manutencao hyster h40 70ft, maintenance hyster h40 70ft

PERIODIC

MAINTENANCE

S40-70FT, S55FTS [F187];

H40-70FT [L177]

PART NO. 1580525 8000 SRM 1150

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-

uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service

Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-

rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service

Manual could result in damage to the products, personal injury, property damage or death.

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load

being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the

load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON

BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the

specifications of the original equipment manufacturer.

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

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs

repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure

to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make

sure the area is well ventilated.

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

manual:

WARNINGIndicates a hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTIONIndicates a hazardous situation which, if not avoided, could result in

minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-

ground. The CAUTION symbol and word are on yellow background.

Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ................................................................................................................................................................. 1

Serial Number Data ........................................................................................................................................ 1

How to Move Disabled Lift Truck................................................................................................................... 2

How to Tow Lift Truck ................................................................................................................................ 2

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

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

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

How to Clean a Lift Truck............................................................................................................................... 4

Maintenance Schedule......................................................................................................................................... 5

Maintenance Procedures Every 8 Hours or Daily............................................................................................ 30

How to Make Checks With Engine Stopped................................................................................................. 30

Tires and Wheels....................................................................................................................................... 30

Safety Labels ............................................................................................................................................. 30

Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 31

Operator Restraint System....................................................................................................................... 32

Automatic Locking Retractor (ALR) .................................................................................................... 32

Emergency Locking Retractor (ELR) ................................................................................................... 32

Adjust Seat - Full Suspension .............................................................................................................. 32

Adjust Seat - Internal Suspension ....................................................................................................... 34

Hood and Seat Latches ............................................................................................................................. 35

Engine Compartment................................................................................................................................ 35

Paper Application ...................................................................................................................................... 35

Fuel, Oil, and Coolant Leaks, Check........................................................................................................ 36

Hydraulic Hoses ........................................................................................................................................ 36

Coolant Hoses ............................................................................................................................................ 36

Steering Column Gas Cylinder................................................................................................................. 36

Transmission ............................................................................................................................................. 36

Hydraulic System Oil ................................................................................................................................ 36

Engine Oil .................................................................................................................................................. 37

Air Filter .................................................................................................................................................... 43

Forks .......................................................................................................................................................... 43

Remove .................................................................................................................................................. 43

Inspect ................................................................................................................................................... 45

Install..................................................................................................................................................... 45

Adjust..................................................................................................................................................... 45

How to Make Checks With Engine Running................................................................................................ 46

Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 46

Service Brakes ........................................................................................................................................... 48

Brake Fluid Level ................................................................................................................................. 48

Operation, Check .................................................................................................................................. 49

Parking Brake ........................................................................................................................................... 49

Engine Oil Pressure .................................................................................................................................. 49

Cooling System .......................................................................................................................................... 50

Steering System ........................................................................................................................................ 51

Control Levers and Pedals ........................................................................................................................ 51

Lift System, Operate ................................................................................................................................. 51

First Service After First 100 Hours of Operation ............................................................................................ 51

Mazda and GM Engine Oil and Oil Filter.................................................................................................... 51

Yanmar Engine Oil and Oil Filter ................................................................................................................ 52

Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 53

Mazda and GM Engine Oil and Oil Filter.................................................................................................... 53

©2013 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Drive Belt ....................................................................................................................................................... 54

Mazda 2.0L and 2.2L Engines .................................................................................................................. 54

Fan and Alternator Drive Belt ............................................................................................................. 54

GM 2.4L Engine ........................................................................................................................................ 54


Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) .............................. 55

Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only).................................. 56

Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 57

Hydraulic System Oil .................................................................................................................................... 57

Hydraulic Tank Breather .............................................................................................................................. 57

Inspect........................................................................................................................................................ 57

Battery ........................................................................................................................................................... 58

Yanmar Engine Oil and Oil Filter ................................................................................................................ 58

Drive Belt ....................................................................................................................................................... 58

Yanmar Diesel Engine............................................................................................................................... 58


PCV Valve ...................................................................................................................................................... 59

Clean Debris From Radiator Core ................................................................................................................ 59

Transmission Oil Level ................................................................................................................................. 59

Wet Brake Planetary Housing Oil Level Check........................................................................................... 61

Forks............................................................................................................................................................... 63

Mast Lubrication ........................................................................................................................................... 63

Header Hose Checks...................................................................................................................................... 66

Lift Chain Lubrication .................................................................................................................................. 66

Tilt Cylinder Lubrication .............................................................................................................................. 67

Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 68

Manual Hydraulic Levers Lubrication ......................................................................................................... 69

Brake Fluid .................................................................................................................................................... 69

Tie Rod Lubrication (H40-70FT)................................................................................................................... 70

Differential and Drive Axle Oil (Dry Brake) ................................................................................................ 71

Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 72

Valve Clearance, Check and Adjust.............................................................................................................. 72

Ignition System.............................................................................................................................................. 72

GM 2.4L Engine ........................................................................................................................................ 72

Mazda 2.0L and 2.2L Engines .................................................................................................................. 72

LPG Fuel Filter Element Replace, GM 2.4L Engine ................................................................................... 72

Remove....................................................................................................................................................... 72

Install ......................................................................................................................................................... 72

LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant

Engines) ......................................................................................................................................................... 73

LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only ............................................... 74

Remove....................................................................................................................................................... 74

Clean/Inspect ............................................................................................................................................. 74

Install ......................................................................................................................................................... 74

Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only ............................... 75

Remove and Replace ................................................................................................................................. 75

Fuel Filter Replacement, Yanmar Engine.................................................................................................... 76

Priming the Fuel System (Yanmar).............................................................................................................. 77

Lift Chains Wear Check ................................................................................................................................ 78

Lift Chain Lubrication .................................................................................................................................. 78

Integral Sideshift Carriage, Check Bearings ............................................................................................... 79

ii

Periodic Maintenance Table of Contents


Integral Sideshift Carriage, Check Lower Mounting Hooks....................................................................... 79

Steering Axle.................................................................................................................................................. 80

Control Levers and Pedals ............................................................................................................................ 80

Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 81

Hydraulic System .......................................................................................................................................... 81

Hydraulic Filter, Replace .......................................................................................................................... 81

Hydraulic Tank Breather, Replace ........................................................................................................... 82

Air Filter ........................................................................................................................................................ 83

PCV Valve ...................................................................................................................................................... 84

Oxygen Sensor .............................................................................................................................................. 85

LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ........... 86

Remove and Replace ................................................................................................................................. 86

LPG Regulator Fuel Filter, GM Engines...................................................................................................... 87

Remove....................................................................................................................................................... 87

Install ......................................................................................................................................................... 87

Gasoline Fuel Filter....................................................................................................................................... 88

Remove and Replace for Lift Trucks Equipped with GFI ....................................................................... 88

Timing Belt .................................................................................................................................................... 89

Mazda Engines .......................................................................................................................................... 89

GM 2.4L Engine ........................................................................................................................................ 89

LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ......................... 89

Gasoline Fuel Injector, Mazda Engines........................................................................................................ 89

LPG Fuel Injector, GM Engines.................................................................................................................... 89

Gasoline Fuel Injector, GM Engines............................................................................................................. 89

Fuel Injector, Yanmar Engines ..................................................................................................................... 89

Forks............................................................................................................................................................... 89

Integral Sideshift Carriage ........................................................................................................................... 89

Bearings, Replace ...................................................................................................................................... 89

Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 89

Iron Transmission Housing ...................................................................................................................... 89

Aluminum Transmission Housing ........................................................................................................... 90

Remove .................................................................................................................................................. 90

Clean and Inspect ................................................................................................................................. 94

Install..................................................................................................................................................... 94

Transmission Oil Change, Wet Brake Drive Axle ....................................................................................... 95

Iron Transmission Housing ...................................................................................................................... 95

Aluminum Transmission Housing ........................................................................................................... 96

Wet Brake Axle Center Section and Planetary Housing, Oil Change ........................................................ 99

Brake Fluid (Master Cylinder), Change..................................................................................................... 103

Brake Fluid (Dry Brake), Remove .............................................................................................................. 104

Service Brakes (Dry Brake) ........................................................................................................................ 104

Differential (Dry Brake) .............................................................................................................................. 105

Maintenance Procedures Every 4000 Hours or 2 Years................................................................................. 106

Hydraulic Oil, Replace ................................................................................................................................ 106

Cooling System ............................................................................................................................................ 106

Safety Procedures When Working Near Mast................................................................................................ 108

Hood Latch Check ............................................................................................................................................ 110

Lift Chain Adjustments ................................................................................................................................... 111

Jump-Starting the Lift Truck.......................................................................................................................... 112

Jump-Starting Using a Battery Charger ................................................................................................... 112

Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................. 112

iii

Table of Contents Periodic Maintenance


Welding Repairs ............................................................................................................................................... 113

Overhead Guard Changes ............................................................................................................................... 113

Wheel and Tire Replacement .......................................................................................................................... 113

General ......................................................................................................................................................... 113

Solid Rubber Tire, Change (S Series) ......................................................................................................... 113

Remove and Install Tire on Wheel ......................................................................................................... 114

Pneumatic Tire With Tube, Repair............................................................................................................. 115

Remove Wheels From Lift Truck............................................................................................................ 115

Remove Tire From Wheel ....................................................................................................................... 115

Remove Tire From Two-Piece Wheel ................................................................................................. 116

Remove Tire From Three- and Four-Piece Wheels ........................................................................... 117

Install Wheel in Tire ............................................................................................................................... 118

Install Three-Piece or Four-Piece Wheel in Tire ............................................................................... 118

Install Tire on Two-Piece Wheel ........................................................................................................ 120

Install Two-Piece Wheel in Tire ......................................................................................................... 120

Add Air to Pneumatic Tires With Tube...................................................................................................... 121

Install the Wheels ................................................................................................................................... 121

Dual Drive Wheels, Install ..................................................................................................................... 121

Pneumatic Tubeless Tire, Repair................................................................................................................ 122

Remove Wheels From Lift Truck............................................................................................................ 122


Install Tire on Wheel .............................................................................................................................. 124

Add Air to Pneumatic Tubeless Tire ...................................................................................................... 127

Wheels, Install......................................................................................................................................... 127

Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... 127


Install Tire on Wheel .............................................................................................................................. 129

Adhesives and Sealants ................................................................................................................................... 131

This section is for the following models:

S40-70FT, S55FTS [F187];

H40-70FT [L177]

iv

8000 SRM 1150 General

General

WARNINGDO NOT make repairs or adjustments unless

you have both authorization and training. Re-

pairs and adjustments that are not correct can

make a dangerous operating condition.

WARNINGDONOT operate a lift truck that needs repairs.

Report the need for repairs immediately. If re-

pair is necessary, put a DO NOT OPERATE tag

in the operator’s area. Remove the key from

the key switch.

CAUTIONDisposal of lubricants and fluids must meet lo-

cal environmental regulations.

This section contains a Maintenance Schedule and

the instructions for maintenance and inspection.

The Maintenance Schedule has time intervals for in-

spection, lubrication, and maintenance of your lift

truck. The service intervals are provided in both op-

erating hours recorded on the lift truck hourmeter

and in calendar time. The recommendation is to use

the interval that comes first.

The recommendations for the time intervals provided

is for eight hours of operation per day. The time inter-

vals must be decreased from the recommendations

in the Maintenance Schedule for the following condi-

tions:

• 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 equipment

and trained service personnel to do a complete pro-

gram of inspection, lubrication, and maintenance. A

regular program of inspection, lubrication, andmain-

tenance will help your lift truck provide more effi-

cient performance and operate for a longer period of

time.

Some users have service personnel and equipment

to do the inspection, lubrication, and maintenance

shown in the Maintenance Schedule. Service man-

uals are available from your dealer for Hyster lift

trucks to help users who do their own maintenance.

SERIAL NUMBER DATA

The serial number for the lift truck is on the Name-

plate. It is also on the right side of the frame, under

the floor plate.

1

General 8000 SRM 1150

HOW TO MOVE DISABLED LIFT TRUCK

How to Tow Lift Truck

WARNINGUse extra caution when towing a lift truck if

any of the following conditions exist:

• Brakes do not operate correctly.

• Steering does not operate correctly.

• Tires are damaged.

• Traction conditions are bad.

• The lift truck must be towed on a slope.

If the engine cannot run, there is no power

available for the hydraulic steering system

and the service brakes. This condition can

make the lift truck difficult to steer and stop.

If the lift truck uses power from the engine to

help apply the brakes, the application of the

brakes will be more difficult. Poor traction can

cause the disabled lift truck or towing vehicle

to slide. A slope will also make the lift truck

more difficult to stop.

Never lift and move a disabled lift truck unless

the disabled lift truck MUST be moved and

cannot be towed. A lift truck used to move

a disabled lift truck MUST have a capacity

rating equal to or greater than the weight of

the disabled lift truck. The capacity of the lift

truck used to move a disabled lift truck must

have a load center equal to half the width of

the disabled lift truck. See the Nameplate of

the disabled lift truck for the approximate

total weight. The forks must extend the full

width of the disabled lift truck. Put the weight

center of the disabled lift truck on load center

of the forks. Be careful to not damage the

underside of the lift truck.

1. The towed lift truck must have an operator.

2. Tow truck slowly.

3. Using a lift truck or a lifting device that could

be attached to the mast (I.E. come-a-long), raise

carriage and forks approximately 30 cm (12 in.)

from surface. Install chain around a mast cross-

member and carriage to prevent carriage and

mast channels from moving.

4. If another lift truck is used to tow the disabled lift

truck, that lift truckmust have an equal or larger

capacity than the disabled lift truck. Install ap-

proximately 1/2 of a capacity load on forks of lift

truck that is being used to tow disabled lift truck.

This 1/2 capacity load will increase traction of lift

truck. Keep load as low as possible.

5. Use a towing link made of steel that fastens to

tow pins in counterweights of both lift trucks.

Slowly and carefully remove the slack out of the

towing link. See Figure 1.

1. STEEL TOW LINK 2. TOW PIN

Figure 1. Towing the Lift Truck

2

8000 SRM 1150 General

HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires

WARNINGThe lift truck must be put on blocks for some

types of maintenance and repair. The removal

of the following assemblies will cause large

changes in the center of gravity: mast, drive

axle, engine, transmission, and counterweight.

When the lift truck is put on blocks, put ad-

ditional blocks in the following positions to

maintain stability:

• Before removing the mast and drive axle, put

blocks under the counterweight so the lift

truck cannot fall backward.

• Before removing the counterweight, put

blocks under the mast assembly so the lift

truck cannot fall forward.

The surfacemust be solid, even, and level when

the lift truck is put on blocks. Make sure any

blocks used to support the lift truck are solid,

one-piece units.

CAUTIONThese lift trucks are equipped with cowl lifting

eyes. The cowl lifting eyes are to be used to

lift the front of the lift truck only. Lifting more

than the front of the lift truck with the cowl

lifting eyes will damage the cowl section.

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

ing tires to prevent movement of lift truck. See

Figure 2.

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

each outer mast channel.

3. Tiltmast fully forward until drive tires are raised

from surface.

4. Put additional blocks under frame behind drive

tires.

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

draulic jack under the side of the frame near the

front. Make sure jack has a capacity equal to at

least half the weight of the lift truck. See Name-

plate.

How to Raise Steering Tires

NOTE: Some lift trucks are equipped with lifting eyes

for the purpose of lifting the entire lift truck. If lift

truck is equipped with these type of lifting eyes, the

lift truck can be lifted and blocks installed.

1. Apply parking brake. Put blocks on both sides

(front and back) of drive tires to prevent move-

ment of lift truck. See Figure 2.

2. Use hydraulic jack to raise steering tires. Make

sure jack has a capacity of at least 2/3 of total

weight of lift truck as shown on the Nameplate.

3. Put jack under steering axle or frame to raise

lift truck. Put blocks under frame to support lift

truck.

3

General 8000 SRM 1150

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK

WARNINGEngine, exhaust system components and other

components are hot to the touch. Be sure lift

truck components are cool before starting in-

spection and cleaning, or personal injury may

occur.

WARNINGCompressed air canmove particles so that they

cause injury to the user or to other personnel.

Make sure that the path of the compressed air

is away from all personnel. Wear protective

goggles or a face shield to prevent injury to the

eyes.

CAUTIONUnits may be washed with a non-heated pres-

sure washer. Steam cleaning is not recom-

mended in most instances, as condensation

may form in electrical components causing

damage or erratic behavior.

NOTE: Lift trucks used in paper applications may

need cleaning beyond what is described here. Please

refer to Paper Application section in the applicable

Operating Manual and to available Service Gram/

Bulletin for more detail.

If it becomes necessary to clean the fork lift, follow

the guidelines listed below.

1. Assure truck components are cool before starting

the cleaning procedure.

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

move the traction battery.

3. Remove accumulated debris using a compressed

air line and nozzle.

4. Lightly spray a non-corrosive cleaning agent onto

the areas to be cleaned. This will help loosen

grime, so close contact direct spraying will not be

necessary.

5. Be sure to avoid directing the spray into electri-

cal panel compartment. Ensure overspray does

not 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 egress

under pressure or if connector is damaged.

4

8000 SRM 1150 Maintenance Schedule

6. Avoid spraying in areas containing electrical

components such as:

• Floor Plates

• Battery Compartment

• Dash/cowl assembly

• Armrests with electrical components

7. Clean the battery compartment by using a clean

cloth to wash the battery with water. Dry with

compressed air. Care should be taken to keep

moisture at a minimum as some units have a

traction or hydraulic motor directly below the

battery compartment.

8. DO NOT pressure wash the battery. Do not use

hot water. For cleaning traction batteries, refer

to the Battery section of the Service Manual.

9. DO NOT pressure wash lift chains, sheaves or

load rollers in the mast assembly. Refer to the

Chains, Sheaves and Load Rollers maintenance

section in the Service Manual for proper clean-

ing procedures.

10. After cleaning, immediately start and run the lift

truck to dry out components.

Maintenance Schedule

NOTE: The lift trucks shown in Figure 3 through

Figure 10 and Figure 12 through Figure 16 repre-

sent S40-70FT, S55FTS (F187) lift trucks, H40-70FT

(L177) are similar.

The lift truck shown in Figure 11 represents H40-

70FT (L177) lift trucks only.

5

Maintenance Schedule 8000 SRM 1150

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

6


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

7


Figure 5. Mazda 2.0L and 2.2L Gas Trucks (Except 2007 Emission Compliant Engines)

8


Figure 6. Mazda 2.0L and 2.2L LPG Trucks (Except 2007 Emission Compliant Engines)

9


Figure 7. Mazda 2.0L and 2.2L Gas Trucks (2007 Emission Compliant Engines Only)

10


Figure 8. Mazda 2.0L and 2.2L LPG Trucks (2007 Emission Compliant Engines Only)

11


Figure 9. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (Prior to Jan. 2011)

12


Figure 10. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (Prior to Jan. 2011)

13


Figure 11. Yanmar 2.6L and 3.3L Diesel Trucks (Prior to Jan. 2011)

14


Figure 12. GM 2.4L Gas Trucks with Aluminum Case Transmission (After January, 2011)

15


Figure 13. GM 2.4L LPG Trucks with Aluminum Case Transmission (After January, 2011)

16


Figure 14. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (After January,

2011)

17


Figure 15. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (After January,

2011)

18


Figure 16. Yanmar 2.6L and 3.3L Diesel Trucks (After January, 2011)

19


Table 1. Maintenance Schedule

Item

No.

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 or

Quantity

Specification

27 Tires X Check Condition See Nameplate

Safety Labels X Replace as

Necessary

See Parts Manual

30,

31Mast, Carriage, Header

Hoses, Lift Chains,

Attachment

X Check Condition

and Lubrication

See Parts Manual

Seat Belt, Hip

Restraints, and Seat

Rails

X Check Condition

and Operation

Hood and Seat Latches X Check Condition

and Operation

Engine Compartment X Remove

Combustible

Materials

See NOTE 5

Paper Application:

Engine Compartment,

Truck Components,

Exhaust Wraps,

Radiator, Radiator

Screen if equipped,

Belly Pan if equipped

X Check Condition

Clean as

Required

Replace as

Required

See NOTE 10

Check for Leaks - Fuel,

Oil, Water

X Check for Leaks

See NOTE 1

Hydraulic Hoses X Check Condition See Parts Manual

13 Coolant Hoses X Check Condition See Parts Manual

18 Fuel Tank (Gas)

S40-70FT, S55FTS

(F187)

CIL 40.5 liter

(10.7 gal)

85 Octane Gasoline

Minimum

18 Fuel Tank (Gas)

H40-70FT (L177)

CIL 52 liter (13.7 gal) 85 Octane Gasoline

Minimum

18 Fuel Tank (LPG) CIL 29.9 liter

(7.9 gal)

15.2 kg (33.5 lb)

LPG - HD 5, HD 10

18 Fuel Tank (Diesel)

H40-70FT (L177)

CIL 52 liter (13.7 gal) Diesel No. 2

Horn, Lights, Alarms X Check Operation

1 Service Brakes X Check Operation

25 Parking Brake X Check Operation

Steering Controls and

Steering Column Gas

Cylinder

X Check Condition

and Operation

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

20


Table 1. Maintenance Schedule (Continued)

Item

No.

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 or

Quantity

Specification

24 Transmission X Check for Leaks

24 Transmission X Check Operation

3 Hydraulic Oil

S40-70FT, S55FTS

(F187)

X X C 30.1 liter (32 qt)

See NOTE 2,

NOTE 3 and

NOTE 16.

ISO VG 46

Hydraulic Oil

15°C (5°F) and

Above

3 Hydraulic Oil

H40-70FT (L177)

X X C 39.8 liter (42 qt)

See NOTE 2,

NOTE 3 and

NOTE 16.

ISO VG 46

Hydraulic Oil

15°C (5°F) and

Above

6 Hydraulic Oil Filter C 1 Filter

See NOTE 16.

See Parts Manual

10 Hydraulic Tank

Breather

X C Inspect and

Replace as

Required

See Parts Manual

8 Battery and Cable

Terminals

X Clean

9 Engine Oil

Mazda

2.0L Engine

(Gas/LPG)

X

CILC 3.9 liter (4.1 qt)

See NOTE 4 and

NOTE 5.

7°C (20°F)

and Below

SAE 5W-20

16°C (60°F)

and Below

SAE 5W-30

18°C (0°F)

and Above

SAE 10W-30

API SM

ILSAC GF4

SAE J2362

9 Engine Oil

Mazda 2.2L

Engine

(Gas/LPG)

X


See NOTE 4 and

NOTE 5.

7°C (20°F)

and Below

SAE 5W-20

16°C (60°F)

and Below

SAE 5W-30

18°C (0°F)

and Above

SAE 10W-30

API SM

ILSAC GF4

SAE J2362


21



Item

No.

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 or

Quantity

Specification

9 Engine Oil

GM 2.4L Engine

(Gas/LPG)

X


See NOTE 4 and

NOTE 5.

7°C (20°F)

and Below

SAE 5W-20

16°C (60°F)

and Below

SAE 5W-30

18°C (0°F)

and Above

SAE 10W-30

API SM

ILSAC GF4

SAE J2362

21 Engine Oil Filter

Mazda 2.0L

and 2.2L and GM

2.4L Engines

(Gasoline)

C 1 Filter

See NOTE 4

and NOTE 5.

See Parts Manual

9 Engine Oil

Yanmar 2.6L

and 3.3L

Engine

(Diesel)

X

CILC 10.2 liter

(10.8 qt)

See NOTE 4

and NOTE 5.

20°C (68°F)

and Over

SAE 40

10 to 30°C (50 to 86°F)

SAE 30

0 to 20°C (32 to 68°F)

SAE 20

16 to 40°C

(3 to 103°F)

SAE 15W-40

20 to 30°C

( 4 to 86°F)

SAE 10W-30

10 to 10°C

(14 to 50°F)

SAE 20W

20 to 10°C

( 4 to 50°F)

SAE 10W

21 Engine Oil Filter

Yanmar 2.6L

and 3.3L

(Diesel)

C 1 Filter

See NOTE 4

and NOTE 5.

See Parts Manual

20 Air Filter CIL C 1 Filter

See NOTE 5,

NOTE 6, and

NOTE 13.

See Parts Manual

20 Air Filter X C 1 Filter

See NOTE 5,

NOTE 6, and

NOTE 13.

See Parts Manual


22



Item

No.

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 or

Quantity

Specification

16 Drive Belt

Mazda 2.0L

and 2.2L

(Gas/LPG)

X Check for Wear

and Damage.

Adjust as

Needed.

16 Drive Belt

GM 2.4L Engines

(Gas/LPG)

X Check for Wear

and Damage.

No adjustment

needed.

16 Drive Belt

Yanmar 2.6L and

3.3L Engines

(Diesel)

X Check for Wear

and Damage.

Adjust as

Needed.

LPG Regulator

Mazda 2.0L

and 2.2L Engines

X Drain Tar See

NOTE 5.

Engine Idle Speed

Mazda 2.0L

and 2.2L Engines

(Gas/LPG)

X See NOTE 5. 800 ±25 rpm

Engine Governed Speed

Mazda 2.0L

and 2.2L Engines

(Gas/LPG)


LPG Regulator GM

2.4L Engine

X Drain Tar See

NOTE 5.

Engine Idle Speed

GM 2.4L

(Gas/LPG)



GM 2.4L

(Gas/LPG)


Engine Idle Speed

Yanmar 2.6L

and 3.3L

(Diesel)



Yanmar 2.6L

(Diesel)



Yanmar 3.3L

(Diesel)


17 PCV Valve X C Replace as

Necessary

See NOTE 14.

See Parts Manual


23



Item

No.

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 or

Quantity

Specification

Oxygen Sensor X Check Indicator Light

4 Valve Adjustment

Mazda 2.0L

and 2.2L Engines

(Gas/LPG)

X Adjust as

Required

Intake

0.15 mm (0.006 in.)

Cold

Exhaust

0.35 mm (0.014 in.)

Cold

4 Valve Adjustment

Yanmar 2.6L

and 3.3L

Diesel Engines

X Adjust as

Required

Intake

0.20 mm (0.008 in.)

Cold

Exhaust

0.20 mm (0.008 in.)

Cold

Timing

Mazda 2.0L

and 2.2L Engines

(Gas)

X Adjust as

Required

6°±1° BTDC

(Orange Mark)

Timing

Mazda 2.0L

and 2.2L Engines

(LPG)

X Adjust as

Required

6°±1° BTDC

(Orange Mark)

19 LPG Fuel Filter

Mazda 2.0L

and 2.2L Engines

(2007 Emission

Compliant Engines

Only)

C 1 Filter See Parts Manual

LPG Fuel Regulator

Filter

Mazda 2.0L

and 2.2L Engines

(Except 2007 Emis-

sion Compliant En-

gines)


19 LPG Fuel Injector

Vapor Filter

Mazda 2.0L

and 2.2L Engines

(Except 2007 Emis-

sion Compliant En-

gines)


19 Fuel Filter, LPG

GM 2.4L Engines



24



Item

No.

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 or

Quantity

Specification

19 Fuel Filter

Mazda 2.0L

and 2.2L (Except

2007 Emission Com-

pliant Engines) and

GM 2.4L Engines

(Gasoline)


19 Fuel Filter

Mazda 2.0L

and 2.2L Engines

(2007 Emission

Compliant Engines

Only )

(Gasoline)


19 Fuel Water Separator

Yanmar 2.6L

and 3.3L Engines

(Diesel)


19 In-line Fuel Filter

Yanmar 2.6L and

3.3L Engines

(Diesel)


15 Timing Belt C Replace

See NOTE 7.

See Parts Manual

22 Fuel Injector

Mazda 2.0L

and 2.2L Engines

(LPG, Except 2007

Emission Compliant

Engines)

1 Injector

See NOTE 8.Check and Clean

If Required

22 Fuel Injectors

Mazda 2.0L

and 2.2L Engines

(Gas)

4 Injectors

See NOTE 8.Check and Replace

If Required

5 Spark Plugs

Mazda 2.0L

and 2.2L Engines

(Gas/LPG)

C Check

Plug Wires

4 Plugs

See Parts Manual

0.8 ±0.1 mm (0.031

±0.004 in.)

22 Fuel Injectors

GM 2.4L Engines

Gas/LPG

X 4 Injectors Check and Replace

If Required

5 Spark Plugs

GM 2.4L Engines

(Gas/LPG)

C Check

Plug Wires

4 Plugs

See Parts Manual

0.8 to 0.9 mm

(0.032 to 0.035 in.)


25



Item

No.

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 or

Quantity

Specification

22 Fuel Injectors

Yanmar 2.6L

and 3.3L Engine

(Diesel)

X 4 Injectors Check and Replace

If Required

12,

14Cooling System

Mazda 2.0L

and 2.2L Engines

(Serpentine

and Square

Wave)

X

CILC 11.0 liter

(11.6 qt)

See NOTE 15

12,

14Cooling System

Mazda 2.0L

and 2.2L Engines

(Square Wave

w/Air Oil

Cooler)

X

CILC 10.6 liter

(11.2 qt)

See NOTE 15

12,

14Cooling System

GM 2.4L Engine

X

CILC 10.6 liter

(11.2 qt)

See NOTE 15

12,

14Cooling System

Yanmar 2.6L

and 3.3L Engines

X

CILC 11.5 liter

(12.1 qt)

See NOTE 15

Clean Debris From

Radiator Core

X See NOTE 5

7 Transmission Oil

Dry Brakes- Iron

Case

X C 20 liter (21 qt) John Deere

JDM J20C

7 Transmission Oil

Dry Brakes- Alu-

minum Case


JDM J20C

23 Transmission Oil Filter C 1 Filter

See NOTE 4.

See Parts Manual

28 Forks X X X Check Condition

29 Mast

Sliding Surfaces

and Load Roller Sur-

faces

L Lubricate

As Required

See NOTE 11.

Multipurpose Grease

See NOTE 9.

29 Header Hoses X Check Condition

30 Lift Chains L X, L Lube as

Required. Check

for Wear

SAE 30W

Engine Oil

30 Lift Chains X Check

Lubrication

See NOTE 12.

SAE 30W

Engine Oil


26



Item

No.

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 or

Quantity

Specification

Mast

Sideshift

Carriage

X L Lube as

Required

2 Fittings

Multipurpose Grease

See NOTE 9.

Integral Sideshift

Carriage

Fork

Positioner

L Lube as

Required

2 Fittings

See NOTE 5.

Multipurpose Grease

See NOTE 9.

Mast

Pivots

L 2 Fittings Multipurpose Grease

See NOTE 9.

Mast

Integral

Sideshift

Carriage

(Upper/Lower

Bearings)

L X C Lube as

Required

2 Fittings

4 Bearings

Multipurpose Grease

See NOTE 9.

2.5 mm (3/32 in.) is

minimum thickness

Mast

Integral

Sideshift

Carriage

(Lower Mounting

Hooks)

X Check for Wear

and Clearance.

See NOTE 2 and

NOTE 5

0.76 mm (0.03 in.)

Minimum Wear

Limit.

Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

See NOTE 9.

Brake Master Cylinder

Rod End Pin

L SAE 10W-30

API SM

ILSAC GF4

SAE J2362

Manual Hydraulic

Hand Levers

L SAE 10W-30

API SM

ILSAC GF4

SAE J2362

26 Brake Fluid

Master Cylinder

Dry Brakes

CIL X C 0.25 liter

(0.53 pt)

SAE J-1703

DOT-3

26 Brake Oil

Master Cylinder

Wet Brakes

CIL X C 0.35 liter

(0.74 pt)

Dexron III from

Sealed Container

11 Steering Axle

Tie Rod Ends H40-

70FT (L177)


See NOTE 9.

11 Steering Axle

King Pin

H40-70FT (L177)


See NOTE 9.


27



Item

No.

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 or

Quantity

Specification

11 Steering Axle

Spindle

Bearings S40-70FT,

S55FTS (F187)


See NOTE 9.

2 Pedals, Levers, Seat

Rails, Cables, Hinges,

Linkages, Hood Latch

L Lubricate as

Necessary

Hyster Part No.

328388

1 Service Brakes

Dry Brakes

X Check Lining

Thickness

1.0 mm (0.040 in.)

Minimum

32 Differential and Drive

Axle Oil

Dry Brakes

S40-70FT, S55FTS

(F187)

X C 5.0 liter (5.3 qt) SAE 80W-90 or

85W-140

32 Differential and Drive

Axle Oil

Dry Brakes

H40-70FT (L177)

X C 6.5 liter (6.9 qt) SAE 80W-90 or

85W-140

7 Transmission Oil

Wet Brakes- Iron

Case

H40-70FT (L177)


JDM J20C

7 Transmission Oil

Wet Brakes- Alu-

minum Case

H40-70FT (L177)


JDM J20C

32 Wet Brake Axle

Planetary Housing

Oil, Left Side

X C 0.5 liter (0.5 qt) SAE 80W/90

32 Wet Brake Axle

Planetary Housing

Oil, Right Side

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

32 Wet Brake Axle, Center

Section Oil

X C 1.0 liter (1.1 qt) John Deere JDM

J20C

NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.

NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.

NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.

NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours

of operation.


28



Item

No.

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 or

Quantity

Specification

NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications in-

volving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive

compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require

more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based on

an application survey.

NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.

NOTE 7: Replace timing belt on Mazda engines every 3500 hours. Use only hour interval.

NOTE 8: Check fuel injectors at 5000 hours or 7 years.

NOTE 9: Multipurpose grease with 2 to 4% Molybdenum Disulfide.

NOTE 10: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should

be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and

steam clean as necessary.

NOTE 11: Lubricate mast every three months if unit has less than 1000 hours.

NOTE 12: Lubricate at first sign of visible surface rust.

NOTE 13: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every

2000 Hours or Annually to change air filter element.

NOTE 14: Replace after 3000 hours. Use hour interval only.

NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with

50% distilled water or deionized water.

NOTE 16: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures

1900 SRM 1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or

highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less

frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.


29

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1150

Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE

STOPPED


Report the need for repairs immediately. If

repair is necessary, put a DO NOT OPERATE

tag in the operator’s area. If the lift truck is

equipped with a key switch, remove the key

from the key switch.

Put lift truck on a level surface. Lower carriage

and forks, stop the engine, and apply parking brake.

Open hood and check for leaks and conditions that

are not normal. Clean any oil or fuel spills. Ensure

all surfaces are free of oils, lubricants, fuel, and or-

ganic dust or fibers (paper, wood, cotton, agricultural

grass/grain, etc.).

Tires and Wheels

Check tires for damage. Check tread and remove any

objects that will cause damage. Check for bent or

damaged rims. Check for loose or missing hardware.

Remove any wire, strapping, or other material that

is wrapped around the axle. See Figure 17.

Safety Labels

WARNINGSafety labels are installed on the lift truck to

provide information about operation and pos-

sible hazards. It is important that all safety la-

bels are installed on the lift truck and can be

read.

Check that all safety labels are installed in the cor-

rect location on lift truck. See the Parts Manual,

Model Description section in theOperatingMan-

ual or section Frame 100 SRM 1120 for correct lo-

cation of safety labels. See Parts Manual for part

numbers of the safety labels.

1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)2. MAKE SMOOTH EDGES3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)

Figure 17. Tire Check

30

8000 SRM 1150 Maintenance Procedures Every 8 Hours or Daily

Mast, Carriage, Lift Chains, Header Hoses,

Attachment

WARNINGLower the lift mechanism completely. Never

allow any person under a raised carriage. DO

NOT put any part of your body in or through

the lift mechanism unless all parts of the mast

are completely lowered and the engine is

STOPPED. DO NOT try to correct the align-

ment of the fork tips by bending the forks or

adding shims. Never repair damaged forks by

heating or welding. Forks are made of special

steel using special procedures. If either fork is

damaged, replace the forks as a set.

1. Inspect welds on mast and carriage for cracks.

Make sure that capscrews and nuts are tight.

2. Inspect channels for wear in areas where the

rollers travel. Inspect rollers for wear or dam-

age.

3. Inspect load backrest extension for cracks and

damage.

4. If lift truck is equipped with an integral sideshift

carriage or attachment, inspect the parts for

cracks and wear. Make sure the parts that fas-

ten the integral sideshift carriage or attachment

to carriage are in good condition.

5. Visually inspect hoses/fittings for hydraulic

leaks; hose cover for cuts, cracks or exposed re-

inforcement; defective/broken clamping devices

or sheaves; proper tracking during operation.

Adjust/repair/replace hose/components as nec-

essary. See Mast Repairs, 2-, 3-, and 4-Stage

Masts 4000 SRM 1148 for quick disconnect pro-

cedures.

6. Check that lift chains are correctly lubricated.

Use SAE 30W engine oil as necessary to lubricate

lift chains.

7. Inspect lift chains for cracks or broken links, and

worn or turned pins. See Figure 18.

8. Inspect chain anchors and pins for cracks and

damage.

9. Make sure lift chains are adjusted so that they

have equal tension. Adjustments or replace-

ment of the lift chains must be done by au-

thorized personnel.

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

5. LOOSE LEAVES6. TURNED PIN7. CORROSION

Figure 18. Lift Chain Check

31


Operator Restraint System

NOTE: The seat belt can be either black or red.

The seat belt, hip restraint, seat, hood, and hood

latch are all part of the operator restraint system.

Each item must be checked to make sure it is fas-

tened correctly, functions correctly, and is in good

condition. See Figure 19.

Automatic Locking Retractor (ALR)

NOTE: S40-70FT, S55FTS (F187) lift trucks produced

before November 2005 are equipped with the ALR

type seat belts.

The seat belt must fasten securely. Make sure the

seat belt extends and retracts smoothly and is not

frayed or torn. If the seat belt is damaged or does not

operate properly, it must be replaced. See Figure 19.

Emergency Locking Retractor (ELR)

NOTE: Lift trucks produced after November 2005

are equipped with the Emergency Locking Retractor

(ELR) style seat belt.

When the ELR style seat belt is properly buckled

across the operator, the belt will permit slight op-

erator repositioning without activating the locking

mechanism. If truck tips, travels off a dock, or comes

to a sudden stop, the locking mechanism will be acti-

vated and hold the operator’s lower torso in the seat.

A seat belt that is damaged, worn, or does not op-

erate properly will not provide protection when it is

needed. The end of the belt must fasten correctly in

the latch. The seat belt must be in good condition.

Replace the seat belt if damage or wear is seen. See

Figure 19.

NOTE: The following seat belt operation checks must

be performed three times before replacing the seat

belt 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 retracts

smoothly. If the seat belt cannot be pulled from the

retractor 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 the

seat belt will not pull from the retractor assembly.

If the seat belt can be pulled from the retractor,

when it is pulled with a sudden jerk, replace the

seat belt assembly.

• With the hood in the open position, make sure the

seat belt will not pull from the retractor assembly.

If the seat belt can be pulled from the retractor,

with the hood in the open position, replace the seat

belt assembly.

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 horizon-

tal to the ground in order to achieve the best er-

gonomic position. See Figure 19.

Seat Position Adjustment (Swivel Seat)

• The seat swivels 12 degrees to the right to allow the

operator a more ergonomic position when driving

in reverse.

• The seat swivels 5 degrees to the left to allow an

easier exit of the truck.

• The neutral position is shown in Figure 19.

Seat Adjustment for Operator Weight

CAUTIONAmajor cause for highWhole Body Vibration is

caused by the operator not adjusting the seat to

his/her weight.

NOTE: It is important to adjust the weight setting for

each operator.

NOTE: The seat is designed for maximum weight of

135 kg (298 lb).

• The target is for the "ride indicator" to fall between

the arrows when the operator sits upright in the

seat with the feet positioned on the pedals. This

ensures that the operator is set at the midpoint of

the 80 mm (3.15 in.) suspension.

• The handle can be turned as shown to increase or

decrease 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 decrease

on which way the handle is turned.

32


NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR ANDSWIVEL SEAT

1. LATCH STRIKER2. HOOD LATCH3. FORWARD/BACKWARD ADJUSTMENT4. HOOD5. OPERATOR WEIGHT ADJUSTMENT6. SEAT RAIL7. ARM REST

8. SEAT BELT9. SEAT10. HIP RESTRAINT11. HOOD HINGE12. SWIVEL ADJUSTMENT13. BACKREST ANGLE ADJUSTMENT

Figure 19. Hood, Standard Seat, and Swivel Seat Check

33


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 an

easier exit of the truck.

• The neutral position is shown in Figure 20.

Seat Adjustment for Operator Weight

CAUTIONAmajor cause for highWhole Body Vibration is

caused by the operator not adjusting the seat to

his/her weight.

NOTE: It is important to adjust the weight setting for

each operator.

NOTE: The seat is designed for maximum weight of

135 kg (298 lb).

• The target is for the "ride indicator" to fall between

the arrows when the operator sits upright in the

seat with the feet positioned on the pedals. This

ensures that the operator is set at the midpoint of

the 40 mm (1.57 in.) suspension.

• The weight adjustment knob can be turned left or

right to increase or decrease the weight resistance.

As the weight adjustment knob is turned the "stiff-

ness" of the suspension can be felt to increase or de-

crease on which way the weight adjustment knob

is turned.

NOTE: OPTIONAL SWIVEL SEAT SHOWN.

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 20. Seat Adjustment

34


Hood and Seat Latches

Make sure seat rails and latch striker are not loose.

Seat rails must lock tightly in position, but move

freely when unlocked. See Figure 19. Seat rails must

be correctly fastened to the hood and the hood fas-

tened to hinges on frame. Try to lift the hood to make

sure it is fastened correctly and will not move. If ad-

justment is required, go to Hood Latch Check.

Engine Compartment

Check for the presence of any combustible material

such as paper, leaves, etc. Remove any combustible

materials.

Paper Application

Vehicles used in paper applications require regular

inspection and cleaning to minimize the risk of fire.

This should be done at least once every eight hours

or more frequently depending upon operating en-

vironment. The paper application option will help

limit the contact of paper or tissue scraps to hot

surfaces under the hood, but frequent maintenance

is required.

WARNINGEngine and exhaust system components are

hot to touch. Be sure lift truck components are

cool before starting inspection and cleaning or

personal injury may occur.

Ensure truck engine cools properly by allowing it to

idle for several minutes. Shutting truck down while

hot will not allow engine to cool quickly due to the

loss of coolant circulation. The heat trapped under

the hood may actually increase engine temperature

because of no heat transfer through the radiator.

With engine off and lift truck components cooled,

check and clean the radiator and if equipped, radi-

ator screen. Check engine manifold, exhaust pipes,

muffler and catalytic converter for paper scraps.

Clean as required. Check and clean engine compart-

ment components, transmission, fan shroud, belly

pan if equipped, and inside frame ledges to avoid

paper, dust and oil accumulation. Check axle and

cowl openings for paper buildup and bailing wire.

Remove any debris.






eyes.

CAUTIONAir pressure, nozzle or extension tube may

cause damage to exhaust wraps and radiator

fins. Assure that air pressure, nozzle or exten-

sion tube does not damage exhaust wraps or

radiator fins.

Paper removal can generally be accomplished using a

compressed air line and nozzle. An extension may be

helpful to access hard to reach places. Remove floor

plates and side covers for better access to engine com-

partment. Open or removed belly pan, if equipped.

Clean components with compressed air. Take care

to maintain the integrity of the exhaust wraps when

cleaning with compressed air and use caution to not

force debris into openings. Check the condition of ex-

haust wraps for wear, proper fit, contamination with

oil or antifreeze, gaps in coverage, failed fasteners

and replace as necessary. Do not reuse wraps if they

have been removed for some other service operation.

WARNINGBe careful when cleaning with steam. Steam

can cause serious burns. Wear protective cloth-

ing, gloves, and eye protection. Never expose

your skin to steam.

If compressed air did not adequately remove debris,

steam clean to remove any persistent accumulation

of material or oil. Protect electrical components from

moisture when steam cleaning. Do not spray exhaust

wraps directly with high pressure steam. Allow lift

truck to air dry before returning to work in a con-

taminated environment. Paper dust and scraps will

adhere to wet surfaces.

Check the condition of exhaust wraps for wear,

proper fit, contamination with oil or antifreeze, gaps

in coverage, failed fasteners and replace as neces-

sary. Do not reuse wraps if they have been removed

for some other service operation.

35


Fuel, Oil, and Coolant Leaks, Check

WARNINGAll fuels are very flammable and can burn or

cause an explosion. DO NOT use an open flame

to check the fuel level or to check for leaks in

the fuel system. If there is a leak in the fuel sys-

tem, extra care must be used during the repair.

DO NOT operate the lift truck until a leak is re-

paired.

Make a visual check for leaks on and under the lift

truck. If possible, find and report leaks to mainte-

nance for repair. Leaks often indicate a need for re-

pair of damaged or worn components. Leaks in the

LPG fuel system are usually not visible unless ice

is present. There is however, usually a strong odor.

Fuel leaks MUST be repaired IMMEDIATELY.

Check fuel system for leaks and the condition of

parts. When fuel is added to lift truck, see section

HOW TO ADD FUEL TO THE LIFT TRUCK in the

Operating Manual.

Also check the condition of radiator or heater hoses

that are not leaking. Soft or cracked hoses need to be

replaced before a major leak occurs.

Hydraulic Hoses

Check condition of hydraulic hoses for serviceabil-

ity by inspecting for cracks or other obvious dam-

age. Check to ensure that the hydraulic hoses are

not leaking. If any hose is leaking, report it to main-

tenance for repair.

Coolant Hoses

Check condition of coolant hoses for serviceability by

inspecting for cracks or other obvious damage. Check

to ensure that the coolant hoses are not leaking. If

any hose is leaking, report it to maintenance for re-

pair.

Steering Column Gas Cylinder

Make sure the gas cylinder for steering column oper-

ates correctly. The cylinder must NOT allow column

to move unless tilt lever is released. See Figure 21.

Transmission

Check transmission for leaks and damaged or loose

components. Heavy-duty or high temperature oper-

ations can require more frequent checks.

1. TILT LEVER 2. GAS CYLINDER

Figure 21. Steering Column Gas Cylinder and

Tilt Lever

Hydraulic System Oil

WARNINGAt operating temperature, the hydraulic oil is

HOT. DO NOT permit the hot oil to touch the

skin and cause a burn.

CAUTIONDO NOT permit dirt to enter the hydraulic sys-

tem when the oil level is checked or the filter

is changed.

Never operate the hydraulic pump without oil

in the hydraulic system. The operation of the

hydraulic pump without oil will damage the

pump.

After engine has stopped, wait one minute before

checking the oil level. Keep hydraulic oil at the cor-

rect level as indicated on dipstick. Use correct oil as

shown in the Maintenance Schedule.

Check hydraulic system for leaks and damaged or

loose components. Heavy-duty or high-temperature

operations can require more frequent checks.

36


Engine Oil

After engine has stopped, wait one minute before

checking oil level. Keep oil at correct level as indi-

cated on the dipstick. Use the correct oil as shown in

the Maintenance Schedule.

See Figure 22 for lift trucks equipped with a Yanmar

2.6L and 3.3L diesel engine.

See Figure 23 for lift trucks equipped with GM en-

gine.

See Figure 24 for lift trucks equipped with a Mazda

engine (except 2007 emission compliant engines).


engine (2007 emission compliant engines).

There is an indicator light for the engine oil pressure

on the Display Switch Cluster. During normal opera-

tion, the red indicator light will illuminate when the

key switch is turned to ON, if the truck is equipped

with a key switch, or when the Power ON/OFF but-

ton is pressed, if the truck is equipped with a Power

ON/OFF option, and will stay illuminated until cor-

rect oil pressure is obtained, at which time the light

will go OFF.

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

ning, the engine oil pressure is low. Stop the engine

and check the oil level. Do not restart the engine un-

til the low pressure condition has been corrected.

1. BATTERY2. AUXILIARY COOLANT RESERVOIR3. RADIATOR CAP4. DRIVE BELT5. AIR FILTER6. ENGINE OIL FILTER7. DIPSTICK ENGINE OIL8. FUEL FILTER9. FUEL INJECTOR10. ENGINE OIL FILL

Figure 22. Yanmar 2.6L and 3.3L Diesel Engine

Maintenance Points

37


Figure 23. GM Engine Maintenance Points

38


Legend for Figure 23

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. PCV VALVE11. SPARK PLUGS12. FUEL INJECTOR

39


Figure 24. Mazda Engine Maintenance Points (Except 2007 Emission Compliant Engines)

40



A. GAS ENGINE B. LPG ENGINE


7. AIR FILTER8. FUEL FILTER9. ENGINE OIL FILTER10. PCV VALVE11. SPARK PLUGS12. FUEL INJECTOR

41


Figure 25. Mazda Engine Maintenance Points (2007 Emission Compliant Engines Only)

42



A. LPG ENGINE B. GAS ENGINE


7. AIR FILTER8. FUEL FILTER9. ENGINE OIL FILTER10. PCV VALVE11. SPARK PLUGS12. FUEL INJECTORS (GAS ONLY)

Air Filter

The air filter canister should not be opened until an

air filter element replacement is required. An air

filter element replacement is required when one of

the following occurs:

• The optional air flow restriction indicator light on

the dash illuminates.

• If equipped, the manual air flow indicator is red.

• The specified number of hours has passed since the

last filter element replacement.

DONOT operate lift truck until the air filter element

has been replaced.

Forks

NOTE: Forksmust be removed or installed by trained

personnel only.

The identification of a fork describes how the fork is

connected to the carriage. These lift trucks have hook

forks.

Remove

WARNINGDO NOT try to move a fork without a lifting

device. Each hook fork for these lift trucks can

weigh 45 to 115 kg (99 to 253 lb).

CAUTIONRemove fork latch pins if adding a fork posi-

tioner attachment. Damage to forks and other

carriage components can occur if fork latch

pins are not removed prior to using attach-

ment.

NOTE: Forks are to be replaced only in sets and not

individually.

NOTE: If lift truck is equipped with a fork positioner

attachment, perform Step 1 and Step 2. If lift truck

is not equipped with a fork positioner attachment, go

to Step 4.

NOTE: Depending on the size and configuration of

the forks installed on the lift trucks equipped with

a fork positioner, there may be a spacer bar between

the inner and outer fork carriers. See Figure 26.

1. Lower the carriage and remove four capscrews

from inner fork carriers. Remove inner fork car-

riers from integral sideshift carriage. See Fig-

ure 27.

1. OUTER FORK CARRIER2. CAPSCREW3. SPACER BAR*4. INNER FORK CARRIER

*SPACER BAR USED ON 977 mm (38.5 in.) AND

1067 mm (42 in.) CLASS II CARRIAGES.

Figure 26. Fork Carrier Spacer Bar

43


1. OUTER FORK CARRIER2. FORKS3. INNER FORK CARRIER4. SIDESHIFT CARRIAGE ASSEMBLY

5. FORK POSITIONER6. CAPSCREWS7. FORK REMOVAL NOTCH

Figure 27. Fork Removal, Lift Trucks Equipped With Fork Positioner Attachment

2. Slide fork to fork removal notch in bottom bar of

carriage. See Figure 27.

3. Lower fork onto blocks so bottom hook of fork

moves through the fork removal notch. Lower

carriage further so top hook of the fork is disen-

gaged from top carriage bar. Move carriage away

from fork or use a lifting device tomove fork away

from carriage. See Figure 28.

4. A fork can be removed from the carriage for re-

placement of the fork or other maintenance. Lift

lock pin and slide a hook fork to the fork removal

notch on carriage. See Figure 28 and Figure 29.

Lower fork onto blocks so that the bottom hook of

the fork moves through fork removal notch. See

Figure 29. Lower carriage further so that the top

hook of fork is disengaged from the top carriage

bar. Move carriage away from the fork, or use

a lifting device to move fork away from the car-

riage.

1. CARRIAGE BARS2. HOOK FORK

3. BLOCKS

Figure 28. Hook Fork Removal

44


Inspect

1. Inspect forks for cracks and wear. Check that the

fork tips are aligned as shown in Figure 29.

2. Check that the bottom of fork is not worn. See

Figure 29, item 4.

3. Replace any damaged or broken parts that are

used to keep the forks locked in position.

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 29. Forks Check

Install

WARNINGDO NOT try to move a fork without a lifting

device. Each hook fork for these lift trucks can

weigh 45 to 115 kg (99 to 253 lb).

CAUTIONRemove fork latch pins if adding a fork posi-

tioner attachment. Damage to forks and other

carriage components can occur if fork latch

pins are not removed prior to using attach-

ment.

NOTE: Forks are to be replaced only in sets and not

individually.

NOTE: If lift truck is not equipped with fork posi-

tioner, go to Step 1. If lift truck is equipped with fork

positioner, go to Step 2.

1. Move the fork and carriage so that the top

hook on the fork can engage the upper carriage

bar. Raise the carriage to move the lower hook

through the fork removal notch. Slide the fork on

the carriage so that both upper and lower hooks

engage the carriage. Engage the lock pin with a

notch in the upper carriage bar. See Figure 30.

2. If lift truck is equipped with a fork positioner

attachment, install inner fork carriers using

four capscrews. Tighten capscrews to 35 N•m

(25 lbf ft). See Figure 27.

Adjust

NOTE: During the adjustment of the forks, the heel

of the forks should not be touching the ground.

NOTE: The information below applies to lift trucks

NOT equipped with fork positioner attachment.

The forks are connected to the carriage by hooks and

lock pins. See Figure 28 and Figure 30. Lock pins are

installed through the top fork hooks and fit into slots

in the top carriage bar. If pin does not remain en-

gaged in carriage slot, replace with new pin. Adjust

forks as far apart as possible for maximum support

of the load. Hook forks will slide along carriage bars

to adjust for the load to be lifted. Raise the lock pin in

each fork to slide the fork on the carriage bar. Make

sure lock pin is engaged in the carriage bar to lock

fork in position after the width adjustment is made.

45


1. FORK2. LOCK PIN3. SPRING4. WASHER

5. WEDGE6. KNOB7. LOCK PIN

ASSEMBLY

Figure 30. Fork Lock Pin Assembly

HOW TO MAKE CHECKS WITH ENGINE

RUNNING


Report the need for repair immediately. If re-

pair is necessary, put a DO NOT OPERATE tag

in the operator’s area. If lift truck is equipped

with a key switch, remove the key.

WARNINGFASTEN YOUR SEAT BELT! The seat belt is in-

stalled to help the operator stay on the truck if

the lift truck tips over. IT CAN ONLY HELP IF

IT IS FASTENED.

Make sure that the area around the lift truck is clear

before starting the engine or making any checks of

the operation. Be careful when making the checks.

If the lift truck is stationary during a check, apply

the parking brake and put the transmission inNEU-

TRAL. Make the checks carefully.

Indicator Lights, Horn, Fuses, and Relays

If lift truck is equipped with a key switch, turn

key to ON position. If lift truck is equipped with a

Power ON/OFF button, press button to turn system

power ON. All warning lights and indicator lights

will light up for two seconds (start check) when

system power is turned ON. See Figure 31. Check

all indicator lights for correct operation as described

in the Operating Manual. Check the operation of

the horn. Start the engine by turning the key switch

to the Start position, if truck is equipped with a key

switch, or press the engine start button, if lift truck

is equipped with this button. If any indicator lights

do not operate correctly, stop the engine and check

the fuses. The fuses are located in the Power Distri-

bution Module (PDM) which is under the hood and

next to the battery on the right side. See Figure 32.

46


Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light

2 Warning Light, System Malfunction Light

3 Indicator Light, Air Filter Restriction

4 Indicators Light, Direction and Transmission

5 Warning Light, Brake Oil Level Malfunction Indicator

6 Warning Light, Fasten Seat Belt Malfunction Indicator

7 Warning Light, Parking Brake Malfunction Indicator

8 Warning Light, Alternator Malfunction Indicator

9 Warning Light, Transmission Oil Temperature Malfunction Indicator

10 Warning Light, Engine Oil Pressure Malfunction Indicator

11 Warning Light, Engine Coolant Temperature Malfunction Indicator

12 Warning Light, Coolant Level in Radiator Malfunction Indicator

13 Warning Light, Fuel Level Indicator

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

15 Indicator Light, Water Separator (Diesel Only)

16 Indicator Light, Cold Start (Diesel Only)

Figure 31. Warning and Indicator Lights

47


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)20. SEMICONDUCTOR TRANSZORB

Figure 32. PDM Showing Fuses and Relays

Service Brakes

Brake Fluid Level

WARNINGSmall amounts of water in the brake system

can cause reduced braking performance if the

water reaches the wheel cylinder areas. DO

NOT allow water entry. Ensure that the sealed

reservoir lid is properly replaced.

On lift trucks with wet brake drive axles, only

use Dexron III oil from sealed container in the

master cylinder.

On lift trucks with dry brake drive axles, only

use SAE J-1703 (DOT 3) brake fluid in the mas-

ter cylinder.

WARNINGIf the brake system has a power assist (or

boosted master cylinder), braking will be more

difficult if the engine is not running.

Loss of fluid from the brake fluid reservoir in-

dicates a leak. Repair the brake system before

using the lift truck. Replace the brake fluid in

the system if there is dirt or water in the sys-

tem.

48


There is an indicator light on the Display Switch

Cluster for the brake fluid. The red light is ON

when the key switch is in the START position or

the Power ON/OFF button is pressed, and must go

OFF when the engine is running. If the light is on

when the engine is running, the brake fluid level in

the reservoir is too low.

Operation, Check

Check the operation of the service brakes. Push on

the inching/brake pedal. The service brakes must be

applied before the inching/brake pedal reaches the

floor plate. The pedal must stop firmly and must

not move slowly down after the brakes are applied.

The service brakes must apply equally to both drive

wheels. The service brakes must not pull the lift

truck to either side of the direction of travel when

they are applied. The service brakes are automat-

ically adjusted when the transmission is in reverse

and the lift truck is moving and the brakes are firmly

applied. Full application of the inching/brake pedal

applies the service brakes and puts the transmission

in NEUTRAL.

Lift trucks with a MONOTROL® pedal. When

the inching/brake pedal is fully applied, a switch in

the starting circuit is closed so that the engine can be

started.

Parking Brake

Make sure service brakes are adjusted and the oper-

ation of the automatic adjuster mechanism is correct

before parking brake is adjusted.

Lift trucks with a MONOTROL® pedal. The

switch energizes the seat warning circuit when hand

lever is released. This switch puts the transmis-

sion in NEUTRAL by de-energizing the direction

solenoid. There is also a switch on the left side of

bracket. This switch prevents engine from starting

unless parking brake is applied.

NOTE: Make sure parking brake is released before

making adjustment.

1. Turn adjustment knob to raise the equalized link

and tighten parking brake cables shown in Fig-

ure 33. DO NOT tighten the adjustment so that

brake is applied when the lever is released. The

lever for the parking brake has a lock. Use your

thumb or finger to release lock on lever when

parking brake is released.

2. For burnished brakes, test the operation of the

parking brake. The lift truck with a capacity load

must not move when parking brake is applied on

a 15 percent grade [a slope that increases 1.5 m

in 10 m (1.5 ft in 10 ft)].

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

Figure 33. Parking Brake

Engine Oil Pressure

NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30 second countdown,

if engine oil pressure is less than 34.5 kPa (5 psi) on

lift trucks equipped with a Mazda engine and power-

train protection system. Lift trucks equipped with a

Yanmar diesel engine will enter the shutdown mode

when the engine oil pressure is less than 49 kPa

(7 psi) on lift trucks with powertrain protection

system. See the Engine Shutdown procedures in

the Operating Manual.

There is an indicator light for the engine oil pressure

on the Display Switch Cluster. During normal opera-

tion, the red indicator light will illuminate when the

key switch is turned to ON, if the truck is equipped

49


with a key switch, or when the power ON/OFF but-

ton is pressed, if the truck is equipped with this op-

tion, and will stay illuminated until correct oil pres-

sure is obtained, at which time the light will go off.

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

ning, the engine oil pressure is low. Stop the engine

and check the oil level. Do not restart the engine un-

til the low pressure condition has been corrected.

See Figure 22 for lift trucks equipped with a Yanmar

2.6L and 3.3L diesel engine.

See Figure 23 for lift trucks equipped with GM en-

gine.





Cooling System

WARNINGDONOT remove the radiator cap from the radi-

ator when the engine is hot. When the radiator

cap is removed, the pressure is released from

the system. If the system is hot, the steam and

boiling coolant can cause burns.

NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown,

if coolant temperature reaches 121°C (250°F) or

above on lift trucks with powertrain protection sys-

tem and a Mazda engine. Lift trucks equipped with

a Yanmar diesel engine will enter shutdown mode

when coolant temperature reaches 110°C (230°F)

or above on lift trucks with powertrain protection

system. See ENGINE SHUTDOWN procedures in

the Operating Manual.

There is an indicator light on the Display Switch

Cluster for the coolant temperature. The red light

is on when key switch is in the START position or

the Power ON/OFF button is pressed, and must go

off when the engine is running. If light is on when

engine is running, the coolant and engine are too hot.

Stop engine and check coolant level in the coolant

recovery reservoir.

Make sure coolant level is between the ADD and

FULL marks on the auxiliary coolant reservoir. See

Figure 34. The coolant will expand as it is heated

and the level in the auxiliary coolant reservoir will

increase.

CAUTIONAdditives may damage the cooling system. Be-

fore using additives, contact your local Hyster

dealer.

If coolant is added, seeMaintenance Schedule for cor-

rect solution.






eyes.

Check the radiator fins. Turn engine OFF and clean

the radiator with compressed air or water as needed.

Check for and remove any debris on the radiator core.

If the indicator light turns on again after restarting,

shut down the lift truck and do not operate the lift

truck until the problem is corrected.

1. FILL CAP2. AUXILIARY COOLANT RESERVOIR3. FULL MARK4. ADD MARK5. RADIATOR CAP

Figure 34. Auxiliary Coolant Reservoir

50

8000 SRM 1150 First Service After First 100 Hours of Operation

Steering System

WARNINGThe lift truck has hydraulic power steering.

The steering can be difficult if the engine is

not running.

Make sure steering system operates smoothly and

provides good steering control. Make sure steering

column can be adjusted and the gas cylinder function

is correct.

Control Levers and Pedals

Check that control levers for the transmission, mast,

and attachment operate as described in Operating

Manual. Check that pedals operate correctly as de-

scribed in Operating Manual.

Lift System, Operate

WARNINGWhen working on or near the mast, see Safety

Procedures When Working Near Mast at the

end of this section.

Lower the lift mechanism completely. Never

allow any person under a raised carriage. DO

NOT put any part of your body in or through

the lift mechanism unless all parts of the mast

are completely lowered and the engine is

STOPPED.

If the mast cannot be lowered, use chains on

the mast weldments and carriage so that they

cannot move. Make sure the moving parts are

attached to a part that does not move.

DO NOT try to find hydraulic leaks by putting

hands on pressurized hydraulic components.

Hydraulic oil can be injected into the body by

the pressure.

Perform the following checks and inspections:

1. Turn engine OFF and check for leaks in the

hydraulic system. Check condition of hydraulic

hoses and tubes.

NOTE: Some parts of the mast move at different

speeds during raising and lowering.

2. Slowly raise and lower mast several times with-

out a load. Raise mast to its full height at least

once. Themast componentsmust raise and lower

smoothly in the correct sequence. Hose must

track properly during operation.

3. The inner weldments and the carriage must

lower completely.

4. Raise the mast 1 m (3 ft) with a capacity load.

The inner weldments and the carriagemust raise

smoothly. Lower the mast. All moving compo-

nents must lower smoothly.

5. Lower the load to approximately 0.3 m (1 ft). Tilt

mast forward and backward. The mast must

tilt smoothly and both tilt cylinders must stop

evenly.

6. Check that the controls for the attachment op-

erate the functions of the attachment. See the

symbols by each of the controls. Make sure all of

the hydraulic lines are connected correctly and

do not leak.

First Service After First 100 Hours of Operation

MAZDA AND GM ENGINE OIL AND OIL

FILTER

NOTE: The engine oil and oil filter must also be

changed after the first 100 hours of operation for a

newly installed engine.

Change engine oil and oil filter. Apply clean oil to

gasket of new filter. Install new filter. Turn filter un-

til gasket touches, then tighten 1/2 to 3/4 turn with

your hand. Fill engine with oil as specified in Main-

tenance Schedule, until full mark reached on the dip-

stick. Start engine. Check area around oil filter for

leaks, shut engine off and check oil dipstick, if low

add oil. See Figure 35.

51

First Service After First 100 Hours of Operation 8000 SRM 1150

NOTE: BOTTOM VIEW OF ENGINE SHOWN.

A. MAZDA B. GM

1. OIL FILTER 2. DRAIN PLUG

Figure 35. Engine Oil Change

YANMAR ENGINE OIL AND OIL FILTER

Change engine oil and oil filter. Apply clean oil to

gasket of new filter. Install new filter. Turn filter un-

til gasket touches, then tighten 1/2 to 3/4 turn with

your hand. Fill engine with oil as specified in Main-

tenance Schedule, until full mark reached on the dip-

stick. Start engine. Check area around oil filter for

leaks, shut engine off and check oil dipstick, if low

add oil. See Figure 36.



Figure 36. Engine Oil Change Yanmar Diesel

52

8000 SRM 1150 Maintenance Procedures Every 250 Hours or 6 Months

Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform 8-hour checks prior to performing

procedures in this section.

MAZDA AND GM ENGINE OIL AND OIL

FILTER

NOTE: Change oil and oil filter for engine at first 100

hours of operation on new lift trucks.

Change engine oil and engine oil filter. Use correct oil

according to Maintenance Schedule. Apply clean oil

to gasket of new filter. Install new filter. Turn filter

until gasket touches, then tighten 1/2 to 3/4 turn with

your hand. Start engine. Check area around oil filter

for leaks. See Figure 37.


A. MAZDA B. GM


Figure 37. Engine Oil Change

53

Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1150

DRIVE BELT

Mazda 2.0L and 2.2L Engines

Fan and Alternator Drive Belt

Check drive belt for fan and alternator for wear and

damage.

Check tension by pushing on drive belt to check de-

flection. When pressure is 98 N (22 lbf), correct de-

flection is approximately 7 to 8 mm (0.3 in.). Loosen

alternator support bracket to adjust tension of belt.

See Figure 38.

1. CHECK TENSION HERE2. ALTERNATOR SUPPORT BRACKET

Figure 38. Drive Belts Check and Adjustment,

Mazda Engines

GM 2.4L Engine


Check drive belt for fan and alternator for wear and

damage. See Figure 39. The belt tensioner on GM

2.4L engine is a nonadjustable, self-tensioning device

with two positions: tension applied and tension re-

lieved. Adjustments are not needed.

1. BELT2. DRIVE TOOL SLOT3. SELF-ADJUSTING TENSIONER

Figure 39. GM 2.4L Engine Drive Belt

54


DRAIN TAR FROM LPG REGULATOR

(EXCEPT 2007 MAZDA EMISSION

COMPLIANT ENGINES)

NOTE: For 2007Mazda Emission Compliant Engines

go to Drain Tar From LPG Regulator (2007 Mazda

Emission Compliant Engines Only).

1. Warm engine to operating temperature.

2. Shut fuel valve off and run engine until engine

runs out of fuel and stops.

3. Raise hood.

4. Remove tar drain screw from regulator. Allow tar

to drain from regulator. When tar has completely

drained, install tar drain screw in regulator. See

Figure 40 and Figure 41.

1. TAR DRAIN SCREW

Figure 40. Mazda LPG Regulator

1. TAR DRAIN SCREW

Figure 41. GM LPG Regulator

55


DRAIN TAR FROM LPG REGULATOR (2007

MAZDA EMISSION COMPLIANT ENGINES

ONLY)

NOTE: The following procedures are for 2007 Mazda

Emission Compliant Engines Only.

NOTE: Draining the LPG regulator when engine is

warm will help the oils to flow freely from the regu-

lator.

1. Warm engine to operating temperature.

2. Close fuel valve on tank and run engine until it

runs out of fuel and stops. Try to restart engine

2-3 times until it no longer starts.

3. Turn the key to the OFF position.

4. Raise hood and disconnect negative battery ca-

ble.

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

tem,Mazda 2.0L and 2.2L Emission Compli-

ant Engines 900 SRM 1326.

6. Remove the retaining pin in the fuel temperature

sensor and remove from the electronic pressure

regulator (EPR). See Figure 42.

7. Using a suitable container, rotate the EPR 90° so

that the outlet fitting is pointing down and drain

the EPR.

8. Inspect and remove any tar or debris from the

secondary chamber.

9. Install fuel temperature sensor and retaining

pin. See Figure 42.

10. Install EPR assembly, see LPG Fuel System,

Mazda 2.0L and 2.2L Emission Compliant

Engines 900 SRM 1326.

1. FUEL TEMPERATURE SENSOR2. RETAINING PIN3. ELECTRONIC PRESSURE REGULATOR (EPR)

Figure 42. 2007 Mazda Emission Compliant

EPR Assembly

56



NOTE: Perform the 8-hour and 250-hour checks prior

to performing the procedures in this section.

HYDRAULIC SYSTEM OIL






is changed.




pump.

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.

See Figure 47 for lift trucks equippedwith iron trans-

mission housing.

See Figure 48 for lift trucks equipped with aluminum

transmission housing.

Add hydraulic oil only as needed. If hydraulic oil

is above the FULL level, the hydraulic oil will leak

from the breather during operation. The oil level in-

dicated by the dipstick is most accurate when the oil

temperature is 53 to 93°C (130 to 200°F).

HYDRAULIC TANK BREATHER

Inspect

NOTE:When inspecting the breather, do not remove

it. The breather element is a non serviceable part. If

it is damaged, replace with a new breather element.






eyes.

CAUTIONDirect air pressure on the filter element can

cause damage. Direct air pressure away from

filter element.

1. Using compressed air, remove any dirt and de-

bris in the frame cavity around the breather. See

Figure 43.

2. Replace the breather if oil has accumulated in

the cavity or on the breather, or if dirt has accu-

mulated at the breather passages at the bottom

of the breather.

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

Figure 43. Hydraulic Tank Breather

57


BATTERY

WARNINGThe acid in the electrolyte can cause injury.

If the electrolyte is spilled, use water to flush

the area. Use a solution of sodium bicarbon-

ate (soda) to make the acid neutral. Acid in the

eyes must be flushed with water immediately.

Wear eye protection.

WARNINGBatteries generate explosive fumes. Keep the

vents in the caps clean. Keep sparks or open

flame away from the battery area. DO NOT

make sparks from the battery connections.

Disconnect the battery ground cable when

doing maintenance.

Disconnect the negative and positive terminals of the

battery. 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 and

positive cables to their respective terminals.

YANMAR ENGINE OIL AND OIL FILTER

NOTE: Change the oil and oil filter for the engine at

the first 100 hours of operation on new lift trucks.

Change engine oil and engine oil filter. See Mainte-

nance Schedule for correct oil type and amount. Ap-

ply clean oil to gasket of new filter. Install new filter.

Turn filter until gasket touches, then tighten 1/2 to

3/4 turn with your hand. Start engine. Check area

around oil filter for leaks. Figure 44.



Figure 44. Engine Oil Change Yanmar Diesel

DRIVE BELT

Yanmar Diesel Engine


NOTE: The drive belt tension may be checked at any

of the three positions A, B, or C shown in Figure 45

which ever is most easily accessible.

Check the drive belt for the fan and alternator for

wear and damage. Check tension by pushing on drive

belt with a force of 98 N (22 lbf) to check deflection

at any one of three possible positions. See Figure 45.

Check Table 2 for the correct deflection of the V-belt.

Loosen alternator support bracket bolt to adjust ten-

sion of belt. See Figure 46. When the tension of

the V-belt is correct, tighten the alternator support

bracket bolt, and check the belt tension again.

Table 2. V-Belt Deflection Table

Used V-Belt Tension New V-Belt Tension

A B C A B C

10-13 mm

(0.375-0.5 in.)

7-10 mm

(0.250-0.375 in.)

8-13 mm

(0.3125-0.5 in.)8-11 mm (0.3125-

0.4375 in.)

5-8 mm (0.1875-

0.3125 in.)

7-11 mm

(0.250-0.4375 in.)

58


Figure 45. Yanmar Diesel Engine Drive Belt

1. SUPPORTBRACKET BOLT

2. ALTERNATOR

3. PRY BAR

Figure 46. Yanmar Diesel Engine Drive Belt

Adjustment

PCV VALVE

Remove the PCV Valve (positive crankcase ventila-

tion valve) from the valve cover. Check the operation

of the PCV Valve by shaking the PCV Valve and lis-

ten for the check ball rattling inside. If the check ball

does not rattle, replace the PCV Valve.

See Figure 23 for lift trucks equipped with a GM en-

gine.





CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and remove

material causing radiator core to be plugged or re-

stricted.






eyes.

Clean with compressed air, adjusted to a maximum

output of 103 kPa (15 psi), and blow debris from core

and fan shroud.

TRANSMISSION OIL LEVEL

WARNINGAt operating temperature, the transmission oil

is HOT. DO NOT permit the hot oil to touch the


CAUTIONDO NOT permit dirt to enter the transmission

when the oil level is checked or the filter is

changed.

NOTE: Transmission oil temperature should be at

least 50°C (120°F) when checking oil level.

If engine has been running, the engine must be shut

down for one minute or longer prior to checking the

oil level.

59


See Figure 47 for lift trucks equippedwith iron trans-

mission housing.

See Figure 48 for lift trucks equipped with aluminum

transmission housing.

If the transmission oil is low, add oil to transmission

at the dipstick tube at the correct level as indicated

on the dipstick. Use the correct oil as shown in the

Maintenance Schedule.

NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

Figure 47. Transmission and Hydraulic Oil Check

Figure 48. Transmission and Hydraulic Oil Check

60



NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

WET BRAKE PLANETARY HOUSING OIL

LEVEL CHECK

WARNINGAt operating temperature, the transmission

and wet brake planetary carrier housing oil is



CAUTIONDO NOT permit dirt to enter the center body

when the oil level is checked. Dirt will contam-

inate the oil and cause damage to the center

body of the axle.

1. Remove the planetary housing fill/level plugs

and O-rings. See Figure 49.

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

the right fill/level port for the right planetary

housing and at the left fill/level port for the

left planetary housing until the oil/level port

has overflowed. The correct oil is shown in the

Maintenance Schedule or Figure 50.

3. Install the planetary housing fill/level plug and

O-rings and tighten to 40 N•m (29.5 lbf ft).

1. RIGHT PLANETARY HOUSING2. LEFT PLANETARY HOUSING3. O-RING

4. FILL/LEVEL PLUG5. CENTER SECTION

Figure 49. Planetary Housings Fill/Level Plugs

61


A. LEFT PLANETARY HOUSING - USE SAE 80W/90B. RIGHT PLANETARY SECTION - USE SAE 80W/90C. CENTER HOUSING (BRAKE COOLING CHAMBER) - USE JDM J20C

1. OIL FILL/LEVEL PLUG2. OIL BREATHER

3. COOLING OIL INLET PORT

Figure 50. Oil Application Diagram

62


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 where

there is no wear. This thickness is dimension X. Now

measure thickness at heel of fork (see Figure 29). If

the thickness of the heel is not greater than 90% of

dimension X, replace fork.

MAST LUBRICATION


Procedures When Working Near Mast in this

section.

NOTE:The load rollers and sheaves have sealed bear-

ings and do not need additional lubrication.

1. Lubricate sliding surfaces and load roller sur-

faces along full length of channels as shown in

Figure 51.

A. UPPER LOAD ROLLERSB. LOWER LOAD ROLLERS

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

Figure 51. Mast Lubrication

NOTE: When lubricating the mast mounting/pivot

pins, the load must be removed from the normal

contact surface to allow grease to properly lubricate

the normal contact surfaces of the mast bushings.

2. Raise carriage about 61 cm (2 ft), and tilt the

mast fully back. Place blocks under the outer

mast channels to within 13 mm (0.5 in.) of the

channels. See Figure 52.

3. Tilt the mast fully forward. See Figure 52.

A. MAST TILTED FULLY BACKB. MAST TILTED FORWARD

1. BLOCK 2. MAST

Figure 52. Blocking the Mast

63


4. Tilt mast fully back. Remove the blocks from un-

der the channels.

5. If a integral sideshift carriage is installed, lu-

bricate sliding surfaces at grease fittings with

multipurpose grease shown in the Maintenance

Schedule. See Figure 55

Lubricate the mast pivot bushings at grease fit-

tings on outer mast. Use multipurpose grease

shown in the Maintenance Schedule. See Fig-

ure 53 and Figure 54.

6. If a fork positioner is installed, lubricate slid-

ing surfaces at lube fittings with multipurpose

grease shown in the Maintenance Schedule. See

Figure 56.

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 53. Mast Mounting Hanger Lubrication

64


1. OUTER MAST2. MAST PIVOT BUSHING

3. LUBRICATION FITTING

Figure 54. Pivot Pin Lubrication

Figure 55. Integral Sideshift Carriage


1. UPPER BEARINGS2. LOWER HOOKS3. LOAD ROLLER4. SNAP RING5. SIDESHIFT CYLINDER6. LOWER BEARINGS7. SHIMS8. INNER CARRIAGE9. LUBE FITTINGS10. OUTER FRAME

65


1. LUBE FITTING, SIDESHIFT CARRIAGE2. LUBE FITTING, FORK POSITIONER3. FORK CARRIER

4. UPPER FORK POSITIONER CYLINDER5. LOWER FORK POSITIONER CYLINDER6. SIDESHIFT CYLINDER

Figure 56. Fork Positioner Lubrication

HEADER HOSE CHECKS

Daily inspection plus; kinked, crushed, flattened or

twisted hose; hard, stiff or charred hose; hose fitting

slippage; proper hose tensioning. Adjust/repair/re-

place hose/components as necessary. See Mast Re-

pairs, 2-, 3-, and 4-Stage Masts 4000 SRM 1148

for quick disconnect procedures.

LIFT CHAIN LUBRICATION


Procedures When Working Near Mast in this

section.

DO NOT repair worn or damaged lift chains. If

a lift chain is worn or damaged, both lift chains

must be replaced.

NOTE: The 500 Hour/6 Months Lift Chain Lubrica-

tion should not be performed in combination with the

1000 Hour/6 Months Lift Chain Lubrication.

Lubricate lift chains with SAE 30W engine oil. The

best procedure is to remove the chains from the lift

truck and soak them in engine oil. Be sure to clean

any dirt or grease from chains before lubricating. DO

NOT USE STEAM TO CLEAN THE LIFT CHAINS.

66


TILT CYLINDER LUBRICATION

NOTE: The floor plate must be removed in order to

lubricate the rear tilt cylinder lubrication fittings.

Lubricate the tilt cylinder ends. Use multipurpose

grease shown in the Maintenance Schedule. There

are four lubrication fittings. See Figure 57.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW2. RETAINER3. ANCHOR PIN

4. LUBRICATION FITTING5. TILT SPACER

Figure 57. Tilt Cylinder Lubrication

67


MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION

Lubricate the master brake cylinder rod end pin. Use

engine oil as shown in the Maintenance Schedule.

See Figure 58 and Figure 59.

1. ROD END PIN2. COTTER PIN (LOCKING)

Figure 58. Master Brake Cylinder Rod End Pin

Lubrication (Dry Brake)

1. ROD END PIN2. COTTER PIN (LOCKING)

Figure 59. Master Brake Cylinder Rod End Pin

Lubrication (Wet Brake)

68


MANUAL HYDRAULIC LEVERS

LUBRICATION

Lubricate the bushings for the manual hydraulic

levers. Use spray lubricant as listed in the Mainte-

nance Schedule. See Figure 60.

NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.

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

Figure 60. Manual Hydraulic Levers

Lubrication

BRAKE FLUID








master cylinder.

Replace the brake oil in the system if there is

dirt or water in the system.



ter cylinder.

Remove the dash board from the cowl. The brake

fluid reservoir is located on the cowl, at the mas-

ter cylinder. Add brake fluid, as necessary. Use the

brake fluid shown in the Maintenance Schedule. See

Figure 61 and Figure 62.

1. BRAKE FLUID RESERVOIR2. MOUNTING BRACKET3. COWL

Figure 61. Brake Fluid Reservoir (Dry Brakes)

69


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

Figure 62. Brake Oil Change (Wet Brakes)

TIE ROD LUBRICATION (H40-70FT)

Lubricate the tie rods. Use multipurpose grease

shown in the Maintenance Schedule. There are two

lubrication fittings on each tie rod. See Figure 63.

1. AXLE2. LUBRICATION FITTING

Figure 63. Tie Rod Lubrication

70


DIFFERENTIAL AND DRIVE AXLE OIL

(DRY BRAKE)

The differential and drive axle use the same oil sup-

ply. The oil level must be between 0 to 10 mm (0 to

0.40 in.) below the bottom edge of fill hole. The fill

hole for checking the oil level is on the front of the

differential housing. Remove fill plug and check fluid

level by sticking a finger into the fill hole to feel if the

fluid level is at the bottom edge of the fill hole. See

Figure 64. If oil is low, add oil shown in the Main-

tenance Schedule until the oil level is between 0 to

10 mm (0 to 0.40 in.) below the bottom edge of fill

hole. Install fill plug and check for leaks.

1. DRIVE AXLE2. CHECK/FILL PLUG

3. DRAIN PLUG

Figure 64. Drive Axle Fluid Fill

71



NOTE: Perform the 8-hour, 250-hour, and 500-hour

checks prior to performing the procedures in this sec-

tion.

VALVE CLEARANCE, CHECK AND

ADJUST

The GM 2.4L engine has hydraulic valve lifters and

does not require valve clearance adjustments dur-

ing normal service. Check the valve clearance on

Mazda and Yanmar engines and make adjustments

as needed. See the Maintenance Schedule for valve

clearances.

Additional engine information is available in the fol-

lowing sections:

• GM Engine Repair, GM 2.4 Liter Engine 600

SRM 1121

• Mazda Engine, 2.0L and 2.2L 600 SRM 1122

IGNITION SYSTEM

GM 2.4L Engine

The GM 2.4L gasoline and LPG engines have an elec-

tronic control unit (ECU) that controls the ignition

timing. There are no adjustments. Change the spark

plugs every 1000 hours. The correct spark plug gap

is 0.8 to 0.9 mm (0.032 to 0.035 in.).

Mazda 2.0L and 2.2L Engines

The Mazda 2.0L and 2.2L engines have an electronic

ignition system. Change the spark plugs and check

the timing every 1000 hours. The correct spark plug

gap is 0.8 ±0.1 mm (0.031 ±0.004 in.).

The correct timing for the Mazda 2.0L and 2.2L en-

gines is as follows:

• Gasoline = 6° ±1° BTDC at 800 ±25 rpm (Orange

mark)

• LPG = 6° ±1° BTDC at 800 ±25 rpm (Orange mark)

For all Mazda engines except 2007 emission compli-

ant engines, see Electrical System, Mazda 2.0L

and 2.2L 2200 SRM 1143. For 2007 Mazda emission

compliant engines, see Electrical System, Mazda

2.0L and 2.2LEmissionCompliant Engines 2200

SRM 1327.

LPG FUEL FILTER ELEMENT REPLACE,

GM 2.4L ENGINE

Remove

WARNINGLPG can cause an explosion. DO NOT permit

any sparks or open flames in the work area.

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

stops.

2. Disconnect negative battery cable.

WARNINGA small amount of fuel may still be present in

the fuel line. Use gloves to prevent burns and

wear eye protection. If liquid fuel continues

to flow from the connections when loosened,

check to make sure the manual valve is fully

closed.

3. Remove the bolt and seal washer retaining the

top section of the fuel filter housing. Discard seal

washer. See Figure 65.

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 65.

3. Install new housing O-ring.

4. Install top section of fuel filter housing.

5. Install bolt and new seal washer. Tighten bolt to

13 N•m (115 lbf in).

72


1. BOLT2. SEAL WASHER3. FUEL FILTER HOUSING TOP SECTION4. FUEL FILTER5. FUEL FILTER O-RING6. HOUSING O-RING7. FUEL FILTER HOUSING BOTTOM SECTION

Figure 65. Fuel Filter Removal and Installation

NOTE: Opening the fuel valve too quickly can cause

the internal excessive flow valve to close, restricting

the flow of fuel. If this happens, close the fuel valve,

wait a few seconds, and then slowly open the fuel

valve again. This will reset the excess fuel valve.

6. Slowly open the fuel valve on tank.

7. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.

Check for leaks.

8. Check for leaks at connections by using soapy

solution or electronic leak detector. If leaks are

detected, make proper repairs.

LPG VAPOR FUEL FILTER REPLACE,

MAZDA ENGINES (EXCEPT 2007 MAZDA

EMISSION COMPLIANT ENGINES)



Remove and install a new LPG vapor fuel filter ele-

ment as follows:

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

is gone and engine stops.


3. Slowly loosen all hose fittings to filter. Let any

fuel drain from fittings before disassembling fil-

ter unit.

4. Remove capscrews and filter cover.

5. Remove O-ring, filter element, and spring. Dis-

card spring, filter element, and O-ring. See Fig-

ure 66.

6. Install new spring, new filter element, and new

O-ring.

7. Install filter cover to filter body with capscrews.

Tighten hose fittings.

NOTE: Leaks are normally indicated by a buildup of

frost around a loose fitting. A leak may also be dis-

covered by using soapy water.

8. Open fuel valve on LPG tank and check for leaks.

If leaks are found, tighten fittings.

73


1. FILTER BODY2. SPRING3. O-RING

4. FILTER ELEMENT5. FILTER COVER6. CAPSCREW

Figure 66. Mazda LPG Vapor Fuel Filter

LPG FUEL FILTER REPLACE, MAZDA 2007

EMISSION COMPLIANT ENGINES ONLY

Remove



1. Close fuel valve on tank and run engine until it

runs out of fuel and stops. Try to restart engine

2-3 times until it no longer starts.


WARNINGA small amount of fuel may still be present in

the fuel line. Use gloves to prevent burns and

wear eye protection. If liquid fuel continues

to flow from the connections when loosened,

check to make sure the manual valve is fully

closed.

3. Remove the bolt and seal washer from the fuel

filter housing top section. Discard seal washer.

See Figure 67.

4. Remove fuel filter housing top section from fuel

filter housing bottom section.

1. BOLT*2. SEAL WASHER3. FUEL FILTER HOUSING TOP SECTION*4. FUEL FILTER5. FUEL FILTER O-RING6. HOUSING O-RING7. FUEL FILTER HOUSING BOTTOM SECTION*8. LOW PRESSURE SWITCH

*NOT SERVICED SEPARATELY

Figure 67. Mazda 2007 Emission Compliant

Fuel Filter Removal/Installation

5. Remove and discard housing O-ring.

6. Remove and discard fuel filter and fuel filter

O-ring.

Clean/Inspect

1. Clean and inspect the fuel filter housing top sec-

tion for contamination or damage. If damaged,

replace the housing.

2. Clean and inspect the fuel filter housing bottom

section for contamination or damage. If dam-

aged, replace the housing.

Install

1. Install the new fuel filter and fuel filter O-ring.

See Figure 67.

2. Install new housing O-ring.

3. Install fuel filter housing top section onto fuel

filter housing bottom section.

4. Install bolt and new seal washer. Tighten bolt to

13 N•m (115 lbf in).

74


NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the

flow of fuel. If this happens, close the fuel valve, wait

a few seconds, and then slowly open the fuel valve

again. This will reset the excess flow valve.

5. Slowly open the fuel valve on tank.

6. Connect the negative battery cable.

7. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.

Check for leaks.

8. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are

detected, make proper repairs.

GASOLINE FUEL FILTER REPLACEMENT,

MAZDA 2007 EMISSION COMPLIANT

ENGINES ONLY

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 68.

3. Install the new fuel filter and tighten the clamp

screws to 2.45 to 2.77 N•m (22 to 25 lbf in).

4. Connect the negative terminal of the battery and

close the hood.

1. SCHRADER VALVE2. FUEL FILTER3. FUEL PUMP/SENDER UNIT

Figure 68. Fuel Filter Replacement, Mazda

2007 Emission Compliant Engines Only

75


FUEL FILTER REPLACEMENT, YANMAR

ENGINE



Replace the fuel filter at specified intervals to pre-

vent contaminants from adversely affecting the

diesel fuel flow.

NOTE: See Figure 69 for all steps in the following

procedure.

1. Stop the engine and allow it to cool.

2. Close all fuel cocks in the line.

NOTE: Tag connectors prior to disconnecting to aid

in reconnecting.

3. Disconnect fuel filter sensor connector.

4. Place an approved container under the fuel filter.

5. Open the drain plug to drain fuel from the fuel

filter.

6. Remove the fuel filter from the fuel filter head.

Wipe up any spilled fuel immediately.

7. Remove the drain plug from the fuel filter. Dis-

card the O-ring.

8. Remove the fuel filter sensor from the fuel filter

element and discard the O-ring.

9. Remove the inline fuel filter from the inlet nip-

ple that goes to the fuel injection pump. See Fig-

ure 70.

10. Dispose of the fuel, fuel filters, and O-ring in ac-

cordance with local directives.

11. Install the new inline fuel filter into the inlet nip-

ple.

12. Install the fuel filter sensor assembly in the new

fuel filter using the new O-ring supplied with the

fuel filter.

1. FUEL FILTER ASSEMBLY2. FUEL FILTER ELEMENT3. FUEL FILTER SENSOR CONNECTOR4. FUEL FILTER HEAD5. O-RING6. DRAIN PLUG7. FUEL FILTER SENSOR8. INLINE FUEL FILTER9. INLET NIPPLE

Figure 69. Yanmar Fuel Filter Replacement

76


1. INLINE FUEL FILTER2. FUEL LINE3. WATER SEPARATOR/FUEL FILTER4. FUEL SUPPLY VALVE

Figure 70. In-Line Fuel Filter Replacement

13. Install the new O-ring on the drain plug, and in-

stall the drain plug on the new fuel filter element.

Hand tighten only.

14. Clean the fuel filter head mounting surface and

apply a small amount of diesel fuel to the gasket

on the new fuel filter element.

15. Install the new fuel filter element until it con-

tacts the fuel filter head mounting surface.

Tighten one additional turn.

16. Open all the fuel cocks in the fuel line.

17. Reconnect the fuel filter sensor connector.

18. Prime the fuel system. See Priming the Fuel Sys-

tem (Yanmar).

19. Check for fuel leaks.

PRIMING THE FUEL SYSTEM (YANMAR)

1. Place an approved container under the air bleed

port. See Figure 71.

2. Loosen the air bleed port 2 or 3 turns.

CAUTIONNEVER use the starter motor to crank the en-

gine in order to prime the fuel system. This

may cause the starter to overheat and damage

the coils and/or the ring gear.

3. Operate the fuel priming pump until the fuel

coming out of the air bleed port is free of bubbles.

See Figure 71.

4. Tighten the air bleed port.

5. Wipe up any fuel that may have spilled, and dis-

pose of the fuel and rags in accordance with local

directives.

1. AIR BLEED PORT2. FUEL PRIMING PUMP

Figure 71. Priming the Fuel System

77


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 over

sheaves. Using a chain scale, (Hyster P/N 871796)

check lift chains as shown in Figure 72.

LIFT CHAIN LUBRICATION

WARNINGCleaning solvents can be flammable and toxic

and can cause skin irritation. When using

cleaning solvents, always follow the recom-

mendations of the manufacturer.

Compressed air can move particles so they




goggles or a face shield to prevent injury to

the eyes.

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

ing them in a solvent that has a petroleum base for

at least 30 minutes. Use compressed air, adjusted to

a maximum output of 103 kPa (15 psi), to completely

dry the chains when they are clean.

Lubricate the lift chains by soaking them in 30W en-

gine oil for at least 30 minutes. Remove the chains

from the oil. Hang the chains for one hour so excess

oil will drain from the chains.

PitchTotal Length

of 20 Links

(Pitch) of New

Chain

Wear Limit

(The

Maximum

Length 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.)

254.0 mm

(10.0 in.)

317.5 mm

(12.5 in.)

381.0 mm

(15.0 in.)

508.0 mm

(20.0 in.)

261.6 mm

(10.3 in.)

327.0 mm

(12.9 in.)

392.4 mm

(15.4 in.)

523.3 mm

(20.6 in.)

1. CHAIN WEAR SCALE

Figure 72. Lift Chains Check

78


INTEGRAL SIDESHIFT CARRIAGE, CHECK

BEARINGS

1. Lower carriage completely and remove forks.

2. Remove backrest and the lower mounting hooks

from sideshift carriage. See Figure 73.

3. Use a lifting device with a capacity of at least

450 kg (1000 lb) to lift outer frame away from

inner carriage.

4. Clean bearing areas. Inspect sideshift bearings

for wear as follows:

a. If either upper bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both up-

per bearings by driving upper bearings out of

carriage bar.

b. If either lower bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both

lower bearings by prying lower bearings from

lower carriage bar.

Figure 73. Integral Sideshift Carriage


1. UPPER BEARING2. LOWER HOOK3. LOAD ROLLER4. SNAP RING5. SIDESHIFT CYLINDER6. LOWER BEARING7. SHIMS8. INNER CARRIAGE9. LUBE FITTING10. OUTER FRAME

INTEGRAL SIDESHIFT CARRIAGE, CHECK

LOWER MOUNTING HOOKS

Inspect the lower mounting hooks for wear. Replace

the hooks if they are worn beyond the wear limit.

The wear limit clearance range is 0.76 mm (0.03 in.)

minimum and 1.52 mm (0.06 in.) maximum. See A

in Figure 74.

A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND1.52 mm (0.06 in.) MAXIMUM.

B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.

Figure 74. Lower Mounting Hooks Wear Limit

and Clearance Adjustment

79


STEERING AXLE

Lubricate the spindle bearings on the steering axle.

There are four lubrication fittings, two on each side of

the steering axle. See Figure 75. Use multipurpose

grease as shown in the Maintenance Schedule.

CONTROL LEVERS AND PEDALS

Lubricate linkages, pedal shafts, control cables

(throttle, hood, parking brake), and seat rails. Use a

silicone spray lubricant, Hyster Part No. 328388.

A. S40-70FT, S55FTS (F187)B. H40-70FT (L177)

1. STEERING AXLE2. LUBRICATION FITTING

Figure 75. Lubricate Spindle Bearings

80

8000 SRM 1150 Maintenance Procedures Every 2000 Hours or Annually

Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and

1000-hour checks prior to performing the procedures

in this section.

HYDRAULIC SYSTEM

Hydraulic Filter, Replace






is changed. Dirt can cause damage to the com-

ponents of the hydraulic system.




pump.



1. Put lift truck on a level surface and lower car-

riage.

2. Unscrew and remove lid and spring from head.

Remove and discard O-ring from lid. See Fig-

ure 76.

NOTE:Have container large enough to hold the filter

element and allow for final hydraulic oil draining.

NOTE: Note placement of filter element and handle

prior to removal to aid in installation.

3. Remove filter element and O-ring from bowl and

place in container. Cover head to prevent any

foreign material from getting into the hydraulic

tank. See Figure 76.

4. After filter element has drained, discard filter el-

ement and O-ring.

5. Remove and discard O-ring from top of bowl. See

Figure 76.

6. Remove and discard quad ring from head. See

Figure 76.

7. Clean housing and cover plate as necessary.

8. Inspect filter housing, especially sealing sur-

faces, for damage. Replace if damaged.

9. Inspect dipstick plug. Replace O-ring and plug

as necessary.

10. Lubricate sealing surfaces on filter housing and

cover plate with clean hydraulic oil.

11. Lubricate new quad ring with clean hydraulic oil

and install onto head. See Figure 76.

12. Lubricate new O-ring with clean hydraulic oil

and install onto top of bowl. See Figure 76.


and install on bottom of new filter element. See

Figure 76.

14. Install new filter element into bowl as noted dur-

ing removal. See Figure 76.


and install on lid. See Figure 76.

16. Install spring and lid onto head. See Figure 76.

Hand tighten lid.



ter dealer.

17. Start the truck, and allow it to run for 30 seconds.

Check for leaks. Stop engine and check hydraulic

oil level. Add oil, if necessary. Use hydraulic oil

shown in the Maintenance Schedule. To change

the hydraulic oil, see Hydraulic Oil, Replace.

81

Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1150

1. O-RING2. SPRING3. LID4. HEAD5. QUAD RING

6. FILTER ELEMENT7. BOWL8. DIPSTICK PLUG9. FILTER HOUSING10. COVER PLATE

Figure 76. Hydraulic Filter

Hydraulic Tank Breather, Replace

1. Raise the hood and remove the right rear side

panel. See Figure 77.

2. Unscrew and remove old hydraulic tank

breather, and replace with new hydraulic tank

breather.

3. Install right rear side panel and close hood. See

Figure 77.

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

Figure 77. Hydraulic Tank Breather

82


AIR FILTER

The air filter canister should not be opened until an

air filter element replacement is required. An air

filter element replacement is required when one of

the following occurs:

• The optional air flow restriction indicator light on

the dash illuminates.

• The optional manual air flow indicator button pops

up.

• The specified number of hours has passed since the

last filter element replacement.

CAUTIONDO NOT to allow dirt to enter the engine air

intake when replacing the air filter element. A

small amount of dirt could cause engine dam-

age.

1. Shut off engine. Never open air filter canister or

remove filter element with engine running.

2. Unlatch and remove cover. To remove filter el-

ement, press and rotate filter element counter-

clockwise about 1/8 turn until the filter element

is free. To assist removal, gently move the end

back and forth to help break the seal. See Fig-

ure 78.

3. Gently pull the filter element from the canister.

Avoid dislodging contaminants from the element

or knocking it against the canister.

4. With a clean, soft rag, clean the inside surface

of the canister. Remove liner assembly to make

cleaning easier. Clean well around the locking

tabs that retain the element. Clean tabs make

new filter element installation easier. Be careful

not to knock any contaminants into the outlet

tube to the engine.

5. Inspect liner and O-ring assembly for damage. If

damaged, replace liner and O-ring assembly.

6. Install liner assembly into canister by pushing

in. Make sure liner assembly is properly seated

in the canister. It will fit snugly into and be cen-

tered 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-sealing

surfaces. Do not use if damage is detected.

1. CANISTER2. DUST EVACUATION VALVE3. LINER ASSEMBLY

4. FILTER ELEMENT5. COVER

Figure 78. Air Filter

83


CAUTIONThe element must be properly installed to en-

sure adequate engine protection. An improp-

erly installed element may allow dirt and dust

to enter and damage the engine.

NOTE: Proper element installation is required to al-

low the cover to be installed correctly. Never reinstall

a used element. Never install a damaged element.

Always use a Hyster-approved filter element.

8. Install the new filter element into the canister.

Press and rotate the filter element 1/8 turn clock-

wise until fully engaged in the canister. See Fig-

ure 79.

1. PUSH IN 2. TWIST TO LOCK

Figure 79. Air Filter Label

CAUTIONDuring cover installation, DO NOT force the

cover on the canister. To do so will result in

damage to the filter element, cover, and possi-

bly the canister.

NOTE: If the filter element is properly installed, the

cover will fit easily into the canister with no gap be-

tween the cover and the canister. If cover does not

fit easily, the filter element is not installed properly.

Do not use a cover that is bent, damaged, or missing

latches.

9. Install cover into the canister and ensure the IN-

LET arrow is in line with the canister inlet.

NOTE: Do not use latches to pull cover down against

the canister. If cover does not fit completely against

the canister with no gaps, the element is not installed

correctly.

10. Fasten the latches to secure the cover to the can-

ister. Make sure the latches penetrate the slots

in both the canister and the cover.

11. Inspect the entire air intake system for leaks.

Inspect all clamps for tightness and tighten if

necessary. Inspect all hoses for damage. Re-

place damaged hoses. Inspect the dust evacua-

tion valve for damage. If damaged, replace the

dust evacuation valve.

PCV VALVE

Install a new PCV valve.

See Figure 23 for lift trucks equipped with a GM en-

gine.





84


OXYGEN SENSOR

NOTE: The 2007 Mazda emission compliant engines

are equipped with Pre and Post Catalytic Converter

Oxygen Sensors.

Check that the oxygen sensor electrical connector is

seated and locked. Check wires for cracks, splits,

chaffing, or burn through. If necessary, repair.

See Figure 80 for lift trucks equipped with a GM or

Mazda engine.


engine (2007 Mazda emission compliant engines).

A. MAZDA EXHAUST SYSTEMB. GM EXHAUST SYSTEM

1. OXYGEN SENSOR2. EXHAUST PIPE

3. MANIFOLD

Figure 80. Oxygen Sensor

85


1. MUFFLER2. POST-CATALYTIC CONVERTER OXYGEN

SENSOR3. PRE-CATALYTIC CONVERTER OXYGEN

SENSOR

4. EXHAUST PIPE (EXHAUST MANIFOLD TOCATALYTIC CONVERTER)

5. EXHAUST PIPE (CATALYTIC CONVERTER TOMUFFLER)

6. CATALYTIC CONVERTER

Figure 81. Oxygen Sensors for 2007 Mazda Emission Compliant Engines

LPG REGULATOR FUEL FILTER, MAZDA

ENGINES (EXCEPT 2007 MAZDA

EMISSION COMPLIANT ENGINES)

Remove and Replace

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

stops.

2. Remove six capscrews, fuel filter cover, and two

filter elements. Discard filter elements. See Fig-

ure 82.

3. Install two new filter elements and six capscrews

on fuel filter cover. Tighten six capscrews to 6.4

to 7.9 N•m (57 to 70 lbf in).

1. FILTER ELEMENTS2. CAPSCREWS

3. FUEL FILTERCOVER

Figure 82. Mazda LPG Regulator Fuel Filter

86


LPG REGULATOR FUEL FILTER, GM

ENGINES

Remove

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

stops.

2. Disconnect the hose from the inlet fitting.

3. Remove the inlet fitting from the LPG regulator.

Discard the O-ring. See Figure 83.

4. Remove and discard the plastic cap, foam filter,

paper filter, and rubber washer from the LPG

regulator.

5. Disconnect the hose from the outlet fitting. Re-

move three screws and the outlet fitting from the

LPG 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. Using

three screws, install the outlet fitting on the LPG

regulator.

3. Install new rubber washer, paper filter, foam fil-

ter, and plastic cap in the LPG regulator.

4. Install new O-ring on the inlet fitting. Install

inlet fitting into the LPG regulator and connect

hose to the inlet fitting.

5. Open shutoff valve on LPG tank and check for

leaks.

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

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

Figure 83. GM LPG Regulator

87


GASOLINE FUEL FILTER

Remove and Replace for Lift Trucks

Equipped with GFI

1. Raise the hood and disconnect the negative ter-

minal of the battery.

2. Remove and discard the fuel filter. See Figure 84.

3. Install the new fuel filter and tighten the clamp

screws to 2.45 to 2.77 N•m (22 to 25 lbf in).

4. Connect the negative terminal of the battery and

close the hood.

A. MAZDA (EXCEPT 2007 EMISSION COMPLIANTENGINES)

B. GM 2.4L

1. FUEL FILTER2. FUEL TANK3. FUEL PUMP/SENDER UNIT

Figure 84. Fuel Filter Replacement

88


TIMING BELT

Mazda Engines

Change timing belt after 3500 hours of operation.

The cover for the timing belt must be removed for

checks and adjustments. See the sectionMazda En-

gine, 2.0L and 2.2L 600 SRM 1122 for more infor-

mation.

GM 2.4L Engine

The cover for the timing belt must be removed for

checks and adjustments. See the sectionGMEngine

Repair, GM 2.4 Liter Engine 600 SRM 1121 for

more information.

LPG FUEL INJECTOR, MAZDA ENGINES

(EXCEPT 2007 MAZDA EMISSION

COMPLIANT ENGINES)

For removal and cleaning instructions, see the sec-

tion LPG Fuel System,Mazda 2.0L and 2.2L En-

gines 900 SRM 1125.

GASOLINE FUEL INJECTOR, MAZDA

ENGINES


tionGasoline Fuel System,Mazda 2.0L and 2.2L

900 SRM 1127 for all Mazda engines except 2007

emission compliant engines. For 2007 emission com-

pliant engines, see the section Gasoline Fuel Sys-

tem, Mazda 2.0L and 2.2L Emission Compliant

Engines 900 SRM 1325.

LPG FUEL INJECTOR, GM ENGINES


tion LPG Fuel System, GM 2.4L Engine 900 SRM

1124.

GASOLINE FUEL INJECTOR, GM ENGINES


tion Gasoline Fuel System, GM 2.4L Engine 900

SRM 1126.

FUEL INJECTOR, YANMAR ENGINES


tion Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L

600 SRM 1205.

FORKS

WARNINGNever repair damaged forks. DO NOT heat,

weld, cut, drill, or bend the forks. Forks are

made of special steel using special methods.

Replace damaged forks as a set.

Check heel and attachment points of forks with a

penetrant or by magnetic particle inspection.

INTEGRAL SIDESHIFT CARRIAGE

Bearings, Replace

Replace all four bearings regardless of wear. See sec-

tion, Maintenance Procedures Every 1000 Hours or

6 Months for the procedure.

TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACE

Iron Transmission Housing






changed. Dirt can cause damage to the trans-

mission components.



NOTE: Change the transmission oil filter at the first

500 hours of operation on new lift trucks. Before re-

moving the oil filter, make a hole at the top of the

filter and allow five minutes for the oil to drain down

into the transmission. This will reduce the oil that

will run out of the filter and onto the transmission

when the filter is removed.

NOTE: The drain plug for the transmission is on the

lower right side of the cover of the transmission, to-

ward the rear of the lift truck.

89


1. Remove drain plug, spring, and screen. Drain oil

into a container.

NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR THE SAKE OF

CLARITY.

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

Figure 85. Transmission Oil Change



cleaning solvents, always follow the solvent

manufacturer’s recommended safety proce-

dures.



Make sure the path of the compressed air is

away from all personnel. Wear protective gog-

gles or a face shield to prevent injury to the

eyes.

2. Clean screen with cleaning solvent, and dry with

compressed air, adjusted to the maximum output

of 103 kPa (15 psi).

3. When oil has drained, first install screen, then

spring, and transmission drain plug.

4. Remove and discard transmission breather.

Install new transmission breather and hand

tighten.

5. Remove and discard old transmission oil filter.

Apply clean oil to gasket of new transmission oil

filter. Install new filter and hand tighten.

6. Add oil to transmission at the dipstick tube. The

correct oil is shown in theMaintenance Schedule.

7. Start and run the engine for approximately five

minutes after fill to allow oil to lubricate parts

within the transmission.



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

and check oil level. Top off oil, if necessary.

Aluminum Transmission Housing

Remove







mission components.




500 hours of operation on new lift trucks.

1. Remove drain plug. When oil is completely

drained, install drain plug.

See Figure 86 for lift trucks equipped with an

aluminum gear drive manufactured before Jan-

uary, 2011.

90



aluminum gear drive manufactured after Jan-

uary, 2011.


aluminum gear drive manufactured after July,

2013.



2013.

2. Remove capscrews washers, charge pump, and

charge pump gasket. Discard gasket.



uary, 2011.



uary, 2011.



2013.



2013.

3. Remove suction screen spring and suction screen.



uary, 2011.



uary, 2011.



2013.



2013.

4. Remove flange head capscrews and hydraulic

gear pump.



uary, 2011.



uary, 2011.



2013.



2013.

5. Remove and discard transmission oil filter.



uary, 2011.



uary, 2011.



2013.



2013.




uary, 2011.



uary, 2011.



2013.



2013.

91


1. TRANSMISSION2. TRANSMISSION OIL FILTER3. TRANSMISSION DIPSTICK4. TRANSMISSION BREATHER5. TRANSMISSION DRAIN PLUG6. SUCTION SCREEN7. SUCTION SCREEN SPRING8. CHARGE PUMP GASKET9. CHARGE PUMP10. WASHER11. CAPSCREW12. FLANGE HEAD CAPSCREW13. HYDRAULIC GEAR PUMP

Figure 86. Transmission Oil Filter Change -

Aluminum Gear Drive (Prior to January, 2011)



Aluminum Chain Drive (After January, 2011)

92




Aluminum Gear Drive (After July, 2013)



Aluminum Chain Drive (After July, 2013)

93


Clean and Inspect





dures.






eyes.

1. Clean suction screen spring and suction screen

with cleaning solvent and dry with compressed

air. Inspect spring and screen for damage. Re-

place if damaged.

2. Wipe exterior surfaces of transmission housing,

hydraulic gear pump and charge pump with sol-

vent soaked clot and dry with a lint-free cloth.

Inspect housing and pumps for damage. Replace

if damaged.

3. Clean metal threaded components with solvent

and dry with compressed air. Clean plastic

threaded components with warm soapy water

and dry with a lint-free cloth. Inspect compo-

nents for damage. Replace if damaged.

Install

1. Install new transmission breather.



uary, 2011.



uary, 2011.



2013.



2013.

2. Install suction screen and suction screen spring.



uary, 2011.



uary, 2011.



2013.



2013.

3. Using seven washers and seven capscrews in-

stall new charge pump gasket and charge pump.

Tighten capscrews to 19 N•m (168 lbf in).



uary, 2011.



uary, 2011.



2013.



2013.

4. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of

sealant to either hydraulic gear pump or trans-

mission housing face. Hold pump in the correct

position on the transmission. Install flange head

capscrews into pump and transmission housing.

Tighten capscrews to 38 N•m (28 lbf ft).



uary, 2011.



uary, 2011.



2013.

94




2013.

5. Apply clean oil to gasket of new transmission oil

filter and install filter onto transmission.



uary, 2011.



uary, 2011.



2013.



2013.

6. Add oil to transmission at dipstick tube. The cor-

rect oil is shown in the Maintenance Schedule.

7. Start and run engine for approximately five min-

utes after fill to allow oil to lubricate parts within

transmission.



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

check oil level. Top off oil, if necessary.

TRANSMISSION OIL CHANGE, WET

BRAKE DRIVE AXLE

Iron Transmission Housing







mission components.




500 hours of operation on new lift trucks. Before re-

moving the oil filter, make a hole at the top of the

filter and allow five minutes for the oil to drain down

into the transmission. This will reduce the oil that

will run out of the filter and onto the transmission

when the filter is removed.

NOTE: The drain plug for the transmission is on the

lower right side of the cover of the transmission, to-

ward the rear of the lift truck.

1. Remove drain plug, spring, and screen. Drain oil

into a container. See Figure 90.

NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR THE SAKE OF

CLARITY.

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

Figure 90. Transmission Oil Change

95






dures.






eyes.


compressed air, adjusted to the maximum output


3. When oil has drained, first install screen, then

spring, and transmission drain plug. See Fig-

ure 90.


Install new transmission breather and hand

tighten. See Figure 90.

5. Remove and discard old transmission oil filter.

Apply clean oil to gasket of new transmission oil

filter. Install new filter and hand tighten. See

Figure 90.

6. Add oil to transmission at the dipstick tube. The




within the transmission.



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

and check oil level. Top off oil, if necessary.

Aluminum Transmission Housing

WARNINGThe oil used for the transmission should not be

contaminated. If the transmission oil becomes

contaminated, the oil must be drained and re-

placed with new oil.






changed. Dirt will contaminate the oil and

cause damage to the transmission and wet

brake planetary carrier housing components.




500 hours of operation on new lift trucks.

1. Place a container under transmission. Remove

transmission temperature sensor to drain oil.

See Figure 91. When oil is completely drained,

install transmission temperature sensor.

2. Using clamp pliers, slide two clamps toward mid-

dle of brake cooling hose. See Figure 92.

3. Remove brake cooling hose from wet brake drive

axle and transmission assembly. See Figure 92.

4. Remove capscrews, washers, charge pump, and

charge pump gasket. Discard gasket. See Fig-

ure 91.

5. Remove suction screen spring and suction screen.

See Figure 91.

6. Remove flange head capscrews and hydraulic

gear pump. See Figure 91.

7. Remove and discard transmission oil filter. See

Figure 91.

8. Remove and discard transmission breather. See

Figure 91.

96


1. TRANSMISSION2. TRANSMISSION OIL FILTER3. TRANSMISSION DIPSTICK4. TRANSMISSION BREATHER5. SUCTION SCREEN SPRING6. SUCTION SCREEN7. CHARGE PUMP GASKET

8. CHARGE PUMP9. WASHER10. CAPSCREW11. FLANGE HEAD CAPSCREW12. HYDRAULIC GEAR PUMP13. TRANSMISSION TEMPERATURE SENSOR

Figure 91. Transmission Oil Change - Aluminum Housing

97


1. WET BRAKE DRIVE AXLE2. CLAMP

3. BRAKE COOLING HOSE4. TRANSMISSION ASSEMBLY

Figure 92. Brake Cooling Line Remove/Install

9. Drain oil from left planetary housing as de-

scribed below:

a. Place container under left planetary housing.

b. Remove drain plug from housing. See Fig-

ure 94. Remove and discard O-ring from

drain plug.

c. Remove fill/level plug from housing. Re-

moving fill/level plug allows oil to drain at a

faster rate. See Figure 93.

d. Drain oil into container. When oil has com-

pletely drained, install new O-ring on drain

plug then install drain plug in housing.

Tighten drain plug to 40 N•m (29.5 lbf ft).





dures.






eyes.


compressed air, adjusted to a maximum output


11. Install new transmission breather. See Fig-

ure 91.

12. Install suction screen and suction screen spring.

See Figure 91.

13. Using seven washers and seven capscrews in-

stall new charge pump gasket and charge pump.

See Figure 91. Tighten capscrews to 19 N•m

(168 lbf in).

14. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of

sealant to either hydraulic gear pump or trans-

mission housing face. Hold pump in the correct

position on the transmission. Install flange head

capscrews into pump and transmission housing.

See Figure 91. Tighten capscrews to 38 N•m

(28 lbf ft).

98


15. Apply clean oil to gasket of new transmission oil

filter. Install oil filter and hand tighten. See

Figure 91.

16. Install brake cooling hose to wet brake drive axle

and transmission assembly. See Figure 92.

17. Using clamp pliers, slide hose clamps into posi-

tion on each end of brake cooling hose to secure

cooling hose in proper position. See Figure 92.

18. Add transmission oil to transmission at the dip-

stick tube. The correct oil and volume is shown

in the Maintenance Schedule.





within the transmission. Add transmission oil to

transmission at the dipstick tube as needed.

20. Turn the key to the OFF position and check for

leaks and check oil level.

WET BRAKE AXLE CENTER SECTION

AND PLANETARY HOUSING, OIL CHANGE

1. Remove the planetary housing fill/level plugs

and O-rings. Discard O-rings. Removing the

fill/level plug will allow the oil to drain at a

faster rate. See Figure 93.

2. Place an empty container under the center sec-

tion drain plug and under the right and left plan-

etary housing drain plugs.

3. Remove drain plugs and wait until oil has

drained completely. Remove and discard O-rings

from drain plugs. See Figure 94.

4. Install new O-rings on drain plugs. Install

drain plugs. Tighten the drain plugs to 40 N•m

(29.5 lbf ft).

CAUTIONBefore adding oil, ensure the truck is parked

and on level ground.

5. Add oil at the fill/level port for the right and left

planetary housing until the oil/fill level port has

overflowed. The correct oil is shown in the Main-

tenance Schedule or Figure 95.

6. Install new O-ring on planetary fill/level plugs.

Install fill/level plugs.

7. The center section (cooling chamber) will fill with

fluid automatically as it circulates through and

back to the transmission.

99


1. RIGHT PLANETARY HOUSING2. LEFT PLANETARY HOUSING3. O-RING

4. FILL/LEVEL PLUG5. CENTER SECTION (COOLING CHAMBER)

Figure 93. Planetary Housings Fill/Level Plugs

100


1. LEFT PLANETARY HOUSING2. O-RING3. DRAIN PLUG

4. CENTER SECTION (COOLING CHAMBER)5. RIGHT PLANETARY HOUSING

Figure 94. Center Section and Planetary Housings Drain Plugs

101


A. LEFT PLANETARY HOUSING - USE SAE 80W/90B. RIGHT PLANETARY HOUSING - USE SAE 80W/90C. CENTER SECTION (COOLING HOUSING) - USE JDM J20C

1. OIL FILL/LEVEL PLUG2. OIL BREATHER

3. COOLING OIL INLET PORT

Figure 95. Oil Application Diagram

102


BRAKE FLUID (MASTER CYLINDER),

CHANGE








master cylinder.



ter cylinder.

1. Remove dashboard from cowl.



2. Remove brake fluid reservoir from bracket on

cowl. See Figure 96 and Figure 97.

3. Remove the brake oil reservoir cover and cylin-

drical block drain plug. Pour the fluid into a suit-

able container with a 0.25 liter (0.53 pt) mini-

mum capacity. Install the cylindrical block drain

plug. Refill reservoir with clean oil from a sealed

container and install cover on the reservoir. The


4. Install reservoir into bracket located on cowl.

1. BRAKE FLUID RESERVOIR2. MOUNTING BRACKET3. COWL

Figure 96. Brake Fluid Change (Dry Brake)

103


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

Figure 97. Brake Oil Change (Wet Brakes)

BRAKE FLUID (DRY BRAKE), REMOVE

Perform the following procedure to remove used

brake fluid from the remainder of the brake system.

1. Ensure that the master cylinder reservoir is

filled with brake fluid.

2. Put one end of a rubber hose on the special fitting

of the wheel cylinder. Put the other end of the

hose into a empty container.

3. Loosen special fitting at wheel cylinder one turn

so that used brake fluid can be removed from

brake system. Slowly push brake pedal and hold

it at the end of its stroke. Close special fitting.

Release brake pedal.

NOTE: New brake fluid will be easily recognized, as

the color will be more clear than the used fluid, which

will be darker.

4. Repeat Step 1 through Step 3 until there is new

brake fluid in the container.

5. Check level of brake fluid in reservoir for master

cylinder during the procedure. Make sure to keep

brake fluid at the correct level.

6. Repeat the procedure for the other wheel cylin-

der.

SERVICE BRAKES (DRY BRAKE)

Check brake lining and parts of the brake assembly

for wear or damage. The minimum acceptable brake

lining thickness is 1.0mm (0.040 in.). If brake linings

are worn thinner than the specification, replace the

brake linings. See sectionBrake System 1800 SRM

1135 for the removal and installation procedures of

the drive wheels and brake drums. If the brake lin-

ings or brake shoes are worn or damaged, they must

be replaced. Brake shoes must be replaced in com-

plete sets. Inspect brake drums for cracks or dam-

age. Replace any damaged parts.

WARNINGBrake linings can contain dangerous fibers.

Breathing the dust from these brake linings

is a cancer or lung disease hazard. DO NOT

create dust! DO NOT clean brake parts with

compressed air or by brushing. Follow the

cleaning procedure in this section. When the

brake drums are removed, DO NOT create

dust.

DONOT sand, grind, chisel, hammer, or change

linings in any way that will create dust. Any

changes to brake linings must be done in a re-

stricted area with special ventilation. Protec-

tive clothing and a respirator must be used.

104


Brake cleaning procedures are as follows:

CAUTIONDO NOT use an oil solvent to clean the wheel

cylinder. Use a solvent approved for cleaning

of brake parts. DO NOT permit oil or grease in

the brake fluid or on the brake linings.

1. DO NOT release brake lining dust from brake

linings into the air when brake drum is removed.

2. Use a solvent approved for cleaning of brake

parts to wet lining dust. Follow the instructions

and cautions of the manufacturer for the use of

the solvent. If a solvent spray is used, do not

create brake lining dust with the spray.

3. When the brake lining dust is wet, clean parts.

Put any cloth or towels in a plastic bag or an

airtight container while they are still wet. Put

a DANGEROUS FIBERS warning label on the

plastic bag or airtight container.

4. Any cleaning cloths that will be washed must be

cleaned so that fibers are not released into the

air.

DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential can

be found in the sectionDriveAxle andDifferential

Assembly Repair 1400 SRM 1132 or Drive Axle

and Differential Assembly Repair, (Dry Brake)

1400 SRM 1214.

1. Place lift truck on blocks. See How to Raise Drive

Tires in this manual.

2. The differential and drive axle use the same oil

supply. Place a container with aminimum capac-

ity of 5 liter (5.3 qt) under the differential. Re-

move drain plug located in the bottom of the dif-

ferential and drain oil from the differential com-

pletely. Install drain plug.

3. The fill hole is on the front of the differential

housing. Add oil shown in the Maintenance

Schedule until oil level is at the lower edge of

the fill hole. Install fill plug and rotate the drive

wheels in order to get oil pumped into the axle.

Remove the fill plug and check the oil level. Add

oil, as necessary. Install fill plug and check for

leaks. See Figure 98.

1. DRIVE AXLE2. CHECK/FILL PLUG

3. DRAIN PLUG

Figure 98. Drive Axle Fluid Fill

105

Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1150

Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000-

hour, and 2000-hour checks prior to performing the

procedures in this section.

HYDRAULIC OIL, REPLACE

WARNINGAt operating temperature the hydraulic oil is





is changed. Dirt can cause damage to the com-

ponents of the hydraulic system.




pump.



NOTE:Heavy-duty or contaminated applications will

require hydraulic oil change at 2000 hours.

NOTE: Replace the hydraulic oil filter at the same

time the oil is changed.

1. Replace hydraulic oil as described below:

a. Place a container with a minimum capacity

of 30.1 liter (32 qt) under the drain plug at

the bottom of the hydraulic tank. To drain

the oil, remove drain plug from the bottom of

the hydraulic tank. See Figure 99.

b. When tank is empty, inspect the inside of the

tank for any foreign matter or possible fun-

gus. If necessary, clean the inside of the tank

in accordance with the instructions found in

section Frame 100 SRM 1120.

c. When either the inspection or the cleaning

of the tank is completed, install drain plug

in the bottom of the hydraulic tank. Tighten

drain plug to 38 N•m (28 lbf ft).



ter dealer.

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

tenance Schedule.

3. When oil level is correct, operate system and

check for leaks.

COOLING SYSTEM

1. Put lift truck on a level surface. Stop engine.

Place a container with a minimum capacity of

30.1 liter (32 qt) under the radiator drain valve

which could be located on either the lower left or

right side of the radiator on the engine side of the

radiator.

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 released

from the system. If the system is hot, the steam

and boiling coolant can cause burns. DO NOT

remove the cover for the radiator when the en-

gine is running.



2. Open drain valve and remove radiator cap. Drain

coolant into the container. Flush cooling sys-

tem. Check hoses for damage. Replace with new

hoses, as needed.

3. Disconnect the hose leading from the auxiliary

reservoir to fitting at the top of the radiator un-

der the radiator cap, and drain the reservoir into

the same container used for the radiator coolant.

Check the reservoir for contaminants and flush,

as necessary. Connect the hose back on the fit-

ting at the top of the radiator.

106

8000 SRM 1150 Maintenance Procedures Every 4000 Hours or 2 Years

CAUTIONAdditives may damage the cooling system. Be-

fore using additives, contact your local Hyster

dealer.

4. Close drain valve. Fill cooling system, use Ethy-

lene Glycol Boron-free Antifreeze. Purchase a

pre-diluted 50/50 solution; or mix 50% concen-

trate with 50% distilled or deionized water. Fill

the auxiliary reservoir to a level between the

ADD and FULL marks on the reservoir.

5. Install radiator cap. Start engine. Check for

leaks. Add coolant to auxiliary coolant reservoir

as needed. Coolant level should be between the

ADD and FULL marks on the reservoir.

1. HYDRAULIC TANK 2. DRAIN PLUG

Figure 99. Hydraulic Oil Change

107

Safety Procedures When Working Near Mast 8000 SRM 1150

Safety Procedures When Working Near Mast

The following proceduresmust be usedwhen inspect-

ing or working near themast. Additional precautions

and procedures can be required when repairing or re-

moving themast. See the correct ServiceManual sec-

tion for the specific mast being repaired.

WARNINGMast parts are heavy and can move. Distances

between parts are small. Serious injury or

death can result if part of the body is hit by

parts of the mast or the carriage.

• Never put any part of the body into or under

the mast or carriage unless all parts of the

mast are completely lowered or a safety chain

is installed. Also make sure that the power is

off and the key is removed. Put aDONOTOP-

ERATE tag in the operator’s compartment.

• Be careful of the forks. When the mast is

raised, the forks can be at a height to cause

an injury.

• DO NOT climb on themast or lift truck at any

time. Use a ladder or personnel lift to work

on the mast.

• DO NOT use blocks to support the mast weld-

ments nor to restrain their movement.

• Mast repairs require disassembly and re-

moval of parts and can require removal of

the mast or carriage. Follow the repair pro-

cedures in the correct Service Manual for

the mast.

NOTE: If there is no power to lower the mast on lift

trucks equipped with Electronic Hydraulic System,

there is an emergency load lowering valve located

on the hoist/lower valve section of the main control

valve. See the Operating Manual for the 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 there

is no movement in the mast. Make sure all parts

of 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 themoving parts

of the mast. Connect moving parts to a part that

does not move. Follow these procedures:

a. Put mast in vertical position.

b. Raise mast to align bottom crossmember

of weldment that moves in outer weldment

with a crossmember on outer weldment.

On the two-stage and free-lift mast, the

moving part is the inner weldment. On

the three-stage mast, it is the intermediate

weldment. See Figure 100.

c. Use a 3/8-in. minimum safety chain with a

hook to fasten the crossmembers together so

the movable member cannot lower. Put the

hook on the back side of the mast. Make sure

the hook is completely engaged with a link in

the chain. Make sure the safety chain does

not touch lift chains or chain sheaves, tubes,

hoses, fittings, or other parts on the mast.

d. Lower the mast until there is tension in the

safety chain and the free-lift cylinder (free-

lift, three-stage, and four-stage masts only)

is completely retracted. If running, stop en-

gine. Apply parking brake. Install a DO

NOT 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 the

outer weldment.

3. Apply parking brake. After lowering or restrain-

ing the mast, shut off power and remove key. Put

aDONOTOPERATE tag in the operator’s com-

partment.

108

8000 SRM 1150 Safety Procedures When Working Near Mast

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

Figure 100. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

109

manutencao hyster h40 70ft, maintenance hyster h40 70ft

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