hyster 110ft periodic maintenance

PERIODICMAINTENANCES80, 100, 120FT; S80, 100FT-

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

PART NO. 1624742 8000 SRM 1248

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, andthat the load being lifted is balanced. Make sure the crane, cables, and chains have the capacityto 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 electriclift 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 LIFTTRUCK 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 meetor exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using forceto remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if theunit 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 areflammable. Be sure to follow the necessary safety precautions when handling these fuels andwhen working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away fromthe area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a hazardous situation which, if not avoided, could result indeath or serious injury.

CAUTIONIndicates a hazardous situation which, if not avoided, could result inminor 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 ................................................................................................................................................................. 1Serial Number Data ........................................................................................................................................ 1How to Move Disabled Lift Truck................................................................................................................... 1

How to Tow Lift Truck ................................................................................................................................ 1How to Put Lift Truck on Blocks .................................................................................................................... 3

How to Raise Drive Tires ............................................................................................................................ 3How to Raise Steering Tires ....................................................................................................................... 3

How to Clean a Lift Truck............................................................................................................................... 4Maintenance Schedule....................................................................................................................................... 11Maintenance Procedures Every 8 Hours or Daily............................................................................................ 21

How to Make Checks With Engine Stopped................................................................................................. 21Tires and Wheels....................................................................................................................................... 21Safety Labels ............................................................................................................................................. 22Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 22Operator Restraint System....................................................................................................................... 23

Emergency Locking Retractor (ELR) ................................................................................................... 23Adjust Seat - Full Suspension .............................................................................................................. 24Adjust Seat - Internal Suspension ....................................................................................................... 25

Hood and Seat Latches ............................................................................................................................. 26Engine Compartment................................................................................................................................ 26Paper Application ...................................................................................................................................... 26Fuel, Oil, and Coolant Leaks, Check........................................................................................................ 27Hydraulic Hoses ........................................................................................................................................ 27Coolant Hoses ............................................................................................................................................ 27Steering Column Gas Cylinder................................................................................................................. 27Transmission ............................................................................................................................................. 28Hydraulic System Oil ................................................................................................................................ 28Engine Oil .................................................................................................................................................. 28Air Filter .................................................................................................................................................... 32Forks .......................................................................................................................................................... 32

Remove .................................................................................................................................................. 32Inspect ................................................................................................................................................... 33Install..................................................................................................................................................... 33Adjust..................................................................................................................................................... 34

Integral Sideshift Carriage....................................................................................................................... 34How to Make Checks With Engine Running................................................................................................ 35

Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 35Service Brakes ........................................................................................................................................... 37

Brake Oil Level ..................................................................................................................................... 37Operation, Check .................................................................................................................................. 38

Parking Brake ........................................................................................................................................... 38Engine Oil Pressure .................................................................................................................................. 38Cooling System .......................................................................................................................................... 39Steering System ........................................................................................................................................ 39Control Levers and Pedals ........................................................................................................................ 40Lift System, Operate ................................................................................................................................. 40

First Service After First 100 Hours of Operation ............................................................................................ 41GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 41Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. 41

Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 42GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 42

©2011 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Drive Belt ....................................................................................................................................................... 42GM 4.3L Engine ........................................................................................................................................ 42

Fan and Alternator Drive Belt ............................................................................................................. 42Drain Tar From LPG Regulator.................................................................................................................... 43Drain Tar From LPG Converter ................................................................................................................... 43

Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 44Hydraulic System Oil .................................................................................................................................... 44Hydraulic Tank Breather .............................................................................................................................. 44

Inspect........................................................................................................................................................ 44Battery ........................................................................................................................................................... 45Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. 45Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ................................... 46

Remove....................................................................................................................................................... 46Install ......................................................................................................................................................... 46

Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) .................................................................... 48Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ............................................................. 49

Controlled Venting .................................................................................................................................... 49Manual Bleeding ....................................................................................................................................... 49

Drive Belt ....................................................................................................................................................... 50Cummins 4.5L and QSB 3.3L Diesel Engine........................................................................................... 50

Fan and Alternator Drive Belt ............................................................................................................. 50Clean Debris From Radiator Core ................................................................................................................ 51Transmission Oil Level ................................................................................................................................. 51Wet Brake Center Body Oil Level Check ..................................................................................................... 52Forks............................................................................................................................................................... 54Mast Lubrication ........................................................................................................................................... 54Header Hose Checks...................................................................................................................................... 56Lift Chain Lubrication .................................................................................................................................. 57Tilt Cylinder Lubrication .............................................................................................................................. 57Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 58Manual Hydraulic Levers Lubrication ......................................................................................................... 58Brake Oil ........................................................................................................................................................ 59Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS;S120FTPRS (G004)........................................................................................................................................ 59Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) ................................. 60Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ 60

Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 61Valve Clearance, Check and Adjust.............................................................................................................. 61Ignition System.............................................................................................................................................. 61

GM 4.3L Engine ........................................................................................................................................ 61LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... 61

Remove....................................................................................................................................................... 61Install ......................................................................................................................................................... 61

In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... 62Remove....................................................................................................................................................... 62Install ......................................................................................................................................................... 62

Lift Chains Wear Check ................................................................................................................................ 64Lift Chain Lubrication .................................................................................................................................. 64Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... 64Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS;S120FTS; S120FTPRS (G004) ...................................................................................................................... 65

ii

Periodic Maintenance Table of Contents


Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)............ 65Control Levers and Pedals ............................................................................................................................ 66Inspect Engine Electrical System, Connectors ............................................................................................ 66

Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 66Hydraulic System .......................................................................................................................................... 66

Hydraulic Filter, Replace .......................................................................................................................... 66Hydraulic Tank Breather, Replace ........................................................................................................... 67

Ignition System; Distributor Cap, Rotor, and Spark Plug Wires................................................................ 67Cooling System, GM 4.3L and Cummins 4.5L and QSB 3.3L Engines ...................................................... 68Air Filter ........................................................................................................................................................ 68Oxygen Sensor GM 4.3L LPG Engines Equipped with GFI Installed........................................................ 70LPG Regulator Fuel Filter, GM 4.3L Engines Equipped With GFI Installed............................................ 71

Remove....................................................................................................................................................... 71Install ......................................................................................................................................................... 71

Gasoline Fuel Filter....................................................................................................................................... 71Remove and Replace ................................................................................................................................. 71

LPG Fuel Injector, GM 4.3L Engines Equipped With GFI Installed.......................................................... 72Gasoline Fuel Injector, GM Engines............................................................................................................. 72Fuel Injector, Cummins 4.5L and QSB 3.3L Engine ................................................................................... 72Forks............................................................................................................................................................... 72Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 72Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... 73Wet Brake Center Section Oil Change ......................................................................................................... 75

Remove....................................................................................................................................................... 75Install ......................................................................................................................................................... 75

Brake Oil (Master Cylinder), Change........................................................................................................... 76Brake Oil (Dry Brake), Remove .................................................................................................................... 77Service Brakes (Dry Brake) .......................................................................................................................... 78Differential (Dry Brake) ................................................................................................................................ 78Test LPG/GAS Regulator Pressure............................................................................................................... 79Check Throttle Shaft for Sticking................................................................................................................. 79Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... 79Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. 79

Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 81Hydraulic Oil, Replace .................................................................................................................................. 81Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... 82Weld Inspection.............................................................................................................................................. 84

Safety Procedures When Working Near Mast.................................................................................................. 87Fuel Filter Water Removal ................................................................................................................................ 89Hood Latch Check .............................................................................................................................................. 90Lift Chain Adjustments ..................................................................................................................................... 91Jump-Starting the Lift Truck............................................................................................................................ 92

Jump-Starting Using a Battery Charger ..................................................................................................... 92Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... 92

Welding Repairs ................................................................................................................................................. 93Overhead Guard Changes ................................................................................................................................. 93Wheel and Tire Replacement ............................................................................................................................ 94

General ........................................................................................................................................................... 94Solid Rubber Tire, Change (S Series) ........................................................................................................... 94

Remove and Install Tire on Wheel ........................................................................................................... 94Pneumatic Tire With Tube, Repair............................................................................................................... 95

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Table of Contents Periodic Maintenance


Remove Wheels From Lift Truck.............................................................................................................. 95Remove Tire From Wheel ......................................................................................................................... 96

Remove Tire From Two-Piece Wheel ................................................................................................... 96Remove Tire From Three- and Four-Piece Wheels ............................................................................. 97

Install Wheel in Tire ................................................................................................................................. 98Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. 99Install Tire on Two-Piece Wheel ........................................................................................................ 100Install Two-Piece Wheel in Tire ......................................................................................................... 100

Add Air to Pneumatic Tires With Tube...................................................................................................... 101Install the Wheels ................................................................................................................................... 101Dual Drive Wheels, Install ..................................................................................................................... 102

Pneumatic Tubeless Tire, Repair................................................................................................................ 103Remove Wheels From Lift Truck............................................................................................................ 103Remove Tire From Wheel ....................................................................................................................... 103Install Tire on Wheel .............................................................................................................................. 105Add Air to Pneumatic Tubeless Tire ...................................................................................................... 107Wheels, Install......................................................................................................................................... 108

Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... 108Remove Wheel From Tire ....................................................................................................................... 108Install Tire on Wheel .............................................................................................................................. 110

Adhesives and Sealants ................................................................................................................................... 112

This section is for the following models:

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

iv

8000 SRM 1248 General

General

WARNINGDO NOT make repairs or adjustments unlessyou have both authorization and training. Re-pairs and adjustments that are not correct canmake a dangerous operating condition.

WARNINGDO NOT operate a lift truck that needs repairs.Report the need for repairs immediately. If re-pair is necessary, put a DO NOT OPERATE tagin the operator’s area. Remove the key fromthe key switch.

CAUTIONDisposal of lubricants and fluids must meet lo-cal environmental regulations.

This section contains a Maintenance Schedule andthe instructions for maintenance and inspection.

The Maintenance Schedule has time intervals for in-spection, lubrication, and maintenance of your lifttruck. The service intervals are given in both oper-ating hours recorded on the lift truck hourmeter andin calendar time. The recommendation is to use theinterval that comes first.

The recommendations for the time intervals given foreight hours of operation per day. The time intervalsmust be decreased from the recommendations in theMaintenance Schedule for the following conditions:• The lift truck is used more than eight hours per

day.• The lift truck must work in dirty operating condi-

tions.• Poor ground conditions.• Intensive usage at high performance levels or

other abnormal conditions will require more fre-quent servicing.

Your dealer for Hyster lift trucks has the equipmentand trained service personnel to do a complete pro-gram of inspection, lubrication, and maintenance. Aregular program of inspection, lubrication, and main-tenance will help your lift truck provide more effi-cient performance and operate for a longer period oftime.

Some users have service personnel and equipmentto do the inspection, lubrication, and maintenance

shown in the Maintenance Schedule. Service Man-uals are available from your dealer for Hyster lifttrucks to help users who do their own maintenance.

SERIAL NUMBER DATA

The serial number for the lift truck is on the name-plate. It is also on the right side of the frame, underthe floor plate.

HOW TO MOVE DISABLED LIFT TRUCK

How to Tow Lift Truck

WARNINGUse extra caution when towing a lift truck ifany 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 poweravailable for the hydraulic steering systemand the service brakes. This condition canmake the lift truck difficult to steer and stop.If the lift truck uses power from the engine tohelp apply the brakes, the application of thebrakes will be more difficult. Poor traction cancause the disabled lift truck or towing vehicleto slide. A slope will also make the lift truckmore difficult to stop.

Never lift and move a disabled lift truck unlessthe disabled lift truck MUST be moved andcannot be towed. A lift truck used to movea disabled lift truck MUST have a capacityrating equal to or greater than the weight ofthe disabled lift truck. The capacity of the lifttruck used to move a disabled lift truck musthave a load center equal to half the width ofthe disabled lift truck. See the nameplate ofthe disabled lift truck for the approximatetotal weight. The forks must extend the fullwidth of the disabled lift truck. Put the weightcenter of the disabled lift truck on load centerof the forks. Be careful to not damage theunderside of the lift truck.

1. The towed lift truck must have an operator.

2. Tow truck slowly.

1

General 8000 SRM 1248

3. Using a lift truck or a lifting device that couldbe attached to the mast (I.E. come-a-long), raisecarriage and forks approximately 30 cm (12 in.)from surface. Install chain around a mast cross-member and the carriage to prevent carriage andmast channels from moving.

4. If another lift truck is used to tow the disabled lifttruck, that lift truck must have an equal or largercapacity than the disabled lift truck. Install ap-proximately 1/2 of a capacity load on forks of lifttruck that is being used to tow disabled lift truck.This 1/2 capacity load will increase traction of lifttruck. Keep load as low as possible.

5. If lift trucks are equipped with a tow pin in thecounterweight (standard counterweight), use a

towing link made of steel that fastens to the towpins in the counterweights of both lift trucks. SeeFigure 1. Slowly and carefully remove the slackout of the towing link.

6. If lift trucks are equipped with a leaded counter-weight without a tow pin (see Figure 1), use atowing link made of steel that fastens to the twocenter grill bars of both lift trucks. Slowly andcarefully remove the slack out of the towing link.

Lift truck models that are equipped with a leadedcounterweight, that are covered in this SRM areS80FTBCS, S100FTBCS, S120FTS, and S120FT-PRS (G004).

A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)B. COUNTERWEIGHT WITH TOW PIN (STANDARD COUNTERWEIGHT)

1. TOWING LINK 2. CENTER GRILL BARS 3. TOW PIN

Figure 1. Counterweight Types

2


HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires

WARNINGThe lift truck must be put on blocks for sometypes of maintenance and repair. The removalof the following assemblies will cause largechanges in the center of gravity: mast, driveaxle, engine, transmission, and counterweight.When the lift truck is put on blocks, put ad-ditional blocks in the following positions tomaintain stability:• Before removing the mast and drive axle, put

blocks under the counterweight so the lifttruck cannot fall backward.

• Before removing the counterweight, putblocks under the mast assembly so the lifttruck cannot fall forward.

The surface must be solid, even, and level whenthe lift truck is put on blocks. Make sure anyblocks used to support the lift truck are solid,one-piece units.

CAUTIONThese lift trucks are equipped with cowl liftingeyes. The cowl lifting eyes are to be used tolift the front of the lift truck only. Lifting morethan the front of the lift truck with the cowllifting eyes will damage the cowl section.

1. Put blocks on each side (front and back) of steer-ing tires to prevent movement of lift truck. SeeFigure 2.

2. Put mast in vertical position. Put a block undereach outer mast channel.

3. Tilt mast fully forward until drive tires are raisedfrom surface.

4. Put additional blocks under frame behind drivetires.

5. If hydraulic system will not operate, use a hy-draulic jack under the side of the frame near thefront. Make sure jack has a capacity equal to atleast half the weight of the lift truck. See Name-plate.

How to Raise Steering Tires

NOTE: Some lift trucks are equipped with lifting eyesfor the purpose of lifting the entire lift truck. If thelift truck is equipped with this type of lifting eyes, thelift truck can be lifted and blocks installed.

1. Apply parking brake. Put blocks on both sides(front and back) of drive tires to prevent move-ment of lift truck. See Figure 2.

2. Use hydraulic jack to raise steering tires. Makesure jack has a capacity of at least 2/3 of totalweight of lift truck as shown on the nameplate.

3. Put jack under steering axle or frame to raiselift truck. Put blocks under frame to support lifttruck.

3


1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK

WARNINGEngine, exhaust system components and othercomponents are hot to the touch. Be sure lifttruck components are cool before starting in-spection and cleaning, or personal injury mayoccur.

WARNINGCompressed air can move particles so that theycause injury to the user or to other personnel.Make sure that the path of the compressed airis away from all personnel. Wear protectivegoggles or a face shield to prevent injury to theeyes.

CAUTIONUnits may be washed with a non-heated pres-sure washer. Steam cleaning is not recom-mended in most instances, as condensationmay form in electrical components causingdamage or erratic behavior.

NOTE: Lift trucks used in paper applications mayneed cleaning beyond what is described here. Please

refer to Paper Application section in the applicableOperating Manual and to available Service Gram/Bulletin for more detail.

If it becomes necessary to clean the fork lift, followthe guidelines listed below.

1. Assure truck components are cool before startingthe cleaning procedure.

2. Disconnect the battery. If an electric truck, re-move the traction battery.

3. Remove accumulated debris using a compressedair line and nozzle.

4. Lightly spray a non-corrosive cleaning agent ontothe areas to be cleaned. This will help loosengrime, so close contact direct spraying will not benecessary.

5. Be sure to avoid directing the spray into electri-cal panel compartment. Ensure overspray doesnot come in contact with electrical components;do not spray water directly at electrical compo-nents, wiring connectors or electrical enclosures.Even sealed connectors may allow water egressunder pressure or if connector is damaged.

4


6. Avoid spraying in areas containing electricalcomponents such as:• Floor Plates• Battery Compartment• Dash/cowl assembly• Armrests with electrical components

7. Clean the battery compartment by using a cleancloth to wash the battery with water. Dry withcompressed air. Care should be taken to keepmoisture at a minimum as some units have atraction or hydraulic motor directly below thebattery compartment.

8. DO NOT pressure wash the battery. Do not usehot water. For cleaning traction batteries, referto the Battery section of the Service Manual.

9. DO NOT pressure wash lift chains, sheaves orload rollers in the mast assembly. Refer to theChains, Sheaves and Load Rollers maintenancesection in the Service Manual for proper clean-ing procedures.

10. After cleaning, immediately start and run the lifttruck to dry out components.

5


Figure 3. GM 4.3L LPG Trucks With GFI Installed

6


Figure 4. GM 4.3L LPG Trucks With PSI Installed

7


Figure 5. GM 4.3 Gasoline Trucks

8


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

9


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

10

8000 SRM 1248 Maintenance Schedule

Maintenance ScheduleNOTE: The lift trucks shown in Figure 3, Figure 4,and Figure 5 represent SSE 100, 120FT; S80, 100FT-BCS; 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/6-month maintenance services are performed either atthe specified hours or at 6 months whichever occursfirst.

Table 1. Maintenance Schedule

ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr

Procedure orQuantity

Specification

25 Tires and Wheels X CheckCondition

See Nameplate

Safety Labels X Replace asNecessary

See Parts Manual

28,29

Mast, Carriage,Header Hoses,Lift Chains,Attachment

X CheckCondition and

Lubrication

See Parts Manual

Seat Belt, HipRestraints, andSeat Rails


Operation

Hood and SeatLatches


Operation

EngineCompartment

X RemoveCombustible

MaterialsSee NOTE 5.

Paper Application:EngineCompartment,Truck Components,Exhaust Wraps,Radiator, RadiatorScreen if equipped,Belly Pan ifequipped

X CheckConditionClean asRequired

Replace asRequired

See NOTE 8.

Check for Leaks -Fuel, Oil, Water

X Checkfor Leaks

See NOTE 1.

Hydraulic Hoses X CheckCondition

See Parts Manual

13 Coolant Hoses X CheckCondition

See Parts Manual

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

11

Maintenance Schedule 8000 SRM 1248

Table 1. Maintenance Schedule (Continued)

ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

16 Fuel Tank (LPG) CIL 15.1 - 20.4 kg(33.5 - 45.0 lb)

Full

LPG - HD 5, HD 10

16 Fuel TankGM 4.3L(Gasoline)[S80, 100, 120FT;]S80, 100FTBCS;S120FTS;S120FTPRS (G004)U.S. Only

CIL 44.7 liter(11.8 gal)

86 Octane - GasolineMinimum

16 Fuel Tank (ShortWheel Base)GM 4.3L(Gasoline)H80, 90, 100, 110,120FT (N005, P005)U.S. Only

CIL 79 liter(20.8 gal)

86 Octane Minimum

16 Fuel Tank (LongWheel Base)GM 4.3L(Gasoline)H80, 90, 100, 110,120FT (N005, P005)U.S. Only


86 Octane Minimum

16 Fuel Tank (ShortWheel Base)Cummins 4.5L andQSB 3.3L (Diesel)H80, 90, 100, 110,120FT (N005, P005)

CIL 79 liter(20.8 gal)

Diesel No. 2

16 Fuel Tank (LongWheel Base)Cummins 4.5L andQSB 3.3L (Diesel)H80, 90, 100, 110,120FT (N005, P005)


Diesel No. 2

Horn, Lights,Alarms, Fuses,and Relays

X CheckOperation

1 Service Brakes X CheckOperation

23 Parking Brake X CheckOperation


12



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

Steering Controlsand SteeringColumn GasCylinder


Operation

22 Transmission X Check forLeaks

John DeereJDM J20C

22 Transmission X CheckOperation

3 Hydraulic OilGM 4.3L [S80,100, 120FT];S80, 100FTBCS,S120FTS;S120FTPRS (G004)

X X C 39.4 liter(41.6 qt)

See NOTE 2and NOTE 3.

ISO VG 46Hydraulic Oil15°C (5°F) and

Above

3 Hydraulic Oil(Short Wheel Base)H80, 90, 100, 110,120FT (N005, P005)


See NOTE 2and NOTE 3


Above

3 Hydraulic Oil(Long Wheel Base)H80, 90, 100, 110,120FT (N005, P005)


See NOTE 2and NOTE 3


Above

6 Hydraulic Oil Filter C 1 Filter See Parts Manual

10 Hydraulic TankBreather

X C Inspect andReplace asRequired

See NOTE 5.

See Parts Manual

8 Battery and CableTerminals

X Clean

9 Engine OilGM 4.3L Engine(Gasoline/LPG)

XCIL

C 4.7 liter (5.0 qt)See NOTE 4and NOTE 5.

7°C (20°F)and BelowSAE 5W-2016°C (60°F)and BelowSAE 5W-30

18°C (0°F)and Above

SAE 10W-30API SM

ILSAC GF4SAE J2362

19 Engine Oil FilterGM 4.3L Engine

C 1 FilterSee NOTE 4and NOTE 5.

See Parts Manual


13



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

9 Engine OilCummins 4.5LEngine (Diesel)

XCIL

C 13.0 liter(13.7 qt)


0°C (32°F)and BelowSAE 0W-30

25 to 20°C( 13 to 68°F)SAE 5W-30

20 to 20°C( 4 to 68°F)SAE 10-3015°C (5°F)

and AboveSAE 5W-40or 15W-40

API CH-4 or CI-4

9 Engine OilCumminsQSB 3.3LEngine (Diesel)

XCIL

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

0°C (32°F)and BelowSAE 0W-30

25 to 20°C( 13 to 68°F)SAE 5W-30

20 to 20°C( 4 to 68°F)SAE 10-3015°C (5°F)

and AboveSAE 5W-40or 15W-40

API CH-4 or CI-4

19 Engine Oil FilterCummins 4.5Land QSB 3.3L(Diesel)

C 1 FilterSee NOTE 4and NOTE 5.

See Parts Manual

18 Air Filter(with premiummonitoring)

CIL C 1 FilterSee NOTE 5,NOTE 6, and

NOTE 12.

See Parts Manual

18 Air Filter X C 1 FilterSee NOTE 5,NOTE 6, and

NOTE 12.

See Parts Manual


14



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

Engine OilPressure

CIL Check OilPressure

GM Engine207 to 380 kPa(30 to 55 psi)Cummins 4.5LDiesel Engineat High Idle

207 kPa (30 psi)at Low Idle

69 kPa (10 psi)Cummins QSB

3.3L Diesel Engine49 kPa (7 psi)

Minimum

15 Drive BeltGM Engine

X Check for Wearand Damage.

No AdjustmentNeeded.

See NOTE 5.

15 Drive BeltCummins 4.5Land QSB 3.3L(Diesel)

X Check for Wearand Damage.

No AdjustmentNeeded.

See NOTE 5.

LPG RegulatorGM 4.3L EngineWith GFI Installed

X Drain TarSee NOTE 5.

33 LPG Converter4.3L LPG EngineWith PSI Installed

X Drain TarSee NOTE 5.

Engine Idle SpeedGM 4.3L(Gasoline/LPG)

X 750 ±25 rpm

Engine GovernedSpeed

GM 4.3L(Gasoline/LPG)

X 2400 ±25 rpm

Engine Idle SpeedCold EngineCummins 4.5L(Diesel)

X CoolantTemperature

Less than77°C (170°F)

770 ±50 rpm

Engine Idle SpeedHot EngineCummins 4.5L(Diesel)

X CoolantTemperatureGreater than77°C (170°F)

800 ±50 rpm


15



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

Engine GovernedSpeed (No Load)

Cummins 4.5LDiesel

X 2250 ±50 rpm

PCV ValveGM 4.3L En-gine with GFI In-stalled

X Replace asNecessary

See NOTE 14

See Parts Manual

Engine Idle SpeedCold EngineCummins QSB3.3L (Diesel)

X CoolantTemperature

Less than 30°C(86°F)

1000 ±25 rpm

Engine Idle SpeedHot EngineCummins QSB3.3L (Diesel)

X CoolantTemperatureGreater than30°C (86°F)

800 ±25 rpm

Engine GovernedSpeed

Cummins QSB3.3L (Diesel)

X 2230 ±25 rpm

Oxygen SensorGM 4.3L EngineWith GFI Installed

XCIL

Replace asNecessary

4 Valve AdjustmentGM 4.3L Engine

Not Adjustable

4 Valve AdjustmentCummins 4.5LDiesel Engines

X Adjust asRequired

Intake0.254 mm (0.010 in.)

ColdExhaust

0.508 mm (0.020 in.)Cold

4 Valve AdjustmentCummins QSB3.3L DieselEngines

X Adjust asRequired

See NOTE 13.

Intake0.35 mm (0.014 in.)

ColdExhaust

0.50 mm (0.02 in.)Cold

17 Fuel Filter, LPG(GM)

C 1 Filter See Parts Manual

17 Fuel FilterGasoline (GM)


17 Fuel WaterSeparator Filter

Cummins 4.5Land QSB 3.3LDiesel Engine

CIL C 1 FilterDrain Water

from Filter asRequired

See Parts Manual


16



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

17 In-Line Fuel FilterCummins 4.5LDiesel Engine


17 Final Fuel FilterCummins QSB3.3L DieselEngine


20 Fuel InjectorsGM 4.3L Gas

X Check andReplace IfRequired

6 Injectors

20 Fuel InjectorsGM 4.3L LPGWith GFI In-stalled

X Check andReplace IfRequired

6 Injectors

5 Spark PlugsGM 4.3L Engine

C CheckPlug Wires

6 Plugs

See NOTE 9.

12,14

Cooling SystemGM 4.3LEngine

XCIL

C 15.1 liter(15.9 qt)

See NOTE 15.

12,14

Cooling SystemCummins 4.5LDiesel Engine

XCIL

C 13.5 liter(14.2 qt)

See NOTE 15.

12,14

Cooling SystemCummins QSB3.3L DieselEngine

XCIL

C 10.4 liter(11 qt)

See NOTE 15.

Clean Debris FromRadiator Core

X See NOTE 5.

7 Transmission OilDry Brake

X C 20 liter (21 qt) John DeereJDM J20C

21 Transmission OilFilter and Breather

C 1 Filter1 Breather

See NOTE 4.

See Parts Manual

26 Forks X X X CheckCondition

26 Fork Latches L Lubricate asNecessary

MultipurposeGrease

See NOTE 7.

Lift System,Operate

X CheckOperation


17



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

27 MastSliding Surfacesand Load RollerSurfaces

L Lubricateas Required


MultipurposeGrease

See NOTE 7.

27 Header Hoses X CheckCondition

28 Lift Chains X CheckLubrication.

See NOTE 11.

SAE 30WEngine Oil

28 Lift Chains L L, X Check for Wear.Lube as

Required.

SAE 30WEngine Oil

MastPivots

L 2 Fittings MultipurposeGrease

See NOTE 7.

MastIntegralSideshiftCarriageSliding Surfaces

X L X Lube asRequired.8 Fittings4 Bearing

Strips

MultipurposeGrease

See NOTE 7

Tilt Cylinder Ends L 4 Fittings MultipurposeGrease

See NOTE 7

Brake MasterCylinder Rod EndPin

L SAE 10W-30API SM

ILSAC GF4SAE J2362

Manual HydraulicHand Levers

L SAE 10W-30API SM

ILSAC GF4SAE J2362

24 Brake Oil(Master Cylinder)

CIL X C 0.35 liter(0.74 pt)

Dexron III fromSealed Container

11 Steering AxleSpindle Bear-ings


See NOTE 7.

11 Steering AxleTie Rods[S80, 100,120FT;] S80,100FTBCS;S120FTS;S120FTPRS(G004)


See NOTE 7.


18



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

11 Steering AxleTie RodsH80, 90, 100,110, 120FT(N005, P005)


See NOTE 7.

2 Pedals, Levers,Seat Rails, Cables,Hinges, Linkages,Hood Latch

L Lubricate asNecessary

Use Silicone SprayHyster Part No.

328388

1 Service Brakes(Dry Brake)

X Check LiningThickness

1.0 mm (0.040 in.)Minimum

23 Parking Brake L Lubricate asNecessary

Use Silicone Spray(Hyster Part

Number 328388)

30 Differential andDrive Axle Oil(Dry Brake)

X C 6.0 liter (6.3 qt) SAE 80W-90 or85W-140

7/30 Transmissionand Wet BrakePlanetary CarrierHousing OilS80FT, FTBCS(G004)

X C 28.8 liter(30.4 qt)

John DeereJDM J20C

7/30 Transmissionand Wet BrakePlanetary CarrierHousing OilS100FT, FTBCSS120FT, FTS,FTPRS (G004)

X C 29.8 liter(31.4 qt)

John DeereJDM J20C

7/30 Transmissionand Wet BrakePlanetary CarrierHousing OilH80, 90, 100, 110,120FT) (N005,P005)

X C 31.3 liter(33.0 qt)

John DeereJDM J20C

30 Wet Brake CenterSection Oil[S80, 100, 120FT;]S80, 100FTBCS;S120FTS;S120FTPRS (G004)

X C 2.0 liter (2.1 qt) SAE 80W/90

30 Wet Brake CenterSection OilH80, 90, 100, 110,120FT (N005, P005)

X C 2.0 liter (2.1 qt) SAE 80W-90


19



ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

Inspect EngineElectrical System,Connectors

X

Inspect EngineVacuum, FuelLines, and Fittings

X

InspectLock-Off for Leaks,and EnsureLock-Off Closing

X

Test LPG/GASRegulator Pressure

X

CheckAir InductionSystem for Leaks

X

CheckManifold forVacuum Leaks

X

CheckThrottle Shaft forSticking

X

CheckInjectors and Railsfor leaks

X

InspectExhaust Manifoldsand Piping forLeaks

X

InspectCatalyst Inletand Outlet

X

31 Ignition SystemDistributor, Rotor,and Spark PlugWires

C Replace

Inspect MufflerInlet and Outlet

X Replace asRequired

Mast and Carriagewith Paper RollClamp

X InspectSee 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.


20

8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily


ItemNo.

Item 8 hr/1 day

250 hr/6 mo

500 hr/6 mo

1000 hr/6 mo

2000 hr/1 yr

4000 hr/2 yr


Specification

NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hoursof 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 abrasivecompounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will requiremore frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based onan 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 shouldbe done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air andsteam 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 Every2000 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 with50% distilled or deionized water.

NOTE 16: Inspect after an impact likely to cause damage. In large diameter paper-roll production applications, inspect atfirst 4000 hours with subsequent inspection at 2000 hour intervals. At your request, your Hyster dealer will advise youof the appropriate service intervals based on an application survey.


Maintenance Procedures Every 8 Hours or DailyHOW TO MAKE CHECKS WITH ENGINESTOPPED

WARNINGDO NOT operate a lift truck that needs repairs.Report the need for repairs immediately. Ifrepair is necessary, put a DO NOT OPERATEtag in the operator’s area. If the lift truck isequipped with a key switch, remove the keyfrom the key switch.

Put the lift truck on a level surface. Lower the car-riage and forks, stop the engine, and apply the park-ing brake. Open the hood and check for leaks and

conditions that are not normal. Clean any oil or fuelspills. 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 thetread and remove any objects that will cause damage.Check for bent or damaged rims. Check for loose ormissing hardware. Remove any wire, strapping, orother 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 EDGES3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)

Figure 8. Tire Check

Safety Labels

WARNINGSafety labels are installed on the lift truck togive information about operation and possiblehazards. It is important that all safety labelsare installed on the lift truck and can be read.

Check that all safety labels are installed in the cor-rect location on the lift truck. See the Parts Man-ual, Model Description section in the OperatingManual or the section Frame 100 SRM 1243 for thecorrect location of the safety labels. See the PartsManual for the part numbers of the safety labels.

Mast, Carriage, Lift Chains, Header Hoses,Attachment

WARNINGLower the lift mechanism completely. Neverallow any person under a raised carriage. DONOT put any part of your body in or throughthe lift mechanism unless all parts of the mastare completely lowered and the engine isSTOPPED. DO NOT try to correct the align-ment of the fork tips by bending the forks oradding shims. Never repair damaged forks byheating or welding. Forks are made of specialsteel using special procedures. If either fork isdamaged, replace the forks as a set.

1. Inspect the welds on the mast and carriage forcracks. Make sure that the capscrews and nutsare tight.

2. Inspect the channels for wear in the areas wherethe rollers travel. Inspect the rollers for wear ordamage.

3. Inspect the load backrest extension for cracksand damage.

4. If the lift truck is equipped with an integralsideshift carriage or attachment, inspect theparts for cracks and wear. Make sure the partsthat fasten the integral sideshift carriage orattachment to the carriage are in good condition.

5. Visually inspect hoses/fittings for hydraulicleaks; hose cover for cuts, cracks or exposed re-inforcement; defective/broken clamping devicesor sheaves; proper tracking during operation.Adjust/repair/replace hose/components as neces-sary. See Mast Repairs, 2- and 3-Stage Masts4000 SRM 1250 for quick disconnect procedures.

6. Check that the lift chains are correctly lubri-cated. Use SAE 30 engine oil as necessary tolubricate 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 anddamage.

22


9. Make sure the lift chains are adjusted so thatthey have equal tension. Adjustments or re-placement of the lift chains must be doneby authorized personnel.

1. WORN PIN2. CRACKS3. EDGE WEAR4. HOLE WEAR

5. LOOSE LEAVES6. TURNED PIN7. CORROSION

Figure 9. Lift Chain Check

Operator Restraint System

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

Emergency Locking Retractor (ELR)

NOTE: Lift trucks produced after November 2005are equipped with the Emergency Locking Retractor(ELR) style seat belt.

When the ELR style seat belt is properly buckledacross the operator, the belt will permit slight op-erator repositioning without activating the lockingmechanism. If the truck tips, travels off a dock, orcomes to a sudden stop, the locking mechanism willbe activated and hold the operator’s lower torso inthe seat.

A seat belt that is damaged worn or does not operateproperly will not give protection when it is needed.The end of the belt must fasten correctly in the latch.

The seat belt must be in good condition. Replace theseat belt if damage or wear is seen. See Figure 10.

NOTE: The following seat belt operation checks mustbe performed three times before replacing the seatbelt assembly.

• With the hood closed and in the locked position,pull the seat belt slowly from the retractor assem-bly. Make sure the seat belt pulls out and retractssmoothly. If the seat belt cannot be pulled from theretractor assembly or the belt will not retract, re-place the seat belt assembly.

• With the hood closed and in the locked position,pull the seat belt with a sudden jerk. Make sure theseat 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 theseat belt assembly.

• With the hood in the open position, make sure theseat 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 seatbelt assembly.

1. LATCH STRIKER2. HOOD LATCH3. FORWARD/BACKWARD ADJUSTMENT4. HOOD5. OPERATOR WEIGHT ADJUSTMENT6. SEAT RAIL7. ARM REST8. SEAT BELT9. SEAT10. HIP RESTRAINT11. HOOD HINGE

Figure 10. Hood and Seat Check

23


NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE

1. FORWARD/BACKWARD ADJUSTMENT2. SWIVEL ADJUSTMENT3. OPERATOR WEIGHT ADJUSTMENT4. SEAT POSITION ADJUSTMENT (SEAT RAIL)5. SEAT BELT

Figure 11. Swivel Seat Controls

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

to the ground so that the best ergonomic positionis 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 drivingin reverse.

• The seat swivels 5 degrees to the left to allow aseasier exit of the truck.

• The neutral position is shown in Figure 12.

Seat Adjustment for Operator Weight

CAUTIONA major cause for high Whole Body Vibration iscaused by the operator not adjusting the seat tohis/her weight.

NOTE: It is important to adjust the weight setting foreach operator.

NOTE: The seat is designed for maximum weight of135 kg (298 lb).

• The target is for the "ride indicator" to fall betweenthe arrows when the operator sits upright in theseat with the feet positioned on the pedals. Thisensures that the operator is set at the midpoint ofthe 80mm suspension.

• The handle can be turned as shown to increase ordecrease the weight resistance, pull handle out be-fore turning. As the handle is turned the "stiffness"of the suspension can be felt to increase or decreaseon which way the handle is turned.

24


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

1. SEAT BELT2. WEIGHT ADJUSTMENT KNOB3. RIDE POSITION INDICATOR4. FORWARD/BACKWARD ADJUSTMENT LEVER

5. BACKREST ANGLE ADJUSTMENT LEVER6. ARMREST7. 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 driv-ing in reverse.

• The seat swivels 5 degrees to the left to allow aseasier exit of the truck.

• The neutral position is shown in Figure 13.

Seat Adjustment for Operator Weight

CAUTIONA major cause for high Whole Body Vibration iscaused by the operator not adjusting the seat tohis/her weight.

NOTE: It is important to adjust the weight setting foreach operator.

NOTE: The seat is designed for maximum weight of135 kg (298 lb).

• The target is for the "ride indicator" to fall betweenthe arrows when the operator sits upright in theseat with the feet positioned on the pedals. Thisensures that the operator is set at the midpoint ofthe 40 mm (1.57 in.) suspension.

• The weight adjustment knob can be turned left orright to increase or decrease the weight resistance.As the weight adjustment knob is turned the "stiff-ness" of the suspension can be felt to increase or de-crease on which way the weight adjustment knobis turned.

25


1. SEAT BELT2. WEIGHT ADJUSTMENT KNOB3. RIDE POSITION INDICATOR4. FORWARD/BACKWARD ADJUSTMENT LEVER

5. BACKREST ANGLE ADJUSTMENT LEVER6. ARMREST7. SWIVEL LATCH RELEASE LEVER

Figure 13. Seat Adjustment

Hood and Seat Latches

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

Engine Compartment

Check for the presence of any combustible materialsuch as paper, leaves, etc. Remove any combustiblematerials.

Paper Application

Vehicles used in paper applications require regularinspection and cleaning to minimize the risk of fire.This should be done at least once every 8 hoursor more frequently depending upon operating en-vironment. The paper application option will helplimit the contact of paper or tissue scraps to hotsurfaces under the hood, but frequent maintenanceis required.

WARNINGEngine and exhaust system components arehot to touch. Be sure lift truck components arecool before starting inspection and cleaning orpersonal injury may occur.

Ensure the truck engine cools properly by allowingit to idle for several minutes. Shutting the truckdown while hot will not allow the engine to coolquickly due to the loss of coolant circulation. Theheat trapped under the hood may actually increasethe engine temperature because of no heat transferthrough the radiator. With engine off and lift truckcomponents cooled, check and clean the radiator andif equipped, radiator screen. Check engine manifold,exhaust pipes, muffler and catalytic converter forpaper scraps. Clean as required. Check and cleanthe engine compartment components, transmission,fan shroud, belly pan if equipped, and inside frameledges to avoid paper, dust and oil accumulation.Check axle and cowl openings for paper buildup andbailing wire. Remove any debris.

26



CAUTIONAir pressure, nozzle or extension tube maycause damage to exhaust wraps and radiatorfins. Assure that air pressure, nozzle or exten-sion tube does not damage exhaust wraps orradiator fins.

Paper removal can generally be accomplished using acompressed air line and nozzle. An extension may behelpful to access hard to reach places. Remove floorplates and side covers for better access to engine com-partment. Open or removed belly pan, if equipped.Clean components with compressed air. Take careto maintain the integrity of the exhaust wraps whencleaning with compressed air and use caution to notforce debris into openings. Check the condition of ex-haust wraps for wear, proper fit, contamination withoil or antifreeze, gaps in coverage, failed fastenersand replace as necessary. Do not reuse wraps if theyhave been removed for some other service operation.

WARNINGBe careful when cleaning with steam. Steamcan cause serious burns. Wear protective cloth-ing, gloves, and eye protection. Never exposeyour skin to steam.

If compressed air did not adequately remove debris,steam clean to remove any persistent accumulationof material or oil. Protect electrical components frommoisture when steam cleaning. Do not spray exhaustwraps directly with high pressure steam. Allow lifttruck to air dry before returning to work in a con-taminated environment. Paper dust and scraps willadhere to wet surfaces.

Check the condition of exhaust wraps for wear,proper fit, contamination with oil or antifreeze, gapsin coverage, failed fasteners and replace as neces-sary. Do not reuse wraps if they have been removedfor some other service operation.

Fuel, Oil, and Coolant Leaks, Check

WARNINGAll fuels are very flammable and can burn orcause an explosion. DO NOT use an open flameto check the fuel level or to check for leaks inthe fuel system. If there is a leak in the fuel sys-tem, extra care must be used during the repair.DO NOT operate the lift truck until a leak is re-paired.

Make a visual check for leaks on and under the lifttruck. If possible, find and report the leak to main-tenance for repair. Leaks often indicate a need forrepair of damaged or worn components. Leaks in theLPG fuel system are usually not visible unless iceis present. There is however, usually a strong odor.Fuel leaks MUST be repaired IMMEDIATELY.

Check the fuel system for leaks and the condition ofparts. When fuel is added to the lift truck, see thesection HOW TO ADD FUEL TO THE LIFT TRUCKin the Operating Manual.

Also check the condition of the radiator or heaterhoses that are not leaking. Soft or cracked hoses needto be replaced before a major leak occurs.

Hydraulic Hoses

Check the condition of the hydraulic hoses for ser-viceability by inspecting for cracks or other obviousdamage. Check to insure that the hydraulic hosesare not leaking. If any hose is leaking, report it tomaintenance for repair.

Coolant Hoses

Check the condition of the coolant hoses for service-ability by inspecting for cracks or other obvious dam-age. Check to insure that the coolant hoses are notleaking. If any hose is leaking, report it to mainte-nance for repair.

Steering Column Gas Cylinder

Make sure the gas cylinder for the steering columnoperates correctly. The cylinder must NOT allow thecolumn to move unless the tilt lever is released. SeeFigure 14.

27


1. TILT LEVER 2. GAS CYLINDER

Figure 14. Steering Column Gas Cylinder andTilt Lever

Transmission

Check the transmission for leaks and damaged orloose components. Heavy-duty or high temperatureoperations can require more frequent checks.

Hydraulic System Oil

WARNINGAt operating temperature, the hydraulic oil isHOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the hydraulic sys-tem when the oil level is checked or the filteris changed.

Never operate the hydraulic pump without oilin the hydraulic system. The operation of thehydraulic pump without oil will damage thepump.

After the engine has stopped, wait one minute beforechecking the oil level. Keep the hydraulic oil at thecorrect level as indicated on the dipstick. Use thecorrect oil as shown in the Maintenance Schedule.

Check the hydraulic system for leaks and damaged orloose components. Heavy-duty or high-temperatureoperations can require more frequent checks.

Engine Oil

WARNINGAt operating temperature, the engine oil isHOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the engine whenthe oil level is checked or the filter is changed.

Never operate the engine without oil. The op-eration of the engine without oil will damagethe engine.

After the engine has stopped, wait one minute beforechecking the oil level. See Figure 15, Figure 16, andFigure 17. Keep the oil at the correct level as indi-cated on the dipstick. Use the correct oil as shown inthe Maintenance Schedule.

28


Figure 15. Cummins 4.5L Diesel EngineMaintenance Points for Lift Truck Models H80,

90, 100, 110, 120FT (N005)

Legend for Figure 15

A. TOP VIEWB. RIGHT HAND SIDE SHOWN

1. BATTERY2. AUXILIARY COOLANT RESERVOIR3. RADIATOR CAP4. WATER SEPARATOR5. AIR FILTER6. LIFT PUMP7. FUEL INJECTION PUMP8. ENGINE OIL FILL CAP9. INLINE FUEL FILTER10. DIPSTICK ENGINE OIL11. FUEL INJECTOR12. DRIVE BELT

29


A. RIGHT SIDE FRONT VIEW B. LEFT SIDE FRONT VIEW

1. DIPSTICK2. TURBOCHARGER3. OIL FILL CAP4. AIR INLET HOUSING5. FUEL PRIMER PUMP6. FUEL/WATER SEPARATOR7. ECM8. FUEL FILTER9. STARTER10. FUEL RAIL11. ELECTRONIC FUEL PUMP12. WATER PUMP13. CRANK POSITIONING SENSOR14. CAM POSITIONING SENSOR

15. ALTERNATOR16. ALTERNATOR BELT ADJUSTMENT17. TEMPERATURE SENDING UNIT18. WATER INLET/THERMOSTAT HOUSING19. TURBOCHARGER AIR INLET20. TURBOCHARGER WASTEGATE21. TURBOCHARGER EXHAUST22. TURBOCHARGER EXHAUST MANIFOLD23. OIL FILTER24. TURBOCHARGER OIL DRAIN LINE25. TURBOCHARGER OIL FEEL LINE26. OIL PAN27. OIL PAN DRAIN PLUG28. DRIVE BELT

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

30


A. GAS ENGINE B. LPG ENGINE

1. DIPSTICK ENGINE OIL2. BATTERY3. AUXILIARY COOLANT RESERVOIR4. RADIATOR CAP5. ENGINE OIL FILL6. DRIVE BELT

7. AIR FILTER8. FUEL FILTER9. ENGINE OIL FILTER10. SPARK PLUGS11. FUEL INJECTOR

Figure 17. GM Engine Maintenance Points With GFI Installed

31


1. DIPSTICK ENGINE OIL2. BATTERY3. AUXILIARY COOLANT RESERVOIR4. RADIATOR CAP5. ENGINE OIL FILL6. DRIVE BELT

7. AIR FILTER8. ENGINE OIL FILTER9. SPARK PLUGS10. ENGINE LABEL11. LPG CONVERTER

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

Air Filter

The air filter canister should not be opened until anair filter element replacement is required. An airfilter element replacement is required when one ofthe 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 ele-ment has been replaced.

Forks

NOTE: Forks must be removed or installed by trainedpersonnel only.

The identification of a fork describes how the fork isconnected to the carriage. These lift trucks have hookforks.

Remove

WARNINGDO NOT try to move a fork without a liftingdevice. Each hook fork for these lift trucks canweigh 45 to 115 kg (99 to 253 lb).

NOTE: Forks are to be replaced only in sets and notindividually.

1. A fork can be removed from the carriage for re-placement of the fork or other maintenance. Liftthe lock pin and slide a hook fork to the fork re-moval notch on the carriage. See Figure 19 andFigure 20. Lower the fork onto blocks so that thebottom hook of the fork moves through the forkremoval notch. See Figure 20. Lower the car-riage further so that the top hook of the fork is

32


disengaged from the top carriage bar. Move thecarriage away from the fork, or use a lifting de-vice to move the fork away from the carriage.

1. CARRIAGE BARS2. HOOK FORK

3. BLOCKS

Figure 19. Hook Fork Removal

Inspect

1. Inspect the forks for cracks and wear. Check thatthe fork tips are aligned as shown in Figure 20.Check that the bottom of the fork is not worn. SeeFigure 20, item 4.

2. Replace any damaged or broken parts that areused to keep the forks locked in position.

Install

Move the fork and carriage so that the top hook onthe fork can engage the upper carriage bar. Raisethe carriage to move the lower hook through the forkremoval notch. Slide the fork on the carriage so thatboth upper and lower hooks engage the carriage. En-gage the lock pin with a notch in the upper carriagebar.

Fork Tip Alignment

Length of Forks 3% Dimension

915 mm (36 in.)1067 mm (42 in.)1220 mm (48 in.)1372 mm (54 in.)1524 mm (60 in.)1830 mm (72 in.)

27 mm (1.10 in.)32 mm (1.26 in.)37 mm (1.46 in.)41 mm (1.61 in.)46 mm (1.81 in.)55 mm (2.17 in.)

1. TIP ALIGNMENT (MUST BE WITHIN 3% OFFORK LENGTH)

2. CRACKS3. LATCH DAMAGE4. HEEL OF FORK (MUST BE 90% OF

DIMENSION X)5. CARRIAGE6. LOAD BACKREST EXTENSION7. MAXIMUM ANGLE 93°8. FORK REMOVAL NOTCH

Figure 20. Forks Check

33


Adjust

NOTE: During the adjustment of the forks, the heelof the forks should not be touching the ground.

The forks are connected to the carriage by hooks andlock pins. See Figure 19 and Figure 21. The lockpins are installed through the top fork hooks and fitinto slots in the top carriage bar. If pin does not re-main engaged in carriage slot, replace with new pin.Adjust the forks as far apart as possible for maxi-mum support of the load. Hook forks will slide alongthe carriage bars to adjust for the load to be lifted.Raise the lock pin in each fork to slide the fork onthe carriage bar. Make sure the lock pin is engagedin the carriage bar to lock the fork in position afterthe width adjustment is made.

1. FORK2. LOCK PIN3. SPRING4. WASHER

5. WEDGE6. KNOB7. LOCK PIN

ASSEMBLY

Figure 21. Fork Lock Pin Assembly

Integral Sideshift Carriage

Check for cracks, wear and damage. If damaged, seeMast Repairs, 2- and 3-Stage Masts 4000 SRM1250 for repair procedures. If necessary, lubricatesliding surfaces at grease fittings with multipurposegrease shown in the Maintenance Schedule. See Fig-ure 22.

1. CAPSCREWS2. LOWER HOOK3. APRON4. LOWER BEARING STRIPS5. UPPER BEARING STRIPS6. GREASE FITTINGS7. CYLINDER ROD8. SNAP RING9. ROD SCRAPER10. ROD BUSHINGS11. SEAL12. FIXED FRAME

Figure 22. Integral Sideshift Carriage

34


HOW TO MAKE CHECKS WITH ENGINERUNNING

WARNINGDO NOT operate a lift truck that needs repairs.Report the need for repair immediately. If re-pair is necessary, put a DO NOT OPERATE tagin the operator’s area. If lift truck is equippedwith a key switch, remove the key.

WARNINGFASTEN YOUR SEAT BELT! The seat belt is in-stalled to help the operator stay on the truck ifthe lift truck tips over. IT CAN ONLY HELP IFIT IS FASTENED.

Make sure that the area around the lift truck is clearbefore starting the engine or making any checks ofthe operation. Be careful when making the checks.If the lift truck is stationary during a check, apply

the parking brake and put the transmission in NEU-TRAL. Make the checks carefully.

Indicator Lights, Horn, Fuses, and Relays

If lift truck is equipped with a key switch, turnkey to ON position. If lift truck is equipped with aPower ON/OFF button, press button to turn systempower on. All warning light and indicator lights willlight up for two seconds (start check) when systempower is turned ON. See Figure 23. Check all in-dicator lights for correct operation as described inthe Operating Manual. Check the operation of thehorn. Start the engine by turning the key switch tothe Start position, if truck is equipped with a keyswitch, or press the engine start button, if lift truckis equipped with this button. If any indicator lightsdo not operate correctly, check the fuses. The fusesare located in the Power Distribution Module (PDM)which is under the hood next to the battery on theright side. See Figure 24.

35


Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light

2 Warning Light, System Malfunction Light

3 Indicator Light, Air Filter Restriction

4 Indicators Light, Direction and Transmission

5 Warning Light, Brake Oil Level Malfunction Indicator

6 Warning Light, Fasten Seat Belt Malfunction Indicator

7 Warning Light, Parking Brake Malfunction Indicator

8 Warning Light, Alternator Malfunction Indicator

9 Warning Light, Transmission Oil Temperature Malfunction Indicator

10 Warning Light, Engine Oil Pressure Malfunction Indicator

11 Warning Light, Engine Coolant Temperature Malfunction Indicator

12 Warning Light, Coolant Level in Radiator Malfunction Indicator

13 Warning Light, Fuel Level Indicator Malfunction Indicator

14 Indicator Light, 1st Gear Locking (Duramatch Plus 2™ Transmissions)

15 Indicator Light, Water Separator (Diesel Only)

16 Indicator Light, Cold Start (Diesel Only)

Figure 23. Warning and Indicator Lights

36


NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY2. PDM3. RESISTOR (68 OHM)4. START RELAY5. STARTER (30-AMP FUSE)6. IGNITION 3 RELAY7. BACKUP RELAY8. BACKUP (20-AMP FUSE)9. IGNITION (30-AMP FUSE)10. SPARE FUEL PUMP (20-AMP FUSE)

11. SPARE FUEL PUMP RELAY12. BATTERY (25-AMP FUSE)13. FRONT WORK LIGHT (20-AMP FUSE)14. FRONT/REAR WORK LIGHT RELAYS15. BATTERY (25-AMP FUSE)16. REAR WORK LIGHT (20-AMP FUSE)17. IGNITION 1 (20-AMP FUSE)18. IGNITION RELAY19. BATTERY (25-AMP FUSE)

Figure 24. PDM Showing Fuses and Relays

Service Brakes

Brake Oil Level

WARNINGSmall amounts of water in the brake systemcan cause reduced braking performance if thewater reaches the wheel cylinder areas. DONOT allow water entry. Ensure that the sealedreservoir lid is properly replaced.

The brake system has a boosted master cylin-der, braking will be more difficult if the engineis not running.

Loss of oil from the brake oil reservoir indi-cates a leak. Repair the brake system before

using the lift truck. Replace the brake oil inthe system if there is dirt or water in the sys-tem.

DO NOT use "DOT" fluid, only use Dexron III oilfrom sealed container to prevent possible dam-age to the brake system. Failure to observe theabove Warning could result in death or seriousinjury.

There is an indicator light on the Display SwitchCluster for the brake oil. The red light is ON whenthe key switch is in the START position or the PowerON/OFF button is pressed, and must go OFF whenthe engine is running. If the light is on when theengine is running, the brake fluid oil in the reservoiris too low.

37


Operation, Check

Check the operation of the service brakes. Push onthe inching/brake pedal. The service brakes must beapplied before the inching/brake pedal reaches thefloor plate. The pedal must stop firmly and mustnot move slowly down after the brakes are applied.The service brakes must apply equally to both drivewheels. The service brakes must not pull the lifttruck to either side of the direction of travel whenthey are applied. The service brakes are automat-ically adjusted when the transmission is in reverseand the lift truck is moving and the brakes are firmlyapplied. Full application of the inching/brake pedalapplies the service brakes and puts the transmissionin NEUTRAL.

Lift trucks with a MONOTROL® pedal. Whenthe inching/brake pedal is fully applied, a switch inthe starting circuit is closed so that the engine can bestarted.

Parking Brake

Make sure the service brakes are adjusted and theoperation of the automatic adjuster mechanism iscorrect before the parking brake is adjusted.

Lift trucks with a MONOTROL® pedal. Theswitch energizes the seat warning circuit when handlever is released. This switch puts the transmissionin NEUTRAL by de-energizing the direction sole-noid. There is also a switch on the left-hand side ofbracket. This switch prevents engine from startingunless parking brake is applied.

NOTE: Make sure parking brake is released beforemaking adjustment.

1. Turn the adjustment knob to raise the equalizedlink and tighten the parking brake cables shownin Figure 25. Do not tighten the adjustment sothat the brake is applied when the lever is re-leased. The lever for the parking brake has alock. Use your thumb or finger to release the lockon the lever when the parking brake is released.

2. For burnished brakes, test the operation of theparking brake. The lift truck with a capacity loadmust not move when parking brake is applied ona 15 percent grade [a slope that increases 1.5 min 10 m (1.5 ft in 10 ft)].

1. LOCK BUTTON RELEASE2. OFF POSITION3. ON POSITION4. ADJUSTMENT KNOB

Figure 25. Parking Brake

Engine Oil Pressure

NOTE: The engine will enter shutdown mode after awarning buzzer sounds and a 30 second countdown,if engine oil pressure is less than 34.5 kPa (5 psi) onlift trucks with powertrain protection system. Lifttrucks equipped with a Cummins diesel engine willenter the shutdown mode when the engine oil pres-sure is less than 49 kPa (7 psi) on lift trucks with pow-ertrain protection system. See the Engine Shut-down procedures in the Operating Manual.

There is an indicator light for the engine oil pressureon the Display Switch Cluster. During normal opera-tion, the red indicator light will illuminate when thekey switch is turned to ON, if the truck is equippedwith a key switch, or when the power ON/OFF but-ton is pressed, if the truck is equipped with a key-less option, and will stay illuminated until correct oilpressure is obtained, at which time the light will gooff.

38


If the light continues to stay on when engine is run-ning, the engine oil pressure is low. Stop the engineand check the oil level. See Figure 17 for lift truckmodels S80, 100, 120FT; S80, 100FTBCS; 120FTS;S120FTPRS) (G004) and Figure 15, Figure 16, andFigure 17 for lift truck models H80, 90, 100, 110,120FT) (N005, P005) Do not restart the engine un-til the low pressure condition has been corrected.

Cooling System

WARNINGDO NOT remove the radiator cap from the radi-ator when the engine is hot. When the radiatorcap is removed, the pressure is released fromthe system. If the system is hot, the steam andboiling coolant can cause burns.

NOTE: The engine will enter shutdown mode after awarning buzzer sounds and a 30-second countdown ifcoolant temperature reaches 118°C (245°F) or abovefor GM 4.3L lift trucks with powertrain protectionsystem. Lift trucks equipped with a Cummins 4.5Lor QSB 3.3L diesel engine will enter the shutdownmode when the coolant temperature reaches 114°C(238°F) or above on lift trucks with powertrain pro-tection system. See the Engine Shutdown proce-dures in the Operating Manual.

There is an indicator light on the Display SwitchCluster for the coolant temperature. The red lightis on when the key switch is in the START positionor the Power ON/OFF button is pressed, and mustgo off when the engine is running. If the light is onwhen the engine is running, the coolant and engineare too hot. Stop the engine and check the coolantlevel in the coolant recovery reservoir.

Make sure the coolant level is between the ADD andFULL marks on the auxiliary coolant reservoir. SeeFigure 26. The coolant will expand as it is heatedand the level in the auxiliary coolant reservoir willincrease.

CAUTIONAdditives may damage the cooling system. Be-fore using additives, contact your local Hysterdealer.

If coolant is added, see Maintenance Schedule for cor-rect solution.


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 indicatorlight turns on again after restarting, shut down thelift truck and do not operate the lift truck until theproblem is corrected.

1. FILL CAP2. FULL HOT MARK3. FULL COLD MARK4. ADD COLD MARK

Figure 26. Auxiliary Coolant Reservoir

Steering System

WARNINGThe lift truck has hydraulic power steering.The steering can be difficult if the engine isnot running.

Make sure the steering system operates smoothlyand provides good steering control. Make sure thesteering column can be adjusted and the gas cylinderfunction is correct.

39


Control Levers and Pedals

Check that the control levers for the transmission,mast, and attachment operate as described in Oper-ating Manual. Check that the pedals operate cor-rectly as described in Operating Manual.

Lift System, Operate

WARNINGWhen working on or near the mast, see SafetyProcedures When Working Near Mast at theend of this section.

Lower the lift mechanism completely. Neverallow any person under a raised carriage. DONOT put any part of your body in or throughthe lift mechanism unless all parts of the mastare completely lowered and the engine isSTOPPED.

If the mast cannot be lowered, use chains onthe mast weldments and carriage so that theycannot move. Make sure the moving parts areattached to a part that does not move.

DO NOT try to find hydraulic leaks by puttinghands on pressurized hydraulic components.Hydraulic oil can be injected into the body bythe pressure.

Perform the following checks and inspections:

1. Check for leaks in the hydraulic system. Checkthe condition of the hydraulic hoses and tubes.

NOTE: Some parts of the mast move at differentspeeds during raising and lowering.

2. Slowly raise and lower the mast several timeswithout a load. Raise the mast to its full heightat least once. The mast components must raiseand lower smoothly in the correct sequence. Hosemust track properly during operation.

3. The inner weldments and the carriage mustlower completely.

4. Raise the mast 1 m (3 ft) with a capacity load.The inner weldments and the carriage must raisesmoothly. Lower the mast. All moving compo-nents must lower smoothly.

5. Lower the load to approximately 0.3 m (1 ft). Tiltthe mast forward and backward. The mast musttilt smoothly and both tilt cylinders must stopevenly.

6. Check that the controls for the attachment op-erate the functions of the attachment. See thesymbols by each of the controls. Make sure all ofthe hydraulic lines are connected correctly anddo not leak.

40

8000 SRM 1248 First Service After First 100 Hours of Operation

First Service After First 100 Hours of OperationGM 4.3L ENGINE OIL AND OIL FILTER

NOTE: The engine oil and oil filter must also bechanged after the first 100 hours of operation for anewly installed engine.

Change engine oil and oil filter. See Figure 27. Ap-ply clean oil to gasket of new filter. Install new fil-ter. Turn filter until gasket touches, then tighten 1/2to 3/4 turn with your hand. Fill engine with oil asspecified in Maintenance Schedule, until full markreached on the dipstick. Start engine. Check areaaround oil filter for leaks, shut engine off and checkoil dipstick, if low add oil.

NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG-END FOR GM 4.3L ENGINES EQUIPPED WITH GFIOR PSI ARE LOCATED IN THE SAME AREA.

1. OIL FILTER2. DRAIN PLUG3. ENGINE OIL DIPSTICK4. ENGINE OIL FILL

Figure 27. GM 4.3L Engine Filter Oil Change

CUMMINS 4.5L AND QSB 3.3L ENGINEOIL AND OIL FILTER

Change engine oil and oil filter. See Figure 28. Ap-ply clean oil to gasket of new filter. Install new filter.Turn filter until gasket touches, then tighten 1/2 to3/4 turn with your hand. Fill engine with oil as speci-fied in Maintenance Schedule until full mark reachedon the dipstick. Start engine. Check area around oilfilter for leaks, shut engine off and check oil dipstick,if low add oil.

NOTE: BOTTOM LEFT-HAND SIDE SHOWN

1. OIL FILTER 2. DRAIN PLUG

Figure 28. Engine Oil Filter Change, Cummins4.5L Diesel (Shown)

41

Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1248

Maintenance Procedures Every 250 Hours or 6 MonthsNOTE: Perform the 8-hour checks prior to performingthe procedures in this section.

GM 4.3L ENGINE OIL AND OIL FILTER

NOTE: Change the oil and oil filter for the engine atthe first 100 hours of operation on new lift trucks.

Change engine oil and engine oil filter. See Fig-ure 29. Use the correct oil according to the Main-tenance Schedule. Apply clean oil to gasket of newfilter. Install new filter. Turn filter until gaskettouches, then tighten 1/2 to 3/4 turn with your hand.Start engine. Check area around oil filter for leaks.

NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG-END FOR GM4.3L ENGINES EQUIPPED WITH GFIOR PSI ARE LOCATED IN THE SAME AREA.

1. OIL FILTER2. DRAIN PLUG3. ENGINE OIL DIPSTICK4. ENGINE OIL FILL

Figure 29. GM 4.3L Engine Oil Change

DRIVE BELT

GM 4.3L Engine

Fan and Alternator Drive Belt

Check drive belt for wear and damage. See Figure 30.A few small cracks that run across belt are accept-able. A belt with cracks that run length of belt or abelt with missing pieces is not acceptable. See Fig-ure 31 for the drive belt arrangement.

1. ACCEPTABLE CRACKS2. NOT ACCEPTABLE CRACKS AND DAMAGE

Figure 30. Drive Belt Inspection

Figure 31. GM 4.3L Drive Belt Arrangement

42

8000 SRM 1248 Maintenance Procedures Every 250 Hours or 6 Months


NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTINGTENSIONERS.

1. FAN PULLEY2. WATER PUMP PULLEY3. CRANKSHAFT PULLEY4. SERPENTINE BELT5. TENSIONER CENTERING PULLEY6. ALTERNATOR PULLEY

DRAIN TAR FROM LPG REGULATOR

1. Warm engine to operating temperature.

2. Shut fuel valve off and run engine until the en-gine runs out of fuel and stops.

3. Raise the hood.

4. Remove tar drain screw from regulator. Allow tarto drain from regulator. When tar has completelydrained, install tar drain screw in regulator. SeeFigure 32.

1. TAR DRAIN SCREW

Figure 32. GM LPG Regulator

DRAIN TAR FROM LPG CONVERTER

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

1. Move the lift truck to a well ventilated area, andensure 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 orkeyless switch to OFF position, and disconnectthe negative terminal on the battery.

CAUTIONA small amount of fuel may remain in the fuelline. To prevent the possibility of burns weargloves and eye protection. If fuel continues toflow check to make sure the LPG tank valve iscompletely closed.

5. Disconnect the inlet line and outlet hose from theLPG converter. See Figure 33.

6. Remove the mounting bolts and LPG converterfrom the mounting bracket.

1. LPG CONVERTER2. INLET LINE3. OUTLET HOSE4. MOUNTING BOLTS

Figure 33. LPG Converter Removal

43


CAUTIONEngine components may be hot. Use gloveswhen handling the LPG Converter to preventthe possibility of burns.

CAUTIONDrain the tar into a container and dispose inaccordance with local environmental regula-tions.

7. Rotate the LPG converter sightly so that outletopening is pointing toward the container and al-low tar to drain from LPG converter. If the LPGconverter cannot be rotated a sufficient amountto drain the tar, disconnect the two cooling hoses.

8. Using mounting bolts, install the LPG converteron the mounting bracket.

9. Connect the fuel line and outlet hose to the LPGconverter. If disconnected, connect the two cool-ing hoses.

10. Connect the negative terminal on the battery.

11. Open the valve on the LPG tank and check forleaks on the LPG converter using soapy water ora leak detector. If any leaks are found, tightenfittings or replace hose clamps as applicable.

12. Start the engine and recheck for leaks at the con-verter.

Maintenance Procedures Every 500 Hours or 6 MonthsNOTE: Perform the 8-hour and 250-hour checks priorto performing the procedures in this section.

HYDRAULIC SYSTEM OIL


CAUTIONDO NOT permit dirt to enter the hydraulic sys-tem when the oil level is checked or the filteris changed.


CAUTIONAdditives may damage the hydraulic system.Before using additives, contact your local Hys-ter dealer.

Check the hydraulic oil level when the oil is at operat-ing temperature with the mast in a vertical position,the carriage lowered, and the engine stopped. SeeFigure 41 and Figure 42. Add hydraulic oil only asneeded. If hydraulic oil is above the FULL level, thehydraulic oil will leak from the breather during oper-ation. The oil level indicated by the dipstick is most

accurate when the oil temperature is 53 to 93°C (130to 200°F).

HYDRAULIC TANK BREATHER

Inspect

NOTE: When inspecting the breather, do not removeit. The breather element is a non serviceable part. Ifit is damaged, replace with a new breather element.

1. Raise the hood and remove the right rear sidepanel See Figure 34.


CAUTIONDirect air pressure on the filter element cancause damage. Direct air pressure away fromfilter element.

2. Using compressed air, remove any dirt and de-bris in the frame cavity around the breather. SeeFigure 34.

3. If necessary, unscrew and replace the breatherif oil has accumulated in the cavity or on the

44


breather, or if dirt has accumulated at thebreather passages at the bottom of the breather

4. Install right rear side panel and close hood. SeeFigure 34.

1. HOOD/SEAT ASSEMBLY2. SIDE PANEL3. HYDRAULIC TANK BREATHER

Figure 34. Hydraulic Tank Breather

BATTERY

WARNINGThe acid in the electrolyte can cause injury.If the electrolyte is spilled, use water to flushthe area. Use a solution of sodium bicarbon-ate (soda) to make the acid neutral. Acid in theeyes must be flushed with water immediately.Wear eye protection.

WARNINGBatteries generate explosive fumes. Keep thevents in the caps clean. Keep sparks or openflame away from the battery area. DO NOTmake sparks from the battery connections.Disconnect the battery ground cable whendoing maintenance.

Disconnect the negative and positive terminals of thebattery. Using a damp cloth clean the case of the bat-tery. If the terminals are corroded, clean the termi-nals with a wire brush. Connect the negative andpositive cables to their respective terminals.

CUMMINS 4.5L AND QSB 3.3L ENGINEOIL AND OIL FILTER

NOTE: Change the oil and oil filter for the engine atthe first 100 hours of operation on new lift trucks.

Change engine oil and engine oil filter. See Fig-ure 35. Use the correct oil according to the Main-tenance Schedule. Apply clean oil to gasket of newfilter. Install new filter. Turn filter until gaskettouches, then tighten 1/2 to 3/4 turn with your hand.Start engine. Check area around oil filter for leaks.

NOTE: BOTTOM LEFT HAND SIDE.

1. OIL FILTER 2. DRAIN PLUG

Figure 35. Engine Oil Change Cummins 4.5LDiesel (Shown)

45


FUEL/WATER SEPARATOR FILTERREPLACEMENT, CUMMINS 4.5L AND QSB3.3L ENGINE


Replace the fuel filter at specified intervals to pre-vent contaminants from adversely affecting thediesel fuel flow.

Remove

1. Stop engine and allow it to cool.

2. Disconnect air inlet elbow to access the fuel filterelement. See Figure 36.

3. Disconnect fuel filter sensor connector from thefuel filter element.

CAUTIONDrain the water/fuel into a container and dis-pose in accordance with local environmentalregulations.

4. Open the drain valve by turning the valve coun-terclockwise approximately 3 1/2 turns untildraining occurs. Drain until fuel filter elementis empty.

5. Remove and discard fuel filter element.

Install

1. Clean the fuel filter head mounting surface andapply a small amount of diesel fuel to the gasketon the new fuel filter element. See Figure 36 andFigure 37.

2. Before installing the filter element, fill the filterelement with diesel fuel. This method will aid inbleeding the fuel system.

CAUTIONDO NOT overtighten the filter element. Over-tightening the filter element may distort thethreads.

3. Install the new fuel filter element until it con-tacts the fuel filter head mounting surface.Tighten one additional turn.

4. Connect the fuel sensor connector to fuel filterelement

5. Connect air inlet elbow hose.

6. Open the fuel supply valve.

7. Prime the fuel system. See Priming the Fuel Sys-tem (Cummins 4.5L and QSB 3.3L Engine).

8. Check for fuel leaks.


A. RIGHT SIDE VIEW B. FRONT VIEW

1. FUEL FILTER ELEMENT2. DRAIN VALVE3. LIFT PUMP4. FUEL PUMP5. IN-LINE FUEL FILTER

6. FUEL SUPPLY VALVE7. FUEL SENDING UNIT8. FUEL FILTER SENSOR CONNECTOR9. AIR INLET ELBOW10. FUEL LINE INJECTOR FITTINGS (4)

46


Figure 36. Cummins 4.5L Engine Fuel System

47


Figure 37. Cummins QSB 3.3L Engine FuelSystem


A. RIGHT VIEWB. TOP VIEW

1. TURBO2. HEAD3. BELL HOUSING4. FLYWHEEL5. OIL PAN6. ENGINE BLOCK7. ELECTRONIC FUEL PUMP8. FUEL FILTER9. WATER OUTLET HOUSING10. WATER PUMP BELT11. WATER INLET HOUSING12. OIL FILL CAP13. WATERGATE14. AIR INLET HOUSING15. OIL DIPSTICK16. EXHAUST MANIFOLD17. EXHAUST OUTLET18. ENGINE ECM19. STARTER20. FUEL/WATER SEPARATOR21. PRIMER PUMP22. INTAKE MANIFOLD23. AIR INLET24. INJECTOR LINE

FINAL FUEL FILTER REPLACEMENT(CUMMINS QSB 3.3L ENGINE)



1. Close any OEM fuel valves (if applicable) to pre-vent fuel from draining.

2. Clean the area around the fuel filter head.

CAUTIONDrain the fuel into a container and dispose inaccordance with local environmental regula-tions.

3. Remove the fuel filter.

4. Clean the gasket surface.

48


CAUTIONDO NOT pour fuel directly into the center ofthe filter, since this will allow unfiltered fuelto enter the system and may cause damage tofuel system components.

5. Pre-fill new filters, both pressure side and suc-tion side, with clean fuel prior to assembly. Usethe clean side block off plug packed with the fil-ter.

6. Lubricate the gasket with clean engine oil.

7. Install fuel filter. Tighten filter until gasket con-tacts filter head surface. Tighten filter an addi-tional 3/4 turn after contact.

8. Start engine and check for leaks around the fuelfilter.

PRIMING THE FUEL SYSTEM (CUMMINS4.5L AND QSB 3.3L ENGINE)

Controlled Venting

CAUTIONWhen using the starting motor to vent the sys-tem, DO NOT engage it for more than 30 sec-onds, or starter motor damage will occur. Wait2 minutes before engaging the starter again.

Controlled venting is provided at the injection pumpthrough the fuel drain manifold. Small amounts ofair introduced by changing the filters or injectionpump supply line will be vented automatically ifthe fuel filter element is changed and filled prior toinstallation.

Manual Bleeding

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

• The fuel injection pump is replaced.• The high pressure fuel line connections are loos-

ened, 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 (CumminsQSB 3.3L), with the accelerator pedal or lever in theidle position, turn the key to the ON position. Waitfor the "Wait to Start" light to go out. Start the truck.

If the engine does not start after 3 attempts, checkfuel supply system. The lack of blue or white smokeindicates the lack of fuel being supplied to the engine.

1. Crack open the fuel line to the injector pump. SeeFigure 36.

2. Operate the hand lever until fuel is expelled fromthe loosened fitting.

3. Tighten the fuel line to the injector pump to9 N•m (80 lbf in). See Figure 36.

4. Crack open one of more of the injector lines lo-cated on the cylinder head.

WARNINGThe pressure spray released by the fuel injec-tors can penetrate the skin and cause seriouspersonal injury. Wear clothes and protectiveclothing.

5. Crank the engine until fuel is expelled from theloosen fittings. Tighten the injector line fittingswhile cranking. The engine should fire.


6. Wipe up any fuel that may have spilled and dis-pose of the fuel and rags in accordance with localdirectives.

49


DRIVE BELT

Cummins 4.5L and QSB 3.3L DieselEngine

Fan and Alternator Drive Belt

Check drive belt for wear and damage. See Figure 38.A few small cracks that run across belt are accept-able. A belt with cracks that run length of belt or abelt with missing pieces is not acceptable. See Fig-ure 39 and Figure 40 for the drive belt arrangement.

1. ACCEPTABLE CRACKS2. NOT ACCEPTABLE CRACKS AND DAMAGE

Figure 38. Drive Belt Inspection

Figure 39. Cummins 4.5L Diesel Engine DriveBelt Arrangement


NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD-JUSTING TENSIONERS.

1. ALTERNATOR PULLEY2. CAMSHAFT PULLEY3. WATER PUMP PULLEY4. CRANKSHAFT PULLEY5. TENSIONER CENTERING PULLEY

1. ALTERNATOR BELT ADJUSTMENT BRACKET2. DRIVE BELT3. CAMSHAFT PULLEY4. CRANKSHAFT PULLEY5. ALTERNATOR PULLEY

Figure 40. Cummins QSB 3.3L Diesel EngineDrive Belt Arrangement

50


CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and removematerial causing radiator core to be plugged or re-stricted.


Clean with compressed air, adjusted to a maximumoutput of 103 kPa (15 psi), and blow debris from coreand fan shroud.

TRANSMISSION OIL LEVEL

WARNINGAt operating temperature, the transmission oilis HOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the transmissionwhen the oil level is checked or the filter ischanged.

NOTE: Transmission oil temperature should be atleast 50°C (120°F) when checking oil level.

If engine has been running, the engine must be shutdown for one minute or longer prior to checking theoil level. See Figure 41 or Figure 42. If the trans-mission oil is low, add oil to transmission at the dip-stick tube at the correct level as indicated on the dip-stick. Use the correct oil as shown in the Mainte-nance Schedule.

NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

Figure 41. Transmission and Hydraulic Oil Check

51


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 LEVELCHECK

WARNINGAt operating temperature, the center sectionoil is HOT. DO NOT permit the hot oil to touchthe skin and cause a burn.

CAUTIONDO NOT permit dirt to enter the center bodywhen the oil level is checked. Dirt will contam-inate the oil and cause damage to the centerbody of the axle.

1. Remove the center body fill/level plug. See Fig-ure 43 for lift truck models S80, 100, 120FT;S80, 100, 120FTBCS; S120FTPRS (G004) andFigure 44 for lift truck models H80, 90, 100, 110,120FT (N005, P005).

2. Visually check oil level. If necessary, add oil atthe fill/level port until the oil/fill level port hasoverflowed. The Correct oil is shown in the Main-tenance Schedule.

3. Install center body oil/level fill level plug andtighten to 30 to 50 N•m (22 to 37 lbf ft).

52


A. REAR VIEW SHOWNB. FRONT VIEW SHOWN

1. PLANETARY CARRIER HOUSING FILL/LEVELPLUGS

2. PLANETARY CARRIER HOUSING DRAINPLUGS

3. CENTER SECTION DRAIN PLUG4. CENTER SECTION FILL/LEVEL PLUG5. PLANETARY CARRIER HOUSING (RH)6. PLANETARY CARRIER HOUSING (LH)7. CENTER SECTION

Figure 43. Wet Brake Drive Axle Drain andFill/Level Plug Location for Lift Truck Models

S80, 100, 120FT; S80, 100FTBCS; S120FTS;S120FTPRS (G004)




3. CENTER SECTION FILL/LEVEL PLUG4. CENTER SECTION DRAIN PLUG5. PLANETARY CARRIER HOUSING (RH)6. PLANETARY CARRIER HOUSING (LH)7. CENTER SECTION


H80, 90, 100, 110, 120FT (N005, P005)

53


FORKS

WARNINGNever repair damaged forks. DO NOT heat,weld, or bend the forks. Forks are made of spe-cial steel using special methods. Replace dam-aged forks as a complete set.

Measure thickness of forks with a fork arm caliper(Hyster Part No. 3020387) at a vertical section wherethere is no wear. This thickness is dimension X. Nowmeasure thickness at heel of fork (see Figure 20). Ifthe thickness of the heel is not greater than 90% ofdimension X, replace fork.

MAST LUBRICATION

WARNINGWhen working on or near the mast, see SafetyProcedures When Working Near Mast in thissection.

NOTE: The load rollers and sheaves have sealed bear-ings and do not need additional lubrication.

1. Lubricate sliding surfaces and load roller sur-faces along full length of channels as shown inFigure 45.

A. UPPER LOAD ROLLERSB. LOWER LOAD ROLLERS

1. LUBRICATE STRIP BEARING SURFACES2. LUBRICATE LOAD ROLLER SURFACES3. LOAD ROLLER

Figure 45. Mast Lubrication

NOTE: When lubricating the mast mounting/pivotpins, the load must be removed from the normal

contact surface to allow grease to properly lubricatethe normal contact surfaces of the mast bushings

2. Raise the carriage about 61 cm (2 ft), and tilt themast fully back. Place blocks under the outermast channels to within 13 mm (0.5 in.) of thechannels See Figure 46.

3. Tilt the mast fully forward. See Figure 46.

4. Lubricate the mast pivot bushings at grease fit-tings on outer mast. See Figure 47 and Figure 48.Use multipurpose grease shown in the Mainte-nance Schedule.

A. MAST TILTED FULLY BACKB. MAST TILTED FORWARD

1. BLOCK 2. MAST

Figure 46. Blocking the Mast

54


1. MAST HANGER BUSHINGS2. LUBE FITTINGS3. MAST BUSHING PLUGS4. TILT PIN5. ROD END6. ANCHOR PIN

7. CAPSCREW8. NUT9. WASHER10. ROD END BUSHING11. TILT CYLINDER ASSEMBLY12. MAST MOUNTING CAP

Figure 47. Mast Mounting Hanger Lubrication

5. Tilt mast fully back. Remove the blocks from un-der the channels

6. If a sideshift carriage is installed, lubricate slid-ing surfaces at grease fittings with multipurpose

grease shown in the Maintenance Schedule. SeeFigure 49.

55


1. OUTER MAST 2. MAST PIVOT BUSHING 3. LUBRICATION FITTING

Figure 48. Pivot Pin Lubrication



1. CAPSCREWS2. LOWER HOOK3. APRON4. LOWER BEARING

STRIPS5. UPPER BEARING

STRIPS

6. GREASE FITTINGS7. CYLINDER ROD8. SNAP RING9. ROD SCRAPER10. ROD BUSHING11. SEAL12. FIXED FRAME

HEADER HOSE CHECKS

Daily inspection plus; kinked, crushed, flattened ortwisted hose; hard, stiff or charred hose; hose fittingslippage; proper hose tensioning. Adjust/repair/re-place hose/components as necessary. See Mast Re-pairs, 2- and 3-Stage Masts 4000 SRM 1250 forquick disconnect procedures.

56


LIFT CHAIN LUBRICATION


DO NOT repair worn or damaged lift chains. Ifa lift chain is worn or damaged, both lift chainsmust be replaced.

NOTE: The 500 Hour/6 Months Lift Chain Lubrica-tion should not be performed in combination with the1000 Hour/6 Months Lift Chain Lubrication.

Lubricate lift chains with SAE 30 engine oil. The bestprocedure is to remove the chains from the lift truckand soak them in engine oil. Be sure to clean any dirtor grease from chains before lubricating. DO NOTUSE STEAM TO CLEAN THE LIFT CHAINS.

TILT CYLINDER LUBRICATION

NOTE: The floor plate must be removed in order tolubricate the rear tilt cylinder lubrication fittings.

Lubricate the tilt cylinder ends. Use multipurposegrease shown in the Maintenance Schedule. Thereare four lubrication fittings. See Figure 50.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW2. RETAINER

3. ANCHOR PIN4. LUBRICATION FITTING

5. TILT SPACER

Figure 50. Tilt Cylinder Lubrication

57


MASTER BRAKE CYLINDER ROD ENDPIN LUBRICATION

Lubricate the master brake cylinder rod end pin. Useengine oil shown in the Maintenance Schedule. SeeFigure 51.

1. ROD END PIN2. COTTER PIN (LOCKING)

Figure 51. Master Brake Cylinder Rod End PinLubrication

MANUAL HYDRAULIC LEVERSLUBRICATION

Lubricate the bushings for the manual hydrauliclevers. Use spray lubricant as listed in the Mainte-nance Schedule. See Figure 52.

NOTE: FOUR FUNCTION LEVERS WITH DETENTSHOWN.

1. BUSHINGS2. ROD END PIN3. HYDRAULIC LEVERS4. LOCKING RING (COTTER PIN)

Figure 52. Manual Hydraulic LeversLubrication

58


BRAKE OIL


Replace the brake oil in the system if there isdirt or water in the system.

CAUTIONDO NOT use "DOT" fluid, only use Dexron IIIoil from sealed container to prevent possibledamage to the brake system.

Remove the dash board from the cowl. The brake oilreservoir is located on the cowl, at the master cylin-der. See Figure 53. Add brake oil, as necessary. Usethe brake fluid shown in the Maintenance Schedule.

Figure 53. Brake Oil Reservoir


1. RESERVOIR CAP2. BRAKE OIL RESERVOIR3. RESERVOIR MOUNTING BRACKET4. COWL5. UPPER BRAKE OIL SUPPLY HOSE6. CYLINDRICAL BLOCK OUTLET FITTING7. LOWER BRAKE OIL SUPPLY HOSE8. NIPPLE9. MASTER CYLINDER10. CYLINDRICAL BLOCK DRAIN PLUG11. CYLINDRICAL BLOCK12. CYLINDRICAL BLOCK MOUNTING BRACKET

CAPSCREW

TIE ROD LUBRICATION FOR LIFT TRUCKMODELS S80, 100, 120FT; S80, 100FTBCS;S120FTS; S120FTPRS (G004)

Lubricate the tie rods. Use multipurpose greaseshown in the Maintenance Schedule. There is onelubrication fittings on each tie rod. See Figure 54.

1. STEERING AXLE2. LUBRICATION FITTING (TIE ROD)3. LUBRICATION FITTING (SPINDLE)

Figure 54. Tie Rod Lubrication for Lift TruckModels S80, 100, 120FT; S80, 100FTBCS;

S120FTS; S120FTPRS (G004)

59


TIE ROD LUBRICATION FOR LIFT TRUCKMODELS H80, 90, 100, 110, 120FT (N005,P005)

Lubricate the tie rods. Use multipurpose greaseshown in the Maintenance Schedule. There is onelubrication fittings on each tie rod. See Figure 55.

1. LUBRICATION FITTING (TIE ROD)2. LUBRICATION FITTING (SPINDLE)3. STEERING AXLE

Figure 55. Tie Rod Lubrication for Lift TruckModels 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 sup-ply. The oil level must be between 0 to 10 mm (0 to0.40 in.) below the bottom edge of fill hole. The fillhole for checking the oil level is on the front of thedifferential housing. Remove fill plug and check fluidlevel by sticking a finger into the fill hole to feel if thefluid level is at the bottom edge of the fill hole. SeeFigure 56 and Figure 57. If oil is low, add oil shownin the Maintenance Schedule until the oil level is be-tween 0 to 10 mm (0 to 0.40 in.) below the bottomedge of fill hole. Install fill plug and check for leaks.

1. DRIVE AXLE2. CHECK/FILL PLUG3. DRAIN PLUG

Figure 56. Drive Axle (Dry Brake) Fluid Fillfor Lift Truck Models S80, 100, 120FT; S80,

100FTBCS; S120FTS; S120FTPRS (G004)

1. CHECK/FILL PLUG2. DRAIN PLUG3. DRIVE AXLE

Figure 57. Drive Axle (Dry Brake) Fluid Fillfor Lift Truck Models H80, 90, 100, 110, 120FT

(N005, P005)

60


Maintenance Procedures Every 1000 Hours or 6 MonthsNOTE: Perform the 8-hour, 250-hour, and 500-hourchecks prior to performing the procedures in this sec-tion.

VALVE CLEARANCE, CHECK ANDADJUST

The GM 4.3L engine has hydraulic valve lifters anddoes not require valve clearance adjustments duringnormal service.

See the Maintenance Schedule for valve clearances.

Additional engine information is available in the fol-lowing 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 elec-tronic control unit (ECU) that controls the ignitiontiming. There are no adjustments. Change the sparkplugs every 1000 hours. The correct spark plug gapis 1.5 mm (0.059 in.).

LPG FUEL FILTER ELEMENT REPLACE,GM 4.3L ENGINE

Remove

WARNINGLPG can cause an explosion. DO NOT permitany sparks or open flames in the work area.

1. Close fuel valve on tank. Run engine until itstops.

2. Disconnect negative battery cable.

WARNINGA small amount of fuel may still be present inthe fuel line. Use gloves to prevent burns andwear eye protection. If liquid fuel continuesto flow from the connections when loosened,check to make sure the manual valve is fullyclosed.

3. Remove the bolt and seal washer retaining thetop section of the fuel filter housing. Discard sealwasher. See Figure 58.

1. BOLT2. SEAL WASHER3. FUEL FILTER HOUSING TOP SECTION4. FUEL FILTER5. FUEL FILTER O-RING6. HOUSING O-RING7. 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 con-tamination 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.

5. Install bolt and new seal washer. Tighten bolt to13 N•m (115 lbf in).

61


NOTE: Opening the fuel valve too quickly can causethe internal excessive flow valve to close, restrictingthe flow of fuel. If this happens, close the fuel valve,wait a few seconds, and then slowly open the fuelvalve 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 tothe OFF position to pressurize the fuel system.Check for leaks.

8. Check for leaks at connections by using soapysolution or electronic leak detector. If leaks aredetected, make proper repairs.

IN-LINE FILTER REPLACEMENT,CUMMINS 4.5L ENGINE



Remove

1. Stop Engine and allow it to cool.

2. Close fuel supply valve located on the fuel send-ing unit. See Figure 59.

CAUTIONDrain the fuel into a container and dispose inaccordance with local environmental regula-tions.

3. Loosen clamps and disconnect two fuel lines fromthe inline fuel filter. Remove and discard the in-line fuel filter

Install

1. Install inline fuel filter by connecting the two fuellines and tighten clamps. See Figure 59.

2. Open the fuel supply valve.

3. Check for fuel leaks.


A. RIGHT SIDE VIEW B. FRONT VIEW

1. FUEL FILTER ELEMENT2. DRAIN VALVE3. LIFT PUMP4. FUEL PUMP5. INLINE FUEL FILTER

6. FUEL SUPPLY VALVE7. FUEL SENDING UNIT8. FUEL FILTER SENSOR CONNECTOR9. AIR INLET ELBOW10. FUEL LINE INJECTOR FITTINGS (4)

62


Figure 59. Cummins 4.5L Engine Fuel System

63


LIFT CHAINS WEAR CHECK

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

Pitch Total Lengthof 20 Links

(Pitch) of NewChain

Wear Limit(The

MaximumLength of 20

Links)

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

LIFT CHAIN LUBRICATION

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When using

cleaning solvents, always follow the recom-mendations of the manufacturer.

Compressed air can move particles so theycause injury to the user or to other personnel.Make sure that the path of the compressed airis away from all personnel. Wear protectivegoggles or a face shield to prevent injury tothe eyes.

Remove the lift chains. Clean the lift chains by soak-ing them in a solvent that has a petroleum base forat least 30 minutes. Use compressed air, adjusted toa maximum output of 103 kPa (15 psi), to completelydry the chains when they are clean.

Lubricate the lift chains by soaking them in 30W en-gine oil for at least 30 minutes. Remove the chainsfrom the oil. Hang the chains for one hour so excessoil will drain from the chains.

INTEGRAL SIDESHIFT CARRIAGE, CHECKSLIDING SURFACES

1. Check the sideshift carriage sliding surfaces,and if necessary lubricate sliding surface at thegrease fittings with multipurpose grease shownin the Maintenance Schedule. See Figure 61.

1. CAPSCREWS2. LOWER HOOK3. APRON4. LOWER BEARING

STRIPS5. UPPER BEARING

STRIPS

6. GREASE FITTINGS7. CYLINDER ROD8. SNAP RING9. ROD SCRAPER10. ROD BUSHING11. SEAL12. FIXED FRAME


64


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 ofthe steering axle. See Figure 62. Use multipurposegrease as shown in the Maintenance Schedule.

1. STEERING AXLE2. LUBRICATION FITTING (TIE ROD)3. LUBRICATION FITTING (SPINDLE BEARINGS)

Figure 62. Lubricate Spindle Bearings for LiftTruck Models S80, 100, 120FT; S80, 100FTBCS;

S120FTS; S120FTPRS (G004)

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 ofthe steering axle. See Figure 63. Use multipurposegrease as shown in the Maintenance Schedule.

1. LUBRICATION FITTING (TIE ROD)2. LUBRICATION FITTING (SPINDLE BEARINGS)3. STEERING AXLE

Figure 63. Lubricate Spindle Bearings for LiftTruck Models H80, 90, 100, 110, 120FT (N005,

P005)

65

Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

CONTROL LEVERS AND PEDALS

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

INSPECT ENGINE ELECTRICAL SYSTEM,CONNECTORS

When inspecting the electrical system, check the fol-lowing:

• Check and clean battery connection. Ensure thatconnections 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 bothends.

• Check engine wire harness for rubbing, chaffing,pinching, and cracks or breaks in the wiring.

• Check engine harness connectors. Check to ensureconnectors are fitted and locked by pushing theconnectors together. Pull on the connector halvesto make sure they are locked.

• Check ignition coil wire and spark plug wires forhardening, cracking, arching, chaffing, separation,split boot covers, and proper fit. Replace sparkplugs at the recommended interval as shown in theMaintenance Schedule.

• Check that all electrical components are securelymounted and retained to the engine or chassis.

• Check the MIL, charging, and oil pressure lightsfor operation by starting the engine and checkingthat the light illuminates before turning out.

Maintenance Procedures Every 2000 Hours or AnnuallyNOTE: Perform the 8-hour, 250-hour, 500-hour, and1000-hour checks prior to performing the proceduresin this section.

HYDRAULIC SYSTEM

Hydraulic Filter, Replace


CAUTIONDO NOT permit dirt to enter the hydraulic sys-tem when the oil level is checked or the filteris changed. Dirt can cause damage to the com-ponents of the hydraulic system.



1. Put lift truck on a level surface and lower thecarriage. Unscrew and remove filter lid, gasket,

and spring from head. See Figure 64. Lift thehydraulic filter element enough to allow the hy-draulic oil to drain.

NOTE: Have container large enough to hold the filterelement and allow for final hydraulic oil draining.

2. Remove the hydraulic filter element and O-ringfrom the bowl and place into the container. Coverthe head to prevent any foreign materials fromgetting into the hydraulic tank.

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.

4. Inspect gasket for damage. If damaged, replace.

5. Lubricate gasket with hydraulic oil and seat iton filter lid and install spring and lid onto head.Tighten lid to 15 N•m (132.8 lbf in).


6. Start the truck, and allow it to run for 30 seconds.Check for leaks. Stop engine and check hydraulicoil level. Add oil, if necessary. Use hydraulic oilshown in the Maintenance Schedule. To changethe hydraulic oil, see Hydraulic Oil, Replace.

66

8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

1. LID2. SPRING3. O-RING4. CAPSCREW5. HEAD

6. FITTING7. QUAD RING8. FILTER ELEMENT9. BOWL

Figure 64. Hydraulic Filter

Hydraulic Tank Breather, Replace

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

2. Unscrew and remove old hydraulic tankbreather, and replace with new hydraulic tankbreather.

3. Install right rear side panel and close hood. SeeFigure 65.

1. HOOD/SEAT ASSEMBLY2. SIDE PANEL3. 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 andthe negative battery cable has been removed from thebattery before removing the ignition system.

Remove and discard spark plug wire assembly, coilwire, spark plugs, distributor cap, and rotor. Forprocedures see High Voltage Switch (HVS) Igni-tion, GM 4.3L EPA Compliant Engines and GM5.7L LPG EPA Compliant Engine 2200 SRM 1097for Spark Plug Wire Removal/Installation, Distribu-tor Cap Removal/Installation, and Rotor Disassem-ble, Ignition Coil Wire Removal, and Spark Plug Re-placement.

67


COOLING SYSTEM, GM 4.3L ANDCUMMINS 4.5L AND QSB 3.3L ENGINES

1. Put lift truck on a level surface. Stop engine.Place a container with a minimum capacity of15.1 liter (15.9 qt) under the radiator drain valvewhich could be located on either the lower left orright side of the radiator on the engine side of theradiator.

WARNINGDO NOT remove the radiator cap from the ra-diator when the engine is hot. When the radi-ator cap is removed, the pressure is releasedfrom the system. If the system is hot, the steamand boiling coolant can cause burns. DO NOTremove the cover for the radiator when the en-gine is running.


2. Open drain valve and remove radiator cap. Draincoolant into the container. Flush cooling sys-tem. Check hoses for damage. Replace with newhoses, as needed.

3. Disconnect the hose leading from the auxiliaryreservoir to fitting at the top of the radiator un-der the radiator cap, and drain the reservoir intothe same container used for the radiator coolant.Check the reservoir for contaminants and flush,as necessary. Connect the hose back on the fit-ting at the top of the radiator.

CAUTIONAdditives may damage the cooling system. Be-fore using additives, contact your local Hysterdealer.

4. Close drain valve. Fill cooling system with asolution of ethylene glycol boron-free antifreeze.See Maintenance Schedule for correct solution.Fill the auxiliary reservoir to a level between theADD and FULL marks on the reservoir.

5. Install radiator cap. Start engine. Check forleaks. Add coolant to auxiliary coolant reservoiras needed. Coolant level should be between theADD and FULL marks on the reservoir.

AIR FILTER

The air filter canister should not be opened until anair filter element replacement is required. An airfilter element replacement is required when one ofthe 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

CAUTIONDO NOT to allow dirt to enter the engine airintake when replacing the air filter element. Asmall amount of dirt could cause engine dam-age.

1. Shut off the engine. Never open the air filter can-ister or remove the filter element with the enginerunning.

2. Unlatch and remove the cover. To remove filterelement, press and rotate filter element counter-clockwise about 1/8 turn until the filter elementis free. To assist removal, gently move the endback and forth to help break the seal. See Fig-ure 66.

68


1. CANISTER2. DUST EVACUATION VALVE3. LINER ASSEMBLY

4. FILTER ELEMENT5. COVER

Figure 66. Air Filter

3. Gently pull the filter element from the canister.Avoid dislodging contaminants from the elementor knocking it against the canister.

4. With a clean, soft rag, clean the inside surface ofthe canister. Remove the liner assembly to makecleaning easier. Clean well around the lockingtabs that retain the element. Clean tabs makenew filter element installation easier. Be carefulnot to knock any contaminants into the outlettube to the engine.

5. Inspect the liner and O-ring assembly for dam-age. If damaged, replace the liner and O-ring as-sembly.

6. Install the liner assembly into the canister bypushing in. Make sure the liner assembly isproperly seated in the canister. It will fit snuglyinto and be centered in the canister.

If your air filter assembly is equipped with a sec-ondary element in place of the liner assembly, re-place the secondary element with every 2 to 3 pri-mary element replacements.

7. Inspect the new filter element for voids, cuts,tears or indentations in the urethane-sealingsurfaces. Do not use if damage is detected.

CAUTIONThe element must be properly installed to en-sure adequate engine protection. An improp-erly installed element may allow dirt and dustto enter and damage the engine.

NOTE: Proper element installation is required to al-low the cover to be installed correctly. Never reinstalla 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 clock-wise until fully engaged in the canister. See Fig-ure 67.

1. PUSH IN 2. TWIST TO LOCK

Figure 67. Air Filter Label

69


CAUTIONDuring cover installation, DO NOT force thecover on the canister. To do so will result indamage to the filter element, cover, and possi-bly the canister.

NOTE: If the filter element is properly installed, thecover will fit easily into the canister with no gap be-tween the cover and the canister. If the cover does notfit easily, the filter element is not installed properly.Do not use a cover that is bent, damaged, or missinglatches.

9. Install the cover into the canister and ensure theINLET arrow is in line with the canister inlet.

NOTE: Do not use the latches to pull the cover downagainst the canister. If the cover does not fit com-pletely against the canister with no gaps, the elementis not installed correctly.

10. Fasten the latches to secure the cover to the can-ister. Make sure the latches penetrate the slotsin both the canister and the cover.

11. Inspect the entire air intake system for leaks.Inspect all clamps for tightness and tighten ifnecessary. Inspect all hoses for damage. Re-place damaged hoses. Inspect the dust evacua-tion valve for damage. If damaged, replace thedust evacuation valve.

OXYGEN SENSOR GM 4.3L LPG ENGINESEQUIPPED WITH GFI INSTALLED

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

1. OXYGEN SENSOR2. ELECTRICAL CONNECTOR3. EXHAUST PIPES TO EXHAUST MANIFOLD

Figure 68. Oxygen Sensor Location for LiftTruck Models H80, 90, 100, 110, 120FT) (N005,

P005) and S80, 100, 120FT; S80, 100FTBCS;S120FTS; S120FTPRS (G004)

1. OXYGEN SENSOR (POST-CATALYTIC)2. MUFFLER3. OXYGEN SENSOR (PRE-CATALYTIC)

Figure 69. Oxygen Sensor (BCS Only) for LiftTruck Models S80, 100FTBCS (G004)

70


LPG REGULATOR FUEL FILTER, GM4.3L ENGINES EQUIPPED WITH GFIINSTALLED

Remove

1. Close shutoff valve on tank. Run engine until itstops.

2. Disconnect the hose from the inlet fitting.

3. Remove the inlet fitting from the LPG regulator.Discard the O-ring. See Figure 70.

1. LPG REGULATOR2. INLET FITTING3. O-RING4. PLASTIC CAP5. FOAM FILTER

6. PAPER FILTER7. RUBBER WASHER8. SCREWS9. OUTLET FITTING10. SCREEN

Figure 70. GM LPG Regulator

4. Remove and discard the plastic cap, foam filter,paper filter, and rubber washer from the LPGregulator.

5. Disconnect the hose from the outlet fitting. Re-move three screws and the outlet fitting from theLPG regulator. Discard the O-ring.

6. Remove and discard the screen from the LPG reg-ulator.

Install

1. Install a new screen in the LPG regulator.

2. Install a new O-ring on the outlet fitting. Usingthree screws, install the outlet fitting on the LPGregulator.

3. Install new rubber washer, paper filter, foam fil-ter, and plastic cap in the LPG regulator.

4. Install new O-ring on the inlet fitting. Installinlet fitting into the LPG regulator and connecthose to the inlet fitting.

5. Open shutoff valve on LPG tank and check forleaks.

GASOLINE FUEL FILTER

Remove and Replace

1. Raise the hood and disconnect the negative ter-minal of the battery.

2. Remove and discard the fuel filter. See Figure 71.

3. Install the new fuel filter and tighten the clampscrews to 2.45 to 2.77 N•m (22 to 25 lbf in).

4. Connect the negative terminal of the battery andclose the hood.

Figure 71. Fuel Filter Replacement (GM 4.3L)

71



1. FUEL FILTER2. FUEL PUMP/SENDER UNIT

LPG FUEL INJECTOR, GM 4.3L ENGINESEQUIPPED WITH GFI INSTALLED

For removal and cleaning instructions, see the sec-tion LPG Fuel System, GM 4.3L Engine with GFI900 SRM 1242.

GASOLINE FUEL INJECTOR, GM ENGINES

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

FUEL INJECTOR, CUMMINS 4.5L ANDQSB 3.3L ENGINE

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

FORKS

WARNINGNever repair damaged forks. DO NOT heat,weld, cut, drill, or bend the forks. Forks aremade of special steel using special methods.Replace damaged forks as a set.

Check heel and attachment points of forks with apenetrant or by magnetic particle inspection.

TRANSMISSION OIL AND FILTER (DRYBRAKE), REPLACE

WARNINGAt operating temperature, the transmission oilis HOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the transmissionwhen the oil level is checked or the filter ischanged. Dirt can cause damage to the trans-mission components.


NOTE: Change the transmission oil filter at the first500 hours of operation on new lift trucks. Before re-moving the oil filter, make a hole at the top of thefilter and allow five minutes for the oil to drain downinto the transmission. This will reduce the oil thatwill run out of the filter and onto the transmissionwhen the filter is removed.

NOTE: The drain plug for the transmission is on thelower right side of the cover of the transmission, to-ward the rear of the lift truck.

1. Remove drain plug, spring, and screen. See Fig-ure 72. Drain oil into a container.

NOTE: ALL MAJOR COMPONENTS AND FRAMECOMPONENTS REMOVED FOR THE SAKE OFCLARITY.

1. TRANSMISSION2. TRANSMISSION DRAIN PLUG3. SPRING4. SCREEN5. TRANSMISSION OIL FILTER6. TRANSMISSION DIPSTICK7. TRANSMISSION BREATHER

Figure 72. Transmission Oil Change

72


WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the solventmanufacturer’s recommended safety proce-dures.

Compressed air can move particles so theycause injury to the user or to other personnel.Make sure the path of the compressed air isaway from all personnel. Wear protective gog-gles or a face shield to prevent injury to theeyes.

2. Clean screen with cleaning solvent, and dry withcompressed air, adjusted to a maximum outputof 103 kPa (15 psi).

3. When oil has drained, first install screen, thenspring, and drain plug.

4. Remove and discard transmission breather.Install new transmission breather and handtighten.

5. Remove and discard old oil filter. Apply clean oilto gasket of new filter. Install new filter and handtighten.

6. Add oil to transmission at the dipstick tube. Thecorrect oil is shown in the Maintenance Schedule.


7. Start and run the engine for approximately 5minutes after fill to allow oil to lubricate partswithin the transmission and wet brake portionof the drive axle center section. With the truckin the ON position, See Maintenance Scheduleto add additional oil at the transmission dipsticktube that will need to be added to properly fill thewet brake portion of the drive axle center sectionand transmission.


8. Turn the key to the OFF position and check forleaks and check oil level. If necessary, top off oil.

TRANSMISSION AND WET BRAKEPLANETARY CARRIER HOUSING OILCHANGE

WARNINGThe oil used for the wet brake drive axle ortransmission should not be contaminated. If ei-ther the wet brake planetary carrier housingsand/or transmission oil becomes contaminated,the oil must be drained and replaced with newoil.

WARNINGAt operating temperature, the transmissionand wet brake planetary carrier housing oil isHOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the transmissionor wet brake planetary carrier housing whenthe oil level is checked or the filter is changed.Dirt will contaminate the oil and cause dam-age to the transmission and wet brake plane-tary carrier housing components.


NOTE: Change the transmission oil filter at the first500 hours of operation on new lift trucks. See Fig-ure 73. Before removing the oil filter, make a holeat the top of the filter and allow five minutes for theoil to drain down into the transmission. This will re-duce the oil that will run out of the filter and onto thetransmission when the filter is removed.

1. The drain plug for the transmission is on thelower right side of the cover of the transmission,toward the rear of the lift truck. Remove drainplug, spring, and screen. See Figure 73. Drain oilinto a container, once oil is completely drained,reinstall drain plug.

73


NOTE: ALL MAJOR COMPONENTS AND FRAMECOMPONENTS REMOVED FOR CLARITY.

1. TRANSMISSION2. TRANSMISSION DRAIN PLUG3. SPRING4. SCREEN5. TRANSMISSION OIL FILTER6. TRANSMISSION DIPSTICK7. TRANSMISSION BREATHER

Figure 73. Transmission Oil Change

2. Remove planetary carrier housing drain plug andfill/level plug. Drain oil into a suitable container.When oil is completely drained, reinstall drainplug and fill/level plug. Tighten to 30 to 50 N•m(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.

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the solventmanufacturer’s recommended safety proce-dures.

Compressed air can move particles so theycause injury to the user or to other personnel.

Make sure the path of the compressed air isaway from all personnel. Wear protective gog-gles or a face shield to prevent injury to theeyes.

3. Clean screen with cleaning solvent, and dry withcompressed air, adjusted to a maximum outputof 103 kPa (15 psi).

4. When oil has drained, first install screen, thenspring, and drain plug.




3. CENTER BODY DRAIN PLUG4. CENTER BODY FILL/LEVEL PLUG5. PLANETARY CARRIER HOUSING (RH)6. PLANETARY CARRIER HOUSING (LH)7. CENTER BODY


S80, 100, 120FT; S80, 100FTBCS; S120FTS;S120FTPRS (G004)

74





3. CENTER BODY FILL/LEVEL PLUG4. CENTER BODY DRAIN PLUG5. PLANETARY CARRIER HOUSING (RH)6. PLANETARY CARRIER HOUSING (LH)7. CENTER BODY


H80, 90, 100, 110, 120FT (N005, P005)

5. Remove and discard transmission breather.Install new transmission breather and handtighten.

6. Remove and discard old oil filter. Apply clean oilto gasket of new filter. Install new filter and handtighten.

7. Add oil to transmission at the dipstick tube. Thecorrect oil is shown in the Maintenance Schedule.

8. Start and run the engine for approximately 5minutes after fill to allow oil to lubricate partswithin the transmission and wet brake planetarycarrier housings. With the truck in the ON po-sition, See Maintenance Schedule to add addi-tional oil at the transmission dipstick tube thatwill need to be added to properly fill the plane-tary carrier housings and transmission. For lifttruck models S80, 100, 120FT; S80, 100FTBCS;S120FTS; S120FTPRS (G004) see Figure 74. Forlift truck models H80, 90, 100, 110, 120FT (N005,P005) see Figure 75.


9. Turn the key to the OFF position and check forleaks and check oil level.

WET BRAKE CENTER SECTION OILCHANGE

Remove

1. Remove the center body fill/level plug. Remov-ing the fill/level plug will allow the oil to drainat 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.

2. Place and empty container under the center bodydrain plug.

3. Remove the center body drain plug, and wait un-til oil has drained completely.

Install

1. Install drain plug for the center body. Tighten to30 to 50 N•m (22 to 37 lbf ft). For lift truck mod-els S80, 100, 120FT; S80, 100FTBCS; S120FTS;S120FTPRS (G004), see Figure 74. For lift truckmodels H80, 90, 100, 110, 120FT (N005, P005),see Figure 75.

CAUTIONBefore adding oil, ensure the truck is parkedand on level ground.

2. Add oil at the fill/level port for the center bodyuntil the oil/fill level port has overflowed. Thecorrect oil is shown in the Maintenance Sched-ule or Figure 76. For lift truck models S80, 100,120FT; S80, 100FTBCS; S120FTS; S120FTPRS

75


(G004) see Figure 74. For lift truck models H80,90, 100, 110, 120FT (N005, P005) see Figure 75.

3. Install oil fill/level plug. Tighten to 30 to 50 N•m(22 to 37 lbf ft).

A. RIGHT PLANETARY CARRIER HOUSING - USE JDM J20CB. LEFT PLANETARY CARRIER HOUSING - USE JDM J20CC. CENTER BODY - USE SAE 80W/90

1. PLANETARY FILL/LEVEL PLUGS2. PLANETARY DRAIN PLUGS3. CENTER BODY FILL/LEVEL PLUG4. CENTER BODY DRAIN PLUG

5. RIGHT PLANETARY CARRIER HOUSING6. LEFT PLANETARY CARRIER HOUSING7. CENTER BODY

Figure 76. Oil Application Diagram

BRAKE OIL (MASTER CYLINDER),CHANGE

1. Remove the dashboard from the cowl.


2. Remove the brake oil reservoir from the bracketon the cowl. See Figure 77.


CAUTIONDO NOT use "DOT" fluid, only use Dexron IIIoil from a sealed container to prevent possibledamage to the brake system.

3. Remove the brake oil reservoir cover and cylin-drical block drain plug. Pour the oil into asuitable container with a 0.35 liter (0.74 pt)minimum capacity. Install the cylindrical blockdrain plug. Refill the reservoir with clean oilfrom a sealed container and install the cover onthe reservoir. The correct oil is shown in theMaintenance Schedule.

4. Install the reservoir into the bracket located onthe cowl.

76


1. RESERVOIR CAP2. BRAKE OIL

RESERVOIR3. RESERVOIR

MOUNTINGBRACKET

4. COWL5. UPPER BRAKE OIL

SUPPLY HOSE6. CYLINDRICAL

BLOCK OUTLETFITTING

7. LOWER BRAKEOIL SUPPLY HOSE

8. NIPPLE9. MASTER

CYLINDER10. CYLINDRICAL

BLOCK DRAINPLUG

11. CYLINDRICALBLOCK

12. CYLINDRICALBLOCK MOUNTINGBRACKETCAPSCREW

Figure 77. Brake Oil Change

BRAKE OIL (DRY BRAKE), REMOVE

Perform the following procedure to remove usedbrake oil from the remainder of the brake system.

1. Ensure that the master cylinder reservoir isfilled with brake oil.

NOTE: This procedure cannot be performed by oneperson.

2. Put one end of a rubber hose on the bleed screwof the wheel cylinder. Put the other end of thehose into a empty container.

3. Loosen the bleed screw at the wheel cylinder oneturn so that the used brake oil can be removedfrom the brake system. Slowly push the brakepedal and hold it at the end of its stroke. Closethe bleed screw. Release the brake pedal.

NOTE: The new brake oil will be easily recognized, asthe color will be more clear than the used oil whichwill be darker.

4. Repeat Step 1 through Step 3 until there is newbrake oil in the container.

5. Check the level of the brake oil in the reservoirfor the master cylinder during the procedure.Make sure to keep the brake oil at the correctlevel.

6. Repeat the procedure for the other wheel cylin-der.

77


SERVICE BRAKES (DRY BRAKE)

Check brake lining and parts of the brake assemblyfor wear or damage. The minimum acceptable brakelining thickness is 1.0 mm (0.040 in.). If the brakelinings are worn thinner than the specification, re-place the brake linings. See the section Brake Sys-tem 1800 SRM 1247 for the removal and installationprocedures of the drive wheels and brake drums. Ifthe brake linings or brake shoes are worn or dam-aged, they must be replaced. Brake shoes must bereplaced in complete sets. Inspect brake drums forcracks or damage. Replace any damaged parts.

WARNINGBrake linings can contain dangerous fibers.Breathing the dust from these brake liningsis a cancer or lung disease hazard. DO NOTcreate dust! DO NOT clean brake parts withcompressed air or by brushing. Follow thecleaning procedure in this section. When thebrake drums are removed, DO NOT createdust.

DO NOT sand, grind, chisel, hammer, or changelinings in any way that will create dust. Anychanges to brake linings must be done in a re-stricted area with special ventilation. Protec-tive clothing and a respirator must be used.

Brake cleaning procedures are as follows:

CAUTIONDO NOT use an oil solvent to clean the wheelcylinder. Use a solvent approved for cleaningof brake parts. DO NOT permit oil or grease inthe brake fluid or on the brake linings.

1. DO NOT release brake lining dust from brakelinings into the air when brake drum is removed.

2. Use a solvent approved for cleaning of brakeparts to wet lining dust. Follow the instructionsand cautions of the manufacturer for the use ofthe solvent. If a solvent spray is used, do notcreate 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 anairtight container while they are still wet. Puta DANGEROUS FIBERS warning label on theplastic bag or airtight container.

4. Any cleaning cloths that will be washed must becleaned so that fibers are not released into theair.

DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential canbe found in the section Drive Axle and DifferentialAssembly Repair, (Dry Brake) 1400 SRM 1245.

1. Place the lift truck on blocks. See How to RaiseDrive Tires in this manual.

2. The differential and drive axle use the same oilsupply. Place a container with a minimum capac-ity of 5 liter (5.3 qt) under the differential. Re-move the drain plug located in the bottom of thedifferential and drain the oil from the differentialcompletely. Install the drain plug.

3. The fill hole is on the front of the differentialhousing. Add oil shown in the MaintenanceSchedule until the oil level is at the lower edge ofthe fill hole. Install fill plug and rotate the drivewheels in order to get oil pumped into the axle.Remove the fill plug and check the oil level. Addoil, as necessary. Install the fill plug and checkfor leaks. See Figure 78 and Figure 79.

Figure 78. Drive Axle (Dry Brake) Fluid Fillfor Lift Truck Models S80, 100, 120FT; S80,

100FTBCS; S120FTS; S120FTPRS (G004)

78



1. DRIVE AXLE2. CHECK/FILL PLUG3. DRAIN PLUG

1. CHECK/FILL PLUG2. DRAIN PLUG3. DRIVE AXLE

Figure 79. Drive Axle (Dry Brake) Fluid Fillfor Lift Truck Models H80, 90, 100, 110, 120FT

(N005, P005)

TEST LPG/GAS REGULATOR PRESSURE

For more information regarding the Test LPG/GASRegulator Pressure, see the section LPG Fuel Sys-tem, GM 4.3L Engine with GFI 900 SRM 1242 andGasoline Fuel System, GM 4.3L Engine 900 SRM1244.

CHECK THROTTLE SHAFT FOR STICKING

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

INSPECT EXHAUST MANIFOLD ANDPIPING FOR LEAKS

To check the exhaust manifold and piping for leaks,perform the following:

• Check the exhaust manifold at the cylinder headfor leaks. Ensure that all bolts and shields are inplace.

• Check exhaust pipe fasteners to manifold for leaksto ensure they are tight. Repair if necessary.

• Check all exhaust pipe extension connectors forleaks and tighten, if necessary.

• Visually inspect converter for correct mufflermounting and tail pipe mounting.

• Check for any leaks at the inlet and outlet of theconverter.

VALVE CLEARANCE, CHECK ANDADJUST FOR CUMMINS QSB 3.3L DIESELENGINE

The Cummins QSB 3.3L engine does not requirevalve clearance adjustments during normal service.See the Maintenance Schedule for valve clearances.

Check the valve clearance and make adjustments asneeded. To adjust the valve clearances do the follow-ing:

1. Align the TDC mark on the crankshaft pulleywith the engraved mark on the block. See Fig-ure 80.

2. Adjust ONLY the valves shown in Figure 81, byloosening the locknut with a wrench and adjust-ing the valve clearance using a screwdriver orAllen wrench.

1. CRANKSHAFT PULLEY2. DRIVE BELT3. ENGRAVE TIMING MARK

Figure 80. Cummins QSB 3.3L TDC Mark

79


1. EXHAUST VALVE2. INTAKE VALVE3. CYLINDER 1

4. CYLINDER 25. CYLINDER 36. CYLINDER 4

Figure 81. Cummins Valve Adjustment

3. Tighten the lock nut to 24 N•m (212 lbf in) andmeasure valve lash.

4. Mark the vibration damper and rotate the crank-shaft 360 degrees. See Figure 82.

1. TIMING PIN2. VIBRATION DAMPER

Figure 82. Cummins Vibration Damper

5. Perform Step 2 and Step 3 to adjust ONLY thevalves shown in Figure 83. See the MaintenanceSchedule for valve clearances.




80

8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years

Maintenance Procedures Every 4000 Hours or 2 YearsNOTE: Perform the 8-hour, 250-hour, 500-hour, 1000-hour, and 2000-hour checks prior to performing theprocedures in this section.

HYDRAULIC OIL, REPLACE

WARNINGAt operating temperature the hydraulic oil isHOT. DO NOT permit the hot oil to touch theskin and cause a burn.

CAUTIONDO NOT permit dirt to enter the hydraulic sys-tem when the oil level is checked or the filteris changed. Dirt can cause damage to the com-ponents of the hydraulic system.



NOTE: Heavy-duty or contaminated applications willrequire hydraulic oil change at 2000 hours.

NOTE: Replace the hydraulic oil filter at the sametime the oil is changed.

1. Place a container with a minimum capacity of39.4 liter (42 qt) under the drain plug at thebottom of the hydraulic tank. To drain the oil,remove the drain plug from the bottom of thehydraulic tank. See Figure 84. When the tankis empty, inspect the inside of the tank for anyforeign matter or possible fungus. If necessary,clean the inside of the tank in accordance withthe instructions found in the section Frame 100SRM 1243. When either the inspection or thecleaning of the tank is completed, install thedrain plug in the bottom of the hydraulic tank.


2. Fill hydraulic tank with oil specified in the Main-tenance Schedule.

3. When the oil level is correct, operate system andcheck for leaks.

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 ANDADJUST FOR CUMMINS 4.5L DIESELENGINE

The Cummins 4.5L engine does not require valveclearance adjustments during normal service. Seethe Maintenance Schedule for valve clearances.

Check the valve clearance and make adjustments asneeded. To adjust the valve clearance, do the follow-ing:

1. Rotate the engine until it is at TDC for cylindernumber one (intake and exhaust valves closed).Insert timing pin. See Figure 85.

2. Adjust ONLY the valves shown in Figure 86, byloosening the lock nut with a wrench and adjust-ing the clearance using a screwdriver or Allenwrench.

3. Tighten the lock nut to 24 N•m (18 lbf in) andmeasure valve lash.

4. Remove the timing pin. See Figure 85.

5. Mark the vibration damper and rotate the crank-shaft 360 degrees. See Figure 87.

6. Perform Step 2 and Step 3 to adjust ONLY thevalves shown in Figure 88.

82


1. INSERT TIMING PIN HERE2. FUEL/WATER SEPARATOR FILTER3. TIMING BELT

Figure 85. Timing Pin Location, Cummins 4.5L Diesel Engine




1. TIMING PIN2. VIBRATION DAMPER

Figure 87. Cummins Vibration Damper

83





WELD INSPECTION

Initial inspection is suggested at 4000 hours, withsubsequent inspections at 2000 hour intervals. Re-moval of carriage from mast is not required, but rec-ommended, to perform inspection. Removal of at-tachment is recommended for access to carriage.

NOTE: Visual inspection supported by dye penetrantapplication is recommended with focus on areas de-fined below.

NOTE: Dye penetrant checks are made in a three-step process using a cleaner, penetrant, and devel-oper. Follow manufacturers instructions for cleaning

the area to be inspected, then applying penetrant anddeveloper. If a crack is present, it will show up as awell-defined maroon/red line as the dye penetrant isdrawn out into the white developer coating.

Contact your local Hyster dealer for instructions ifa crack is detected.

1. Carriage inspection: welded joints between castinsert and top and vertical carriage bars. SeeFigure 89.

2. Mast inspection:

a. Welded joints of lower crossmember of mastouter channel and related gussets. See Fig-ure 90.

b. Welded joints around tilt anchor and inter-mediate cross member. See Figure 90.

NOTE: The welded boss for tilt lock option is typi-cally located on right side of mast channel above tiltanchor bracket.

c. Right side rail of outer mast channel in areaof welded boss for optional tilt lock rod. SeeFigure 90.

84


A. FRONT VIEW B. REAR VIEW

1. WELDS

Figure 89. Carriage Bar Welds for Inspection

85


A. TYPICAL "XM" MASTB. TYPICAL "FT" MASTC. 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 MastThe following procedures must be used when inspect-ing or working near the mast. Additional precautionsand procedures can be required when repairing or re-moving the mast. See the correct Service Manual sec-tion for the specific mast being repaired.

WARNINGMast parts are heavy and can move. Distancesbetween parts are small. Serious injury ordeath can result if part of the body is hit byparts of the mast or the carriage.

• Never put any part of the body into or underthe mast or carriage unless all parts of themast are completely lowered or a safety chainis installed. Also make sure that the power isoff and the key is removed. Put a DO NOT OP-ERATE tag in the operator’s compartment.

• Be careful of the forks. When the mast israised, the forks can be at a height to causean injury.

• DO NOT climb on the mast or lift truck at anytime. Use a ladder or personnel lift to workon the mast.

• DO NOT use blocks to support the mast weld-ments nor to restrain their movement.

• Mast repairs require disassembly and re-moval of parts and can require removal ofthe mast or carriage. Follow the repair pro-cedures in the correct Service Manual forthe mast.

NOTE: If there is no power to lower the mast on lifttrucks equipped with Electronic Hydraulic System,there is an emergency load lowering valve locatedon the hoist/lower valve section of the main controlvalve. See the Operating Manual for the proce-dures to lower a load using the emergency load low-ering valve.

1. Lower mast and carriage completely. Push lift/lower control lever forward and make sure thereis no movement in the mast. Make sure all partsof the mast that move are fully lowered.

OR

2. If parts of the mast must be in a raised position,install a safety chain to restrain the moving partsof the mast. Connect moving parts to a part thatdoes not move. Follow these procedures:

a. Put mast in vertical position.

b. Raise mast to align bottom crossmemberof weldment that moves in outer weldmentwith a crossmember on outer weldment.On the two-stage and free-lift mast, themoving part is the inner weldment. Onthe three-stage mast, it is the intermediateweldment. See Figure 91.

c. Use a 3/8-in. minimum safety chain with ahook to fasten the crossmembers together sothe movable member cannot lower. Put thehook on the back side of the mast. Make surethe hook is completely engaged with a link inthe chain. Make sure the safety chain doesnot touch lift chains or chain sheaves, tubes,hoses, fittings, or other parts on the mast.

d. Lower the mast until there is tension in thesafety chain and the free-lift cylinder (free-lift, three-stage, and four-stage masts only)is completely retracted. If running, stop en-gine. Apply parking brake. Install a DONOT REMOVE tag on the safety chain(s).

e. Install another safety chain (3/8-in. mini-mum) between the top or bottom crossmem-ber of the carriage and a crossmember on theouter weldment.

3. Apply parking brake. After lowering or restrain-ing the mast, shut off power and remove key. Puta DO NOT OPERATE tag in the operator’s com-partment.

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 Fuel Filter Water Removal


A. TWO-STAGE LFL MASTB. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MASTD. FOUR-STAGE FFL MAST

1. OUTER MAST2. INNER MAST3. INTERMEDIATE MAST4. HOOK

5. FREE-LIFT CYLINDER6. CARRIAGE BAR7. CROSSMEMBER8. FIRST INTERMEDIATE MAST

Fuel Filter Water RemovalNOTE: The following procedure only pertains to lifttrucks equipped with Cummins 4.5L and QSB 3.3Ldiesel engines.

1. Shut off the engine.

NOTE: The drain valve is located on the bottom offuel filter element.

2. To access the fuel filter element and drain valve,remove the air inlet elbow. See Figure 92.

CAUTIONDrain water/fuel into a container and disposein accordance with local environmental regu-lations.

3. Turn the drain valve clockwise approximately3 1/2 turns. Drain fuel filter until clear fuel isvisible.

CAUTIONDO NOT overtighten when closing the drainvalve. Overtightening can damage the threads.

4. Close the drain valve by lifting and turningclockwise until it is hand-tight.

1. AIR INLET ELBOW2. FUEL FILTER ELEMENT3. DRAIN VALVE

Figure 92. Engine Fuel Filter Drain ValveLocation (Cummins 4.5L Shown)

89

Hood Latch Check 8000 SRM 1248

Hood Latch Check

WARNINGThe hood, hood latch, and latch striker must becorrectly adjusted for the correct operation ofthe operator restraint system.

1. Install hood latch on frame of hood. See Fig-ure 93. Tighten capscrews so that hood latch canstill move when hood is closed.

2. Install latch striker in highest slot position.Check that latch striker is in center of jaws ofhood latch when hood closes.

3. Carefully close hood to fully-closed position. Thehood latch has two positions. The hood latch isfully closed after two clicks of the latch.

4. Push down until hood just touches rubberbumper. Make sure latch striker is still in centerof hood latch. Open hood and tighten capscrewsfor latch.

5. Check operation of hood latch. Have an operatorsit in the seat. Make sure hood is fully closed(two clicks). Also check that hood touches rubberbumper. If necessary, repeat Step 4.

1. LATCH STRIKER2. BUMPER3. HOOD

4. HOOD RELEASE HANDLE5. HOOD LATCH6. FRAME

Figure 93. Hood Latch Check

90

8000 SRM 1248 Lift Chain Adjustments

Lift Chain Adjustments


Never allow anyone under a raised carriage.DO NOT put any part of your body in orthrough the lift mechanism unless all partsof the mast are completely lowered and theengine is STOPPED.

DO NOT try to find hydraulic leaks by puttingyour hand on hydraulic components underpressure. Hydraulic oil can be injected intothe body by the pressure.

During test procedures for the hydraulic sys-tem, fasten the load to the carriage with chainsto prevent it from falling. Keep all personnelaway 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 atthe same time.

• Chain length will be correct.• Chains must travel freely through complete cycle.

NOTE: When chain adjustments are complete, makesure the threads on the nuts of the chain anchorsare completely engaged. Make sure all adjustment isnot removed from the chain anchors. Chain anchorsmust be able to move on their mounting.

1. When adjusting lift chains on forklift trucksequipped with the forks installed, go to Step 2.If forklift truck is equipped with an attachmentwithout forks, go to Step 3.

NOTE: Prior to performing adjustment procedures,make sure forklift truck is parked on a level surfaceand the mast is in the vertical position.

2. Adjust chain anchors which support the carriageuntil 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 un-til the bottom of lower carriage bar is above thefloor level as shown in Table 2. See Figure 95.

1. MAST2. CARRIAGE3. FORK4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)

ABOVE THE FLOOR LEVEL.

Figure 94. Lift Chain Adjustments With ForksInstalled

1. MAST2. CARRIAGE3. DISTANCE FROM FLOOR TO LOWER

CARRIAGE BAR

Figure 95. Lift Chain Adjustment WithoutForks Installed

91

Jump-Starting the Lift Truck 8000 SRM 1248

In Table 2, the masts are divided by class. Eachclass is determined by the lifting capability of thelift cylinders. The Class II mast would have thelift capability of 2.5-3.5 tons, Class III has the liftcapability of 3.5-4.0 tons, and Class IV has the liftcapability of 4.0-7.0 tons.

Table 2. Carriage Chain Adjustment,Forks Not Installed

Class II and Class III82.5 ±3 mm

(3.25 ±0.12 in.)

Class IV133.5 ±3 mm

(5.26 ±0.12 in.)

Jump-Starting the Lift TruckJUMP-STARTING USING A BATTERYCHARGER

CAUTIONDO NOT try to start the engine by pushing ortowing the lift truck. Damage to the hydraulicsystem can occur if engine is started by push-ing or towing lift truck.

If the battery becomes discharged and requires abooster battery to start the engine, follow theseprocedures carefully when connecting the jumpercables:

1. Disconnect the negative battery terminal of thelift truck being started.

2. Always connect positive jumper cable to positiveterminal of discharged battery and negativejumper cable to negative terminal.

3. Always connect jumper cable, that is the groundcable, last.

4. Always connect jumper cables to discharged bat-tery before connecting them to booster battery.

JUMP-STARTING A LIFT TRUCK USINGANOTHER LIFT TRUCK

WARNINGTo prevent possible arcing between the two lifttrucks, make sure that the lift trucks are nottouching.

CAUTIONDO NOT try to start the engine by pushing ortowing the lift truck. Damage to the hydraulicsystem can occur if engine is started by push-ing or towing lift truck.

1. Always connect positive jumper cable to positiveterminal of discharged battery and negativejumper cable to negative terminal.

2. Always connect jumper cable, that is the groundcable, last.

3. Always connect jumper cables to discharged lifttruck battery before connecting them to the fully-charged lift truck battery.

92

8000 SRM 1248 Overhead Guard Changes

Welding Repairs

WARNINGWelding can cause a fire or an explosion. Al-ways follow the instructions in the Frame sec-tion if a fuel or hydraulic tank must be welded.Make sure there is no fuel, oil, or grease nearthe weld area. Make sure there is good venti-lation in the area where the welding must bedone.

DO NOT heat, weld, or bend forks. Forks aremade of special steel using special methods.The strength of the overhead guard can be re-duced by welding or heating. Get informationfrom your dealer for Hyster lift trucks beforewelding on a mast.

Forklift frames and components may bepainted with a catalyzed paint such aspolyurethane or a two-part primer. Weld-ing, burning, or other heat sufficient to causethermal decomposition of the paint may re-lease isocyanates. These chemicals are allergicsensitizers to the skin and respiratory tractand overexposure may occur without odor

warning. Should work be performed, utilizegood industrial hygiene practices includingremoval of all paint (prime and finish coats) tothe metal around the area to be welded, localventilation, and/or supplied-air respiratoryprotection.

CAUTIONWhen an arc welder is used, always disconnectthe ground cable from the battery in the lifttruck. This action will prevent damage to thealternator or the battery.

Connect the ground clamp for the arc welder asclose as possible to the weld area. This actionwill prevent damage to a bearing from the largecurrent from the welder.

Some repairs require welding. If an acetylene or arcwelder is used, make sure procedures in previousWARNING and CAUTION are done.

See the American National Standard Safety in Weld-ing and Cutting, AWS Z 49.1 - 1999.

Overhead Guard Changes

WARNINGDO NOT weld mounts for lights or accessoriesto the legs of the overhead guard. Changes thatare made by welding or by drilling holes thatare too big or in the wrong location can reducethe strength of the overhead guard.

See your dealer for Hyster lift trucks BEFOREperforming any changes to the overheadguard.

No welding or drilling on legs of overhead guard ispermitted as per previous WARNING.

93

Wheel and Tire Replacement 8000 SRM 1248

Wheel and Tire ReplacementGENERAL

The S series lift trucks have solid rubber tires (oftencalled cushion tires) that are pressed onto the rim.The H series lift trucks have pneumatic tires or solidrubber tires that look like pneumatic tires. Thesevariations in tires also cause a variation in the typesof wheels and the disassembly and assembly proce-dures.

SOLID RUBBER TIRE, CHANGE(S SERIES)

NOTE:

Solid rubber tires made from softer or harder ma-terial can be installed as optional equipment. Thetread on the sold rubber tires can be either smoothor it can have lugs. Do not mix types of tires or treadon lift truck. See Figure 96.

WARNINGThe type of solid rubber tire is shown on theNameplate. Make sure the Nameplate is cor-rect for the type of tires on the lift truck. The12000 lb. capacity solid rubber tired fork liftmust be equipped with high load capacitysteering tires.

Wheels must be changed and tires repaired bytrained personnel only.

Always wear safety glasses.

1. Raise lift truck as described in How to Put LiftTruck on Blocks in this manual.

2. Remove wheel nuts and remove wheel from lifttruck. Lift truck wheels are heavy.

Remove and Install Tire on Wheel

NOTE: Make sure the tires are installed on thewheels so that the outside edges of the tire andwheel are as shown in Figure 96. Also, check theNameplate of the lift truck for the correct tire sizeand tread width.

1. The correct tools, equipment, and a press ringmust be used for each size of wheel. Use a pressto push wheel from rim and tire. The capacity ofthe press must be approximately 355 to 1779 kN(80,000 to 400,000 lbf). For the tire sizes, see theNameplate.

2. When the drive wheels are installed on the lifttruck, tighten wheel nuts to a torque value of 610to 680 N•m (450 to 502 lbf ft).

A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD

1. OUTSIDE OF SOLID RUBBERTIRE

2. WHEEL 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 Wheel and Tire Replacement

3. The steering wheels are fastened to the spindleof the steering axle with a large castle nut. Makesure inner and outer bearings are correctly lu-bricated with grease. Install inner bearingassembly and wheel on spindle. Install outerbearing cone and castle nut. Tighten castle nutup to 203 N•m (150 lbf ft) while rotating hubin both directions to properly seat the bearings,loosen the castle nut until wheel hub turns freelywith no end play. Tighten castle nut to 34 N•m(25 lbf ft). If the cotter pin cannot be installed,loosen the castle nut to the first position wherethe cotter pin can be installed. Install cap forbearings.

PNEUMATIC TIRE WITH TUBE, REPAIR

Remove Wheels From Lift Truck

WARNINGA solid rubber tire that is the same shape asa pneumatic tire can be installed on a three-piece or four-piece wheel for a pneumatic tire.DO NOT make changes in the parts of the rim ifthis type of solid rubber tire is installed insteadof a pneumatic tire. Changes to the parts of therim can cause a failure of the wheel and causean accident.

WARNINGThe type of tire and the tire pressure (pneu-matic tires) are shown on the nameplate. Make

sure the nameplate is correct for the type oftires on the lift truck.

WARNINGWheels must be changed and tires repaired bytrained personnel only.

Deflate tire completely before removing thewheel from the lift truck. If dual wheels areused, deflate both tires. Air pressure in thetires can cause the tire and rim parts to ex-plode, causing serious injury or death.


Never loosen the nuts that hold the inner andouter wheel halves together when there is airpressure in the tire.

1. Put lift truck on blocks as described in How toPut Lift Truck on Blocks at the beginning of thissection.

2. Remove air from tire. Remove valve core to makesure all air is out of inner tube. Push a wirethrough valve stem to make sure valve stem doesnot have a restriction.

3. Remove wheel nuts and remove wheel and tirefrom lift truck. Lift truck tires and wheels areheavy.

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Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Fig-ure 97. There are several types of wheels used onthis series of lift trucks.

A. TWO-PIECE WHEELB. OPTIONAL RIM ASSEMBLY

C. THREE-PIECE WHEELD. FOUR-PIECE WHEEL

1. WHEEL RIM2. SIDE FLANGE

3. LOCK RING4. FLANGE SEAT

Figure 97. Types of Pneumatic Wheels

Remove Tire From Two-Piece Wheel

WARNINGMake sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressurein 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 forceto cause an injury.

STEP 1.Remove nuts that fasten wheel rims together.

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STEP 2.Loosen tire bead from wheel rim.

STEP 3.Remove wheel rims from tire. Remove inner tube andflap.

Remove Tire From Three- and Four-Piece Wheels

WARNINGMake sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressurein the tires can cause the tire and rim parts to explode, causing serious injury or death.


STEP 1.Loosen tire bead from side flange.

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STEP 2.Put tire tool into slot between lock ring and wheelrim. Remove lock ring and side flange. If there is aflange seat, remove it.

STEP 3.Loosen bead from other side of wheel rim. Removevalve stem from wheel.

STEP 4.Remove wheel from tire.

Install Wheel in Tire

WARNINGDamage to the tire and wheel assembly and in-jury or death can occur if you do not do the fol-lowing procedures:• Clean and inspect all parts of the wheel be-

fore installing the tire.• DO NOT use any damaged or repaired wheel

parts.• Make sure all parts of the wheel are the cor-

rect 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 manufactur-ers on any one lift truck.

DO NOT use a steel hammer on the wheel. Usea rubber, lead, plastic, or brass hammer to put

parts together. Make sure the side ring is in thecorrect position. The ends of the side ring mustnot touch. The clearance at the ends of the lockring will be approximately 13 to 25 mm (0.5 to1.0 in.) after it is installed. If the clearance iswrong, the wrong part has been used.

1. Clean and inspect all parts of wheel. Paint anyparts that have rust or corrosion.

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

3. Apply a rubber lubricant or a soap solution to thetire bead and tube.

4. Install new tire flap.

5. Make sure rim is the correct size for tire. Lubri-cate part of wheel that contacts bead and flap.

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CAUTIONDO NOT use pneumatic-shaped, solid tires ontwo-piece bolt together drive wheels. Spinningmay occur.

6. Install the three-piece or four piece wheel in thetire a shown in Install Three-Piece or Four-PieceWheel in Tire.

7. Install the two-piece wheel in the tire as shownin Install Tire on Two-Piece Wheel.

Install Three-Piece or Four-Piece Wheel in Tire

WARNINGMake sure all of the air pressure is removed from the tire before a wheel is disassembled. Airpressure in the tires can cause the tire and rim parts to explode causing serious injury or death.


STEP 1.Install inner tube and rubber flap in tire.

STEP 2.Install wheel rim in tire. Make sure stem of innertube is aligned with slot in rim.

STEP 3.Turn over rim and tire. Put blocks under rim so rimis 8 to 10 cm (3 to 4 in.) above floor. Install flangeseat (if used) and lock ring.

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

Install Tire on Two-Piece Wheel

WARNINGWheels can explode and cause injury or deathif the following procedures are not followed:• Clean and inspect all parts of the wheel be-

fore installing the tire.• DO NOT use any damaged or repaired wheel

parts.• Make sure all parts of the wheel are the cor-

rect 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 manufactur-ers on any one lift truck.

DO NOT use a steel hammer on the wheel. Usea rubber, lead, plastic, or brass hammer to putparts together. Make sure the side ring is in thecorrect position. The ends of the side ring mustnot touch. The clearance at the ends of the lockring will be approximately 13 to 25 mm (0.5 to1.0 in.) after it is installed. If the clearance iswrong, the wrong part has been used.

CAUTIONDO NOT use pneumatic-shaped solid tires ontwo-piece bolt together drive wheels. Spinningmay occur.

1. Clean and inspect all parts of wheel. Paint anyparts that have rust or corrosion.

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

WARNINGDO NOT lubricate the tire bead with antifreezeor petroleum-based liquid. Vapors from theseliquids can cause an explosion during inflationor use.

3. Apply a rubber lubricant or a soap solution to tirebead and tube.

4. Install new tire flap.

5. Make sure rim is the correct size for tire. Lubri-cate 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 bothhalves of wheel rim in tire. Make sure stem of innertube is aligned with slot in rim.

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STEP 2.Tighten nuts that hold rim halves together to175 N•m (130 lbf ft). Add air pressure to tire (seenameplate).

ADD AIR TO PNEUMATIC TIRES WITHTUBE

WARNINGAdd air pressure to the tires only in a safetycage. Inspect the safety cage for damage beforeuse. When air pressure is added, use a chuckthat fastens onto the valve stem of the innertube. Make sure there is enough hose to permitthe operator to stand away from the safety cagewhen air pressure is added to the tire.

DO NOT sit or stand by the safety cage. DONOT use a hammer to try and correct the po-sition of the side flange or lock ring when thetire 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. SeeFigure 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 tireto the specified pressure.

5. Check that all wheel parts are correctly installed.If installation is not correct, remove all air pres-sure from tire. Remove valve core to make sureall air pressure has been removed and then make

adjustments. The clearance at the ends of thelock ring will be approximately 13 to 25 mm (0.5to 1.0 in.) when the tire has the correct air pres-sure.

Install the Wheels

Install wheel on the hub. Tighten nuts in a crosspattern to a torque value of 610 to 680 N•m (450 to502 lbf ft) for drive wheel nuts and 610 to 680 N•m(450 to 502 lbf ft) for steer wheel nuts. If the wheelsare the two-piece rims, make sure nuts that fastenrim halves together are toward brake drum whenthey are installed.

Figure 98. Add Air to Tires

101


Dual Drive Wheels, Install

NOTE: Some lift trucks have dual drive wheels. Thefollowing procedures describe the steps to install thedual sets of wheels.

1. Install inner wheel on hub. If the wheels arethe two-piece rims, make sure nuts that fastenrim halves together are toward brake drum whenthey are installed.

2. Install wheel adapter spacers on the inner wheelstuds and tighten spacers to 100 to 125 N•m (74to 92 lbf ft). Install the dual hub assembly andinner wheel nuts on the spacers and tighten thewheel nuts to 610 to 680 N•m (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 N•m(450 to 502 lbf ft). If the wheels are the two-piecerims, make sure nuts that fasten rim halvestogether are toward brake drum when they areinstalled.

4. Install the valve extension bracket and tightenthe attaching nut to 8 N•m (70 lbf in). Installthe valve extension hose into the bracket. SeeFigure 99.

1. TIRE2. DUAL HUB ASSEMBLY3. WHEEL NUT4. WHEEL5. WHEEL ADAPTER SPACER6. VALVE EXTENSION7. BRACKET

Figure 99. Dual Drive Wheels Installation

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PNEUMATIC TUBELESS TIRE, REPAIR

Remove Wheels From Lift Truck


Deflate tire completely before removing thewheel from the lift truck. If dual wheels areused, deflate both tires. Air pressure in tirescan cause the tire and rim parts to explodecausing serious injury or death.


Never loosen the nuts that hold the inner andouter wheels halves together when there is airpressure in the tire.

The Tubeless Bead Seal (TBS) enables tubeless tiresto be used on wheel rims that were designed to beused with a tube.

The main component of a TBS is a special rubberring that fits inside the tire between the tire beadsto ensure the air tightness of the existing wheel andthe tubeless tire assembly. See Figure 97.

1. Put lift truck on blocks as described in at begin-ning of this section.

2. Remove the valve cap and core to remove all airfrom the tire.

3. Remove the wheel nuts and remove the wheeland tire from the lift truck. Lift truck tires andwheels are heavy.

Remove Tire From Wheel

WARNINGMake sure all of the air pressure is removed from the tire before a wheel is disassembled. Airpressure 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 forceto 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 thevalve 1/4 turn and remove valve from wheel.

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STEP 2.Put wheel and tire assembly on the press. Positionthe feet of the press on the loose flange. Press downon loose flange to expose the locking ring.

STEP 3.Remove the loose flange locking ring and the advanceband (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 removeit.

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Install Tire on Wheel

WARNINGDamage to the tire and wheel assembly and injury or death can occur if you do not do the followprocedures:• 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.

WARNINGDO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put partstogether.

WARNINGDO 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 thetire 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 theneedle 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 valveslot. 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 holethat will be used (see NOTE) by inserting and remov-ing the lubricated valve several times. If a three- orfour-piece wheel is being used, remove the valve. Ifa two-piece wheel is being used, leave valve in valvehole.

If the TBS has two-valve holes, lubricate the plasticplug and insert into valve hole that will not be used.

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STEP 3.Place the TBS inside the tire, making sure that thewings of the TBS are not folded over. Make a markon the tire to note the position of the valve hole in theTBS.

STEP 4.Apply lubricant to the rim. If a four-piece wheel isbeing used, lubricate the advance band. Slide the tireand the TBS onto the wheel.

Line up the valve hole in the TBS with the valve slotin the wheel. Lubricate and insert the valve into thevalve 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 theedges of the rim valve slot.

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

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STEP 7.Position the advance band. Ensure that it does not goin too far and damage the valve. Position the arms ofthe press onto the loose flange.

Push down on the press to depress the tire beads un-til locking ring groove is fully exposed.

STEP 8.Insert tire tool into the locking ring groove, and avise grip on other end. Remove vise grip. Releasethe press and check that all component parts arecorrectly 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. Removethe press from wheel and tire assembly.

Add Air to Pneumatic Tubeless Tire

WARNINGAdd air pressure to tires only in safety cage.Inspect safety cage for damage before use.When air pressure is added, use a chuck thatfastens onto valve stem. Make sure there isenough hose to permit operator to stand awayfrom safety cage when air pressure is added totire.

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 pressurethat is shown on the Nameplate. Install valvecap to ensure air stays in the tire.

Figure 100. Add Air to Tires

107


Wheels, Install

Install wheel on hub. Tighten nuts in a cross pat-tern to a torque value of 610 to 680 N•m (450 to502 lbf ft) for drive wheel nuts and 610 to 680 N•m(450 to 502 lbf ft) for steer wheel nuts. If wheelsare two-piece rims, make sure nuts that fasten rimhalves together are toward brake drum when theyare installed.

SOLID RUBBER TIRES ON PNEUMATICWHEELS, CHANGE



1. Put lift truck on blocks as described in How toPut Lift Truck on Blocks at the beginning of thissection.

2. Remove wheel nuts and remove wheel and tirefrom lift truck. Lift truck tires and wheels areheavy.

Remove Wheel From Tire

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

WARNINGKeep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force tocause serious injury. Always wear safety glasses.

STEP 1.Put wheel rim on bed of press. Put cage in positionon tire. Use press to push tire away from side flange.

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STEP 2.Put tire tool into slot between lock ring and wheelrim. Remove lock ring and side flange.

STEP 3.Turn tire over. Put a support under wheel rim. Makesure 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 tirefrom wheel rim.

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Install Tire on Wheel

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

WARNINGDamage to tire and wheel assembly and injury or death can occur if you do not do the followingprocedures.• 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 partstogether. Make sure the side ring is in the correct position. The ends of the side ring must nottouch. 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.

CAUTIONToo much lubricant can cause the tire to slide and move around the wheel rim.

STEP 1.Lubricate wheel rim and inner surface of tire withtire lubricant or soap.

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STEP 2.Put wheel rim on bed of press. Put tire over wheelrim. Put cage in position on tire. Use press to installtire on wheel rim.

STEP 3.Remove cage and put flange seat (if used), side ring,and lock ring in position on wheel rim. Install cageon tire. Use press to push tire onto wheel rim so sideflange 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 lockring is in the correct position.

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Adhesives and Sealants 8000 SRM 1248

Adhesives and Sealants

Hyster Part No. Loctite®Part No. Description Size

360387 222 Small Screw Threadlock (Purple) 50 ml

318702* 242 Removable Threadlock (Blue) 10 ml

226414* 271 High Strength Threadlock (Red) 10 ml

318996 277 High Viscosity Threadlock (Red) 50 ml

318650 290 Low Viscosity Threadlock (Green) 0.02 oz

251099 290 Low Viscosity Threadlock (Green) 50 ml

355844* 422 SuperBonder® Adhesive 3 ml

350830 515 Gasket Eliminator (Purple) 6 ml

313022* 515 Gasket Eliminator (Purple) 50 ml

273338* 567 Pipe Sealant with Teflon® 50 ml

318705 595 Super Flex® Silicone 100 ml

318701* 609 Retaining Compound 10 ml

341959 680 Retaining Compound 50 ml

226415 Primer T - Aerosol 6 oz

251979 767 Antiseize Compound 1 lb

360053-10 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz

318700 Adhesive and Sealant Kit (Contains one each of *items)

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

Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.

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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.

hyster 110ft periodic maintenance

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