Академический Документы
Профессиональный Документы
Культура Документы
MAINTENANCE
S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS [G004];
H80, 90, 100, 110, 120FT [N005, P005]
• 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.
• 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.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Serial Number Data ........................................................................................................................................ 1
How to Move Disabled Lift Truck................................................................................................................... 1
How to Tow Lift Truck ................................................................................................................................ 1
How to Put Lift Truck on Blocks .................................................................................................................... 3
How to Raise Drive Tires ............................................................................................................................ 3
How to Raise Steering Tires ....................................................................................................................... 3
How to Clean a Lift Truck............................................................................................................................... 4
Maintenance Schedule....................................................................................................................................... 11
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 21
How to Make Checks With Engine Stopped................................................................................................. 21
Tires and Wheels ....................................................................................................................................... 21
Safety Labels ............................................................................................................................................. 22
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 22
Operator Restraint System....................................................................................................................... 23
Emergency Locking Retractor (ELR) ................................................................................................... 23
Adjust Seat - Full Suspension .............................................................................................................. 24
Adjust Seat - Internal Suspension ....................................................................................................... 25
Hood and Seat Latches ............................................................................................................................. 26
Engine Compartment................................................................................................................................ 26
Paper Application ...................................................................................................................................... 26
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ 27
Hydraulic Hoses ........................................................................................................................................ 27
Coolant Hoses ............................................................................................................................................ 27
Steering Column Gas Cylinder................................................................................................................. 27
Transmission ............................................................................................................................................. 28
Hydraulic System Oil ................................................................................................................................ 28
Engine Oil .................................................................................................................................................. 28
Air Filter .................................................................................................................................................... 32
Forks .......................................................................................................................................................... 32
Remove .................................................................................................................................................. 32
Inspect ................................................................................................................................................... 33
Install..................................................................................................................................................... 33
Adjust..................................................................................................................................................... 34
Integral Sideshift Carriage....................................................................................................................... 34
How to Make Checks With Engine Running................................................................................................ 35
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 35
Service Brakes ........................................................................................................................................... 37
Brake Oil Level ..................................................................................................................................... 37
Operation, Check .................................................................................................................................. 38
Parking Brake ........................................................................................................................................... 38
Engine Oil Pressure .................................................................................................................................. 38
Cooling System .......................................................................................................................................... 39
Steering System ........................................................................................................................................ 39
Control Levers and Pedals ........................................................................................................................ 40
Lift System, Operate ................................................................................................................................. 40
First Service After First 100 Hours of Operation ............................................................................................ 41
GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 41
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. 41
Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 42
GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 42
ii
Periodic Maintenance Table of Contents
iii
Table of Contents Periodic Maintenance
iv
8000 SRM 1248 General
General
shown in the Maintenance Schedule. Service Man-
WARNING uals are available from your dealer for Hyster lift
DO NOT make repairs or adjustments unless trucks to help users who do their own maintenance.
you have both authorization and training. Re-
pairs and adjustments that are not correct can SERIAL NUMBER DATA
make a dangerous operating condition.
The serial number for the lift truck is on the name-
plate. It is also on the right side of the frame, under
WARNING the floor plate.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If re- HOW TO MOVE DISABLED LIFT TRUCK
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from How to Tow Lift Truck
the key switch.
WARNING
CAUTION Use extra caution when towing a lift truck if
Disposal of lubricants and fluids must meet lo- any of the following conditions exist:
cal environmental regulations. • Brakes do not operate correctly.
• Steering does not operate correctly.
This section contains a Maintenance Schedule and • Tires are damaged.
the instructions for maintenance and inspection. • Traction conditions are bad.
• The lift truck must be towed on a slope.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift If the engine cannot run, there is no power
truck. The service intervals are given in both oper- available for the hydraulic steering system
ating hours recorded on the lift truck hourmeter and and the service brakes. This condition can
in calendar time. The recommendation is to use the make the lift truck difficult to steer and stop.
interval that comes first. If the lift truck uses power from the engine to
help apply the brakes, the application of the
The recommendations for the time intervals given for
brakes will be more difficult. Poor traction can
eight hours of operation per day. The time intervals
cause the disabled lift truck or towing vehicle
must be decreased from the recommendations in the
to slide. A slope will also make the lift truck
Maintenance Schedule for the following conditions:
more difficult to stop.
• The lift truck is used more than eight hours per
day. Never lift and move a disabled lift truck unless
• The lift truck must work in dirty operating condi- the disabled lift truck MUST be moved and
tions. cannot be towed. A lift truck used to move
• Poor ground conditions. a disabled lift truck MUST have a capacity
• Intensive usage at high performance levels or rating equal to or greater than the weight of
other abnormal conditions will require more fre- the disabled lift truck. The capacity of the lift
quent servicing. truck used to move a disabled lift truck must
have a load center equal to half the width of
Your dealer for Hyster lift trucks has the equipment
the disabled lift truck. See the nameplate of
and trained service personnel to do a complete pro-
the disabled lift truck for the approximate
gram of inspection, lubrication, and maintenance. A
total weight. The forks must extend the full
regular program of inspection, lubrication, and main-
width of the disabled lift truck. Put the weight
tenance will help your lift truck provide more effi-
center of the disabled lift truck on load center
cient performance and operate for a longer period of
of the forks. Be careful to not damage the
time.
underside of the lift truck.
Some users have service personnel and equipment
1. The towed lift truck must have an operator.
to do the inspection, lubrication, and maintenance
2. Tow truck slowly.
1
General 8000 SRM 1248
3. Using a lift truck or a lifting device that could towing link made of steel that fastens to the tow
be attached to the mast (I.E. come-a-long), raise pins in the counterweights of both lift trucks. See
carriage and forks approximately 30 cm (12 in.) Figure 1. Slowly and carefully remove the slack
from surface. Install chain around a mast cross- out of the towing link.
member and the carriage to prevent carriage and
mast channels from moving. 6. If lift trucks are equipped with a leaded counter-
weight without a tow pin (see Figure 1), use a
4. If another lift truck is used to tow the disabled lift towing link made of steel that fastens to the two
truck, that lift truck must have an equal or larger center grill bars of both lift trucks. Slowly and
capacity than the disabled lift truck. Install ap- carefully remove the slack out of the towing link.
proximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck. Lift truck models that are equipped with a leaded
This 1/2 capacity load will increase traction of lift counterweight, that are covered in this SRM are
truck. Keep load as low as possible. S80FTBCS, S100FTBCS, S120FTS, and S120FT-
PRS (G004).
5. If lift trucks are equipped with a tow pin in the
counterweight (standard counterweight), use a
2
8000 SRM 1248 General
HOW TO PUT LIFT TRUCK ON BLOCKS 2. Put mast in vertical position. Put a block under
each outer mast channel.
How to Raise Drive Tires
3. Tilt mast fully forward until drive tires are raised
from surface.
WARNING
The lift truck must be put on blocks for some 4. Put additional blocks under frame behind drive
types of maintenance and repair. The removal tires.
of the following assemblies will cause large
changes in the center of gravity: mast, drive 5. If hydraulic system will not operate, use a hy-
axle, engine, transmission, and counterweight. draulic jack under the side of the frame near the
When the lift truck is put on blocks, put ad- front. Make sure jack has a capacity equal to at
ditional blocks in the following positions to least half the weight of the lift truck. See Name-
maintain stability: plate.
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift How to Raise Steering Tires
truck cannot fall backward.
NOTE: Some lift trucks are equipped with lifting eyes
• Before removing the counterweight, put
for the purpose of lifting the entire lift truck. If the
blocks under the mast assembly so the lift
lift truck is equipped with this type of lifting eyes, the
truck cannot fall forward.
lift truck can be lifted and blocks installed.
The surface must be solid, even, and level when
1. Apply parking brake. Put blocks on both sides
the lift truck is put on blocks. Make sure any
(front and back) of drive tires to prevent move-
blocks used to support the lift truck are solid,
ment of lift truck. See Figure 2.
one-piece units.
2. Use hydraulic jack to raise steering tires. Make
CAUTION sure jack has a capacity of at least 2/3 of total
These lift trucks are equipped with cowl lifting weight of lift truck as shown on the nameplate.
eyes. The cowl lifting eyes are to be used to 3. Put jack under steering axle or frame to raise
lift the front of the lift truck only. Lifting more lift truck. Put blocks under frame to support lift
than the front of the lift truck with the cowl truck.
lifting eyes will damage the cowl section.
3
General 8000 SRM 1248
HOW TO CLEAN A LIFT TRUCK refer to Paper Application section in the applicable
Operating Manual and to available Service Gram/
WARNING Bulletin for more detail.
Engine, exhaust system components and other If it becomes necessary to clean the fork lift, follow
components are hot to the touch. Be sure lift the guidelines listed below.
truck components are cool before starting in-
spection and cleaning, or personal injury may 1. Assure truck components are cool before starting
occur. the cleaning procedure.
4
8000 SRM 1248 General
6. Avoid spraying in areas containing electrical 8. DO NOT pressure wash the battery. Do not use
components such as: hot water. For cleaning traction batteries, refer
• Floor Plates to the Battery section of the Service Manual.
• Battery Compartment
• Dash/cowl assembly 9. DO NOT pressure wash lift chains, sheaves or
• Armrests with electrical components load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
7. Clean the battery compartment by using a clean section in the Service Manual for proper clean-
cloth to wash the battery with water. Dry with ing procedures.
compressed air. Care should be taken to keep
moisture at a minimum as some units have a 10. After cleaning, immediately start and run the lift
traction or hydraulic motor directly below the truck to dry out components.
battery compartment.
5
General 8000 SRM 1248
6
8000 SRM 1248 General
7
General 8000 SRM 1248
8
8000 SRM 1248 General
Figure 6. Cummins 4.5L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (N005)
9
General 8000 SRM 1248
Figure 7. Cummins QSB 3.3L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (P005)
10
8000 SRM 1248 Maintenance Schedule
Maintenance Schedule
NOTE: The lift trucks shown in Figure 3, Figure 4, NOTE: The 250-hour, 500-hour, and 1000-hour/6-
and Figure 5 represent SSE 100, 120FT; S80, 100FT- month maintenance services are performed either at
BCS; S120FTS, and S120FTPRS (G004) lift trucks. the specified hours or at 6 months whichever occurs
first.
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.
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
25 Tires and Wheels X Check See Nameplate
Condition
11
Maintenance Schedule 8000 SRM 1248
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
16 Fuel Tank (LPG) CIL 15.1 - 20.4 kg LPG - HD 5, HD 10
(33.5 - 45.0 lb)
Full
16 Fuel Tank CIL 44.7 liter 86 Octane - Gasoline
GM 4.3L (11.8 gal) Minimum
(Gasoline)
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
U.S. Only
16 Fuel Tank (Short CIL 79 liter 86 Octane Minimum
Wheel Base) (20.8 gal)
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005, P005)
U.S. Only
16 Fuel Tank (Long CIL 100.3 liter 86 Octane Minimum
Wheel Base) (26.5 gal)
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005, P005)
U.S. Only
16 Fuel Tank (Short CIL 79 liter Diesel No. 2
Wheel Base) (20.8 gal)
Cummins 4.5L and
QSB 3.3L (Diesel)
H80, 90, 100, 110,
120FT (N005, P005)
16 Fuel Tank (Long CIL 100.3 liter Diesel No. 2
Wheel Base) (26.5 gal)
Cummins 4.5L and
QSB 3.3L (Diesel)
H80, 90, 100, 110,
120FT (N005, P005)
Horn, Lights, X Check
Alarms, Fuses, Operation
and Relays
1 Service Brakes X Check
Operation
23 Parking Brake X Check
Operation
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
12
8000 SRM 1248 Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
Steering Controls X Check
and Steering Condition and
Column Gas Operation
Cylinder
22 Transmission X Check for John Deere
Leaks JDM J20C
22 Transmission X Check
Operation
3 Hydraulic Oil X X C 39.4 liter ISO VG 46
GM 4.3L [S80, (41.6 qt) Hydraulic Oil
100, 120FT]; See NOTE 2 15°C (5°F) and
S80, 100FTBCS, and NOTE 3. Above
S120FTS;
S120FTPRS (G004)
3 Hydraulic Oil X X C 62.0 liter ISO VG 46
(Short Wheel Base) (65.5 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 15°C (5°F) and
120FT (N005, P005) and NOTE 3 Above
3 Hydraulic Oil X X C 78.0 liter ISO VG 46
(Long Wheel Base) (82.4 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 15°C (5°F) and
120FT (N005, P005) and NOTE 3 Above
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
13
Maintenance Schedule 8000 SRM 1248
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
9 Engine Oil X C 13.0 liter 0°C (32°F)
Cummins 4.5L CIL (13.7 qt) and Below
Engine (Diesel) See NOTE 4 SAE 0W-30
and NOTE 5. 25 to 20°C
( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
15°C (5°F)
and Above
SAE 5W-40
or 15W-40
API CH-4 or CI-4
9 Engine Oil X C 7.5 liter (8 qt) 0°C (32°F)
Cummins CIL See NOTE 4 and Below
QSB 3.3L and NOTE 5. SAE 0W-30
Engine (Diesel) 25 to 20°C
( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
15°C (5°F)
and Above
SAE 5W-40
or 15W-40
API CH-4 or CI-4
19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins 4.5L See NOTE 4
and QSB 3.3L and NOTE 5.
(Diesel)
18 Air Filter CIL C 1 Filter See Parts Manual
(with premium See NOTE 5,
monitoring) NOTE 6, and
NOTE 12.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
14
8000 SRM 1248 Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
Engine Oil CIL Check Oil GM Engine
Pressure Pressure 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 X Check for Wear
GM Engine and Damage.
No Adjustment
Needed.
See NOTE 5.
15 Drive Belt X Check for Wear
Cummins 4.5L and Damage.
and QSB 3.3L No Adjustment
(Diesel) Needed.
See NOTE 5.
LPG Regulator X Drain Tar
GM 4.3L Engine See NOTE 5.
With GFI Installed
33 LPG Converter X Drain Tar
4.3L LPG Engine See NOTE 5.
With PSI Installed
Engine Idle Speed X 750 ±25 rpm
GM 4.3L
(Gasoline/LPG)
Engine Governed X 2400 ±25 rpm
Speed
GM 4.3L
(Gasoline/LPG)
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature
Cummins 4.5L Less than
(Diesel) 77°C (170°F)
Engine Idle Speed X Coolant 800 ±50 rpm
Hot Engine Temperature
Cummins 4.5L Greater than
(Diesel) 77°C (170°F)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
15
Maintenance Schedule 8000 SRM 1248
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
Engine Governed X 2250 ±50 rpm
Speed (No Load)
Cummins 4.5L
Diesel
PCV Valve X Replace as See Parts Manual
GM 4.3L En- Necessary
gine with GFI In- See NOTE 14
stalled
Engine Idle Speed X Coolant 1000 ±25 rpm
Cold Engine Temperature
Cummins QSB Less than 30°C
3.3L (Diesel) (86°F)
Engine Idle Speed X Coolant 800 ±25 rpm
Hot Engine Temperature
Cummins QSB Greater than
3.3L (Diesel) 30°C (86°F)
Engine Governed X 2230 ±25 rpm
Speed
Cummins QSB
3.3L (Diesel)
Oxygen Sensor X Replace as
GM 4.3L Engine CIL Necessary
With GFI Installed
4 Valve Adjustment Not Adjustable
GM 4.3L Engine
4 Valve Adjustment X Adjust as Intake
Cummins 4.5L Required 0.254 mm (0.010 in.)
Diesel Engines Cold
Exhaust
0.508 mm (0.020 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Cummins QSB Required 0.35 mm (0.014 in.)
3.3L Diesel See NOTE 13. Cold
Engines Exhaust
0.50 mm (0.02 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
17 Fuel Filter C 1 Filter See Parts Manual
Gasoline (GM)
17 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain Water
Cummins 4.5L from Filter as
and QSB 3.3L Required
Diesel Engine
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
16
8000 SRM 1248 Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins 4.5L
Diesel Engine
17 Final Fuel Filter C 1 Filter See Parts Manual
Cummins QSB
3.3L Diesel
Engine
20 Fuel Injectors X Check and
GM 4.3L Gas Replace If
Required
6 Injectors
20 Fuel Injectors X Check and
GM 4.3L LPG Replace If
With GFI In- Required
stalled 6 Injectors
5 Spark Plugs C Check See NOTE 9.
GM 4.3L Engine Plug Wires
6 Plugs
12, Cooling System X C 15.1 liter See NOTE 15.
14 GM 4.3L CIL (15.9 qt)
Engine
12, Cooling System X C 13.5 liter See NOTE 15.
14 Cummins 4.5L CIL (14.2 qt)
Diesel Engine
12, Cooling System X C 10.4 liter See NOTE 15.
14 Cummins QSB CIL (11 qt)
3.3L Diesel
Engine
Clean Debris From X See NOTE 5.
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brake JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check
Condition
26 Fork Latches L Lubricate as Multipurpose
Necessary Grease
See NOTE 7.
Lift System, X Check
Operate Operation
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
17
Maintenance Schedule 8000 SRM 1248
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
27 Mast L Lubricate Multipurpose
Sliding Surfaces as Required Grease
and Load Roller See NOTE 10 See NOTE 7.
Surfaces and NOTE 11.
27 Header Hoses X Check
Condition
28 Lift Chains X Check SAE 30W
Lubrication. Engine Oil
See NOTE 11.
28 Lift Chains L L, X Check for Wear. SAE 30W
Lube as Engine Oil
Required.
Mast L 2 Fittings Multipurpose
Pivots Grease
See NOTE 7.
Mast X L X Lube as Multipurpose
Integral Required. Grease
Sideshift 8 Fittings See NOTE 7
Carriage 4 Bearing
Sliding Surfaces Strips
18
8000 SRM 1248 Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
11 Steering Axle L 4 Fittings Multipurpose
Tie Rods Grease
H80, 90, 100, See NOTE 7.
110, 120FT
(N005, P005)
2 Pedals, Levers, L Lubricate as Use Silicone Spray
Seat Rails, Cables, Necessary Hyster Part No.
Hinges, Linkages, 328388
Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
(Dry Brake) Thickness Minimum
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Hyster Part
Number 328388)
30 Differential and X C 6.0 liter (6.3 qt) SAE 80W-90 or
Drive Axle Oil 85W-140
(Dry Brake)
7/30 Transmission X C 28.8 liter John Deere
and Wet Brake (30.4 qt) JDM J20C
Planetary Carrier
Housing Oil
S80FT, FTBCS
(G004)
7/30 Transmission X C 29.8 liter John Deere
and Wet Brake (31.4 qt) JDM J20C
Planetary Carrier
Housing Oil
S100FT, FTBCS
S120FT, FTS,
FTPRS (G004)
7/30 Transmission X C 31.3 liter John Deere
and Wet Brake (33.0 qt) JDM J20C
Planetary Carrier
Housing Oil
H80, 90, 100, 110,
120FT) (N005,
P005)
30 Wet Brake Center X C 2.0 liter (2.1 qt) SAE 80W/90
Section Oil
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
30 Wet Brake Center X C 2.0 liter (2.1 qt) SAE 80W-90
Section Oil
H80, 90, 100, 110,
120FT (N005, P005)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
19
Maintenance Schedule 8000 SRM 1248
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel
Lines, and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure
Lock-Off Closing
Test LPG/GAS X
Regulator Pressure
Check X
Air Induction
System for Leaks
Check X
Manifold for
Vacuum Leaks
Check X
Throttle Shaft for
Sticking
Check X
Injectors and Rails
for leaks
Inspect X
Exhaust Manifolds
and Piping for
Leaks
Inspect X
Catalyst Inlet
and Outlet
31 Ignition System C Replace
Distributor, Rotor,
and Spark Plug
Wires
Inspect Muffler X Replace as
Inlet and Outlet Required
Mast and Carriage X Inspect Dye Penetrant
with Paper Roll See NOTE 16
Clamp
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
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
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 in-
volving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based on
an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: 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 2000-
hour/2-year intervals, whichever comes first.
NOTE 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled 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
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)
Safety Labels 1. Inspect the welds on the mast and carriage for
cracks. Make sure that the capscrews and nuts
are tight.
WARNING
Safety labels are installed on the lift truck to 2. Inspect the channels for wear in the areas where
give information about operation and possible the rollers travel. Inspect the rollers for wear or
hazards. It is important that all safety labels damage.
are installed on the lift truck and can be read.
3. Inspect the load backrest extension for cracks
Check that all safety labels are installed in the cor- and damage.
rect location on the lift truck. See the Parts Man-
ual, Model Description section in the Operating 4. If the lift truck is equipped with an integral
Manual or the section Frame 100 SRM 1243 for the sideshift carriage or attachment, inspect the
correct location of the safety labels. See the Parts parts for cracks and wear. Make sure the parts
Manual for the part numbers of the safety labels. that fasten the integral sideshift carriage or
attachment to the carriage are in good condition.
Mast, Carriage, Lift Chains, Header Hoses,
5. Visually inspect hoses/fittings for hydraulic
Attachment leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
WARNING or sheaves; proper tracking during operation.
Lower the lift mechanism completely. Never Adjust/repair/replace hose/components as neces-
allow any person under a raised carriage. DO sary. See Mast Repairs, 2- and 3-Stage Masts
NOT put any part of your body in or through 4000 SRM 1250 for quick disconnect procedures.
the lift mechanism unless all parts of the mast
are completely lowered and the engine is 6. Check that the lift chains are correctly lubri-
STOPPED. DO NOT try to correct the align- cated. Use SAE 30 engine oil as necessary to
ment of the fork tips by bending the forks or lubricate the lift chains.
adding shims. Never repair damaged forks by
7. Inspect the lift chains for cracks or broken links,
heating or welding. Forks are made of special
and worn or turned pins. See Figure 9.
steel using special procedures. If either fork is
damaged, replace the forks as a set. 8. Inspect the chain anchors and pins for cracks and
damage.
22
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
9. Make sure the lift chains are adjusted so that The seat belt must be in good condition. Replace the
they have equal tension. Adjustments or re- seat belt if damage or wear is seen. See Figure 10.
placement of the lift chains must be done
by authorized personnel. NOTE: The following seat belt operation checks must
be performed three times before replacing the seat
belt assembly.
When the ELR style seat belt is properly buckled 1. LATCH STRIKER
across the operator, the belt will permit slight op- 2. HOOD LATCH
erator repositioning without activating the locking 3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD
mechanism. If the truck tips, travels off a dock, or 5. OPERATOR WEIGHT ADJUSTMENT
comes to a sudden stop, the locking mechanism will 6. SEAT RAIL
be activated and hold the operator’s lower torso in 7. ARM REST
the seat. 8. SEAT BELT
9. SEAT
A seat belt that is damaged worn or does not operate 10. HIP RESTRAINT
11. HOOD HINGE
properly will not give protection when it is needed.
The end of the belt must fasten correctly in the latch. Figure 10. Hood and Seat Check
23
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
CAUTION
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
24
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Adjust Seat - Internal Suspension NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
Seat Position Adjustment (Swivel Seat)
• The seat swivels 10.5 degrees to the right to allow • The target is for the "ride indicator" to fall between
the operator a more ergonomic position when driv- the arrows when the operator sits upright in the
ing in reverse. seat with the feet positioned on the pedals. This
• The seat swivels 5 degrees to the left to allow as ensures that the operator is set at the midpoint of
easier exit of the truck. the 40 mm (1.57 in.) suspension.
• The neutral position is shown in Figure 13. • The weight adjustment knob can be turned left or
right to increase or decrease the weight resistance.
Seat Adjustment for Operator Weight As the weight adjustment knob is turned the "stiff-
ness" of the suspension can be felt to increase or de-
CAUTION crease on which way the weight adjustment knob
A major cause for high Whole Body Vibration is is turned.
caused by the operator not adjusting the seat to
his/her weight.
25
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
26
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Check the condition of exhaust wraps for wear, Make sure the gas cylinder for the steering column
proper fit, contamination with oil or antifreeze, gaps operates correctly. The cylinder must NOT allow the
in coverage, failed fasteners and replace as neces- column to move unless the tilt lever is released. See
sary. Do not reuse wraps if they have been removed Figure 14.
for some other service operation.
27
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
Engine Oil
28
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
29
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
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
31
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
32
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Inspect
1. Inspect the forks for cracks and wear. Check that Fork Tip Alignment
the fork tips are aligned as shown in Figure 20. Length of Forks 3% Dimension
Check that the bottom of the fork is not worn. See
Figure 20, item 4. 915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
2. Replace any damaged or broken parts that are 1220 mm (48 in.) 37 mm (1.46 in.)
used to keep the forks locked in position. 1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
Install 1830 mm (72 in.) 55 mm (2.17 in.)
Move the fork and carriage so that the top hook on
the fork can engage the upper carriage bar. Raise 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
the carriage to move the lower hook through the fork 2. CRACKS
removal notch. Slide the fork on the carriage so that 3. LATCH DAMAGE
both upper and lower hooks engage the carriage. En- 4. HEEL OF FORK (MUST BE 90% OF
gage the lock pin with a notch in the upper carriage DIMENSION X)
bar. 5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
33
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
1. CAPSCREWS
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
1. FORK 5. WEDGE 8. SNAP RING
2. LOCK PIN 6. KNOB 9. ROD SCRAPER
3. SPRING 7. LOCK PIN 10. ROD BUSHINGS
4. WASHER ASSEMBLY 11. SEAL
12. FIXED FRAME
Figure 21. Fork Lock Pin Assembly
Figure 22. Integral Sideshift Carriage
34
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
HOW TO MAKE CHECKS WITH ENGINE the parking brake and put the transmission in NEU-
RUNNING TRAL. Make the checks carefully.
35
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
36
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Service Brakes using the lift truck. Replace the brake oil in
the system if there is dirt or water in the sys-
Brake Oil Level tem.
WARNING DO NOT use "DOT" fluid, only use Dexron III oil
from sealed container to prevent possible dam-
Small amounts of water in the brake system
age to the brake system. Failure to observe the
can cause reduced braking performance if the
above Warning could result in death or serious
water reaches the wheel cylinder areas. DO
injury.
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced. There is an indicator light on the Display Switch
Cluster for the brake oil. The red light is ON when
The brake system has a boosted master cylin-
the key switch is in the START position or the Power
der, braking will be more difficult if the engine
ON/OFF button is pressed, and must go OFF when
is not running.
the engine is running. If the light is on when the
Loss of oil from the brake oil reservoir indi- engine is running, the brake fluid oil in the reservoir
cates a leak. Repair the brake system before is too low.
37
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
Operation, Check
Parking Brake
Make sure the service brakes are adjusted and the
operation of the automatic adjuster mechanism is 1. LOCK BUTTON RELEASE
correct before the parking brake is adjusted. 2. OFF POSITION
3. ON POSITION
Lift trucks with a MONOTROL® pedal. The 4. ADJUSTMENT KNOB
switch energizes the seat warning circuit when hand Figure 25. Parking Brake
lever is released. This switch puts the transmission
in NEUTRAL by de-energizing the direction sole- Engine Oil Pressure
noid. There is also a switch on the left-hand side of
bracket. This switch prevents engine from starting NOTE: The engine will enter shutdown mode after a
unless parking brake is applied. warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
NOTE: Make sure parking brake is released before lift trucks with powertrain protection system. Lift
making adjustment. trucks equipped with a Cummins diesel engine will
1. Turn the adjustment knob to raise the equalized enter the shutdown mode when the engine oil pres-
link and tighten the parking brake cables shown sure is less than 49 kPa (7 psi) on lift trucks with pow-
in Figure 25. Do not tighten the adjustment so ertrain protection system. See the Engine Shut-
that the brake is applied when the lever is re- down procedures in the Operating Manual.
leased. The lever for the parking brake has a There is an indicator light for the engine oil pressure
lock. Use your thumb or finger to release the lock on the Display Switch Cluster. During normal opera-
on the lever when the parking brake is released. tion, the red indicator light will illuminate when the
2. For burnished brakes, test the operation of the key switch is turned to ON, if the truck is equipped
parking brake. The lift truck with a capacity load with a key switch, or when the power ON/OFF but-
must not move when parking brake is applied on ton is pressed, if the truck is equipped with a key-
a 15 percent grade [a slope that increases 1.5 m less option, and will stay illuminated until correct oil
in 10 m (1.5 ft in 10 ft)]. pressure is obtained, at which time the light will go
off.
38
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Cooling System Check the radiator fins. Clean the radiator with com-
pressed air or water as needed. Check for and re-
move any debris on the radiator core. If the indicator
WARNING light turns on again after restarting, shut down the
DO NOT remove the radiator cap from the radi- lift truck and do not operate the lift truck until the
ator when the engine is hot. When the radiator problem is corrected.
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
CAUTION WARNING
Additives may damage the cooling system. Be-
The lift truck has hydraulic power steering.
fore using additives, contact your local Hyster
The steering can be difficult if the engine is
dealer.
not running.
If coolant is added, see Maintenance Schedule for cor-
Make sure the steering system operates smoothly
rect solution.
and provides good steering control. Make sure the
steering column can be adjusted and the gas cylinder
function is correct.
39
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
Control Levers and Pedals Perform the following checks and inspections:
Check that the control levers for the transmission, 1. Check for leaks in the hydraulic system. Check
mast, and attachment operate as described in Oper- the condition of the hydraulic hoses and tubes.
ating Manual. Check that the pedals operate cor-
rectly as described in Operating Manual. NOTE: Some parts of the mast move at different
speeds during raising and lowering.
Lift System, Operate
2. Slowly raise and lower the mast several times
without a load. Raise the mast to its full height
WARNING at least once. The mast components must raise
When working on or near the mast, see Safety and lower smoothly in the correct sequence. Hose
Procedures When Working Near Mast at the must track properly during operation.
end of this section.
3. The inner weldments and the carriage must
Lower the lift mechanism completely. Never lower completely.
allow any person under a raised carriage. DO
NOT put any part of your body in or through 4. Raise the mast 1 m (3 ft) with a capacity load.
the lift mechanism unless all parts of the mast The inner weldments and the carriage must raise
are completely lowered and the engine is smoothly. Lower the mast. All moving compo-
STOPPED. nents must lower smoothly.
If the mast cannot be lowered, use chains on 5. Lower the load to approximately 0.3 m (1 ft). Tilt
the mast weldments and carriage so that they the mast forward and backward. The mast must
cannot move. Make sure the moving parts are tilt smoothly and both tilt cylinders must stop
attached to a part that does not move. evenly.
DO NOT try to find hydraulic leaks by putting 6. Check that the controls for the attachment op-
hands on pressurized hydraulic components. erate the functions of the attachment. See the
Hydraulic oil can be injected into the body by symbols by each of the controls. Make sure all of
the pressure. the hydraulic lines are connected correctly and
do not leak.
40
8000 SRM 1248 First Service After First 100 Hours of Operation
41
Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1248
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
42
8000 SRM 1248 Maintenance Procedures Every 250 Hours or 6 Months
Legend for Figure 31 1. Move the lift truck to a well ventilated area, and
ensure no external ignition sources are present.
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING
TENSIONERS. 2. Start the engine.
1. FAN PULLEY 3. Close the valve on the LPG tank.
2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY 4. When the engine runs out of fuel, turn key or
4. SERPENTINE BELT keyless switch to OFF position, and disconnect
5. TENSIONER CENTERING PULLEY
6. ALTERNATOR PULLEY the negative terminal on the battery.
1. LPG CONVERTER
2. INLET LINE
3. OUTLET HOSE
4. MOUNTING BOLTS
1. TAR DRAIN SCREW
Figure 33. LPG Converter Removal
Figure 32. GM LPG Regulator
43
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
WARNING Inspect
At operating temperature, the hydraulic oil is NOTE: When inspecting the breather, do not remove
HOT. DO NOT permit the hot oil to touch the it. The breather element is a non serviceable part. If
skin and cause a burn. it is damaged, replace with a new breather element.
CAUTION 1. Raise the hood and remove the right rear side
panel See Figure 34.
DO NOT permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. WARNING
Compressed air can move particles so that they
Never operate the hydraulic pump without oil cause injury to the user or to other personnel.
in the hydraulic system. The operation of the Make sure that the path of the compressed air
hydraulic pump without oil will damage the is away from all personnel. Wear protective
pump. goggles or a face shield to prevent injury to the
eyes.
CAUTION
Additives may damage the hydraulic system. CAUTION
Before using additives, contact your local Hys- Direct air pressure on the filter element can
ter dealer. cause damage. Direct air pressure away from
Check the hydraulic oil level when the oil is at operat- filter element.
ing temperature with the mast in a vertical position, 2. Using compressed air, remove any dirt and de-
the carriage lowered, and the engine stopped. See bris in the frame cavity around the breather. See
Figure 41 and Figure 42. Add hydraulic oil only as Figure 34.
needed. If hydraulic oil is above the FULL level, the
hydraulic oil will leak from the breather during oper- 3. If necessary, unscrew and replace the breather
ation. The oil level indicated by the dipstick is most if oil has accumulated in the cavity or on the
44
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
breather, or if dirt has accumulated at the Disconnect the negative and positive terminals of the
breather passages at the bottom of the breather battery. Using a damp cloth clean the case of the bat-
tery. If the terminals are corroded, clean the termi-
4. Install right rear side panel and close hood. See nals with a wire brush. Connect the negative and
Figure 34. positive cables to their respective terminals.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. 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 bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
Wear eye protection.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. DO NOT NOTE: BOTTOM LEFT HAND SIDE.
make sparks from the battery connections.
1. OIL FILTER 2. DRAIN PLUG
Disconnect the battery ground cable when
doing maintenance. Figure 35. Engine Oil Change Cummins 4.5L
Diesel (Shown)
45
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
2. Disconnect air inlet elbow to access the fuel filter 3. Install the new fuel filter element until it con-
element. See Figure 36. tacts the fuel filter head mounting surface.
Tighten one additional turn.
3. Disconnect fuel filter sensor connector from the
fuel filter element. 4. Connect the fuel sensor connector to fuel filter
element
CAUTION 5. Connect air inlet elbow hose.
Drain the water/fuel into a container and dis-
pose in accordance with local environmental 6. Open the fuel supply valve.
regulations.
7. Prime the fuel system. See Priming the Fuel Sys-
4. Open the drain valve by turning the valve coun- tem (Cummins 4.5L and QSB 3.3L Engine).
terclockwise approximately 3 1/2 turns until
8. Check for fuel leaks.
draining occurs. Drain until fuel filter element
is empty.
46
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
47
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
CAUTION
Drain the fuel into a container and dispose in
accordance with local environmental regula-
tions.
Figure 37. Cummins QSB 3.3L Engine Fuel
3. Remove the fuel filter.
System
4. Clean the gasket surface.
48
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
8. Start engine and check for leaks around the fuel 2. Operate the hand lever until fuel is expelled from
filter. the loosened fitting.
PRIMING THE FUEL SYSTEM (CUMMINS 3. Tighten the fuel line to the injector pump to
4.5L AND QSB 3.3L ENGINE) 9 N•m (80 lbf in). See Figure 36.
CAUTION WARNING
When using the starting motor to vent the sys- The pressure spray released by the fuel injec-
tem, DO NOT engage it for more than 30 sec- tors can penetrate the skin and cause serious
onds, or starter motor damage will occur. Wait personal injury. Wear clothes and protective
2 minutes before engaging the starter again. clothing.
Controlled venting is provided at the injection pump 5. Crank the engine until fuel is expelled from the
through the fuel drain manifold. Small amounts of loosen fittings. Tighten the injector line fittings
air introduced by changing the filters or injection while cranking. The engine should fire.
pump supply line will be vented automatically if
the fuel filter element is changed and filled prior to
installation. CAUTION
Disposal of lubricants and fluids must meet lo-
Manual Bleeding cal environmental regulations.
Manual Bleeding will be required if one of the follow- 6. Wipe up any fuel that may have spilled and dis-
ing conditions exist. pose of the fuel and rags in accordance with local
• The fuel filter is not filled prior to installation. directives.
49
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
Cummins 4.5L and QSB 3.3L Diesel NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD-
Engine JUSTING TENSIONERS.
1. ALTERNATOR PULLEY
Fan and Alternator Drive Belt 2. CAMSHAFT PULLEY
3. WATER PUMP PULLEY
Check drive belt for wear and damage. See Figure 38. 4. CRANKSHAFT PULLEY
A few small cracks that run across belt are accept- 5. TENSIONER CENTERING PULLEY
able. A belt with cracks that run length of belt or a
belt with missing pieces is not acceptable. See Fig-
ure 39 and Figure 40 for the drive belt arrangement.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
50
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
51
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
WET BRAKE CENTER BODY OIL LEVEL 1. Remove the center body fill/level plug. See Fig-
CHECK ure 43 for lift truck models S80, 100, 120FT;
S80, 100, 120FTBCS; S120FTPRS (G004) and
Figure 44 for lift truck models H80, 90, 100, 110,
WARNING
120FT (N005, P005).
At operating temperature, the center section
oil is HOT. DO NOT permit the hot oil to touch 2. Visually check oil level. If necessary, add oil at
the skin and cause a burn. the fill/level port until the oil/fill level port has
overflowed. The Correct oil is shown in the Main-
CAUTION tenance Schedule.
DO NOT permit dirt to enter the center body 3. Install center body oil/level fill level plug and
when the oil level is checked. Dirt will contam- tighten to 30 to 50 N•m (22 to 37 lbf ft).
inate the oil and cause damage to the center
body of the axle.
52
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
Figure 43. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
S80, 100, 120FT; S80, 100FTBCS; S120FTS; PLUGS
S120FTPRS (G004) 3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
53
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
MAST LUBRICATION
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: When lubricating the mast mounting/pivot Figure 46. Blocking the Mast
pins, the load must be removed from the normal
54
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
5. Tilt mast fully back. Remove the blocks from un- grease shown in the Maintenance Schedule. See
der the channels Figure 49.
55
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
56
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
LIFT CHAIN LUBRICATION Lubricate lift chains with SAE 30 engine oil. The best
procedure is to remove the chains from the lift truck
WARNING and soak them in engine oil. Be sure to clean any dirt
or grease from chains before lubricating. DO NOT
When working on or near the mast, see Safety
USE STEAM TO CLEAN THE LIFT CHAINS.
Procedures When Working Near Mast in this
section.
TILT CYLINDER LUBRICATION
DO NOT repair worn or damaged lift chains. If
NOTE: The floor plate must be removed in order to
a lift chain is worn or damaged, both lift chains
lubricate the rear tilt cylinder lubrication fittings.
must be replaced.
Lubricate the tilt cylinder ends. Use multipurpose
NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
grease shown in the Maintenance Schedule. There
tion should not be performed in combination with the
are four lubrication fittings. See Figure 50.
1000 Hour/6 Months Lift Chain Lubrication.
57
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
58
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE)
59
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
60
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months
IGNITION SYSTEM
GM 4.3L Engine
The GM 4.3L gasoline and LPG engines have an elec-
tronic control unit (ECU) that controls the ignition
timing. There are no adjustments. Change the spark
plugs every 1000 hours. The correct spark plug gap
is 1.5 mm (0.059 in.).
1. BOLT
2. SEAL WASHER
LPG FUEL FILTER ELEMENT REPLACE, 3. FUEL FILTER HOUSING TOP SECTION
GM 4.3L ENGINE 4. FUEL FILTER
5. FUEL FILTER O-RING
Remove 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
1. Close fuel valve on tank. Run engine until it 5. Remove and discard housing O-ring.
stops. 6. Remove fuel filter and fuel filter O-ring.
2. Disconnect negative battery cable.
Install
WARNING 1. Clean and inspect the fuel filter housing for con-
A small amount of fuel may still be present in tamination or damage.
the fuel line. Use gloves to prevent burns and
2. Install the new fuel filter and fuel filter O-ring.
wear eye protection. If liquid fuel continues
See Figure 58.
to flow from the connections when loosened,
check to make sure the manual valve is fully 3. Install new housing O-ring.
closed.
4. Install top section of fuel filter housing.
3. Remove the bolt and seal washer retaining the
top section of the fuel filter housing. Discard seal 5. Install bolt and new seal washer. Tighten bolt to
washer. See Figure 58. 13 N•m (115 lbf in).
61
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248
NOTE: Opening the fuel valve too quickly can cause Remove
the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve, 1. Stop Engine and allow it to cool.
wait a few seconds, and then slowly open the fuel
2. Close fuel supply valve located on the fuel send-
valve again. This will reset the excess fuel valve.
ing unit. See Figure 59.
6. Slowly open the fuel valve on tank.
CAUTION
7. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system. Drain the fuel into a container and dispose in
Check for leaks. accordance with local environmental regula-
tions.
8. Check for leaks at connections by using soapy
solution or electronic leak detector. If leaks are 3. Loosen clamps and disconnect two fuel lines from
detected, make proper repairs. the inline fuel filter. Remove and discard the in-
line fuel filter
IN-LINE FILTER REPLACEMENT,
Install
CUMMINS 4.5L ENGINE
1. Install inline fuel filter by connecting the two fuel
CAUTION lines and tighten clamps. See Figure 59.
Disposal of lubricants and fluids must meet lo-
2. Open the fuel supply valve.
cal environmental regulations.
3. Check for fuel leaks.
Replace the fuel filter at specified intervals to pre-
vent contaminants from adversely affecting the
diesel fuel flow.
62
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months
63
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248
LIFT CHAINS WEAR CHECK cleaning solvents, always follow the recom-
mendations of the manufacturer.
If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re- Compressed air can move particles so they
placed. Measure chain for wear where it moves over cause injury to the user or to other personnel.
sheaves. Using a chain scale, Hyster P/N 871796 Make sure that the path of the compressed air
check lift chains as shown in Figure 60. is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
the eyes.
64
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE BEARINGS) 1. LUBRICATION FITTING (TIE ROD)
2. LUBRICATION FITTING (SPINDLE BEARINGS)
Figure 62. Lubricate Spindle Bearings for Lift 3. STEERING AXLE
Truck Models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) 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
CONTROL LEVERS AND PEDALS • Check engine wire harness for rubbing, chaffing,
pinching, and cracks or breaks in the wiring.
Lubricate linkages, pedal shafts, control cables • Check engine harness connectors. Check to ensure
(throttle, hood, parking brake), and seat rails. Use a connectors are fitted and locked by pushing the
silicone spray lubricant, Hyster Part No. 328388. connectors together. Pull on the connector halves
to make sure they are locked.
INSPECT ENGINE ELECTRICAL SYSTEM, • Check ignition coil wire and spark plug wires for
CONNECTORS hardening, cracking, arching, chaffing, separation,
split boot covers, and proper fit. Replace spark
When inspecting the electrical system, check the fol- plugs at the recommended interval as shown in the
lowing: Maintenance Schedule.
• Check and clean battery connection. Ensure that • Check that all electrical components are securely
connections are tight. mounted and retained to the engine or chassis.
• Check battery for damage or cracks to the case. • Check the MIL, charging, and oil pressure lights
Replace if necessary. for operation by starting the engine and checking
• Check positive and negative cables for corrosion, that the light illuminates before turning out.
rubbing, and chaffing. Tighten connections at both
ends.
HYDRAULIC SYSTEM NOTE: Have container large enough to hold the filter
element and allow for final hydraulic oil draining.
Hydraulic Filter, Replace
2. Remove the hydraulic filter element and O-ring
from the bowl and place into the container. Cover
WARNING the head to prevent any foreign materials from
At operating temperature, the hydraulic oil is getting into the hydraulic tank.
HOT. DO NOT permit the hot oil to touch the
skin and cause a burn. 3. Lubricate new O-ring with hydraulic oil and in-
stall it on the bottom of the new filter element.
Install the new filter element into the bowl.
CAUTION
DO NOT permit dirt to enter the hydraulic sys- 4. Inspect gasket for damage. If damaged, replace.
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to the com- 5. Lubricate gasket with hydraulic oil and seat it
ponents of the hydraulic system. on filter lid and install spring and lid onto head.
Tighten lid to 15 N•m (132.8 lbf in).
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
CAUTION
hydraulic pump without oil will damage the
pump. Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
CAUTION
Disposal of lubricants and fluids must meet lo- 6. Start the truck, and allow it to run for 30 seconds.
cal environmental regulations. Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
1. Put lift truck on a level surface and lower the shown in the Maintenance Schedule. To change
carriage. Unscrew and remove filter lid, gasket, the hydraulic oil, see Hydraulic Oil, Replace.
66
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
67
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
COOLING SYSTEM, GM 4.3L AND 4. Close drain valve. Fill cooling system with a
CUMMINS 4.5L AND QSB 3.3L ENGINES solution of ethylene glycol boron-free antifreeze.
See Maintenance Schedule for correct solution.
1. Put lift truck on a level surface. Stop engine. Fill the auxiliary reservoir to a level between the
Place a container with a minimum capacity of ADD and FULL marks on the reservoir.
15.1 liter (15.9 qt) under the radiator drain valve
which could be located on either the lower left or 5. Install radiator cap. Start engine. Check for
right side of the radiator on the engine side of the leaks. Add coolant to auxiliary coolant reservoir
radiator. as needed. Coolant level should be between the
ADD and FULL marks on the reservoir.
WARNING AIR FILTER
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi- The air filter canister should not be opened until an
ator cap is removed, the pressure is released air filter element replacement is required. An air
from the system. If the system is hot, the steam filter element replacement is required when one of
and boiling coolant can cause burns. DO NOT the following occurs:
remove the cover for the radiator when the en- • The optional air flow restriction indicator light on
gine is running. the dash illuminates
• The optional manual air flow indicator button pops
up
CAUTION
• The specified number of hours has passed since the
Disposal of lubricants and fluids must meet lo- last filter element replacement
cal environmental regulations.
68
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
5. Inspect the liner and O-ring assembly for dam- 8. Install the new filter element into the canister.
age. If damaged, replace the liner and O-ring as- Press and rotate the filter element 1/8 turn clock-
sembly. wise until fully engaged in the canister. See Fig-
ure 67.
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.
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 possi-
bly the canister.
70
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
6. Remove and discard the screen from the LPG reg- Figure 71. Fuel Filter Replacement (GM 4.3L)
ulator.
71
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
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.
72
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
73
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
74
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
A. REAR VIEW SHOWN 2. Place and empty container under the center body
B. FRONT VIEW SHOWN drain plug.
1. PLANETARY CARRIER HOUSING FILL/LEVEL 3. Remove the center body drain plug, and wait un-
PLUGS til oil has drained completely.
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER BODY FILL/LEVEL PLUG Install
4. CENTER BODY DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH) 1. Install drain plug for the center body. Tighten to
6. PLANETARY CARRIER HOUSING (LH) 30 to 50 N•m (22 to 37 lbf ft). For lift truck mod-
7. CENTER BODY els S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004), see Figure 74. For lift truck
Figure 75. Wet Brake Drive Axle Drain and
models H80, 90, 100, 110, 120FT (N005, P005),
Fill/Level Plug Location for Lift Truck Models
see Figure 75.
H80, 90, 100, 110, 120FT (N005, P005)
75
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
(G004) see Figure 74. For lift truck models H80, 3. Install oil fill/level plug. Tighten to 30 to 50 N•m
90, 100, 110, 120FT (N005, P005) see Figure 75. (22 to 37 lbf ft).
76
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
77
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
SERVICE BRAKES (DRY BRAKE) 4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
Check brake lining and parts of the brake assembly air.
for wear or damage. The minimum acceptable brake
lining thickness is 1.0 mm (0.040 in.). If the brake DIFFERENTIAL (DRY BRAKE)
linings are worn thinner than the specification, re-
place the brake linings. See the section Brake Sys- NOTE: Additional information on the differential can
tem 1800 SRM 1247 for the removal and installation be found in the section Drive Axle and Differential
procedures of the drive wheels and brake drums. If Assembly Repair, (Dry Brake) 1400 SRM 1245.
the brake linings or brake shoes are worn or dam-
aged, they must be replaced. Brake shoes must be 1. Place the lift truck on blocks. See How to Raise
replaced in complete sets. Inspect brake drums for Drive Tires in this manual.
cracks or damage. Replace any damaged parts.
2. The differential and drive axle use the same oil
supply. Place a container with a minimum capac-
WARNING ity of 5 liter (5.3 qt) under the differential. Re-
Brake linings can contain dangerous fibers. move the drain plug located in the bottom of the
Breathing the dust from these brake linings differential and drain the oil from the differential
is a cancer or lung disease hazard. DO NOT completely. Install the drain plug.
create dust! DO NOT clean brake parts with
compressed air or by brushing. Follow the 3. The fill hole is on the front of the differential
cleaning procedure in this section. When the housing. Add oil shown in the Maintenance
brake drums are removed, DO NOT create Schedule until the oil level is at the lower edge of
dust. the fill hole. Install fill plug and rotate the drive
wheels in order to get oil pumped into the axle.
DO NOT sand, grind, chisel, hammer, or change Remove the fill plug and check the oil level. Add
linings in any way that will create dust. Any oil, as necessary. Install the fill plug and check
changes to brake linings must be done in a re- for leaks. See Figure 78 and Figure 79.
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
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.
78
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
Legend for Figure 78 • Check all exhaust pipe extension connectors for
leaks and tighten, if necessary.
1. DRIVE AXLE • Visually inspect converter for correct muffler
2. CHECK/FILL PLUG
3. DRAIN PLUG mounting and tail pipe mounting.
• Check for any leaks at the inlet and outlet of the
converter.
79
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
1. TIMING PIN
2. VIBRATION DAMPER
80
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
81
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248
VALVE CLEARANCE, CHECK AND 2. Adjust ONLY the valves shown in Figure 86, by
ADJUST FOR CUMMINS 4.5L DIESEL loosening the lock nut with a wrench and adjust-
ENGINE ing the clearance using a screwdriver or Allen
wrench.
The Cummins 4.5L engine does not require valve
clearance adjustments during normal service. See 3. Tighten the lock nut to 24 N•m (18 lbf in) and
the Maintenance Schedule for valve clearances. measure valve lash.
Check the valve clearance and make adjustments as 4. Remove the timing pin. See Figure 85.
needed. To adjust the valve clearance, do the follow- 5. Mark the vibration damper and rotate the crank-
ing: shaft 360 degrees. See Figure 87.
1. Rotate the engine until it is at TDC for cylinder 6. Perform Step 2 and Step 3 to adjust ONLY the
number one (intake and exhaust valves closed). valves shown in Figure 88.
Insert timing pin. See Figure 85.
82
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
83
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248
2. Mast inspection:
1. EXHAUST VALVE 4. CYLINDER 2
2. INTAKE VALVE 5. CYLINDER 3 a. Welded joints of lower crossmember of mast
3. CYLINDER 1 6. CYLINDER 4 outer channel and related gussets. See Fig-
ure 90.
Figure 88. Cummins Valve Adjustment
b. Welded joints around tilt anchor and inter-
WELD INSPECTION mediate cross member. See Figure 90.
Initial inspection is suggested at 4000 hours, with NOTE: The welded boss for tilt lock option is typi-
subsequent inspections at 2000 hour intervals. Re- cally located on right side of mast channel above tilt
moval of carriage from mast is not required, but rec- anchor bracket.
ommended, to perform inspection. Removal of at-
tachment is recommended for access to carriage. c. Right side rail of outer mast channel in area
of welded boss for optional tilt lock rod. See
NOTE: Visual inspection supported by dye penetrant Figure 90.
application is recommended with focus on areas de-
fined below.
84
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
85
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248
86
8000 SRM 1248 Safety Procedures When Working Near Mast
87
Safety Procedures When Working Near Mast 8000 SRM 1248
88
8000 SRM 1248 Fuel Filter Water Removal
CAUTION
Drain water/fuel into a container and dispose
in accordance with local environmental regu-
lations.
4. Close the drain valve by lifting and turning Figure 92. Engine Fuel Filter Drain Valve
clockwise until it is hand-tight. Location (Cummins 4.5L Shown)
89
Hood Latch Check 8000 SRM 1248
90
8000 SRM 1248 Lift Chain Adjustments
91
Jump-Starting the Lift Truck 8000 SRM 1248
In Table 2, the masts are divided by class. Each Table 2. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by push- touching.
ing or towing lift truck.
92
8000 SRM 1248 Overhead Guard Changes
Welding Repairs
warning. Should work be performed, utilize
WARNING good industrial hygiene practices including
Welding can cause a fire or an explosion. Al- removal of all paint (prime and finish coats) to
ways follow the instructions in the Frame sec- the metal around the area to be welded, local
tion if a fuel or hydraulic tank must be welded. ventilation, and/or supplied-air respiratory
Make sure there is no fuel, oil, or grease near protection.
the weld area. Make sure there is good venti-
lation in the area where the welding must be
done. CAUTION
When an arc welder is used, always disconnect
DO NOT heat, weld, or bend forks. Forks are the ground cable from the battery in the lift
made of special steel using special methods. truck. This action will prevent damage to the
The strength of the overhead guard can be re- alternator or the battery.
duced by welding or heating. Get information
from your dealer for Hyster lift trucks before Connect the ground clamp for the arc welder as
welding on a mast. close as possible to the weld area. This action
will prevent damage to a bearing from the large
Forklift frames and components may be current from the welder.
painted with a catalyzed paint such as
polyurethane or a two-part primer. Weld- Some repairs require welding. If an acetylene or arc
ing, burning, or other heat sufficient to cause welder is used, make sure procedures in previous
thermal decomposition of the paint may re- WARNING and CAUTION are done.
lease isocyanates. These chemicals are allergic
See the American National Standard Safety in Weld-
sensitizers to the skin and respiratory tract
ing and Cutting, AWS Z 49.1 - 1999.
and overexposure may occur without odor
93
Wheel and Tire Replacement 8000 SRM 1248
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER 2. WHEEL 3. OVERHANG
TIRE
Figure 96. Tires and Wheels for S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)
Lift Trucks
94
8000 SRM 1248 Wheel and Tire Replacement
3. The steering wheels are fastened to the spindle sure the nameplate is correct for the type of
of the steering axle with a large castle nut. Make tires on the lift truck.
sure inner and outer bearings are correctly lu-
bricated with grease. Install inner bearing WARNING
assembly and wheel on spindle. Install outer
Wheels must be changed and tires repaired by
bearing cone and castle nut. Tighten castle nut
trained personnel only.
up to 203 N•m (150 lbf ft) while rotating hub
in both directions to properly seat the bearings, Deflate tire completely before removing the
loosen the castle nut until wheel hub turns freely wheel from the lift truck. If dual wheels are
with no end play. Tighten castle nut to 34 N•m used, deflate both tires. Air pressure in the
(25 lbf ft). If the cotter pin cannot be installed, tires can cause the tire and rim parts to ex-
loosen the castle nut to the first position where plode, causing serious injury or death.
the cotter pin can be installed. Install cap for
bearings. Always wear safety glasses.
PNEUMATIC TIRE WITH TUBE, REPAIR Never loosen the nuts that hold the inner and
outer wheel halves together when there is air
Remove Wheels From Lift Truck pressure in the tire.
95
Wheel and Tire Replacement 8000 SRM 1248
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.
96
8000 SRM 1248 Wheel and Tire Replacement
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.
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 8000 SRM 1248
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen bead from other side of wheel rim. Remove
valve stem from wheel.
STEP 4.
Remove wheel from tire.
Install Wheel in Tire parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
WARNING not touch. The clearance at the ends of the lock
ring will be approximately 13 to 25 mm (0.5 to
Damage to the tire and wheel assembly and in-
1.0 in.) after it is installed. If the clearance is
jury or death can occur if you do not do the fol-
wrong, the wrong part has been used.
lowing procedures:
• Clean and inspect all parts of the wheel be- 1. Clean and inspect all parts of wheel. Paint any
fore installing the tire. parts that have rust or corrosion.
• DO NOT use any damaged or repaired wheel
parts. 2. Install new inner tube in tire. Used tubes and
• Make sure all parts of the wheel are the cor- flaps can cause tire failure.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or 3. Apply a rubber lubricant or a soap solution to the
manufacturers of wheels. tire bead and tube.
• DO NOT mix types of tires, type of tire tread,
4. Install new tire flap.
or wheel assemblies of different manufactur-
ers on any one lift truck. 5. Make sure rim is the correct size for tire. Lubri-
cate part of wheel that contacts bead and flap.
DO NOT use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
98
8000 SRM 1248 Wheel and Tire Replacement
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.
99
Wheel and Tire Replacement 8000 SRM 1248
STEP 4.
Put lock ring in the correct position on rim. Add air
pressure to tire as described in Install 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.
100
8000 SRM 1248 Wheel and Tire Replacement
STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (130 lbf ft). Add air pressure to tire (see
nameplate).
ADD AIR TO PNEUMATIC TIRES WITH adjustments. The clearance at the ends of the
TUBE lock ring will be approximately 13 to 25 mm (0.5
to 1.0 in.) when the tire has the correct air pres-
sure.
WARNING
Add air pressure to the tires only in a safety Install the Wheels
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck Install wheel on the hub. Tighten nuts in a cross
that fastens onto the valve stem of the inner pattern to a torque value of 610 to 680 N•m (450 to
tube. Make sure there is enough hose to permit 502 lbf ft) for drive wheel nuts and 610 to 680 N•m
the operator to stand away from the safety cage (450 to 502 lbf ft) for steer wheel nuts. If the wheels
when air pressure is added to the tire. are the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
DO NOT sit or stand by the safety cage. DO they are installed.
NOT use a hammer to try and correct the po-
sition of the side flange or lock ring when the
tire has air pressure greater than 20 kPa (3 psi).
101
Wheel and Tire Replacement 8000 SRM 1248
102
8000 SRM 1248 Wheel and Tire Replacement
PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be
Remove Wheels From Lift Truck used with a tube.
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 8000 SRM 1248
STEP 2.
Put wheel and tire assembly on the press. Position
the feet of the press on the loose flange. Press down
on loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel only)
from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove
it.
104
8000 SRM 1248 Wheel and Tire Replacement
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liq-
uids can cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubri-
cate tire beads and the inside of the tire, up to the
tire shoulders. Apply lubricant to the entire under-
side of the TBS.
NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve
slot. The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and remov-
ing the lubricated valve several times. If a three- or
four-piece wheel is being used, remove the valve. If
a two-piece wheel is being used, leave valve in valve
hole.
105
Wheel and Tire Replacement 8000 SRM 1248
STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in the
TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot
in the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
106
8000 SRM 1248 Wheel and Tire Replacement
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.
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.
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.
107
Wheel and Tire Replacement 8000 SRM 1248
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 Wheel and Tire Replacement
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
109
Wheel and Tire Replacement 8000 SRM 1248
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 Wheel and Tire Replacement
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side ring,
and lock ring in position on wheel rim. Install cage
on tire. Use press to push tire onto wheel rim so side
flange and lock ring can be installed.
STEP 4.
While 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.
111
Adhesives and Sealants 8000 SRM 1248
112
TECHNICAL PUBLICATIONS