

15

Drive Belt Cummins 4.5L and QSB 3.3L (Diesel) LPG Regulator GM 4.3L Engine With GFI Installed X

33

LPG Converter 4.3L LPG Engine With PSI Installed Engine Idle Speed GM 4.3L (Gasoline/LPG) Engine Governed Speed GM 4.3L (Gasoline/LPG) Engine Idle Speed Cold Engine Cummins 4.5L (Diesel) Engine Idle Speed Hot Engine Cummins 4.5L (Diesel)

2400 25 rpm

Coolant Temperature Less than 77C (170F) Coolant Temperature Greater than 77C (170F)

770 50 rpm

800 50 rpm

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule

8000 SRM 1248

Table 1. Maintenance Schedule (Continued)


Item No. Item Engine Governed Speed (No Load) Cummins 4.5L Diesel PCV Valve GM 4.3L Engine with GFI Installed Engine Idle Speed Cold Engine Cummins QSB 3.3L (Diesel) Engine Idle Speed Hot Engine Cummins QSB 3.3L (Diesel) Engine Governed Speed Cummins QSB 3.3L (Diesel) Oxygen Sensor GM 4.3L Engine With GFI Installed 4 4 Valve Adjustment GM 4.3L Engine Valve Adjustment Cummins 4.5L Diesel Engines X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Specification 2250 50 rpm

Replace as Necessary See NOTE 14 Coolant Temperature Less than 30C (86F) Coolant Temperature Greater than 30C (86F)

See Parts Manual

1000 25 rpm

800 25 rpm

2230 25 rpm

X CIL

Replace as Necessary Not Adjustable Adjust as Required Intake 0.254 mm (0.010 in.) Cold Exhaust 0.508 mm (0.020 in.) Cold

Valve Adjustment Cummins QSB 3.3L Diesel Engines

Adjust as Intake Required 0.35 mm (0.014 in.) See NOTE 13. Cold Exhaust 0.50 mm (0.02 in.) Cold 1 Filter See Parts Manual See Parts Manual See Parts Manual

17 17 17

Fuel Filter, LPG (GM) Fuel Filter Gasoline (GM) Fuel Water Separator Filter Cummins 4.5L and QSB 3.3L Diesel Engine CIL C

C C

1 Filter 1 Filter Drain Water from Filter as Required

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

16

8000 SRM 1248

Maintenance Schedule

Table 1. Maintenance Schedule (Continued)


Item No. 17 Item In-Line Fuel Filter Cummins 4.5L Diesel Engine Final Fuel Filter Cummins QSB 3.3L Diesel Engine Fuel Injectors GM 4.3L Gas C 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity C 1 Filter Specification See Parts Manual

17

1 Filter

See Parts Manual

20

Check and Replace If Required 6 Injectors Check and Replace If Required 6 Injectors Check Plug Wires 6 Plugs See NOTE 9.

20

Fuel Injectors GM 4.3L LPG With GFI Installed Spark Plugs GM 4.3L Engine Cooling System GM 4.3L Engine Cooling System Cummins 4.5L Diesel Engine Cooling System Cummins QSB 3.3L Diesel Engine Clean Debris From Radiator Core X CIL X CIL X CIL C

12, 14 12, 14 12, 14

15.1 liter (15.9 qt) 13.5 liter (14.2 qt) 10.4 liter (11 qt)

See NOTE 15.

See NOTE 15.

See NOTE 15.

X X C C

See NOTE 5. 20 liter (21 qt) 1 Filter 1 Breather See NOTE 4. Check Condition Lubricate as Necessary Check Operation Multipurpose Grease See NOTE 7. John Deere JDM J20C See Parts Manual

7 21

Transmission Oil Dry Brake Transmission Oil Filter and Breather Forks Fork Latches X

26 26

X L

Lift System, Operate

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

17

Maintenance Schedule

8000 SRM 1248

Table 1. Maintenance Schedule (Continued)


Item No. 27 Item Mast Sliding Surfaces and Load Roller Surfaces Header Hoses Lift Chains X 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity L Lubricate as Required See NOTE 10 and NOTE 11. Check Condition Check Lubrication. See NOTE 11. L L, X Check for Wear. Lube as Required. 2 Fittings SAE 30W Engine Oil SAE 30W Engine Oil Multipurpose Grease See NOTE 7. Multipurpose Grease See NOTE 7 Specification Multipurpose Grease See NOTE 7.

27 28

28

Lift Chains

Mast Pivots Mast Integral Sideshift Carriage Sliding Surfaces Tilt Cylinder Ends X

Lube as Required. 8 Fittings 4 Bearing Strips 4 Fittings

Multipurpose Grease See NOTE 7 SAE 10W-30 API SM ILSAC GF4 SAE J2362 SAE 10W-30 API SM ILSAC GF4 SAE J2362

Brake Master Cylinder Rod End Pin Manual Hydraulic Hand Levers

24 11

Brake Oil (Master Cylinder) Steering Axle Spindle Bearings Steering Axle Tie Rods [S80, 100, 120FT;] S80, 100FTBCS; S120FTS; S120FTPRS (G004)

CIL

X L

0.35 liter (0.74 pt) 4 Fittings

Dexron III from Sealed Container Multipurpose Grease See NOTE 7. Multipurpose Grease See NOTE 7.

11

2 Fittings

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

18

8000 SRM 1248

Maintenance Schedule

Table 1. Maintenance Schedule (Continued)


Item No. 11 Item Steering Axle Tie Rods H80, 90, 100, 110, 120FT (N005, P005) Pedals, Levers, Seat Rails, Cables, Hinges, Linkages, Hood Latch Service Brakes (Dry Brake) Parking Brake L 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity L 4 Fittings Specification Multipurpose Grease See NOTE 7.

Lubricate as Necessary

Use Silicone Spray Hyster Part No. 328388 1.0 mm (0.040 in.) Minimum Use Silicone Spray (Hyster Part Number 328388) SAE 80W-90 or 85W-140 John Deere JDM J20C

1 23

Check Lining Thickness Lubricate as Necessary

30

Differential and Drive Axle Oil (Dry Brake)

6.0 liter (6.3 qt)

7/30 Transmission and Wet Brake Planetary Carrier Housing Oil S80FT, FTBCS (G004) 7/30 Transmission and Wet Brake Planetary Carrier Housing Oil S100FT, FTBCS S120FT, FTS, FTPRS (G004) 7/30 Transmission and Wet Brake Planetary Carrier Housing Oil H80, 90, 100, 110, 120FT) (N005, P005) 30 Wet Brake Center Section Oil [S80, 100, 120FT;] S80, 100FTBCS; S120FTS; S120FTPRS (G004) Wet Brake Center Section Oil H80, 90, 100, 110, 120FT (N005, P005)

28.8 liter (30.4 qt)

29.8 liter (31.4 qt)

John Deere JDM J20C

31.3 liter (33.0 qt)

John Deere JDM J20C

2.0 liter (2.1 qt)

SAE 80W/90

30

2.0 liter (2.1 qt)

SAE 80W-90

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

19

Maintenance Schedule

8000 SRM 1248

Table 1. Maintenance Schedule (Continued)


Item No. Item Inspect Engine Electrical System, Connectors Inspect Engine Vacuum, Fuel Lines, and Fittings Inspect Lock-Off for Leaks, and Ensure Lock-Off Closing Test LPG/GAS Regulator Pressure Check Air Induction System for Leaks Check Manifold for Vacuum Leaks Check Throttle Shaft for Sticking Check Injectors and Rails for leaks Inspect Exhaust Manifolds and Piping for Leaks Inspect Catalyst Inlet and Outlet 31 Ignition System Distributor, Rotor, and Spark Plug Wires Inspect Muffler Inlet and Outlet Mast and Carriage with Paper Roll Clamp 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity X Specification

X X

Replace

X X

Replace as Required Inspect See NOTE 16 Dye Penetrant

NOTE 1: Check fuel system for leaks prior to any service or maintenance activity. 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. X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

20

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily

Table 1. Maintenance Schedule (Continued)


Item No. Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity Specification

NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours of operation - see 2000 Hr/1 Yr service procedures. 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. Use compressed air and steam clean as necessary. NOTE 9: See Capacities and Specifications 8000 SRM 1249 for spark plug gap and type of spark plugs to use. NOTE 10: Lubricate mast every three months if unit has less than 1000 hours. NOTE 11: Lubricate 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: Initial valve adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at 2000hour/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 or deionized water. NOTE 16: Inspect after an impact likely to cause damage. 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. X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

Maintenance Procedures Every 8 Hours or Daily


HOW TO MAKE CHECKS WITH ENGINE STOPPED WARNING
DO NOT operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operators area. If the lift truck is equipped with a key switch, remove the key from the key switch. Put the lift truck on a level surface. Lower the carriage and forks, stop the engine, and apply the parking brake. Open the hood and check for leaks and conditions that are not normal. Clean any oil or fuel spills. Ensure all surfaces are free of oils, lubricants, fuel, and organic dust or fibers (paper, wood, cotton, agricultural grass/grain, etc.).

Tires and Wheels


Check the tires for damage. See Figure 8. Check the tread and remove any objects that will cause damage. Check for bent or damaged rims. Check for loose or missing hardware. Remove any wire, strapping, or other material that is wrapped around the axle.

21

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD) 2. MAKE SMOOTH EDGES 3. CHECK TIRE PRESSURE (PNEUMATIC TIRES) Figure 8. Tire Check

Safety Labels WARNING


Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. Check that all safety labels are installed in the correct location on the lift truck. See the Parts Manual, Model Description section in the Operating Manual or the section Frame 100 SRM 1243 for the correct location of the safety labels. See the Parts Manual for the part numbers of the safety labels.

1. Inspect the welds on the mast and carriage for cracks. Make sure that the capscrews and nuts are tight. 2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage. 3. Inspect the load backrest extension for cracks and damage. 4. If the lift truck is equipped with an integral sideshift carriage or attachment, inspect the parts for cracks and wear. Make sure the parts that fasten the integral sideshift carriage or attachment to the carriage are in good condition. 5. Visually inspect hoses/fittings for hydraulic leaks; hose cover for cuts, cracks or exposed reinforcement; defective/broken clamping devices or sheaves; proper tracking during operation. Adjust/repair/replace hose/components as necessary. See Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250 for quick disconnect procedures. 6. Check that the lift chains are correctly lubricated. Use SAE 30 engine oil as necessary to lubricate the lift chains. 7. Inspect the lift chains for cracks or broken links, and worn or turned pins. See Figure 9. 8. Inspect the chain anchors and pins for cracks and damage.

Mast, Carriage, Lift Chains, Header Hoses, Attachment WARNING


Lower the lift mechanism completely. Never allow any person under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. DO NOT try to correct the alignment of the fork tips by bending the forks or adding shims. Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. If either fork is damaged, replace the forks as a set.

22

8000 SRM 1248 9. Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Maintenance Procedures Every 8 Hours or Daily The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 10. NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly. With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

1. 2. 3. 4.

WORN PIN CRACKS EDGE WEAR HOLE WEAR

5. LOOSE LEAVES 6. TURNED PIN 7. CORROSION

Figure 9. Lift Chain Check

Operator Restraint System


The seat belt, hip restraint, seat, hood, and hood latch are all part of the operator restraint system. See Figure 10. Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition.

Emergency Locking Retractor (ELR)


NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operators lower torso in the seat. A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. LATCH STRIKER HOOD LATCH FORWARD/BACKWARD ADJUSTMENT HOOD OPERATOR WEIGHT ADJUSTMENT SEAT RAIL ARM REST SEAT BELT SEAT HIP RESTRAINT HOOD HINGE Figure 10. Hood and Seat Check

23

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248 to the ground so that the best ergonomic position is achieved, See Figure 10. Seat Position Adjustment (Swivel Seat) The seat swivels 12 degrees to the right to allow the operator a more ergonomic position when driving in reverse. The seat swivels 5 degrees to the left to allow as easier exit of the truck. The neutral position is shown in Figure 12. Seat Adjustment for Operator Weight

CAUTION
A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his/her weight. NOTE: It is important to adjust the weight setting for each operator. NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE 1. 2. 3. 4. 5. FORWARD/BACKWARD ADJUSTMENT SWIVEL ADJUSTMENT OPERATOR WEIGHT ADJUSTMENT SEAT POSITION ADJUSTMENT (SEAT RAIL) SEAT BELT Figure 11. Swivel Seat Controls NOTE: The seat is designed for maximum weight of 135 kg (298 lb). The target is for the "ride indicator" to fall between the arrows when the operator sits upright in the seat with the feet positioned on the pedals. This ensures that the operator is set at the midpoint of the 80mm suspension. The handle can be turned as shown to increase or decrease the weight resistance, pull handle out before turning. As the handle is turned the "stiffness" of the suspension can be felt to increase or decrease on which way the handle is turned.

Adjust Seat - Full Suspension


Seat Position Adjustment (Standard Seat) Fore and aft adjustment - It is recommended that the seat be adjusted so that the thigh is horizontal

24

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily

A. STANDARD, NON SUSPENSION SEAT 1. 2. 3. 4. SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER

B. FULL SUSPENSION SEAT 5. BACKREST ANGLE ADJUSTMENT LEVER 6. ARMREST 7. SWIVEL LATCH RELEASE LEVER

Figure 12. Seat Adjustment

Adjust Seat - Internal Suspension


Seat Position Adjustment (Swivel Seat) The seat swivels 10.5 degrees to the right to allow the operator a more ergonomic position when driving in reverse. The seat swivels 5 degrees to the left to allow as easier exit of the truck. The neutral position is shown in Figure 13. Seat Adjustment for Operator Weight

NOTE: The seat is designed for maximum weight of 135 kg (298 lb). The target is for the "ride indicator" to fall between the arrows when the operator sits upright in the seat with the feet positioned on the pedals. This ensures that the operator is set at the midpoint of the 40 mm (1.57 in.) suspension. The weight adjustment knob can be turned left or right to increase or decrease the weight resistance. As the weight adjustment knob is turned the "stiffness" of the suspension can be felt to increase or decrease on which way the weight adjustment knob is turned.

CAUTION
A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his/her weight. NOTE: It is important to adjust the weight setting for each operator.

25

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

1. 2. 3. 4.

SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER

5. BACKREST ANGLE ADJUSTMENT LEVER 6. ARMREST 7. SWIVEL LATCH RELEASE LEVER

Figure 13. Seat Adjustment

Hood and Seat Latches


Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. See Figure 10 and Figure 11. The seat rails must be correctly fastened to the hood and the hood fastened to the hinges on the frame. Try to lift the hood to make sure it is fastened correctly and will not move. If adjustment is required, go to Hood Latch Check.

WARNING
Engine and exhaust system components are hot to touch. Be sure lift truck components are cool before starting inspection and cleaning or personal injury may occur. Ensure the truck engine cools properly by allowing it to idle for several minutes. Shutting the truck down while hot will not allow the engine to cool quickly due to the loss of coolant circulation. The heat trapped under the hood may actually increase the engine temperature because of no heat transfer through the radiator. With engine off and lift truck components cooled, check and clean the radiator and if equipped, radiator screen. Check engine manifold, exhaust pipes, muffler and catalytic converter for paper scraps. Clean as required. Check and clean the engine compartment components, transmission, fan shroud, belly pan if equipped, and inside frame ledges to avoid paper, dust and oil accumulation. Check axle and cowl openings for paper buildup and bailing wire. Remove any debris.

Engine Compartment
Check for the presence of any combustible material such as paper, leaves, etc. Remove any combustible materials.

Paper Application
Vehicles used in paper applications require regular inspection and cleaning to minimize the risk of fire. This should be done at least once every 8 hours or more frequently depending upon operating environment. The paper application option will help limit the contact of paper or tissue scraps to hot surfaces under the hood, but frequent maintenance is required.

26

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. 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.

Fuel, Oil, and Coolant Leaks, Check WARNING


All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. If there is a leak in the fuel system, extra care must be used during the repair. DO NOT operate the lift truck until a leak is repaired. Make a visual check for leaks on and under the lift truck. If possible, find and report the leak to maintenance for repair. Leaks often indicate a need for repair of damaged or worn components. Leaks in the LPG fuel system are usually not visible unless ice is present. There is however, usually a strong odor. Fuel leaks MUST be repaired IMMEDIATELY. Check the fuel system for leaks and the condition of parts. When fuel is added to the lift truck, see the section HOW TO ADD FUEL TO THE LIFT TRUCK in the Operating Manual. Also check the condition of the radiator or heater hoses that are not leaking. Soft or cracked hoses need to be replaced before a major leak occurs.

CAUTION
Air pressure, nozzle or extension tube may cause damage to exhaust wraps and radiator fins. Assure that air pressure, nozzle or extension tube does not damage exhaust wraps or radiator fins. Paper removal can generally be accomplished using a compressed air line and nozzle. An extension may be helpful to access hard to reach places. Remove floor plates and side covers for better access to engine compartment. Open or removed belly pan, if equipped. Clean components with compressed air. Take care to maintain the integrity of the exhaust wraps when cleaning with compressed air and use caution to not force debris into openings. Check the condition of exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as necessary. Do not reuse wraps if they have been removed for some other service operation.

Hydraulic Hoses
Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage. Check to insure that the hydraulic hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

WARNING
Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. If compressed air did not adequately remove debris, steam clean to remove any persistent accumulation of material or oil. Protect electrical components from moisture when steam cleaning. Do not 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. Check the condition of exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as necessary. Do not reuse wraps if they have been removed for some other service operation.

Coolant Hoses
Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage. Check to insure that the coolant hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

Steering Column Gas Cylinder


Make sure the gas cylinder for the steering column operates correctly. The cylinder must NOT allow the column to move unless the tilt lever is released. See Figure 14.

27

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248 Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. After the engine has stopped, wait one minute before checking the oil level. Keep the hydraulic oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule. Check the hydraulic system for leaks and damaged or loose components. Heavy-duty or high-temperature operations can require more frequent checks.

Engine Oil
1. TILT LEVER 2. GAS CYLINDER

WARNING
At operating temperature, the engine oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

Figure 14. Steering Column Gas Cylinder and Tilt Lever

Transmission CAUTION
Check the transmission for leaks and damaged or loose components. Heavy-duty or high temperature operations can require more frequent checks. DO NOT permit dirt to enter the engine when the oil level is checked or the filter is changed. Never operate the engine without oil. The operation of the engine without oil will damage the engine. After the engine has stopped, wait one minute before checking the oil level. See Figure 15, Figure 16, and Figure 17. Keep the oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule.

Hydraulic System Oil WARNING


At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION
DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

28

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily Legend for Figure 15 A. TOP VIEW B. RIGHT HAND SIDE SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP WATER SEPARATOR AIR FILTER LIFT PUMP FUEL INJECTION PUMP ENGINE OIL FILL CAP INLINE FUEL FILTER DIPSTICK ENGINE OIL FUEL INJECTOR DRIVE BELT

Figure 15. Cummins 4.5L Diesel Engine Maintenance Points for Lift Truck Models H80, 90, 100, 110, 120FT (N005)

29

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

A. RIGHT SIDE FRONT VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. DIPSTICK TURBOCHARGER OIL FILL CAP AIR INLET HOUSING FUEL PRIMER PUMP FUEL/WATER SEPARATOR ECM FUEL FILTER STARTER FUEL RAIL ELECTRONIC FUEL PUMP WATER PUMP CRANK POSITIONING SENSOR CAM POSITIONING SENSOR

B. LEFT SIDE FRONT VIEW 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. ALTERNATOR ALTERNATOR BELT ADJUSTMENT TEMPERATURE SENDING UNIT WATER INLET/THERMOSTAT HOUSING TURBOCHARGER AIR INLET TURBOCHARGER WASTEGATE TURBOCHARGER EXHAUST TURBOCHARGER EXHAUST MANIFOLD OIL FILTER TURBOCHARGER OIL DRAIN LINE TURBOCHARGER OIL FEEL LINE OIL PAN OIL PAN DRAIN PLUG DRIVE BELT

Figure 16. Cummins QSB 3.3L Diesel Engine Maintenance Points for Lift Truck Models

30

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily

A. GAS ENGINE 1. 2. 3. 4. 5. 6. DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT

B. LPG ENGINE 7. 8. 9. 10. 11. AIR FILTER FUEL FILTER ENGINE OIL FILTER SPARK PLUGS FUEL INJECTOR

Figure 17. GM Engine Maintenance Points With GFI Installed

31

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

1. 2. 3. 4. 5. 6.

DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT

7. 8. 9. 10. 11.

AIR FILTER ENGINE OIL FILTER SPARK PLUGS ENGINE LABEL LPG CONVERTER

Figure 18. GM 4.3L Engine Maintenance Points With PSI Installed

Air Filter
The air filter canister should not be opened until an air filter element replacement is required. An air filter element replacement is required when one of the following occurs: The optional air flow restriction indicator light on the dash illuminates If equipped, the manual air flow indicator is red The specified number of hours has passed since the last filter element replacement Do not operate the lift truck until the air filter element has been replaced.

The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook forks.

Remove

WARNING
DO NOT try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (99 to 253 lb). NOTE: Forks are to be replaced only in sets and not individually. 1. A fork can be removed from the carriage for replacement of the fork or other maintenance. Lift the lock pin and slide a hook fork to the fork removal notch on the carriage. See Figure 19 and Figure 20. Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch. See Figure 20. Lower the carriage further so that the top hook of the fork is

Forks
NOTE: Forks must be removed or installed by trained personnel only.

32

8000 SRM 1248 disengaged from the top carriage bar. Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

Maintenance Procedures Every 8 Hours or Daily

1. CARRIAGE BARS 2. HOOK FORK

3. BLOCKS

Figure 19. Hook Fork Removal

Inspect
1. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 20. Check that the bottom of the fork is not worn. See Figure 20, item 4. 2. Replace any damaged or broken parts that are used to keep the forks locked in position. Fork Tip Alignment Length of Forks 915 mm (36 in.) 1067 mm (42 in.) 1220 mm (48 in.) 1372 mm (54 in.) 1524 mm (60 in.) 1830 mm (72 in.) 3% Dimension 27 mm 32 mm 37 mm 41 mm 46 mm 55 mm (1.10 in.) (1.26 in.) (1.46 in.) (1.61 in.) (1.81 in.) (2.17 in.)

Install
Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the upper carriage bar.

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 20. Forks Check

33

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

Adjust
NOTE: During the adjustment of the forks, the heel of the forks should not be touching the ground. The forks are connected to the carriage by hooks and lock pins. See Figure 19 and Figure 21. The lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. If pin does not remain engaged in carriage slot, replace with new pin. Adjust the forks as far apart as possible for maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made.

Integral Sideshift Carriage


Check for cracks, wear and damage. If damaged, see Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250 for repair procedures. If necessary, lubricate sliding surfaces at grease fittings with multipurpose grease shown in the Maintenance Schedule. See Figure 22.

1. 2. 3. 4.

FORK LOCK PIN SPRING WASHER

5. WEDGE 6. KNOB 7. LOCK PIN ASSEMBLY

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS UPPER BEARING STRIPS GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHINGS SEAL FIXED FRAME Figure 22. Integral Sideshift Carriage

Figure 21. Fork Lock Pin Assembly

34

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily the parking brake and put the transmission in NEUTRAL. Make the checks carefully.

HOW TO MAKE CHECKS WITH ENGINE RUNNING WARNING


DO NOT operate a lift truck that needs repairs. Report the need for repair immediately. If repair is necessary, put a DO NOT OPERATE tag in the operators area. If lift truck is equipped with a key switch, remove the key.

Indicator Lights, Horn, Fuses, and Relays


If lift truck is equipped with a key switch, turn key to ON position. If lift truck is equipped with a Power ON/OFF button, press button to turn system power on. All warning light and indicator lights will light up for two seconds (start check) when system power is turned ON. See Figure 23. Check all indicator lights for correct operation as described in the Operating Manual. Check the operation of the horn. Start the engine by turning the key switch to the Start position, if truck is equipped with a key switch, or press the engine start button, if lift truck is equipped with this button. If any indicator lights do not operate correctly, check the fuses. The fuses are located in the Power Distribution Module (PDM) which is under the hood next to the battery on the right side. See Figure 24.

WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if the lift truck tips over. IT CAN ONLY HELP IF IT IS FASTENED. Make sure that the area around the lift truck is clear before starting the engine or making any checks of the operation. Be careful when making the checks. If the lift truck is stationary during a check, apply

35

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Warning and Indicator Light Warning Light, Engine Malfunction Light Warning Light, System Malfunction Light Indicator Light, Air Filter Restriction Indicators Light, Direction and Transmission Warning Light, Brake Oil Level Malfunction Indicator Warning Light, Fasten Seat Belt Malfunction Indicator Warning Light, Parking Brake Malfunction Indicator Warning Light, Alternator Malfunction Indicator Warning Light, Transmission Oil Temperature Malfunction Indicator Warning Light, Engine Oil Pressure Malfunction Indicator Warning Light, Engine Coolant Temperature Malfunction Indicator Warning Light, Coolant Level in Radiator Malfunction Indicator Warning Light, Fuel Level Indicator Malfunction Indicator Indicator Light, 1st Gear Locking (Duramatch Plus 2 Transmissions) Indicator Light, Water Separator (Diesel Only) Indicator Light, Cold Start (Diesel Only) Figure 23. Warning and Indicator Lights

36

8000 SRM 1248

Maintenance Procedures Every 8 Hours or Daily

NOTE: HOOD REMOVED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. BATTERY PDM RESISTOR (68 OHM) START RELAY STARTER (30-AMP FUSE) IGNITION 3 RELAY BACKUP RELAY BACKUP (20-AMP FUSE) IGNITION (30-AMP FUSE) SPARE FUEL PUMP (20-AMP FUSE) 11. 12. 13. 14. 15. 16. 17. 18. 19. SPARE FUEL PUMP RELAY BATTERY (25-AMP FUSE) FRONT WORK LIGHT (20-AMP FUSE) FRONT/REAR WORK LIGHT RELAYS BATTERY (25-AMP FUSE) REAR WORK LIGHT (20-AMP FUSE) IGNITION 1 (20-AMP FUSE) IGNITION RELAY BATTERY (25-AMP FUSE)

Figure 24. PDM Showing Fuses and Relays

Service Brakes
Brake Oil Level

using the lift truck. Replace the brake oil in the system if there is dirt or water in the system. DO NOT use "DOT" fluid, only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury. There is an indicator light on the Display Switch Cluster for the brake oil. The red light is ON when the key switch is in the START position or the Power ON/OFF button is pressed, and must go OFF when the engine is running. If the light is on when the engine is running, the brake fluid oil in the reservoir is too low.

WARNING
Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. DO NOT allow water entry. Ensure that the sealed reservoir lid is properly replaced. The brake system has a boosted master cylinder, braking will be more difficult if the engine is not running. Loss of oil from the brake oil reservoir indicates a leak. Repair the brake system before

37

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248

Operation, Check
Check the operation of the service brakes. Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate. The pedal must stop firmly and must not move slowly down after the brakes are applied. The service brakes must apply equally to both drive wheels. The service brakes must not pull the lift truck to either side of the direction of travel when they are applied. The service brakes are automatically adjusted when the transmission is in reverse and the lift truck is moving and the brakes are firmly applied. Full application of the inching/brake pedal applies the service brakes and puts the transmission in NEUTRAL. Lift trucks with a MONOTROL pedal. When the inching/brake pedal is fully applied, a switch in the starting circuit is closed so that the engine can be started.

Parking Brake
Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake is adjusted. Lift trucks with a MONOTROL pedal. The switch energizes the seat warning circuit when hand lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction solenoid. There is also a switch on the left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied. NOTE: Make sure parking brake is released before making adjustment. 1. Turn the adjustment knob to raise the equalized link and tighten the parking brake cables shown in Figure 25. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parking brake is released. 2. For burnished brakes, test the operation of the parking brake. The lift truck with a capacity load must not move when parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)]. 1. 2. 3. 4. LOCK BUTTON RELEASE OFF POSITION ON POSITION ADJUSTMENT KNOB Figure 25. Parking Brake

Engine Oil Pressure


NOTE: The engine will enter shutdown mode after a warning buzzer sounds and a 30 second countdown, if engine oil pressure is less than 34.5 kPa (5 psi) on lift trucks with powertrain protection system. Lift trucks equipped with a Cummins diesel engine will enter the shutdown mode when the engine oil pressure is less than 49 kPa (7 psi) on lift trucks with powertrain protection system. See the Engine Shutdown procedures in the Operating Manual. There is an indicator light for the engine oil pressure on the Display Switch Cluster. During normal operation, the red indicator light will illuminate when the key switch is turned to ON, if the truck is equipped with a key switch, or when the power ON/OFF button is pressed, if the truck is equipped with a keyless option, and will stay illuminated until correct oil pressure is obtained, at which time the light will go off.

38

8000 SRM 1248 If the light continues to stay on when engine is running, the engine oil pressure is low. Stop the engine and check the oil level. See Figure 17 for lift truck models S80, 100, 120FT; S80, 100FTBCS; 120FTS; S120FTPRS) (G004) and Figure 15, Figure 16, and Figure 17 for lift truck models H80, 90, 100, 110, 120FT) (N005, P005) Do not restart the engine until the low pressure condition has been corrected.

Maintenance Procedures Every 8 Hours or Daily

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Check the radiator fins. Clean the radiator with compressed air or water as needed. Check for and remove any debris on the radiator core. If the indicator light turns on again after restarting, shut down the lift truck and do not operate the lift truck until the problem is corrected.

Cooling System WARNING


DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. NOTE: The engine will enter shutdown mode after a warning buzzer sounds and a 30-second countdown if coolant temperature reaches 118C (245F) or above for GM 4.3L lift trucks with powertrain protection system. Lift trucks equipped with a Cummins 4.5L or QSB 3.3L diesel engine will enter the shutdown mode when the coolant temperature reaches 114C (238F) or above on lift trucks with powertrain protection system. See the Engine Shutdown procedures in the Operating Manual. There is an indicator light on the Display Switch Cluster for the coolant temperature. The red light is on when the key switch is in the START position or the Power ON/OFF button is pressed, and must go off when the engine is running. If the light is on when the engine is running, the coolant and engine are too hot. Stop the engine and check the coolant level in the coolant recovery reservoir. Make sure the coolant level is between the ADD and FULL marks on the auxiliary coolant reservoir. See Figure 26. The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase.

1. 2. 3. 4.

FILL CAP FULL HOT MARK FULL COLD MARK ADD COLD MARK Figure 26. Auxiliary Coolant Reservoir

Steering System WARNING


The lift truck has hydraulic power steering. The steering can be difficult if the engine is not running. Make sure the steering system operates smoothly and provides good steering control. Make sure the steering column can be adjusted and the gas cylinder function is correct.

CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. If coolant is added, see Maintenance Schedule for correct solution.

39

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1248 Perform the following checks and inspections: 1. Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes. NOTE: Some parts of the mast move at different speeds during raising and lowering. 2. Slowly raise and lower the mast several times without a load. Raise the mast to its full height at least once. The mast components must raise and lower smoothly in the correct sequence. Hose must track properly during operation. 3. The inner weldments and the carriage must lower completely. 4. Raise the mast 1 m (3 ft) with a capacity load. The inner weldments and the carriage must raise smoothly. Lower the mast. All moving components must lower smoothly. 5. Lower the load to approximately 0.3 m (1 ft). Tilt the mast forward and backward. The mast must tilt smoothly and both tilt cylinders must stop evenly. 6. Check that the controls for the attachment operate the functions of the attachment. See the symbols by each of the controls. Make sure all of the hydraulic lines are connected correctly and do not leak.

Control Levers and Pedals


Check that the control levers for the transmission, mast, and attachment operate as described in Operating Manual. Check that the pedals operate correctly as described in Operating Manual.

Lift System, Operate WARNING


When working on or near the mast, see Safety Procedures When Working Near Mast at the end of this section. Lower the lift mechanism completely. Never allow any person under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. If the mast cannot be lowered, use chains on the mast weldments and carriage so that they cannot move. Make sure the moving parts are attached to a part that does not move. DO NOT try to find hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by the pressure.

40

8000 SRM 1248

First Service After First 100 Hours of Operation

First Service After First 100 Hours of Operation


GM 4.3L ENGINE OIL AND OIL FILTER
NOTE: The engine oil and oil filter must also be changed after the first 100 hours of operation for a newly installed engine. Change engine oil and oil filter. See Figure 27. Apply clean oil to gasket of new filter. Install new filter. 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.

CUMMINS 4.5L AND QSB 3.3L ENGINE OIL AND OIL FILTER
Change engine oil and oil filter. See Figure 28. Apply clean oil to gasket of new filter. Install new filter. 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: ALL OIL FILL COMPONENTS LISTED IN LEGEND FOR GM 4.3L ENGINES EQUIPPED WITH GFI OR PSI ARE LOCATED IN THE SAME AREA. 1. 2. 3. 4. OIL FILTER DRAIN PLUG ENGINE OIL DIPSTICK ENGINE OIL FILL

NOTE: BOTTOM LEFT-HAND SIDE SHOWN 1. OIL FILTER 2. DRAIN PLUG

Figure 28. Engine Oil Filter Change, Cummins 4.5L Diesel (Shown)

Figure 27. GM 4.3L Engine Filter Oil Change

41

Maintenance Procedures Every 250 Hours or 6 Months

8000 SRM 1248

Maintenance Procedures Every 250 Hours or 6 Months


NOTE: Perform the 8-hour checks prior to performing the procedures in this section.

DRIVE BELT GM 4.3L Engine

GM 4.3L ENGINE OIL AND OIL FILTER


NOTE: Change the oil and oil filter for the engine at the first 100 hours of operation on new lift trucks. Change engine oil and engine oil filter. See Figure 29. Use the correct oil according to the Maintenance Schedule. Apply clean oil to gasket of new filter. Install 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.

Fan and Alternator Drive Belt


Check drive belt for wear and damage. See Figure 30. 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 31 for the drive belt arrangement.

1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 30. Drive Belt Inspection

NOTE: ALL OIL FILL COMPONENTS LISTED IN LEGEND FOR GM4.3L ENGINES EQUIPPED WITH GFI OR PSI ARE LOCATED IN THE SAME AREA. 1. 2. 3. 4. OIL FILTER DRAIN PLUG ENGINE OIL DIPSTICK ENGINE OIL FILL Figure 29. GM 4.3L Engine Oil Change

Figure 31. GM 4.3L Drive Belt Arrangement

42

8000 SRM 1248 Legend for Figure 31 NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING TENSIONERS. 1. 2. 3. 4. 5. 6. FAN PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY SERPENTINE BELT TENSIONER CENTERING PULLEY ALTERNATOR PULLEY

Maintenance Procedures Every 250 Hours or 6 Months 1. Move the lift truck to a well ventilated area, and ensure no external ignition sources are present. 2. Start the engine. 3. Close the valve on the LPG tank. 4. When the engine runs out of fuel, turn key or keyless switch to OFF position, and disconnect the negative terminal on the battery.

DRAIN TAR FROM LPG REGULATOR


1. Warm engine to operating temperature. 2. Shut fuel valve off and run engine until the engine runs out of fuel and stops. 3. Raise the hood. 4. Remove tar drain screw from regulator. Allow tar to drain from regulator. When tar has completely drained, install tar drain screw in regulator. See Figure 32.

CAUTION
A small amount of fuel may remain in the fuel line. To prevent the possibility of burns wear gloves and eye protection. If fuel continues to flow check to make sure the LPG tank valve is completely closed. 5. Disconnect the inlet line and outlet hose from the LPG converter. See Figure 33. 6. Remove the mounting bolts and LPG converter from the mounting bracket.

1. TAR DRAIN SCREW Figure 32. GM LPG Regulator

1. 2. 3. 4.

LPG CONVERTER INLET LINE OUTLET HOSE MOUNTING BOLTS Figure 33. LPG Converter Removal

DRAIN TAR FROM LPG CONVERTER


NOTE: The following procedure is to be used on lift trucks equipped with a GM 4.3L LPG Engine with PSI installed.

43

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248 8. Using mounting bolts, install the LPG converter on the mounting bracket. 9. Connect the fuel line and outlet hose to the LPG converter. If disconnected, connect the two cooling hoses. 10. Connect the negative terminal on the battery. 11. Open the valve on the LPG tank and check for leaks on the LPG converter using soapy water or a leak detector. If any leaks are found, tighten fittings or replace hose clamps as applicable. 12. Start the engine and recheck for leaks at the converter.

CAUTION
Engine components may be hot. Use gloves when handling the LPG Converter to prevent the possibility of burns.

CAUTION
Drain the tar into a container and dispose in accordance with local environmental regulations. 7. Rotate the LPG converter sightly so that outlet opening is pointing toward the container and allow tar to drain from LPG converter. If the LPG converter cannot be rotated a sufficient amount to drain the tar, disconnect the two cooling hoses.

Maintenance Procedures Every 500 Hours or 6 Months


NOTE: Perform the 8-hour and 250-hour checks prior to performing the procedures in this section. accurate when the oil temperature is 53 to 93C (130 to 200F).

HYDRAULIC SYSTEM OIL WARNING


At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

HYDRAULIC TANK BREATHER Inspect


NOTE: When inspecting the breather, do not remove it. The breather element is a non serviceable part. If it is damaged, replace with a new breather element. 1. Raise the hood and remove the right rear side panel See Figure 34.

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 hydraulic pump without oil will damage the pump.

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer. Check the hydraulic oil level when the oil is at operating temperature with the mast in a vertical position, the carriage lowered, and the engine stopped. See Figure 41 and Figure 42. Add hydraulic oil only as needed. If hydraulic oil is above the FULL level, the hydraulic oil will leak from the breather during operation. The oil level indicated by the dipstick is most

CAUTION
Direct air pressure on the filter element can cause damage. Direct air pressure away from filter element. 2. Using compressed air, remove any dirt and debris in the frame cavity around the breather. See Figure 34. 3. If necessary, unscrew and replace the breather if oil has accumulated in the cavity or on the

44

8000 SRM 1248 breather, or if dirt has accumulated at the breather passages at the bottom of the breather 4. Install right rear side panel and close hood. See Figure 34.

Maintenance Procedures Every 500 Hours or 6 Months Disconnect the negative and positive terminals of the battery. Using a damp cloth clean the case of the battery. If the terminals are corroded, clean the terminals with a wire brush. Connect the negative and positive cables to their respective terminals.

CUMMINS 4.5L AND QSB 3.3L ENGINE OIL AND OIL FILTER
NOTE: Change the oil and oil filter for the engine at the first 100 hours of operation on new lift trucks. Change engine oil and engine oil filter. See Figure 35. Use the correct oil according to the Maintenance Schedule. Apply clean oil to gasket of new filter. Install 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 34. Hydraulic Tank Breather

BATTERY WARNING
The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the eyes must be flushed with water immediately. Wear eye protection.

WARNING
Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flame away from the battery area. DO NOT make sparks from the battery connections. Disconnect the battery ground cable when doing maintenance. NOTE: BOTTOM LEFT HAND SIDE. 1. OIL FILTER 2. DRAIN PLUG

Figure 35. Engine Oil Change Cummins 4.5L Diesel (Shown)

45

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248

FUEL/WATER SEPARATOR FILTER REPLACEMENT, CUMMINS 4.5L AND QSB 3.3L ENGINE CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow.

Install
1. Clean the fuel filter head mounting surface and apply a small amount of diesel fuel to the gasket on the new fuel filter element. See Figure 36 and Figure 37. 2. Before installing the filter element, fill the filter element with diesel fuel. This method will aid in bleeding the fuel system.

CAUTION
DO NOT overtighten the filter element. Overtightening the filter element may distort the threads. 3. Install the new fuel filter element until it contacts the fuel filter head mounting surface. Tighten one additional turn. 4. Connect the fuel sensor connector to fuel filter element 5. Connect air inlet elbow hose. 6. Open the fuel supply valve. 7. Prime the fuel system. See Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine). 8. Check for fuel leaks.

Remove
1. Stop engine and allow it to cool. 2. Disconnect air inlet elbow to access the fuel filter element. See Figure 36. 3. Disconnect fuel filter sensor connector from the fuel filter element.

CAUTION
Drain the water/fuel into a container and dispose in accordance with local environmental regulations. 4. Open the drain valve by turning the valve counterclockwise approximately 3 1/2 turns until draining occurs. Drain until fuel filter element is empty. 5. Remove and discard fuel filter element.

Legend for Figure 36 A. RIGHT SIDE VIEW 1. 2. 3. 4. 5. FUEL FILTER ELEMENT DRAIN VALVE LIFT PUMP FUEL PUMP IN-LINE FUEL FILTER B. FRONT VIEW 6. 7. 8. 9. 10. FUEL SUPPLY VALVE FUEL SENDING UNIT FUEL FILTER SENSOR CONNECTOR AIR INLET ELBOW FUEL LINE INJECTOR FITTINGS (4)

46

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months

Figure 36. Cummins 4.5L Engine Fuel System

47

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248 Legend for Figure 37 A. RIGHT VIEW B. TOP VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. TURBO HEAD BELL HOUSING FLYWHEEL OIL PAN ENGINE BLOCK ELECTRONIC FUEL PUMP FUEL FILTER WATER OUTLET HOUSING WATER PUMP BELT WATER INLET HOUSING OIL FILL CAP WATERGATE AIR INLET HOUSING OIL DIPSTICK EXHAUST MANIFOLD EXHAUST OUTLET ENGINE ECM STARTER FUEL/WATER SEPARATOR PRIMER PUMP INTAKE MANIFOLD AIR INLET INJECTOR LINE

FINAL FUEL FILTER REPLACEMENT (CUMMINS QSB 3.3L ENGINE) CAUTION


Disposal of lubricants and fluids must meet local environmental regulations. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. 1. Close any OEM fuel valves (if applicable) to prevent fuel from draining. 2. Clean the area around the fuel filter head.

CAUTION
Drain the fuel into a container and dispose in accordance with local environmental regulations. Figure 37. Cummins QSB 3.3L Engine Fuel System 3. Remove the fuel filter. 4. Clean the gasket surface.

48

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months The fuel injection pump is replaced. The high pressure fuel line connections are loosened, or lines are replaced. It is an initial engine start up after an extended period of no engine operation. If equipped with electronic fuel pump (Cummins QSB 3.3L), with the accelerator pedal or lever in the idle position, turn the key to the ON position. Wait for the "Wait to Start" light to go out. Start the truck. If the engine does not start after 3 attempts, check fuel supply system. The lack of blue or white smoke indicates the lack of fuel being supplied to the engine. 1. Crack open the fuel line to the injector pump. See Figure 36. 2. Operate the hand lever until fuel is expelled from the loosened fitting. 3. Tighten the fuel line to the injector pump to 9 Nm (80 lbf in). See Figure 36. 4. Crack open one of more of the injector lines located on the cylinder head.

CAUTION
DO NOT pour fuel directly into the center of the filter, since this will allow unfiltered fuel to enter the system and may cause damage to fuel system components. 5. Pre-fill new filters, both pressure side and suction side, with clean fuel prior to assembly. Use the clean side block off plug packed with the filter. 6. Lubricate the gasket with clean engine oil. 7. Install fuel filter. Tighten filter until gasket contacts filter head surface. Tighten filter an additional 3/4 turn after contact. 8. Start engine and check for leaks around the fuel filter.

PRIMING THE FUEL SYSTEM (CUMMINS 4.5L AND QSB 3.3L ENGINE) Controlled Venting CAUTION
When using the starting motor to vent the system, DO NOT engage it for more than 30 seconds, or starter motor damage will occur. Wait 2 minutes before engaging the starter again. Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically if the fuel filter element is changed and filled prior to installation.

WARNING
The pressure spray released by the fuel injectors can penetrate the skin and cause serious personal injury. Wear clothes and protective clothing. 5. Crank the engine until fuel is expelled from the loosen fittings. Tighten the injector line fittings while cranking. The engine should fire.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 6. Wipe up any fuel that may have spilled and dispose of the fuel and rags in accordance with local directives.

Manual Bleeding
Manual Bleeding will be required if one of the following conditions exist. The fuel filter is not filled prior to installation.

49

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248 Legend for Figure 39 NOTE: CUMMINS 4.5L ENGINES HAVE SELF-ADJUSTING TENSIONERS. 1. 2. 3. 4. 5. ALTERNATOR PULLEY CAMSHAFT PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY TENSIONER CENTERING PULLEY

DRIVE BELT Cummins 4.5L and QSB 3.3L Diesel Engine


Fan and Alternator Drive Belt
Check drive belt for wear and damage. See Figure 38. 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 39 and Figure 40 for the drive belt arrangement.

1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 38. Drive Belt Inspection 1. 2. 3. 4. 5. ALTERNATOR BELT ADJUSTMENT BRACKET DRIVE BELT CAMSHAFT PULLEY CRANKSHAFT PULLEY ALTERNATOR PULLEY

Figure 40. Cummins QSB 3.3L Diesel Engine Drive Belt Arrangement

Figure 39. Cummins 4.5L Diesel Engine Drive Belt Arrangement

50

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months

CLEAN DEBRIS FROM RADIATOR CORE


Check the radiator core for restrictions and remove material causing radiator core to be plugged or restricted.

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.

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean with compressed air, adjusted to a maximum output of 103 kPa (15 psi), and blow debris from core and fan shroud.

CAUTION
DO NOT permit dirt to enter the transmission when the oil level is checked or the filter is changed. NOTE: Transmission oil temperature should be at least 50C (120F) when checking oil level. If engine has been running, the engine must be shut down for one minute or longer prior to checking the oil level. See Figure 41 or Figure 42. If the transmission oil is low, add oil to transmission at the dipstick tube at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule.

NOTE: IRON TRANSMISSION HOUSING SHOWN. 1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

Figure 41. Transmission and Hydraulic Oil Check

51

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248

NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN. 1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

Figure 42. Transmission and Hydraulic Oil Check

WET BRAKE CENTER BODY OIL LEVEL CHECK WARNING


At operating temperature, the center section oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

1. Remove the center body fill/level plug. See Figure 43 for lift truck models S80, 100, 120FT; S80, 100, 120FTBCS; S120FTPRS (G004) and Figure 44 for lift truck models H80, 90, 100, 110, 120FT (N005, P005). 2. Visually check oil level. If necessary, add oil at the fill/level port until the oil/fill level port has overflowed. The Correct oil is shown in the Maintenance Schedule. 3. Install center body oil/level fill level plug and tighten to 30 to 50 Nm (22 to 37 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.

52

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months

A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER SECTION DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER SECTION Figure 43. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

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 44. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)

53

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248 contact surface to allow grease to properly lubricate the normal contact surfaces of the mast bushings 2. Raise the carriage about 61 cm (2 ft), and tilt the mast fully back. Place blocks under the outer mast channels to within 13 mm (0.5 in.) of the channels See Figure 46. 3. Tilt the mast fully forward. See Figure 46. 4. Lubricate the mast pivot bushings at grease fittings on outer mast. See Figure 47 and Figure 48. Use multipurpose grease shown in the Maintenance Schedule.

FORKS WARNING
Never repair damaged forks. DO NOT heat, weld, or bend the forks. Forks are made of special steel using special methods. Replace damaged forks as a complete set. Measure thickness of forks with a fork arm caliper (Hyster Part No. 3020387) at a vertical section where there is no wear. This thickness is dimension X. Now measure thickness at heel of fork (see Figure 20). If the thickness of the 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 section. NOTE: The load rollers and sheaves have sealed bearings and do not need additional lubrication. 1. Lubricate sliding surfaces and load roller surfaces along full length of channels as shown in Figure 45.

A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS 1. LUBRICATE STRIP BEARING SURFACES 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER Figure 45. Mast Lubrication NOTE: When lubricating the mast mounting/pivot pins, the load must be removed from the normal A. MAST TILTED FULLY BACK B. MAST TILTED FORWARD 1. BLOCK 2. MAST

Figure 46. Blocking the Mast

54

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months

1. 2. 3. 4. 5. 6.

MAST HANGER BUSHINGS LUBE FITTINGS MAST BUSHING PLUGS TILT PIN ROD END ANCHOR PIN

7. 8. 9. 10. 11. 12.

CAPSCREW NUT WASHER ROD END BUSHING TILT CYLINDER ASSEMBLY MAST MOUNTING CAP

Figure 47. Mast Mounting Hanger Lubrication 5. Tilt mast fully back. Remove the blocks from under the channels 6. If a sideshift carriage is installed, lubricate sliding surfaces at grease fittings with multipurpose grease shown in the Maintenance Schedule. See Figure 49.

55

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248

1. OUTER MAST

2. MAST PIVOT BUSHING Figure 48. Pivot Pin Lubrication

3. LUBRICATION FITTING

Legend for Figure 49 CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS 5. UPPER BEARING STRIPS 1. 2. 3. 4. 6. 7. 8. 9. 10. 11. 12. GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHING SEAL FIXED FRAME

HEADER HOSE CHECKS


Daily inspection plus; kinked, crushed, flattened or twisted hose; hard, stiff or charred hose; hose fitting slippage; proper hose tensioning. Adjust/repair/replace hose/components as necessary. See Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250 for quick disconnect procedures.

Figure 49. Integral Sideshift Carriage

56

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months Lubricate lift chains with SAE 30 engine oil. The best procedure is to remove the chains from the lift truck and soak them in engine oil. Be sure to clean any dirt or grease from chains before lubricating. DO NOT USE STEAM TO CLEAN THE LIFT CHAINS.

LIFT CHAIN LUBRICATION WARNING


When working on or near the mast, see Safety Procedures When Working Near Mast in this section. DO NOT repair worn or damaged lift chains. If a lift chain is worn or damaged, both lift chains must be replaced. NOTE: The 500 Hour/6 Months Lift Chain Lubrication should not be performed in combination with the 1000 Hour/6 Months Lift Chain Lubrication.

TILT CYLINDER LUBRICATION


NOTE: The floor plate must be removed in order to lubricate the rear tilt cylinder lubrication fittings. Lubricate the tilt cylinder ends. Use multipurpose grease shown in the Maintenance Schedule. There are four lubrication fittings. See Figure 50.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY. 1. CAPSCREW 2. RETAINER 3. ANCHOR PIN 4. LUBRICATION FITTING 5. TILT SPACER

Figure 50. Tilt Cylinder Lubrication

57

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248

MASTER BRAKE CYLINDER ROD END PIN LUBRICATION


Lubricate the master brake cylinder rod end pin. Use engine oil shown in the Maintenance Schedule. See Figure 51.

MANUAL HYDRAULIC LEVERS LUBRICATION


Lubricate the bushings for the manual hydraulic levers. Use spray lubricant as listed in the Maintenance Schedule. See Figure 52.

1. ROD END PIN 2. COTTER PIN (LOCKING) Figure 51. Master Brake Cylinder Rod End Pin Lubrication NOTE: FOUR FUNCTION LEVERS WITH DETENT SHOWN. 1. 2. 3. 4. BUSHINGS ROD END PIN HYDRAULIC LEVERS LOCKING RING (COTTER PIN) Figure 52. Manual Hydraulic Levers Lubrication

58

8000 SRM 1248

Maintenance Procedures Every 500 Hours or 6 Months Legend for Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. RESERVOIR CAP BRAKE OIL RESERVOIR RESERVOIR MOUNTING BRACKET COWL UPPER BRAKE OIL SUPPLY HOSE CYLINDRICAL BLOCK OUTLET FITTING LOWER BRAKE OIL SUPPLY HOSE NIPPLE MASTER CYLINDER CYLINDRICAL BLOCK DRAIN PLUG CYLINDRICAL BLOCK CYLINDRICAL BLOCK MOUNTING BRACKET CAPSCREW

BRAKE OIL WARNING


Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. DO NOT allow water entry. Ensure that the sealed reservoir lid is properly replaced. Replace the brake oil in the system if there is dirt or water in the system.

CAUTION
DO NOT use "DOT" fluid, only use Dexron III oil from sealed container to prevent possible damage to the brake system. Remove the dash board from the cowl. The brake oil reservoir is located on the cowl, at the master cylinder. See Figure 53. Add brake oil, as necessary. Use the brake fluid shown in the Maintenance Schedule.

TIE ROD LUBRICATION FOR LIFT TRUCK MODELS S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)
Lubricate the tie rods. Use multipurpose grease shown in the Maintenance Schedule. There is one lubrication fittings on each tie rod. See Figure 54.

1. STEERING AXLE 2. LUBRICATION FITTING (TIE ROD) 3. LUBRICATION FITTING (SPINDLE) Figure 54. Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

Figure 53. Brake Oil Reservoir

59

Maintenance Procedures Every 500 Hours or 6 Months

8000 SRM 1248

TIE ROD LUBRICATION FOR LIFT TRUCK MODELS H80, 90, 100, 110, 120FT (N005, P005)
Lubricate the tie rods. Use multipurpose grease shown in the Maintenance Schedule. There is one lubrication fittings on each tie rod. See Figure 55.

1. DRIVE AXLE 2. CHECK/FILL PLUG 3. DRAIN PLUG Figure 56. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

1. LUBRICATION FITTING (TIE ROD) 2. LUBRICATION FITTING (SPINDLE) 3. STEERING AXLE Figure 55. Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)

DIFFERENTIAL AND DRIVE AXLE OIL, LIFT TRUCK MODELS WITH DRY BRAKES
The differential and drive axle use the same oil supply. The oil level must be between 0 to 10 mm (0 to 0.40 in.) below the bottom edge of fill hole. The fill hole for checking the oil level is on the front of the differential housing. Remove fill plug and check fluid level by sticking a finger into the fill hole to feel if the fluid level is at the bottom edge of the fill hole. See Figure 56 and Figure 57. If oil is low, add oil shown in the Maintenance Schedule until the oil level is between 0 to 10 mm (0 to 0.40 in.) below the bottom edge of fill hole. Install fill plug and check for leaks.

1. CHECK/FILL PLUG 2. DRAIN PLUG 3. DRIVE AXLE Figure 57. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)

60

8000 SRM 1248

Maintenance Procedures Every 1000 Hours or 6 Months

Maintenance Procedures Every 1000 Hours or 6 Months


NOTE: Perform the 8-hour, 250-hour, and 500-hour checks prior to performing the procedures in this section.

VALVE CLEARANCE, CHECK AND ADJUST


The GM 4.3L engine has hydraulic valve lifters and does not require valve clearance adjustments during normal service. See the Maintenance Schedule for valve clearances. Additional engine information is available in the following sections: GM Engines, 4.3 Liter V-6 600 SRM 1251

IGNITION SYSTEM GM 4.3L Engine


The GM 4.3L gasoline and LPG engines have an electronic control unit (ECU) that controls the ignition timing. There are no adjustments. Change the spark plugs every 1000 hours. The correct spark plug gap is 1.5 mm (0.059 in.).

LPG FUEL FILTER ELEMENT REPLACE, GM 4.3L ENGINE Remove WARNING


LPG can cause an explosion. DO NOT permit any sparks or open flames in the work area. 1. Close fuel valve on tank. Run engine until it stops. 2. Disconnect negative battery cable.

1. 2. 3. 4. 5. 6. 7.

BOLT SEAL WASHER FUEL FILTER HOUSING TOP SECTION FUEL FILTER FUEL FILTER O-RING HOUSING O-RING FUEL FILTER HOUSING BOTTOM SECTION

Figure 58. Fuel Filter Removal and Installation 4. Remove top section of fuel filter housing. 5. Remove and discard housing O-ring. 6. Remove fuel filter and fuel filter O-ring.

Install
1. Clean and inspect the fuel filter housing for contamination or damage. 2. Install the new fuel filter and fuel filter O-ring. See Figure 58. 3. Install new housing O-ring. 4. Install top section of fuel filter housing.

WARNING
A small amount of fuel may still be present in the fuel line. Use gloves to prevent burns and wear eye protection. If liquid fuel continues to flow from the connections when loosened, check to make sure the manual valve is fully closed. 3. Remove the bolt and seal washer retaining the top section of the fuel filter housing. Discard seal washer. See Figure 58.

5. Install bolt and new seal washer. Tighten bolt to 13 Nm (115 lbf in).

61

Maintenance Procedures Every 1000 Hours or 6 Months NOTE: Opening the fuel valve too quickly can cause the internal excessive flow valve to close, restricting the flow of fuel. If this happens, close the fuel valve, wait a few seconds, and then slowly open the fuel valve again. This will reset the excess fuel valve. 6. Slowly open the fuel valve on tank. 7. Turn the key to the ON position and back to the OFF position to pressurize the fuel system. Check for leaks. 8. Check for leaks at connections by using soapy solution or electronic leak detector. If leaks are detected, make proper repairs.

8000 SRM 1248

Remove
1. Stop Engine and allow it to cool. 2. Close fuel supply valve located on the fuel sending unit. See Figure 59.

CAUTION
Drain the fuel into a container and dispose in accordance with local environmental regulations. 3. Loosen clamps and disconnect two fuel lines from the inline fuel filter. Remove and discard the inline fuel filter

IN-LINE FILTER REPLACEMENT, CUMMINS 4.5L ENGINE CAUTION


Disposal of lubricants and fluids must meet local environmental regulations. Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow.

Install
1. Install inline fuel filter by connecting the two fuel lines and tighten clamps. See Figure 59. 2. Open the fuel supply valve. 3. Check for fuel leaks.

Legend for Figure 59 A. RIGHT SIDE VIEW 1. 2. 3. 4. 5. FUEL FILTER ELEMENT DRAIN VALVE LIFT PUMP FUEL PUMP INLINE FUEL FILTER B. FRONT VIEW 6. 7. 8. 9. 10. FUEL SUPPLY VALVE FUEL SENDING UNIT FUEL FILTER SENSOR CONNECTOR AIR INLET ELBOW FUEL LINE INJECTOR FITTINGS (4)

62

8000 SRM 1248

Maintenance Procedures Every 1000 Hours or 6 Months

Figure 59. Cummins 4.5L Engine Fuel System

63

Maintenance Procedures Every 1000 Hours or 6 Months

8000 SRM 1248 cleaning 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 the lift chains. Clean the lift chains by soaking them in a solvent that has a petroleum base for at least 30 minutes. Use compressed air, adjusted to a maximum output of 103 kPa (15 psi), to completely dry the chains when they are clean. Lubricate the lift chains by soaking them in 30W engine oil for at least 30 minutes. Remove the chains from the oil. Hang the chains for one hour so excess oil will drain from the chains.

LIFT CHAINS WEAR CHECK


If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. Measure chain for wear where it moves over sheaves. Using a chain scale, Hyster P/N 871796 check lift chains as shown in Figure 60.

INTEGRAL SIDESHIFT CARRIAGE, CHECK SLIDING SURFACES


1. Check the sideshift carriage sliding surfaces, and if necessary lubricate sliding surface at the grease fittings with multipurpose grease shown in the Maintenance Schedule. See Figure 61. Pitch Total Length of 20 Links (Pitch) of New Chain 254.0 (10.0 317.5 (12.5 381.0 (15.0 508.0 (20.0 mm in.) mm in.) mm in.) mm in.) Wear Limit (The Maximum Length of 20 Links) 261.6 (10.3 327.0 (12.9 392.4 (15.4 523.3 (20.6 mm in.) mm in.) mm in.) mm in.)

12.7 mm (0.50 in.) 15.9 mm (0.63 in.) 19.1 mm (0.75 in.) 25.4 mm (1.00 in.)

1. CHAIN WEAR SCALE Figure 60. Lift Chains Check 1. 2. 3. 4. CAPSCREWS LOWER HOOK APRON LOWER BEARING STRIPS 5. UPPER BEARING STRIPS 6. 7. 8. 9. 10. 11. 12. GREASE FITTINGS CYLINDER ROD SNAP RING ROD SCRAPER ROD BUSHING SEAL FIXED FRAME

LIFT CHAIN LUBRICATION WARNING


Cleaning solvents can be flammable and toxic and can cause skin irritation. When using

Figure 61. Integral Sideshift Carriage

64

8000 SRM 1248

Maintenance Procedures Every 1000 Hours or 6 Months

STEERING AXLE (SPINDLE BEARINGS) FOR LIFT TRUCK MODELS S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)
Lubricate the spindle bearings on the steering axle. There are four lubrication fittings, two on each side of the steering axle. See Figure 62. Use multipurpose grease as shown in the Maintenance Schedule.

STEERING AXLE (SPINDLE BEARINGS) FOR LIFT TRUCK MODELS H80, 90, 100, 110, 120FT (N005, P005)
Lubricate the spindle bearings on the steering axle. There are four lubrication fittings, two on each side of the steering axle. See Figure 63. Use multipurpose grease as shown in the Maintenance Schedule.

1. STEERING AXLE 2. LUBRICATION FITTING (TIE ROD) 3. LUBRICATION FITTING (SPINDLE BEARINGS) Figure 62. Lubricate Spindle Bearings for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

1. LUBRICATION FITTING (TIE ROD) 2. LUBRICATION FITTING (SPINDLE BEARINGS) 3. STEERING AXLE Figure 63. Lubricate Spindle Bearings for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)

65

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248 Check engine wire harness for rubbing, chaffing, pinching, and cracks or breaks in the wiring. Check engine harness connectors. Check to ensure connectors are fitted and locked by pushing the connectors together. Pull on the connector halves to make sure they are locked. Check ignition coil wire and spark plug wires for hardening, cracking, arching, chaffing, separation, split boot covers, and proper fit. Replace spark plugs at the recommended interval as shown in the Maintenance Schedule. Check that all electrical components are securely mounted and retained to the engine or chassis. Check the MIL, charging, and oil pressure lights for operation by starting the engine and checking that the light illuminates before turning out.

CONTROL LEVERS AND PEDALS


Lubricate linkages, pedal shafts, control cables (throttle, hood, parking brake), and seat rails. Use a silicone spray lubricant, Hyster Part No. 328388.

INSPECT ENGINE ELECTRICAL SYSTEM, CONNECTORS


When inspecting the electrical system, check the following: Check and clean battery connection. Ensure that connections are tight. Check battery for damage or cracks to the case. Replace if necessary. Check positive and negative cables for corrosion, rubbing, and chaffing. Tighten connections at both ends.

Maintenance Procedures Every 2000 Hours or Annually


NOTE: Perform the 8-hour, 250-hour, 500-hour, and 1000-hour checks prior to performing the procedures in this section. and spring from head. See Figure 64. Lift the hydraulic filter element enough to allow the hydraulic oil to drain. NOTE: Have container large enough to hold the filter element and allow for final hydraulic oil draining. 2. Remove the hydraulic filter element and O-ring from the bowl and place into the container. Cover the head to prevent any foreign materials from getting into the hydraulic tank. 3. Lubricate new O-ring with hydraulic oil and install it on the bottom of the new filter element. Install the new filter element into the bowl. 4. Inspect gasket for damage. If damaged, replace. 5. Lubricate gasket with hydraulic oil and seat it on filter lid and install spring and lid onto head. Tighten lid to 15 Nm (132.8 lbf in).

HYDRAULIC SYSTEM Hydraulic Filter, Replace WARNING


At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION
DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer. 6. Start the truck, and allow it to run for 30 seconds. Check for leaks. Stop engine and check hydraulic oil level. Add oil, if necessary. Use hydraulic oil shown in the Maintenance Schedule. To change the hydraulic oil, see Hydraulic Oil, Replace.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 1. Put lift truck on a level surface and lower the carriage. Unscrew and remove filter lid, gasket,

66

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually 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 65.

1. HOOD/SEAT ASSEMBLY 2. SIDE PANEL 3. HYDRAULIC TANK BREATHER Figure 65. Hydraulic Tank Breather

IGNITION SYSTEM; DISTRIBUTOR CAP, ROTOR, AND SPARK PLUG WIRES


NOTE: Make sure the key is in the OFF position and the negative battery cable has been removed from the battery before removing the ignition system. Remove and discard spark plug wire assembly, coil wire, spark plugs, distributor cap, and rotor. For procedures see High Voltage Switch (HVS) Ignition, GM 4.3L EPA Compliant Engines and GM 5.7L LPG EPA Compliant Engine 2200 SRM 1097 for Spark Plug Wire Removal/Installation, Distributor Cap Removal/Installation, and Rotor Disassemble, Ignition Coil Wire Removal, and Spark Plug Replacement.

1. 2. 3. 4. 5.

LID SPRING O-RING CAPSCREW HEAD

6. 7. 8. 9.

FITTING QUAD RING FILTER ELEMENT BOWL

Figure 64. Hydraulic Filter

Hydraulic Tank Breather, Replace


1. Raise the hood and remove the right rear side panel. See Figure 65.

67

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248 4. Close drain valve. Fill cooling system with a solution of ethylene glycol boron-free antifreeze. See Maintenance Schedule for correct solution. Fill the auxiliary reservoir to a level between the ADD and FULL marks on the reservoir. 5. Install radiator cap. Start engine. Check for leaks. Add coolant to auxiliary coolant reservoir as needed. Coolant level should be between the ADD and FULL marks on the reservoir.

COOLING SYSTEM, GM 4.3L AND CUMMINS 4.5L AND QSB 3.3L ENGINES
1. Put lift truck on a level surface. Stop engine. Place a container with a minimum capacity of 15.1 liter (15.9 qt) under the radiator drain valve which could be located on either the lower left or right side of the radiator on the engine side of the radiator.

WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running.

AIR FILTER
The air filter canister should not be opened until an air filter element replacement is required. An air filter element replacement is required when one of the following occurs: The optional air flow restriction indicator light on the dash illuminates The optional manual air flow indicator button pops up The specified number of hours has passed since the last filter element replacement

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 2. Open drain valve and remove radiator cap. Drain coolant into the container. Flush cooling system. Check hoses for damage. Replace with new hoses, as needed. 3. Disconnect the hose leading from the auxiliary reservoir to fitting at the top of the radiator under the radiator cap, and drain the reservoir into the same container used for the radiator coolant. Check the reservoir for contaminants and flush, as necessary. Connect the hose back on the fitting at the top of the radiator.

CAUTION
DO NOT to allow dirt to enter the engine air intake when replacing the air filter element. A small amount of dirt could cause engine damage. 1. Shut off the engine. Never open the air filter canister or remove the filter element with the engine running. 2. Unlatch and remove the cover. To remove filter element, press and rotate filter element counterclockwise about 1/8 turn until the filter element is free. To assist removal, gently move the end back and forth to help break the seal. See Figure 66.

CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

68

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually

1. CANISTER 2. DUST EVACUATION VALVE 3. LINER ASSEMBLY

4. FILTER ELEMENT 5. COVER Figure 66. Air Filter

3. Gently pull the filter element from the canister. Avoid dislodging contaminants from the element or knocking it against the canister. 4. With a clean, soft rag, clean the inside surface of the canister. Remove the liner assembly to make cleaning easier. Clean well around the locking tabs that retain the element. Clean tabs make new filter element installation easier. Be careful not to knock any contaminants into the outlet tube to the engine. 5. Inspect the liner and O-ring assembly for damage. If damaged, replace the liner and O-ring assembly. 6. Install the liner assembly into the canister by pushing in. Make sure the liner assembly is properly seated in the canister. It will fit snugly into and be centered in the canister. If your air filter assembly is equipped with a secondary element in place of the liner assembly, replace the secondary element with every 2 to 3 primary element replacements. 7. Inspect the new filter element for voids, cuts, tears or indentations in the urethane-sealing surfaces. Do not use if damage is detected.

CAUTION
The element must be properly installed to ensure adequate engine protection. An improperly installed element may allow dirt and dust to enter and damage the engine. NOTE: Proper element installation is required to allow the cover to be installed correctly. Never reinstall a used element. Never install a damaged element. Always use a Hyster-approved filter element. 8. Install the new filter element into the canister. Press and rotate the filter element 1/8 turn clockwise until fully engaged in the canister. See Figure 67.

1. PUSH IN

2. TWIST TO LOCK

Figure 67. Air Filter Label

69

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248

CAUTION
During cover installation, DO NOT force the cover on the canister. To do so will result in damage to the filter element, cover, and possibly the canister. NOTE: If the filter element is properly installed, the cover will fit easily into the canister with no gap between the cover and the canister. If the cover does not fit easily, the filter element is not installed properly. Do not use a cover that is bent, damaged, or missing latches. 9. Install the cover into the canister and ensure the INLET arrow is in line with the canister inlet. NOTE: Do not use the latches to pull the cover down against the canister. If the cover does not fit completely against the canister with no gaps, the element is not installed correctly. 10. Fasten the latches to secure the cover to the canister. Make sure the latches penetrate the slots in both the canister and the cover. 11. Inspect the entire air intake system for leaks. Inspect all clamps for tightness and tighten if necessary. Inspect all hoses for damage. Replace damaged hoses. Inspect the dust evacuation valve for damage. If damaged, replace the dust evacuation valve. 1. OXYGEN SENSOR 2. ELECTRICAL CONNECTOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD Figure 68. Oxygen Sensor Location for Lift Truck Models H80, 90, 100, 110, 120FT) (N005, P005) and S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

OXYGEN SENSOR GM 4.3L LPG ENGINES EQUIPPED WITH GFI INSTALLED


Check that the oxygen sensor electrical connector is seated and locked. Check wires for cracks, splits, chaffing, or burn through. If necessary, repair. See Figure 68 and Figure 69..

1. OXYGEN SENSOR (POST-CATALYTIC) 2. MUFFLER 3. OXYGEN SENSOR (PRE-CATALYTIC) Figure 69. Oxygen Sensor (BCS Only) for Lift Truck Models S80, 100FTBCS (G004)

70

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually

LPG REGULATOR FUEL FILTER, GM 4.3L ENGINES EQUIPPED WITH GFI INSTALLED Remove
1. Close shutoff valve on tank. Run engine until it stops. 2. Disconnect the hose from the inlet fitting. 3. Remove the inlet fitting from the LPG regulator. Discard the O-ring. See Figure 70.

Install
1. Install a new screen in the LPG regulator. 2. Install a new O-ring on the outlet fitting. Using three screws, install the outlet fitting on the LPG regulator. 3. Install new rubber washer, paper filter, foam filter, and plastic cap in the LPG regulator. 4. Install new O-ring on the inlet fitting. Install inlet fitting into the LPG regulator and connect hose to the inlet fitting. 5. Open shutoff valve on LPG tank and check for leaks.

GASOLINE FUEL FILTER Remove and Replace


1. Raise the hood and disconnect the negative terminal of the battery. 2. Remove and discard the fuel filter. See Figure 71. 3. Install the new fuel filter and tighten the clamp screws to 2.45 to 2.77 Nm (22 to 25 lbf in). 4. Connect the negative terminal of the battery and close the hood.

1. 2. 3. 4. 5.

LPG REGULATOR INLET FITTING O-RING PLASTIC CAP FOAM FILTER

6. 7. 8. 9. 10.

PAPER FILTER RUBBER WASHER SCREWS OUTLET FITTING SCREEN

Figure 70. GM LPG Regulator 4. Remove and discard the plastic cap, foam filter, paper filter, and rubber washer from the LPG regulator. 5. Disconnect the hose from the outlet fitting. Remove three screws and the outlet fitting from the LPG regulator. Discard the O-ring. 6. Remove and discard the screen from the LPG regulator. Figure 71. Fuel Filter Replacement (GM 4.3L)

71

Maintenance Procedures Every 2000 Hours or Annually Legend for Figure 71 1. FUEL FILTER 2. FUEL PUMP/SENDER UNIT

8000 SRM 1248

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Change the transmission oil filter at the first 500 hours of operation on new lift trucks. Before removing the oil filter, make a hole at the top of the filter and allow five minutes for the oil to drain down into the transmission. This will reduce the oil that will run out of the filter and onto the transmission when the filter is removed. NOTE: The drain plug for the transmission is on the lower right side of the cover of the transmission, toward the rear of the lift truck. 1. Remove drain plug, spring, and screen. See Figure 72. Drain oil into a container.

LPG FUEL INJECTOR, GM 4.3L ENGINES EQUIPPED WITH GFI INSTALLED


For removal and cleaning instructions, see the section LPG Fuel System, GM 4.3L Engine with GFI 900 SRM 1242.

GASOLINE FUEL INJECTOR, GM ENGINES


For removal and cleaning instructions, see the section Gasoline Fuel System, GM 4.3L Engine 900 SRM 1244.

FUEL INJECTOR, CUMMINS 4.5L AND QSB 3.3L ENGINE


For removal and cleaning instructions for lift truck models H80, 90, 100, 110, 120FT) (N005, P005) equipped with the Cummins 4.5L or QSB 3.3L diesel engine, contact your local Hyster dealer or see Hyster Hypass Online.

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 (DRY BRAKE), REPLACE WARNING


At operating temperature, the transmission oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

NOTE: ALL MAJOR COMPONENTS AND FRAME COMPONENTS REMOVED FOR THE SAKE OF CLARITY. 1. 2. 3. 4. 5. 6. 7. TRANSMISSION TRANSMISSION DRAIN PLUG SPRING SCREEN TRANSMISSION OIL FILTER TRANSMISSION DIPSTICK TRANSMISSION BREATHER Figure 72. Transmission Oil Change

CAUTION
DO NOT permit dirt to enter the transmission when the oil level is checked or the filter is changed. Dirt can cause damage to the transmission components.

72

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 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. 4. Remove and discard transmission breather. Install 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. 6. Add oil to transmission at the dipstick tube. The correct oil is shown in the Maintenance Schedule. NOTE: Transmission oil temperature should be at least 50C (120F) when checking oil level. 7. Start and run the engine for approximately 5 minutes after fill to allow oil to lubricate parts within the transmission and wet brake portion of the drive axle center section. With the truck in the ON position, See Maintenance Schedule to add additional oil at the transmission dipstick tube that will need to be added to properly fill the wet brake portion of the drive axle center section and transmission. NOTE: Transmission oil temperature should be at least 50C (120F) when checking oil level. 8. Turn the key to the OFF position and check for leaks and check oil level. If necessary, top off oil.

TRANSMISSION AND WET BRAKE PLANETARY CARRIER HOUSING OIL CHANGE WARNING
The oil used for the wet brake drive axle or transmission should not be contaminated. If either the wet brake planetary carrier housings and/or transmission oil becomes contaminated, 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 level is checked or the filter is changed. Dirt will contaminate the oil and cause damage to the transmission and wet brake planetary carrier housing components.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Change the transmission oil filter at the first 500 hours of operation on new lift trucks. See Figure 73. Before removing the oil filter, make a hole at the top of the filter and allow five minutes for the oil to drain down into the transmission. This will reduce the oil that will run out of the filter and onto the transmission when the filter is removed. 1. The drain plug for the transmission is on the lower right side of the cover of the transmission, toward the rear of the lift truck. Remove drain plug, spring, and screen. See Figure 73. Drain oil into a container, once oil is completely drained, reinstall drain plug.

73

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248 Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 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.

NOTE: ALL MAJOR COMPONENTS AND FRAME COMPONENTS REMOVED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. TRANSMISSION TRANSMISSION SPRING SCREEN TRANSMISSION TRANSMISSION TRANSMISSION DRAIN PLUG OIL FILTER DIPSTICK BREATHER

Figure 73. Transmission Oil Change 2. Remove planetary carrier housing drain plug and fill/level plug. Drain oil into a suitable container. When oil is completely drained, reinstall drain plug and fill/level plug. Tighten to 30 to 50 Nm (22 to 37 lbf ft). For lift truck models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) see Figure 74. For lift truck models H80, 90, 100, 110, 120FT (N005, P005) see Figure 75.

A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER BODY DRAIN PLUG 4. CENTER BODY FILL/LEVEL PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER BODY Figure 74. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel.

74

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually 8. Start and run the engine for approximately 5 minutes after fill to allow oil to lubricate parts within the transmission and wet brake planetary carrier housings. With the truck in the ON position, See Maintenance Schedule to add additional oil at the transmission dipstick tube that will need to be added to properly fill the planetary carrier housings and transmission. For lift truck models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) see Figure 74. For lift truck models H80, 90, 100, 110, 120FT (N005, P005) see Figure 75. NOTE: Transmission oil temperature should be at least 50C (120F) when checking oil level. 9. Turn the key to the OFF position and check for leaks and check oil level.

WET BRAKE CENTER SECTION OIL CHANGE Remove


1. Remove the center body fill/level plug. Removing the fill/level plug will allow the oil to drain at a faster rate. For lift truck models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) see Figure 74. For lift truck models H80, 90, 100, 110, 120FT (N005, P005) see Figure 75. A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER BODY FILL/LEVEL PLUG 4. CENTER BODY DRAIN PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER BODY Figure 75. Wet Brake Drive Axle Drain and Fill/Level Plug Location for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) 5. Remove and discard transmission breather. Install 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. 7. Add oil to transmission at the dipstick tube. The correct oil is shown in the Maintenance Schedule. 2. Place and empty container under the center body drain plug. 3. Remove the center body drain plug, and wait until oil has drained completely.

Install
1. Install drain plug for the center body. Tighten to 30 to 50 Nm (22 to 37 lbf ft). For lift truck models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004), see Figure 74. For lift truck models H80, 90, 100, 110, 120FT (N005, P005), see Figure 75.

CAUTION
Before adding oil, ensure the truck is parked and on level ground. 2. Add oil at the fill/level port for the center body until the oil/fill level port has overflowed. The correct oil is shown in the Maintenance Schedule or Figure 76. For lift truck models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS

75

Maintenance Procedures Every 2000 Hours or Annually (G004) see Figure 74. For lift truck models H80, 90, 100, 110, 120FT (N005, P005) see Figure 75.

8000 SRM 1248 3. Install oil fill/level plug. Tighten to 30 to 50 Nm (22 to 37 lbf ft).

A. RIGHT PLANETARY CARRIER HOUSING - USE JDM J20C B. LEFT PLANETARY CARRIER HOUSING - USE JDM J20C C. CENTER BODY - USE SAE 80W/90 1. 2. 3. 4. PLANETARY FILL/LEVEL PLUGS PLANETARY DRAIN PLUGS CENTER BODY FILL/LEVEL PLUG CENTER BODY DRAIN PLUG 5. RIGHT PLANETARY CARRIER HOUSING 6. LEFT PLANETARY CARRIER HOUSING 7. CENTER BODY

Figure 76. Oil Application Diagram

BRAKE OIL (MASTER CYLINDER), CHANGE


1. Remove the dashboard from the cowl.

CAUTION
DO NOT use "DOT" fluid, only use Dexron III oil from a sealed container to prevent possible damage to the brake system. 3. Remove the brake oil reservoir cover and cylindrical block drain plug. Pour the oil into a suitable container with a 0.35 liter (0.74 pt) minimum capacity. Install the cylindrical block drain plug. Refill the reservoir with clean oil from a sealed container and install the cover on the reservoir. The correct oil is shown in the Maintenance Schedule. 4. Install the reservoir into the bracket located on the cowl.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 2. Remove the brake oil reservoir from the bracket on the cowl. See Figure 77.

WARNING
Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder areas. DO NOT allow water entry. Ensure that the sealed reservoir lid is properly replaced.

76

8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually

BRAKE OIL (DRY BRAKE), REMOVE


Perform the following procedure to remove used brake oil from the remainder of the brake system. 1. Ensure that the master cylinder reservoir is filled with brake oil. NOTE: This procedure cannot be performed by one person. 2. Put one end of a rubber hose on the bleed screw of the wheel cylinder. Put the other end of the hose into a empty container. 3. Loosen the bleed screw at the wheel cylinder one turn so that the used brake oil can be removed from the brake system. Slowly push the brake pedal and hold it at the end of its stroke. Close the bleed screw. Release the brake pedal. NOTE: The new brake oil will be easily recognized, as the color will be more clear than the used oil which will be darker. 4. Repeat Step 1 through Step 3 until there is new brake oil in the container. 1. RESERVOIR CAP 2. BRAKE OIL RESERVOIR 3. RESERVOIR MOUNTING BRACKET 4. COWL 5. UPPER BRAKE OIL SUPPLY HOSE 6. CYLINDRICAL BLOCK OUTLET FITTING 7. LOWER BRAKE OIL SUPPLY HOSE 8. NIPPLE 9. MASTER CYLINDER 10. CYLINDRICAL BLOCK DRAIN PLUG 11. CYLINDRICAL BLOCK 12. CYLINDRICAL BLOCK MOUNTING BRACKET CAPSCREW 5. Check the level of the brake oil in the reservoir for the master cylinder during the procedure. Make sure to keep the brake oil at the correct level. 6. Repeat the procedure for the other wheel cylinder.

Figure 77. Brake Oil Change

77

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.

SERVICE BRAKES (DRY BRAKE)


Check brake lining and parts of the brake assembly for wear or damage. The minimum acceptable brake lining thickness is 1.0 mm (0.040 in.). If the brake linings are worn thinner than the specification, replace the brake linings. See the section Brake System 1800 SRM 1247 for the removal and installation procedures of the drive wheels and brake drums. If the brake linings or brake shoes are worn or damaged, they must be replaced. Brake shoes must be replaced in complete sets. Inspect brake drums for cracks or damage. Replace any damaged parts.

DIFFERENTIAL (DRY BRAKE)


NOTE: Additional information on the differential can be found in the section Drive Axle and Differential Assembly Repair, (Dry Brake) 1400 SRM 1245. 1. Place the lift truck on blocks. See How to Raise Drive Tires in this manual. 2. The differential and drive axle use the same oil supply. Place a container with a minimum capacity of 5 liter (5.3 qt) under the differential. Remove the drain plug located in the bottom of the differential and drain the oil from the differential completely. Install the drain plug. 3. The fill hole is on the front of the differential housing. Add oil shown in the Maintenance Schedule until the oil level is at the lower edge of the fill hole. Install fill plug and rotate the drive wheels in order to get oil pumped into the axle. Remove the fill plug and check the oil level. Add oil, as necessary. Install the fill plug and check for leaks. See Figure 78 and Figure 79.

WARNING
Brake linings can contain dangerous fibers. Breathing the dust from these brake linings is a cancer or lung disease hazard. DO NOT create dust! DO NOT clean brake parts with compressed air or by brushing. Follow the cleaning procedure in this section. When the brake drums are removed, DO NOT create dust. DO NOT sand, grind, chisel, hammer, or change linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. Brake cleaning procedures are as follows:

CAUTION
DO NOT use an oil solvent to clean the wheel cylinder. Use a solvent approved for cleaning of brake parts. DO NOT permit oil or grease in the brake fluid or on the brake linings. 1. DO NOT release brake lining dust from brake linings into the air when brake drum is removed. 2. Use a solvent approved for cleaning of brake parts to wet lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used, do not create brake lining dust with the spray. 3. When the brake lining dust is wet, clean parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container.

Figure 78. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)

78

8000 SRM 1248 Legend for Figure 78 1. DRIVE AXLE 2. CHECK/FILL PLUG 3. DRAIN PLUG

Maintenance Procedures Every 2000 Hours or Annually Check all exhaust pipe extension connectors for leaks and tighten, if necessary. Visually inspect converter for correct muffler mounting and tail pipe mounting. Check for any leaks at the inlet and outlet of the converter.

VALVE CLEARANCE, CHECK AND ADJUST FOR CUMMINS QSB 3.3L DIESEL ENGINE
The Cummins QSB 3.3L engine does not require valve clearance adjustments during normal service. See the Maintenance Schedule for valve clearances. Check the valve clearance and make adjustments as needed. To adjust the valve clearances do the following: 1. Align the TDC mark on the crankshaft pulley with the engraved mark on the block. See Figure 80. 1. CHECK/FILL PLUG 2. DRAIN PLUG 3. DRIVE AXLE Figure 79. Drive Axle (Dry Brake) Fluid Fill for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) 2. Adjust ONLY the valves shown in Figure 81, by loosening the locknut with a wrench and adjusting the valve clearance using a screwdriver or Allen wrench.

TEST LPG/GAS REGULATOR PRESSURE


For more information regarding the Test LPG/GAS Regulator Pressure, see the section LPG Fuel System, GM 4.3L Engine with GFI 900 SRM 1242 and Gasoline Fuel System, GM 4.3L Engine 900 SRM 1244.

CHECK THROTTLE SHAFT FOR STICKING


Check Throttle body return action to ensure throttle shaft is not sticking. Repair if necessary.

INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS


To check the exhaust manifold and piping for leaks, perform the following: Check the exhaust manifold at the cylinder head for leaks. Ensure that all bolts and shields are in place. Check exhaust pipe fasteners to manifold for leaks to ensure they are tight. Repair if necessary. 1. CRANKSHAFT PULLEY 2. DRIVE BELT 3. ENGRAVE TIMING MARK Figure 80. Cummins QSB 3.3L TDC Mark

79

Maintenance Procedures Every 2000 Hours or Annually

8000 SRM 1248 5. Perform Step 2 and Step 3 to adjust ONLY the valves shown in Figure 83. See the Maintenance Schedule for valve clearances.

1. EXHAUST VALVE 2. INTAKE VALVE 3. CYLINDER 1

4. CYLINDER 2 5. CYLINDER 3 6. CYLINDER 4 1. EXHAUST VALVE 2. INTAKE VALVE 3. CYLINDER 1 4. CYLINDER 2 5. CYLINDER 3 6. CYLINDER 4

Figure 81. Cummins Valve Adjustment 3. Tighten the lock nut to 24 Nm (212 lbf in) and measure valve lash. 4. Mark the vibration damper and rotate the crankshaft 360 degrees. See Figure 82.

Figure 83. Cummins Valve Adjustment

1. TIMING PIN 2. VIBRATION DAMPER Figure 82. Cummins Vibration Damper

80

8000 SRM 1248

Maintenance Procedures Every 4000 Hours or 2 Years

Maintenance Procedures Every 4000 Hours or 2 Years


NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000hour, and 2000-hour checks prior to performing the procedures in this section. NOTE: Replace the hydraulic oil filter at the same time the oil is changed. 1. Place a container with a minimum capacity of 39.4 liter (42 qt) under the drain plug at the bottom of the hydraulic tank. To drain the oil, remove the drain plug from the bottom of the hydraulic tank. See Figure 84. When the tank is empty, inspect the inside of the tank for any foreign matter or possible fungus. If necessary, clean the inside of the tank in accordance with the instructions found in the section Frame 100 SRM 1243. When either the inspection or the cleaning of the tank is completed, install the drain plug in the bottom of the hydraulic tank.

HYDRAULIC OIL, REPLACE WARNING


At operating temperature the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION
DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer. 2. Fill hydraulic tank with oil specified in the Maintenance Schedule. 3. When the oil level is correct, operate system and check for leaks.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.

81

Maintenance Procedures Every 4000 Hours or 2 Years

8000 SRM 1248

1. HYDRAULIC TANK

2. DRAIN PLUG Figure 84. Hydraulic Oil Change

VALVE CLEARANCE, CHECK AND ADJUST FOR CUMMINS 4.5L DIESEL ENGINE
The Cummins 4.5L engine does not require valve clearance adjustments during normal service. See the Maintenance Schedule for valve clearances. Check the valve clearance and make adjustments as needed. To adjust the valve clearance, do the following: 1. Rotate the engine until it is at TDC for cylinder number one (intake and exhaust valves closed). Insert timing pin. See Figure 85.

2. Adjust ONLY the valves shown in Figure 86, by loosening the lock nut with a wrench and adjusting the clearance using a screwdriver or Allen wrench. 3. Tighten the lock nut to 24 Nm (18 lbf in) and measure valve lash. 4. Remove the timing pin. See Figure 85. 5. Mark the vibration damper and rotate the crankshaft 360 degrees. See Figure 87. 6. Perform Step 2 and Step 3 to adjust ONLY the valves shown in Figure 88.

82

8000 SRM 1248

Maintenance Procedures Every 4000 Hours or 2 Years

1. INSERT TIMING PIN HERE 2. FUEL/WATER SEPARATOR FILTER 3. TIMING BELT Figure 85. Timing Pin Location, Cummins 4.5L Diesel Engine

1. EXHAUST VALVE 2. INTAKE VALVE 3. CYLINDER 1

4. CYLINDER 2 5. CYLINDER 3 6. CYLINDER 4

1. TIMING PIN 2. VIBRATION DAMPER Figure 87. Cummins Vibration Damper

Figure 86. Cummins Valve Adjustment

83

Maintenance Procedures Every 4000 Hours or 2 Years

8000 SRM 1248 the area to be inspected, then applying penetrant and developer. If a crack is present, it will show up as a well-defined maroon/red line as the dye penetrant is drawn out into the white developer coating. Contact your local Hyster dealer for instructions if a crack is detected. 1. Carriage inspection: welded joints between cast insert and top and vertical carriage bars. See Figure 89. 2. Mast inspection:

1. EXHAUST VALVE 2. INTAKE VALVE 3. CYLINDER 1

4. CYLINDER 2 5. CYLINDER 3 6. CYLINDER 4

Figure 88. Cummins Valve Adjustment

a. Welded joints of lower crossmember of mast outer channel and related gussets. See Figure 90. b. Welded joints around tilt anchor and intermediate cross member. See Figure 90. NOTE: The welded boss for tilt lock option is typically located on right side of mast channel above tilt anchor bracket. c. Right side rail of outer mast channel in area of welded boss for optional tilt lock rod. See Figure 90.

WELD INSPECTION
Initial inspection is suggested at 4000 hours, with subsequent inspections at 2000 hour intervals. Removal of carriage from mast is not required, but recommended, to perform inspection. Removal of attachment is recommended for access to carriage. NOTE: Visual inspection supported by dye penetrant application is recommended with focus on areas defined below. NOTE: Dye penetrant checks are made in a threestep process using a cleaner, penetrant, and developer. Follow manufacturers instructions for cleaning

84

8000 SRM 1248

Maintenance Procedures Every 4000 Hours or 2 Years

A. FRONT VIEW 1. WELDS

B. REAR VIEW

Figure 89. Carriage Bar Welds for Inspection

85

Maintenance Procedures Every 4000 Hours or 2 Years

8000 SRM 1248

A. TYPICAL "XM" MAST B. TYPICAL "FT" MAST C. WELDED BOSS FOR TILT LOCK OPTION 1. WELDS Figure 90. Mast Welds for Inspection

86

8000 SRM 1248

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast


The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired. OR 2. If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put mast in vertical position. b. Raise mast to align bottom crossmember of weldment that moves in outer weldment with a crossmember on outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. See Figure 91. c. Use a 3/8-in. minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (freelift, three-stage, and four-stage masts only) is completely retracted. If running, stop engine. Apply parking brake. Install a DO NOT REMOVE tag on the safety chain(s). e. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. 3. Apply parking brake. After lowering or restraining the mast, shut off power and remove key. Put a DO NOT OPERATE tag in the operators compartment.

WARNING
Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. Never put any part of the body into or under the mast or carriage unless all parts of the mast are completely lowered or a safety chain is installed. Also make sure that the power is off and the key is removed. Put a DO NOT OPERATE tag in the operators compartment. Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. DO NOT use blocks to support the mast weldments nor to restrain their movement. Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast. NOTE: If there is no power to lower the mast on lift trucks equipped with Electronic Hydraulic System, there is an emergency load lowering valve located on the hoist/lower valve section of the main control valve. See the Operating Manual for the procedures to lower a load using the emergency load lowering 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 lowered.

87

Safety Procedures When Working Near Mast

8000 SRM 1248

Figure 91. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

88

8000 SRM 1248 Legend for Figure 91 A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST 1. 2. 3. 4. OUTER MAST INNER MAST INTERMEDIATE MAST HOOK

Fuel Filter Water Removal

C. THREE-STAGE FFL MAST D. FOUR-STAGE FFL MAST 5. 6. 7. 8. FREE-LIFT CYLINDER CARRIAGE BAR CROSSMEMBER FIRST INTERMEDIATE MAST

Fuel Filter Water Removal


NOTE: The following procedure only pertains to lift trucks equipped with Cummins 4.5L and QSB 3.3L diesel engines. 1. Shut off the engine. NOTE: The drain valve is located on the bottom of fuel filter element. 2. To access the fuel filter element and drain valve, remove the air inlet elbow. See Figure 92.

CAUTION
Drain water/fuel into a container and dispose in accordance with local environmental regulations. 3. Turn the drain valve clockwise approximately 3 1/2 turns. Drain fuel filter until clear fuel is visible.

CAUTION
DO NOT overtighten when closing the drain valve. Overtightening can damage the threads. 4. Close the drain valve by lifting and turning clockwise until it is hand-tight.

1. AIR INLET ELBOW 2. FUEL FILTER ELEMENT 3. DRAIN VALVE Figure 92. Engine Fuel Filter Drain Valve Location (Cummins 4.5L Shown)

89

Hood Latch Check

8000 SRM 1248

Hood Latch Check


WARNING
The hood, hood latch, and latch striker must be correctly adjusted for the correct operation of the operator restraint system. 1. Install hood latch on frame of hood. See Figure 93. Tighten capscrews so that hood latch can still move when hood is closed. 2. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. 3. Carefully close hood to fully-closed position. The hood latch has two positions. The hood latch is fully closed after two clicks of the latch. 4. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch. 5. Check operation of hood latch. Have an operator sit in the seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 4.

1. LATCH STRIKER 2. BUMPER 3. HOOD

4. HOOD RELEASE HANDLE 5. HOOD LATCH 6. FRAME Figure 93. Hood Latch Check

90

8000 SRM 1248

Lift Chain Adjustments

Lift Chain Adjustments


WARNING
When working on or near the mast, see Safety Procedures When Working Near Mast in this section. Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests. When lift chains are correctly adjusted: Tension will be the same on each chain of chain set. Check tension by pushing on both chains at the same time. Chain length will be correct. Chains must travel freely through complete cycle. NOTE: When chain adjustments are complete, make sure the threads on the nuts of the chain anchors are completely engaged. Make sure all adjustment is not removed from the chain anchors. Chain anchors must be able to move on their mounting. 1. When adjusting lift chains on forklift trucks equipped with the forks installed, go to Step 2. If forklift truck is equipped with an attachment without forks, go to Step 3. NOTE: Prior to performing adjustment procedures, make sure forklift truck is parked on a level surface and the mast is in the vertical position. 2. Adjust chain anchors which support the carriage until bottom of the fork heel is 6 3 mm (0.24 0.12 in.) above floor level. See Figure 94. 3. Adjust chain anchors which support carriage until the bottom of lower carriage bar is above the floor level as shown in Table 2. See Figure 95. 1. MAST 2. CARRIAGE 3. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR Figure 95. Lift Chain Adjustment Without Forks Installed 1. 2. 3. 4. MAST CARRIAGE FORK HEEL OF FORK IS 6 3 mm (0.24 0.12 in.) ABOVE THE FLOOR LEVEL.

Figure 94. Lift Chain Adjustments With Forks Installed

91

Jump-Starting the Lift Truck In Table 2, 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.

8000 SRM 1248 Table 2. Carriage Chain Adjustment, Forks Not Installed Class II and Class III Class IV 82.5 3 mm (3.25 0.12 in.) 133.5 3 mm (5.26 0.12 in.)

Jump-Starting the Lift Truck


JUMP-STARTING USING A BATTERY CHARGER CAUTION
DO NOT try to start the engine by pushing or towing the lift truck. Damage to the hydraulic system can occur if engine is started by pushing or towing lift truck. If the battery becomes discharged and requires a booster battery to start the engine, follow these procedures carefully when connecting the jumper cables: 1. Disconnect the negative battery terminal of the lift truck being started. 2. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal. 3. Always connect jumper cable, that is the ground cable, last. 4. Always connect jumper cables to discharged battery before connecting them to booster battery.

JUMP-STARTING A LIFT TRUCK USING ANOTHER LIFT TRUCK WARNING


To prevent possible arcing between the two lift trucks, make sure that the lift trucks are not touching.

CAUTION
DO NOT try to start the engine by pushing or towing the lift truck. Damage to the hydraulic system can occur if engine is started by pushing or towing lift truck. 1. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to negative terminal. 2. Always connect jumper cable, that is the ground cable, last. 3. Always connect jumper cables to discharged lift truck battery before connecting them to the fullycharged lift truck battery.

92

8000 SRM 1248

Overhead Guard Changes

Welding Repairs
WARNING
Welding can cause a fire or an explosion. Always follow the instructions in the Frame section if a fuel or hydraulic tank must be welded. Make sure there is no fuel, oil, or grease near the weld area. Make sure there is good ventilation in the area where the welding must be done. DO NOT heat, weld, or bend forks. Forks are made of special steel using special methods. The strength of the overhead guard can be reduced by welding or heating. Get information from your dealer for Hyster lift trucks before welding on a mast. Forklift frames and components may be painted with a catalyzed paint such as Weldpolyurethane or a two-part primer. ing, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection.

CAUTION
When an arc welder is used, always disconnect the 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 current from the welder. Some repairs require welding. If an acetylene or arc welder is used, make sure procedures in previous WARNING and CAUTION are done. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

Overhead Guard Changes


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

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Wheel and Tire Replacement

8000 SRM 1248

Wheel and Tire Replacement


GENERAL
The S series lift trucks have solid rubber tires (often called cushion tires) that are pressed onto the rim. The H series lift trucks have pneumatic tires or solid rubber tires that look like pneumatic tires. These variations in tires also cause a variation in the types of wheels and the disassembly and assembly procedures. Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. 1. Raise lift truck as described in How to Put Lift Truck on Blocks in this manual. 2. Remove wheel nuts and remove wheel from lift truck. Lift truck wheels are heavy.

SOLID RUBBER TIRE, CHANGE (S SERIES)


NOTE: Solid rubber tires made from softer or harder material can be installed as optional equipment. The tread on the sold rubber tires can be either smooth or it can have lugs. Do not mix types of tires or tread on lift truck. See Figure 96.

Remove and Install Tire on Wheel


NOTE: Make sure the tires are installed on the wheels so that the outside edges of the tire and wheel are as shown in Figure 96. Also, check the Nameplate of the lift truck for the correct tire size and tread width. 1. The correct tools, equipment, and a press ring must be used for each size of wheel. Use a press to push wheel from rim and tire. The capacity of the press must be approximately 355 to 1779 kN (80,000 to 400,000 lbf). For the tire sizes, see the Nameplate. 2. When the drive wheels are installed on the lift truck, tighten wheel nuts to a torque value of 610 to 680 Nm (450 to 502 lbf ft).

WARNING
The type of solid rubber tire is shown on the Nameplate. Make sure the Nameplate is correct for the type of tires on the lift truck. The 12000 lb. capacity solid rubber tired fork lift must be equipped with high load capacity steering tires.

A. STEERING TIRE AND WHEEL 1. OUTSIDE OF SOLID RUBBER TIRE

B. DRIVE TIRES AND WHEELS 2. WHEEL

C. WIDE TREAD 3. OVERHANG

Figure 96. Tires and Wheels for S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004) Lift Trucks

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8000 SRM 1248 3. The steering wheels are fastened to the spindle of the steering axle with a large castle nut. Make sure inner and outer bearings are correctly lubricated with grease. Install inner bearing assembly and wheel on spindle. Install outer bearing cone and castle nut. Tighten castle nut up to 203 Nm (150 lbf ft) while rotating hub in both directions to properly seat the bearings, loosen the castle nut until wheel hub turns freely with no end play. Tighten castle nut to 34 Nm (25 lbf ft). If the cotter pin cannot be installed, loosen the castle nut to the first position where the cotter pin can be installed. Install cap for bearings.

Wheel and Tire Replacement sure the nameplate is correct for the type of tires on the lift truck.

WARNING
Wheels must be changed and tires repaired by trained personnel only. Deflate tire completely before removing the wheel from the lift truck. If dual wheels are used, deflate both tires. Air pressure in the 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 wheel halves together when there is air pressure in the tire. 1. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at the beginning of this section. 2. Remove air from tire. Remove valve core to make sure all air is out of inner tube. Push a wire through valve stem to make sure valve stem does not have a restriction. 3. Remove wheel nuts and remove wheel and tire from lift truck. Lift truck tires and wheels are heavy.

PNEUMATIC TIRE WITH TUBE, REPAIR Remove Wheels From Lift Truck WARNING
A solid rubber tire that is the same shape as a pneumatic tire can be installed on a threepiece or four-piece wheel for a pneumatic tire. DO NOT make changes in the parts of the rim if this type of solid rubber tire is installed instead of a pneumatic tire. Changes to the parts of the rim can cause a failure of the wheel and cause an accident.

WARNING
The type of tire and the tire pressure (pneumatic tires) are shown on the nameplate. Make

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8000 SRM 1248

Remove Tire From Wheel


NOTE: When you disassemble the wheels, see Figure 97. There are several types of wheels used on this series of lift trucks.

A. TWO-PIECE WHEEL B. OPTIONAL RIM ASSEMBLY 1. WHEEL RIM 2. SIDE FLANGE

C. THREE-PIECE WHEEL D. FOUR-PIECE WHEEL 3. LOCK RING 4. FLANGE SEAT Figure 97. 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. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause an injury. STEP 1. Remove nuts that fasten wheel rims together.

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8000 SRM 1248 STEP 2. Loosen tire bead from wheel rim.

Wheel and Tire Replacement

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. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause an injury. STEP 1. Loosen tire bead from side flange.

97

Wheel and Tire Replacement 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.

8000 SRM 1248

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 WARNING


Damage to the tire and wheel assembly and injury or death can occur if you do not do the following procedures: Clean and inspect all parts of the wheel before installing the tire. DO NOT use any damaged or repaired wheel parts. Make sure all parts of the wheel are the correct parts for that wheel assembly. DO NOT mix parts between different types or manufacturers of wheels. DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck. DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put

parts together. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used. 1. Clean and inspect all parts of wheel. Paint any parts that have rust or corrosion. 2. Install new inner tube in tire. Used tubes and flaps can cause tire failure. 3. Apply a rubber lubricant or a soap solution to the tire bead and tube. 4. Install new tire flap. 5. Make sure rim is the correct size for tire. Lubricate part of wheel that contacts bead and flap.

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8000 SRM 1248

Wheel and Tire Replacement 6. Install the three-piece or four piece wheel in the tire a shown in Install Three-Piece or Four-Piece Wheel in Tire. 7. Install the two-piece wheel in the tire as shown in Install Tire on Two-Piece Wheel.

CAUTION
DO NOT use pneumatic-shaped, solid tires on two-piece bolt together drive wheels. Spinning may occur.

Install Three-Piece or Four-Piece Wheel in Tire

WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death. Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause an injury. STEP 1. 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.

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Wheel and Tire Replacement STEP 4. Put lock ring in the correct position on rim. Add air pressure to tire as described in Install Wheel in Tire.

8000 SRM 1248

Install Tire on Two-Piece Wheel

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. 2. Install new inner tube in tire. Used tubes and flaps can cause tire failure.

WARNING
Wheels can explode and cause injury or death if the following procedures are not followed: Clean and inspect all parts of the wheel before installing the tire. DO NOT use any damaged or repaired wheel parts. Make sure all parts of the wheel are the correct parts for that wheel assembly. DO NOT mix parts between different types or manufacturers of wheels. DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck. DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used.

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. 3. Apply a rubber lubricant or a soap solution to tire bead and tube. 4. Install new tire flap. 5. Make sure rim is the correct size for tire. Lubricate part of wheel that contacts bead and flap.

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.

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8000 SRM 1248 STEP 2. Tighten nuts that hold rim halves together to 175 Nm (130 lbf ft). Add air pressure to tire (see nameplate).

Wheel and Tire Replacement

ADD AIR TO PNEUMATIC TIRES WITH TUBE WARNING


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 fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. 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 98. 3. Check that all wheel parts are correctly installed. Hit lock ring lightly to make sure it is in the seat. 4. If installation is correct, add air pressure to tire to the specified pressure. 5. Check that all wheel parts are correctly installed. If installation is not correct, remove all air pressure from tire. Remove valve core to make sure all air pressure has been removed and then make

adjustments. 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 correct air pressure.

Install the Wheels


Install wheel on the hub. Tighten nuts in a cross pattern to a torque value of 610 to 680 Nm (450 to 502 lbf ft) for drive wheel nuts and 610 to 680 Nm (450 to 502 lbf ft) for steer wheel nuts. If the wheels are the two-piece rims, make sure nuts that fasten rim halves together are toward brake drum when they are installed.

Figure 98. Add Air to Tires

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8000 SRM 1248

Dual Drive Wheels, Install


NOTE: Some lift trucks have dual drive wheels. The following procedures describe the steps to install the dual sets of wheels. 1. Install inner wheel on hub. If the wheels are the two-piece rims, make sure nuts that fasten rim halves together are toward brake drum when they are installed. 2. Install wheel adapter spacers on the inner wheel studs and tighten spacers to 100 to 125 Nm (74 to 92 lbf ft). Install the dual hub assembly and inner wheel nuts on the spacers and tighten the wheel nuts to 610 to 680 Nm (450 to 502 lbf ft). See Figure 99. 3. Install outer wheel on dual hub assembly. Tighten nuts to a torque value of 610 to 680 Nm (450 to 502 lbf ft). If the wheels are the two-piece rims, make sure nuts that fasten rim halves together are toward brake drum when they are installed. 4. Install the valve extension bracket and tighten the attaching nut to 8 Nm (70 lbf in). Install the valve extension hose into the bracket. See Figure 99.

1. 2. 3. 4. 5. 6. 7.

TIRE DUAL HUB ASSEMBLY WHEEL NUT WHEEL WHEEL ADAPTER SPACER VALVE EXTENSION BRACKET Figure 99. Dual Drive Wheels Installation

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8000 SRM 1248

Wheel and Tire Replacement The Tubeless Bead Seal (TBS) enables tubeless tires to be used on wheel rims that were designed to be used with a tube. The main component of a TBS is a special rubber ring that fits inside the tire between the tire beads to ensure the air tightness of the existing wheel and the tubeless tire assembly. See Figure 97. 1. Put lift truck on blocks as described in at beginning of this section. 2. Remove the valve cap and core to remove all air from the tire. 3. Remove the wheel nuts and remove the wheel and tire from the lift truck. Lift truck tires and wheels are heavy.

PNEUMATIC TUBELESS TIRE, REPAIR Remove Wheels From Lift Truck WARNING
Wheels must be changed and tires repaired by trained personnel only. Deflate tire completely before removing the wheel from the lift truck. If dual wheels are used, deflate 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.

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. Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause injury. NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 97. STEP 1. If wheel rim is a three- or four-piece rim, turn the valve 1/4 turn and remove valve from wheel.

103

Wheel and Tire Replacement 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.

8000 SRM 1248

STEP 3. Remove the loose flange locking ring and the advance band (four-piece wheel only) using a tire tool.

STEP 4. Remove the press and remove the loose flange 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 remove it.

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8000 SRM 1248

Wheel and Tire Replacement

Install Tire on Wheel WARNING


Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow procedures: Clean and inspect all parts of the wheel before installing the tire. DO NOT use any damaged or repaired wheel parts. Make sure that all parts of the wheel are the correct parts for that wheel assembly. DO NOT mix parts between different types or manufacturers of wheels. DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.

WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together.

WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can cause an explosion during inflation or use. STEP 1. Clean interior and exterior bead of the tire. Lubricate tire beads and the inside of the tire, up to the tire shoulders. Apply lubricant to the entire underside of the TBS.

NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve. One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve slot. The valve hole that is not used should be sealed with a small plastic plug. STEP 2. Apply lubricant to the needle valve and the valve hole that will be used (see NOTE) by inserting and removing 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.

105

Wheel and Tire Replacement 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.

8000 SRM 1248

STEP 4. Apply lubricant to the rim. If a four-piece wheel is being used, lubricate the advance band. Slide the tire and the TBS onto the wheel. Line up the valve hole in the TBS with the valve slot in the wheel. Lubricate and insert the valve into the valve hole. Make sure it is fully inserted.

STEP 5. Place the wheel and tire assembly on a flat surface. Turn the valve a 1/4 turn to lock the collar under the edges of the rim valve slot.

STEP 6. Raise the tire and position the base and threaded stem of the press through the hole in the center of the wheel. Insert in wheel assembly, the following parts: Advance band (four-piece wheel only) Loose flange Locking ring

106

8000 SRM 1248 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.

Wheel and Tire Replacement

STEP 8. Insert tire tool into the locking ring groove, and a vise grip on other end. Remove vise grip. Release the press and check that all component parts are correctly positioned. Replace the valve core.

STEP 9. Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to ensure all components are correctly sealed. Remove the press from wheel and tire assembly.

Add Air to Pneumatic Tubeless Tire WARNING


Add air pressure to tires only in safety cage. Inspect safety cage for damage before use. When air pressure is added, use a chuck that fastens onto valve stem. Make sure there is enough hose to permit operator to stand away from safety cage when air pressure is added to tire. DO NOT sit or stand by safety cage. 1. Put tire in safety cage. See Figure 100. 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. Figure 100. Add Air to Tires

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8000 SRM 1248

Wheels, Install
Install wheel on hub. Tighten nuts in a cross pattern to a torque value of 610 to 680 Nm (450 to 502 lbf ft) for drive wheel nuts and 610 to 680 Nm (450 to 502 lbf ft) for steer wheel nuts. If wheels are two-piece rims, make sure nuts that fasten rim halves together are toward brake drum when they are installed.

SOLID RUBBER TIRES ON PNEUMATIC WHEELS, CHANGE WARNING


Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. 1. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at the beginning of this section. 2. Remove wheel nuts and remove wheel and tire from lift truck. Lift truck tires and wheels are heavy.

Remove Wheel From Tire


NOTE: When you disassemble the wheels, see Figure 97. 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.

108

8000 SRM 1248 STEP 2. Put tire tool into slot between lock ring and wheel rim. Remove lock ring and side flange.

Wheel and Tire Replacement

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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Wheel and Tire Replacement

8000 SRM 1248

Install Tire on Wheel


NOTE: When you assemble the wheels, see Figure 97. There are several types of wheels used on these series of lift trucks. DO NOT use a two-piece pneumatic wheel for solid rubber tires.

WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following procedures. Clean and inspect all parts of the wheel before installing the tire. DO NOT use any damaged or repaired wheel parts. Make sure all parts of the wheel are the correct parts for that wheel assembly. DO NOT mix parts between different types or manufacturers of wheels. DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck. DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used.

CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim. STEP 1. Lubricate wheel rim and inner surface of tire with tire lubricant or soap.

110

8000 SRM 1248 STEP 2. Put wheel rim on bed of press. Put tire over wheel rim. Put cage in position on tire. Use press to install tire on wheel rim.

Wheel and Tire Replacement

STEP 3. Remove cage and put flange seat (if used), side ring, and lock ring in position on wheel rim. Install cage on tire. Use press to push tire onto wheel rim so side flange and lock ring can be installed.

STEP 4. While the cage is holding the tire on the wheel rim, install lock ring. Use a tire tool to make sure lock ring is in the correct position.

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Adhesives and Sealants

8000 SRM 1248

Adhesives and Sealants


Hyster Part No. 360387 318702* 226414* 318996 318650 251099 355844* 350830 313022* 273338* 318705 318701* 341959 226415 251979 360053-10 318700 767 Loctite Part No. 222 242 271 277 290 290 422 515 515 567 595 609 680 Description Small Screw Threadlock (Purple) Removable Threadlock (Blue) High Strength Threadlock (Red) High Viscosity Threadlock (Red) Low Viscosity Threadlock (Green) Low Viscosity Threadlock (Green) SuperBonder Adhesive Gasket Eliminator (Purple) Gasket Eliminator (Purple) Pipe Sealant with Teflon Super Flex Silicone Retaining Compound Retaining Compound Primer T - Aerosol Antiseize Compound Chisel Gasket Remover (10 Aerosol cans per case) Adhesive and Sealant Kit (Contains one each of * items) Size 50 ml 10 ml 10 ml 50 ml 0.02 oz 50 ml 3 ml 6 ml 50 ml 50 ml 100 ml 10 ml 50 ml 6 oz 1 lb 18 oz

*Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700. 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.

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TECHNICAL PUBLICATIONS
8000 SRM 1248 8/11 (1/11)(12/10)(8/10)(7/10)(6/10)(2/10)(6/09)(5/08)(10/07)(7/07)(3/07) Printed in U.S.A.