PERIODIC

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

PART NO. 1624742 8000 SRM 1248

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

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

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

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

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

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Serial Number Data ...................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 1
How to Tow Lift Truck............................................................................................................................... 1
How to Put Lift Truck on Blocks................................................................................................................... 3
How to Raise Drive Tires .......................................................................................................................... 3
How to Raise Steering Tires ..................................................................................................................... 3
Maintenance Schedule....................................................................................................................................... 4
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 16
How To Make Checks With Engine Stopped ................................................................................................ 16
Tires and Wheels ....................................................................................................................................... 16
Safety Labels ............................................................................................................................................. 17
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 17
Operator Restraint System....................................................................................................................... 18
Emergency Locking Retractor (ELR) ................................................................................................... 18
Hood and Seat Latches ............................................................................................................................. 19
Engine Compartment................................................................................................................................ 19
Paper Application...................................................................................................................................... 19
Fuel, Oil, and Coolant Leaks, Check........................................................................................................ 20
Hydraulic Hoses ........................................................................................................................................ 20
Coolant Hoses ............................................................................................................................................ 20
Steering Column Gas Cylinder................................................................................................................. 21
Transmission ............................................................................................................................................. 21
Hydraulic System Oil ................................................................................................................................ 21
Engine Oil .................................................................................................................................................. 21
Forks .......................................................................................................................................................... 23
Remove .................................................................................................................................................. 23
Inspect ................................................................................................................................................... 24
Install..................................................................................................................................................... 24
Adjust..................................................................................................................................................... 24
Integral Sideshift Carriage....................................................................................................................... 25
How To Make Checks With Engine Running ............................................................................................... 25
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 25
Service Brakes ........................................................................................................................................... 27
Brake Oil Level ..................................................................................................................................... 27
Operation, Check .................................................................................................................................. 28
Parking Brake ........................................................................................................................................... 28
Engine Oil Pressure .................................................................................................................................. 28
Cooling System .......................................................................................................................................... 29
Steering System ........................................................................................................................................ 30
Control Levers and Pedals........................................................................................................................ 30
Lift System, Operate ................................................................................................................................. 30
First Service After First 100 Hours of Operation ............................................................................................ 31
GM 4.3L Engine Oil Filter ............................................................................................................................ 31
Cummins 4.5L Engine Oil Filter .................................................................................................................. 31
Hydraulic System .......................................................................................................................................... 32
Hydraulic Filter, Replace .......................................................................................................................... 32
Transmission Oil Filter, Replace................................................................................................................... 33
Maintenance Procedures Every 250 Hours or 6 months ................................................................................. 34
GM 4.3L Engine Oil and Filter ..................................................................................................................... 34
Drive Belt ....................................................................................................................................................... 34

©2007 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

GM 4.3L Engine ........................................................................................................................................ 34
Fan and Alternator Drive Belt ............................................................................................................. 34
Drain Tar From LPG Regulator.................................................................................................................... 35
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 35
Hydraulic System Oil .................................................................................................................................... 35
Hydraulic Tank Breather .............................................................................................................................. 35
Inspect........................................................................................................................................................ 35
Battery ........................................................................................................................................................... 36
Cummins 4.5L Engine Oil and Filter ........................................................................................................... 36
Fuel/Water Separator Filter Replacement, Cummins 4.5L Engine............................................................ 37
Remove....................................................................................................................................................... 37
Install ......................................................................................................................................................... 37
Priming the Fuel System (Cummins 4.5L Engine)...................................................................................... 39
Controlled Venting .................................................................................................................................... 39
Manual Bleeding ....................................................................................................................................... 39
Air Filter ........................................................................................................................................................ 39
Drive Belt ....................................................................................................................................................... 41
Cummins 4.5L Diesel Engine ................................................................................................................... 41
Fan and Alternator Drive Belt ............................................................................................................. 41
Clean Debris From Radiator Core ................................................................................................................ 41
Transmission Oil Level.................................................................................................................................. 41
Wet Brake Center Body Oil Level Check ..................................................................................................... 42
Forks............................................................................................................................................................... 44
Mast Lubrication ........................................................................................................................................... 44
Header Hose Checks...................................................................................................................................... 47
Lift Chain Lubrication .................................................................................................................................. 47
Tilt Cylinder Lubrication .............................................................................................................................. 47
Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 48
Manual Hydraulic Levers Lubrication ......................................................................................................... 48
Brake Oil ........................................................................................................................................................ 49
Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004)........................................................................................................................................ 50
Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005)............................................ 50
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ 51
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 51
Valve Clearance, Check and Adjust.............................................................................................................. 51
Ignition System.............................................................................................................................................. 51
GM 4.3L Engine ........................................................................................................................................ 51
LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... 53
Remove....................................................................................................................................................... 53
Install ......................................................................................................................................................... 53
Lift Chains Wear Check ................................................................................................................................ 55
Lift Chain Lubrication .................................................................................................................................. 55
Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... 56
Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) ...................................................................................................................... 56
Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90, 100, 110, 120FT (N005) ...................... 57
Control Levers and Pedals ............................................................................................................................ 57

ii
Periodic Maintenance Table of Contents

TABLE OF CONTENTS (Continued)

Inspect Engine Electrical System, Connectors ............................................................................................ 57
Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 58
Hydraulic System .......................................................................................................................................... 58
Hydraulic Filter, Replace .......................................................................................................................... 58
Hydraulic Tank Breather, Replace ........................................................................................................... 59
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires................................................................ 59
Cooling System, GM 4.3L and Cummins 4.5L Engines .............................................................................. 60
Air Filter Element ......................................................................................................................................... 60
Oxygen Sensor ............................................................................................................................................... 61
LPG Regulator Fuel Filter, GM Engine ....................................................................................................... 61
Remove....................................................................................................................................................... 61
Install ......................................................................................................................................................... 62
Gasoline Fuel Filter....................................................................................................................................... 62
Remove and Replace ................................................................................................................................. 62
LPG Fuel Injector, GM Engines.................................................................................................................... 62
Gasoline Fuel Injector, GM Engines............................................................................................................. 62
Fuel Injector, Cummins 4.5L Engine............................................................................................................ 62
Forks............................................................................................................................................................... 62
Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 63
Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... 64
Wet Brake Center Section Oil Change ......................................................................................................... 66
Remove....................................................................................................................................................... 66
Install ......................................................................................................................................................... 66
Brake Oil (Master Cylinder), Change........................................................................................................... 66
Brake Oil (Dry Brake), Remove .................................................................................................................... 67
Service Brakes (Dry Brake) .......................................................................................................................... 67
Differential (Dry Brake) ................................................................................................................................ 68
Test LPG/GAS Regulator Pressure............................................................................................................... 69
Check Throttle Shaft for Sticking................................................................................................................. 69
Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... 69
Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 69
Hydraulic Oil, Replace .................................................................................................................................. 69
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... 70
Safety Procedures When Working Near Mast.................................................................................................. 71
Fuel Filter Water Removal ................................................................................................................................ 73
Hood Latch Check .............................................................................................................................................. 74
Lift Chain Adjustments ..................................................................................................................................... 75
Jump-Starting the Lift Truck............................................................................................................................ 76
Jump-Starting Using a Battery Charger ..................................................................................................... 76
Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... 76
Welding Repairs ................................................................................................................................................. 77
Overhead Guard Changes ................................................................................................................................. 77
Wheel and Tire Replacement ............................................................................................................................ 78
General ........................................................................................................................................................... 78
Solid Rubber Tire, Change (S Series) ........................................................................................................... 78
Remove and Install Tire on Wheel ........................................................................................................... 78
Pneumatic Tire With Tube, Repair ............................................................................................................... 79
Remove Wheels From Lift Truck.............................................................................................................. 79
Remove Tire From Wheel ......................................................................................................................... 80
Remove Tire From Two-Piece Wheel ................................................................................................... 80
Remove Tire From Three- and Four-Piece Wheels ............................................................................. 81

iii
Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Install Wheel in Tire ................................................................................................................................. 82
Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. 83
Install Tire on Two-Piece Wheel........................................................................................................... 84
Install Two-Piece Wheel in Tire ........................................................................................................... 84
Add Air to Pneumatic Tires With Tube ........................................................................................................ 85
Install the Wheels ..................................................................................................................................... 85
Dual Drive Wheels, Install ....................................................................................................................... 86
Pneumatic Tubeless Tire, Repair.................................................................................................................. 87
Remove Wheels From Lift Truck.............................................................................................................. 87
Remove Tire From Wheel ......................................................................................................................... 87
Install Tire on Wheel................................................................................................................................. 89
Add Air to Pneumatic Tubeless Tire ........................................................................................................ 91
Wheels, Install........................................................................................................................................... 92
Solid Rubber Tires on Pneumatic Wheels, Change ..................................................................................... 92
Remove Wheel From Tire ......................................................................................................................... 92
Install Tire on Wheel................................................................................................................................. 94
Adhesives and Sealants ..................................................................................................................................... 96

This section is for the following models:

S80, 100, 120FT; S80, 100FTBCS;S120FTS; S120FTPRS [G004];

H80, 90, 100, 110, 120FT [N005]

iv
8000 SRM 1248 General

General
shown in the Maintenance Schedule. Service Man-
WARNING uals are available from your dealer for Hyster lift
Do not make repairs or adjustments unless you trucks to help users who do their own maintenance.
have both authorization and training. Repairs
and adjustments that are not correct can make SERIAL NUMBER DATA
a dangerous operating condition.
The serial number for the lift truck is on the name-
plate. It is also on the right side of the frame, under
WARNING the floor plate.
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If re- HOW TO MOVE DISABLED LIFT TRUCK
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from How to Tow Lift Truck
the key switch.
WARNING
CAUTION Use extra caution when towing a lift truck if
Disposal of lubricants and fluids must meet lo- any of the following conditions exist:
cal environmental regulations. • Brakes do not operate correctly.
• Steering does not operate correctly.
This section contains a Maintenance Schedule and • Tires are damaged.
the instructions for maintenance and inspection. • Traction conditions are bad.
• The lift truck must be towed on a slope.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift If the engine cannot run, there is no power
truck. The service intervals are given in both oper- available for the hydraulic steering system
ating hours recorded on the lift truck hourmeter and and the service brakes. This condition can
in calendar time. The recommendation is to use the make the lift truck difficult to steer and stop.
interval that comes first. If the lift truck uses power from the engine to
help apply the brakes, the application of the
The recommendations for the time intervals given for
brakes will be more difficult. Poor traction can
eight hours of operation per day. The time intervals
cause the disabled lift truck or towing vehicle
must be decreased from the recommendations in the
to slide. A slope will also make the lift truck
Maintenance Schedule for the following conditions:
more difficult to stop.
• The lift truck is used more than eight hours per
day. Never lift and move a disabled lift truck unless
• The lift truck must work in dirty operating condi- the disabled lift truck MUST be moved and
tions. cannot be towed. A lift truck used to move
• Poor ground conditions. a disabled lift truck MUST have a capacity
• Intensive usage at high performance levels or rating equal to or greater than the weight of
other abnormal conditions will require more fre- the disabled lift truck. The capacity of the lift
quent servicing. truck used to move a disabled lift truck must
have a load center equal to half the width of
Your dealer for Hyster lift trucks has the equipment
the disabled lift truck. See the nameplate of
and trained service personnel to do a complete pro-
the disabled lift truck for the approximate
gram of inspection, lubrication, and maintenance. A
total weight. The forks must extend the full
regular program of inspection, lubrication, and main-
width of the disabled lift truck. Put the weight
tenance will help your lift truck provide more effi-
center of the disabled lift truck on load center
cient performance and operate for a longer period of
of the forks. Be careful to not damage the
time.
underside of the lift truck.
Some users have service personnel and equipment
1. The towed lift truck must have an operator.
to do the inspection, lubrication, and maintenance
2. Tow truck slowly.

1
General 8000 SRM 1248

3. Using a lift truck or a lifting device that could towing link made of steel that fastens to the tow
be attached to the mast (I.E. come-a-long), raise pins in the counterweights of both lift trucks. See
carriage and forks approximately 30 cm (12 in.) Figure 1. Slowly and carefully remove the slack
from surface. Install chain around a mast cross- out of the towing link.
member and the carriage to prevent carriage and
mast channels from moving. 6. If lift trucks are equipped with a leaded counter-
weight without a tow pin (see Figure 1), use a
4. If another lift truck is used to tow the disabled lift towing link made of steel that fastens to the two
truck, that lift truck must have an equal or larger center grill bars of both lift trucks. Slowly and
capacity than the disabled lift truck. Install ap- carefully remove the slack out of the towing link.
proximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck. Lift truck models that are equipped with a leaded
This 1/2 capacity load will increase traction of lift counterweight, that are covered in this SRM are
truck. Keep load as low as possible. S80FTBCS, S100FTBCS, S120FTS, and S120FT-
PRS (G004).
5. If lift trucks are equipped with a tow pin in the
counterweight (standard counterweight), use a

A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)

B. COUNTERWEIGHT WITH TOW PIN (STANDARD COUNTERWEIGHT)
1. TOWING LINK 2. CENTER GRILL BARS 3. TOW PIN

Figure 1. Counterweight Types

2
8000 SRM 1248 General

HOW TO PUT LIFT TRUCK ON BLOCKS 2. Put mast in vertical position. Put a block under
each outer mast channel.
How to Raise Drive Tires
3. Tilt mast fully forward until drive tires are raised
from surface.
WARNING
The lift truck must be put on blocks for some 4. Put additional blocks under frame behind drive
types of maintenance and repair. The removal tires.
of the following assemblies will cause large
changes in the center of gravity: mast, drive 5. If hydraulic system will not operate, use a hy-
axle, engine, transmission, and counterweight. draulic jack under the side of the frame near the
When the lift truck is put on blocks, put ad- front. Make sure jack has a capacity equal to at
ditional blocks in the following positions to least half the weight of the lift truck. See Name-
maintain stability: plate.
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift How to Raise Steering Tires
truck cannot fall backward.
NOTE: Some lift trucks are equipped with lifting eyes
• Before removing the counterweight, put
for the purpose of lifting the entire lift truck. If the
blocks under the mast assembly so the lift
lift truck is equipped with this type of lifting eyes,
truck cannot fall forward.
the lift truck can be lifted and blocks installed.
The surface must be solid, even, and level when
1. Apply parking brake. Put blocks on both sides
the lift truck is put on blocks. Make sure any
(front and back) of drive tires to prevent move-
blocks used to support the lift truck are solid,
ment of lift truck. See Figure 2.
one-piece units.
2. Use hydraulic jack to raise steering tires. Make
CAUTION sure jack has a capacity of at least 2/3 of total
These lift trucks are equipped with cowl lifting weight of lift truck as shown on the nameplate.
eyes. The cowl lifting eyes are to be used to 3. Put jack under steering axle or frame to raise
lift the front of the lift truck only. Lifting more lift truck. Put blocks under frame to support lift
than the front of the lift truck with the cowl truck.
lifting eyes will damage the cowl section.

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

ing tires to prevent movement of lift truck. See
Figure 2.

3
Maintenance Schedule 8000 SRM 1248

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

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

4
8000 SRM 1248 Maintenance Schedule

Figure 3. GM 4.3L LPG Trucks

5
Maintenance Schedule 8000 SRM 1248

Figure 4. GM 4.3 Gasoline Trucks

6
8000 SRM 1248 Maintenance Schedule

Figure 5. Cummins 4.5L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (N005)

7
Maintenance Schedule 8000 SRM 1248

Table 1. Maintenance Schedule

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
25 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
28, Mast, Carriage, X Check Condition See Parts Manual
29 Header Hoses, and Lubrication
Lift Chains,
Attachment
Seat Belt, Hip X Check Condition
Restraints, and and Operation
Seat Rails
Hood and Seat X Check Condition
Latches and Operation
Engine X Remove
Compartment Combustible
Materials
SeeNOTE 5
Paper Application: X Check Condition
Engine Clean as
Compartment, Required
Truck Components, Replace as
Exhaust Wraps, Required
Radiator, Radiator SeeNOTE 8
Screen if equipped,
Belly Pan if
equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition See Parts Manual
13 Coolant Hoses X Check Condition See Parts Manual
16 Fuel Tank (LPG) CIL 15.1 - 20.4 kg LPG - HD 5, HD 10
(33.5 - 45.0 lb)
Full
16 Fuel Tank CIL 44.7 liter 86 Octane Minimum
GM 4.3L (11.8 gal)
(Gasoline)
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
U.S. Only
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

8
8000 SRM 1248 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
16 Fuel Tank (Short CIL 79 liter (20.8 gal) 86 Octane Minimum
Wheel Base)
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005)
U.S. Only
16 Fuel Tank (Long CIL 100.3 liter 86 Octane Minimum
Wheel Base) (26.5 gal)
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005)
U.S. Only
16 Fuel Tank (Short CIL 79 liter (20.8 gal) Diesel No. 2
Wheel Base)
Cummins 4.5L
(Diesel)
H80, 90, 100, 110,
120FT (N005)
16 Fuel Tank (Long CIL 100.3 liter Diesel No. 2
Wheel Base) (26.5 gal)
Cummins 4.5L
(Diesel)
H80, 90, 100, 110,
120FT (N005)
Horn, Lights, X Check Operation
Alarms, Fuses,
and Relays
1 Service Brakes X Check Operation
23 Parking Brake X Check Operation
Steering Controls X Check Condition
and Steering and Operation
Column Gas
Cylinder
22 Transmission X Check for Leaks John Deere
JDM J20C
22 Transmission X Check Operation
3 Hydraulic Oil X X C 39.4 liter ISO VG 46
GM 4.3L[S80, (41.6 qt) Hydraulic Oil
100, 120FT]; See NOTE 2 and 15 C (5 F) and Above
S80, 100FTBCS, NOTE 3.
S120FTS;
S120FTPRS (G004)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

9
Maintenance Schedule 8000 SRM 1248

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
3 Hydraulic Oil X X C 62.0 liter ISO VG 46
(Short Wheel Base) (65.5 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 and 15 C (5 F) and Above
120FT (N005) NOTE 3
3 Hydraulic Oil X X C 78.0 liter ISO VG 46
(Long Wheel Base) (82.4 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 and 15 C (5 F) and Above
120FT (N005) NOTE 3
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
See NOTE 4.
10 Hydraulic Tank X C Inspect and See Parts Manual
Breather Clean as
Required
See NOTE 5.
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 4.7 liter (5.0 qt) 7 C (20 F) and below
GM 4.3L CIL See NOTE 5. SAE 5W-20
Engine (Gaso- 16 C (60 F) and below
line/LPG) SAE 5W-30
18 C (0 F) and Above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L Engine See NOTE 4 and
NOTE 5.
9 Engine Oil X C 13.0 liter 20 C ( 9 F) and
Cummins 4.5L CIL (13.7 qt) below
Engine See NOTE 5. Synthetic
(Diesel) 5W-20

20 to 5 C ( 9
to 23 F)
SAE 10W-30

API C1-4 or CJ-4

5 C (23 F) and above
SAE 15W-40

API C1-4 or CJ-4

19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins 4.5L See NOTE 4 and
(Diesel) NOTE 5.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

10
8000 SRM 1248 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
18 Air Filter CIL X C Clean or Replace See Parts Manual
See NOTE 5 and
NOTE 6.
Engine Oil Pressure X Check Oil GM Engine
CIL Pressure 207 to 380 kPa (30
to 55 psi)
Cummins 4.5L Diesel
Engine
at high idle 207 kPa
(30 psi)
at low idle 69 kPa
(10 psi)
15 Drive Belt X Check for Wear
GM Engine and Damage.
No adjustment
needed.
See NOTE 5.
15 Drive Belt X Check for Wear
Cummins 4.5L and Damage.
(Diesel) No adjustment
needed.
See NOTE 5.
LPG Regulator GM X Drain Tar
4.3L Engine See NOTE 5.
Engine Idle Speed X 750 ±25 rpm
See NOTE 5.
GM 4.3L
(Gasoline/LPG)
Engine Governed X 2400 ±25 rpm
Speed See NOTE 5.
GM 4.3L
(Gasoline/LPG)
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature
Cummins 4.5L Less than
(Diesel) 77 C (170 F)
Engine Idle Speed X Coolant 800 ±50 rpm
Hot Engine Temperature
Cummins 4.5L Greater than
(Diesel) 77 C (170 F)
Engine Governed X 2250 ±50 rpm
Speed See NOTE 5
Cummins 4.5L
(Diesel)
Oxygen Sensor X Replace As
GM 4.3L Engine CIL Necessary
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

11
Maintenance Schedule 8000 SRM 1248

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
4 Valve Adjustment Not Adjustable
GM 4.3L Engine
4 Valve Adjustment X Adjust as Intake
Cummins 4.5L Required 0.254 mm (0.010 in.)
Diesel Engines Cold
Exhaust
0.508 mm (0.020 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
17 Fuel Filter C 1 Filter See Parts Manual
Gasoline (GM)
17 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain water from
Cummins 4.5L filter as required
Diesel Engine
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins 4.5L
Diesel Engine
20 Fuel Injectors X Check and
GM 4.3L Replace If
Gas/LPG Required
6 Injectors
5 Spark Plugs C Check See NOTE 9.
GM 4.3L Engine Plug Wires
6 Plugs
12, Cooling System X C 15.1 liter 50% Water and 50%
14 GM 4.3L Engine CIL (15.9 qt) Ethylene Glycol
Boron-Free Antifreeze
12, Cooling System X C 13.5 liter 50% Water and 50%
14 Cummins 4.5L CIL (14.2 qt) Ethylene Glycol
Diesel Engine Boron-Free Antifreeze
Clean Debris From X See NOTE 5.
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brake JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check Condition
26 Fork Latches L As Required Multipurpose Grease
See NOTE 7.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

12
8000 SRM 1248 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
Lift System, X Check Operation
Operate
27 Mast L Lubricate Multipurpose Grease
Sliding Surfaces As Required See NOTE 7.
and Load Roller See NOTE 10.
Surfaces
27 Header Hoses X Check Condition
28 Lift Chains X, L Check for Wear SAE 30W
Lube as Required Engine Oil
28 Lift Chains L Lube as Required SAE 30W
Engine Oil
28 Lift Chains X Check SAE 30W
Lubrication Engine Oil
See NOTE 11
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast X L X Lube as Required Multipurpose Grease
Integral 8 Fittings See NOTE 7
Sideshift 4 Bearing Strips
Carriage
Sliding Surfaces

Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

See NOTE 7
Brake Master L SAE 10W-30
Cylinder Rod End API SL
Pin ILSAC GF3
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SL
ILSAC GF3
SAE J2362
24 Brake Oil CIL X C 0.35 liter Dexron III from sealed
(Master Cylinder) (0.74 pt) container
11 Steering Axle L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 7.
11 Steering Axle L 2 Fittings Multipurpose Grease
Tie Rods See NOTE 7.

[S80, 100, 120FT;]

S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

13
Maintenance Schedule 8000 SRM 1248

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 7.

H80, 90, 100, 110,

120FT (N005)
2 Pedals, Levers, L Lubricate as Use Silicone spray
Seat Rails, Cables, Necessary Hyster Part No.
Hinges, Linkages, 328388
Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
(Dry Brake) Thickness Minimum
23 Parking Brake L Lubricate as Use Silicone spray
Necessary (Hyster Part Number
328388)
30 Differential and X C 6.0 liter (6.3 qt) SAE 80W-90 or
Drive Axle Oil 85W-140
(Dry Brake)
7/30 Transmission X C 28.8 liter John Deere
and Wet Brake (30.4 qt) JDM J20C
Planetary Carrier
Housing Oil
S80FT, FTBCS
(G004)
7/30 Transmission X C 29.8 liter John Deere
and Wet Brake (31.4 qt) JDM J20C
Planetary Carrier
Housing Oil
S100FT, FTBCS
S120FT, FTS,
FTPRS (G004)
7/30 Transmission X C 31.3 liter John Deere
and Wet Brake (33.0 qt) JDM J20C
Planetary Carrier
Housing Oil
H80, 90, 100, 110,
120FT) (N005)
30 Wet Brake Center X C 2.0 liter (2.1 qt) John Deere
Section Oil JDM J20C
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
30 Wet Brake Center X C 2.0 liter (2.1 qt) John Deere
Section Oil JDM J20C
H80, 90, 100, 110,
120FT (N005)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

14
8000 SRM 1248 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel
Lines, and Fittings
Inspect X
Lock-Off for
leaks, and ensure
Lock-Off closing
Test LPG/GAS X
Regulator Pressure
Check X
Air Induction
System for Leaks
Check X
Manifold for
Vacuum Leaks
Check X
Throttle Shaft for
Sticking
Check X
Injectors and Rails
for leaks
Inspect X
Exhaust Manifolds
and Piping for
Leaks
Inspect X
Catalyst Inlet and
Outlet
31 Ignition System C Replace
Distributor, Rotor,
and Spark Plug
Wires
GM 4.3L Engine
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, transmission oil, and hydraulic oil filters after first 100 hours of operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

15
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 250 500 hr/ 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ 6 mo hr/ hr/ 2 yr Quantity
6 mo 6 mo 1 yr
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving
contaminated environment, poor ground conditions, intensive usage at high performance levels or other abnormal condi-
tions will require more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service
intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should
be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and
steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000 SRM 1249 for spark plug gap and type of plugs to use.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate at first sign of visible rust.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE conditions that are not normal. Clean any oil or fuel
STOPPED spills. Ensure all surfaces are free of oils, lubricants,
fuel, and organic dust or fibers (paper, wood, cotton,
agricultural grass/grain, etc.).
WARNING
Do not operate a lift truck that needs repairs. Tires and Wheels
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE Check the tires for damage (see Figure 6). Check the
tag in the operator’s area. If the lift truck is tread and remove any objects that will cause damage.
equipped with a key switch, remove the key Check for bent or damaged rims. Check for loose or
from the key switch. missing hardware. Remove any wire, strapping, or
other material that is wrapped around the axle.
Put the lift truck on a level surface. Lower the car-
riage and forks, stop the engine, and apply the park-
ing brake. Open the hood and check for leaks and

16
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

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

Figure 6. Tire Check

Safety Labels 1. Inspect the welds on the mast and carriage for
cracks. Make sure that the capscrews and nuts
are tight.
WARNING
Safety labels are installed on the lift truck to 2. Inspect the channels for wear in the areas where
give information about operation and possible the rollers travel. Inspect the rollers for wear or
hazards. It is important that all safety labels damage.
are installed on the lift truck and can be read.
3. Inspect the load backrest extension for cracks
Check that all safety labels are installed in the cor- and damage.
rect location on the lift truck. See the Parts Man-
ual, Model Description section in the Operating 4. If the lift truck is equipped with an integral
Manual or the section Frame 100 SRM 1243 for the sideshift carriage or attachment, inspect the
correct location of the safety labels. See the Parts parts for cracks and wear. Make sure the parts
Manual for the part numbers of the safety labels. that fasten the integral sideshift carriage or
attachment to the carriage are in good condition.
Mast, Carriage, Lift Chains, Header Hoses,
5. Visually inspect hoses/fittings for hydraulic
Attachment leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
WARNING or sheaves; proper tracking during operation.
Lower the lift mechanism completely. Never Adjust/repair/replace hose/components as neces-
allow any person under a raised carriage. Do sary.
not put any part of your body in or through
the lift mechanism unless all parts of the 6. Check that the lift chains are correctly lubri-
mast are completely lowered and the engine cated. Use SAE 30 engine oil as necessary to
is STOPPED. Do not try to correct the align- lubricate the lift chains.
ment of the fork tips by bending the forks or
7. Inspect the lift chains for cracks or broken links,
adding shims. Never repair damaged forks by
and worn or turned pins. See Figure 7.
heating or welding. Forks are made of special
steel using special procedures. If either fork is 8. Inspect the chain anchors and pins for cracks and
damaged, replace the forks as a set. damage.

17
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

9. Make sure the lift chains are adjusted so that The following seat belt operation checks must be per-
they have equal tension. Adjustments or re- formed:
placement of the lift chains must be done • With the hood closed and in the locked position,
by authorized personnel. 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.

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. TURNED PIN
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR

Figure 7. Lift Chain Check

Operator Restraint System

The seat belt, hip restraint, seat, hood, and hood
latch are all part of the operator restraint system.
See Figure 8. Each item must be checked to make
sure it is fastened correctly, functions correctly, and
is in good condition.

Emergency Locking Retractor (ELR)

1. LATCH STRIKER
When the ELR style seat belt is properly buckled 2. HOOD LATCH
across the operator, the belt will permit slight op- 3. FORWARD/BACKWARD ADJUSTMENT
erator repositioning without activating the locking 4. HOOD
5. OPERATOR WEIGHT ADJUSTMENT
mechanism. If the truck tips, travels off a dock, or 6. SEAT RAIL
comes to a sudden stop, the locking mechanism will 7. ARM REST
be activated and hold the operator’s lower torso in 8. SEAT BELT
the seat. 9. SEAT
10. HIP RESTRAINT
A seat belt that is damaged worn or does not operate 11. HOOD HINGE
properly will not give protection when it is needed.
Figure 8. Hood and Seat Check
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 8.

18
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

surfaces under the hood, but frequent maintenance

is required.

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

Ensure the truck engine cools properly by allowing

it to idle for several minutes. Shutting the truck
down while hot will not allow the engine to cool
quickly due to the loss of coolant circulation. The
heat trapped under the hood may actually increase
the engine temperature because of no heat transfer
through the radiator. With engine off and lift truck
components cooled, check and clean the radiator and
if equipped, radiator screen. Check engine manifold,
exhaust pipes, muffler and catalytic converter for
paper scraps. Clean as required. Check and clean
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE the engine compartment components, transmission,
fan shroud, belly pan if equipped, and inside frame
1. FORWARD/BACKWARD ADJUSTMENT ledges to avoid paper, dust and oil accumulation.
2. SWIVEL ADJUSTMENT Check axle and cowl openings for paper build-up and
3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL) bailing wire. Remove any debris.
5. SEAT BELT

Figure 9. Swivel Seat Controls

WARNING
Compressed air can move particles so that they
Hood and Seat Latches cause injury to the user or to other personnel.
Make sure that the path of the compressed air
Make sure the seat rails and latch striker are not is away from all personnel. Wear protective
loose. The seat rails must lock tightly in position, goggles or a face shield to prevent injury to the
but move freely when unlocked (see Figure 8 and Fig- eyes.
ure 9). The seat rails must be correctly fastened to
the hood and the hood fastened to the hinges on the
frame. Try to lift the hood to make sure it is fas-
CAUTION
tened correctly and will not move. If adjustment is Air pressure, nozzle or extension tube may
required, go to Hood Latch Check. cause damage to exhaust wraps and radiator
fins. Assure that air pressure, nozzle or exten-
Engine Compartment sion tube does not damage exhaust wraps or
radiator fins.
Check for the presence of any combustible material
such as paper, leaves, etc. Remove any combustible Paper removal can generally be accomplished using a
materials. compressed air line and nozzle. An extension may be
helpful to access hard to reach places. Remove floor
Paper Application plates and side covers for better access to engine com-
partment. Open or removed belly pan, if equipped.
Vehicles used in paper applications require regular Clean components with compressed air. Take care
inspection and cleaning to minimize the risk of fire. to maintain the integrity of the exhaust wraps when
This should be done at least once every 8 hours cleaning with compressed air and use caution to not
or more frequently depending upon operating en- force debris into openings. Check the condition of ex-
vironment. The paper application option will help haust wraps for wear, proper fit, contamination with
limit the contact of paper or tissue scraps to hot oil or anti-freeze, gaps in coverage, failed fasteners

19
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

and replace as necessary. Do not reuse wraps if they Make a visual check for leaks on and under the lift
have been removed for some other service operation. truck. If possible, find and report the leak to main-
tenance for repair. Leaks often indicate a need for
repair of damaged or worn components. Leaks in the
WARNING
LPG fuel system are usually not visible unless ice
Be careful when cleaning with steam. Steam is present. There is however, usually a strong odor.
can cause serious burns. Wear protective cloth- Fuel leaks MUST be repaired IMMEDIATELY.
ing, gloves, and eye protection. Never expose
your skin to steam. Check the fuel system for leaks and the condition of
parts. When fuel is added to the lift truck, see the
If compressed air did not adequately remove debris, section HOW TO ADD FUEL TO THE LIFT TRUCK
steam clean to remove any persistent accumulation in the Operating Manual.
of material or oil. Protect electrical components from
moisture when steam cleaning. Do not spray exhaust Also check the condition of the radiator or heater
wraps directly with high pressure steam. Allow lift hoses that are not leaking. Soft or cracked hoses need
truck to air dry before returning to work in a con- to be replaced before a major leak occurs.
taminated environment. Paper dust and scraps will
adhere to wet surfaces. Hydraulic Hoses
Check the condition of exhaust wraps for wear, Check the condition of the hydraulic hoses for ser-
proper fit, contamination with oil or antifreeze, gaps viceability by inspecting for cracks or other obvious
in coverage, failed fasteners and replace as neces- damage. Check to insure that the hydraulic hoses
sary. Do not reuse wraps if they have been removed are not leaking. If any hose is leaking, report it to
for some other service operation. maintenance for repair.

Fuel, Oil, and Coolant Leaks, Check Coolant Hoses

Check the condition of the coolant hoses for service-
WARNING ability by inspecting for cracks or other obvious dam-
All fuels are very flammable and can burn or age. Check to insure that the coolant hoses are not
cause an explosion. Do not use an open flame leaking. If any hose is leaking, report it to mainte-
to check the fuel level or to check for leaks in nance for repair.
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.

20
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

Steering Column Gas Cylinder

CAUTION
Make sure the gas cylinder for the steering column Do not permit dirt to enter the hydraulic sys-
operates correctly. The cylinder must NOT allow the tem when the oil level is checked or the filter
column to move unless the tilt lever is released. See is changed.
Figure 10.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.

After the engine has stopped, wait one minute before

checking the oil level. Keep the hydraulic oil at the
correct level as indicated on the dipstick. Use the
correct oil as shown in the Maintenance Schedule.

Check the hydraulic system for leaks and damaged or

loose components. Heavy-duty or high-temperature
operations can require more frequent checks.

Engine Oil

WARNING
1. TILT LEVER 2. GAS CYLINDER
At operating temperature, the engine oil is
Figure 10. Steering Column Gas Cylinder and HOT. Do not permit the hot oil to touch the
Tilt Lever skin and cause a burn.

Transmission CAUTION
Do not permit dirt to enter the engine when the
Check the transmission for leaks and damaged or
oil level is checked or the filter is changed.
loose components. Heavy-duty or high temperature
operations can require more frequent checks. Never operate the engine without oil. The op-
eration of the engine without oil will damage
Hydraulic System Oil the engine.

WARNING After the engine has stopped, wait one minute before
checking the oil level. See Figure 11 and Figure 12.
At operating temperature, the hydraulic oil is
Keep the oil at the correct level as indicated on the
HOT. Do not permit the hot oil to touch the skin
dipstick. Use the correct oil as shown in the Mainte-
and cause a burn.
nance Schedule.

21
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Legend for Figure 11

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

Figure 11. Cummins 4.5L Diesel Engine

Maintenance Points for Lift Truck Models H80,
90, 100, 110, 120FT (N005)

22
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

A. GAS ENGINE B. LPG ENGINE

1. DIPSTICK ENGINE OIL 7. AIR FILTER
2. BATTERY 8. FUEL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. ENGINE OIL FILTER
4. RADIATOR CAP 10. SPARK PLUGS
5. ENGINE OIL FILL 11. FUEL INJECTOR
6. DRIVE BELT

Figure 12. GM Engine Maintenance Points

Forks hook of the fork is disengaged from the top carriage

bar. Move the carriage away from the fork, or use
The identification of a fork describes how the fork a lifting device to move the fork away from the car-
is connected to the carriage. These lift trucks have riage.
hook forks.

Remove

WARNING
Do not try to move a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 253 lb).

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

individually.

A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Lift the lock
pin and slide a hook fork to the fork removal notch
on the carriage. See Figure 13 and Figure 14. Lower 1. CARRIAGE BARS 3. BLOCKS
the fork onto blocks so that the bottom hook of the 2. HOOK FORK
fork moves through the fork removal notch. See Fig- Figure 13. Hook Fork Removal
ure 14. Lower the carriage further so that the top

23
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Inspect Install

1. Inspect the forks for cracks and wear. Check that Move the fork and carriage so that the top hook on
the fork tips are aligned as shown in Figure 14. the fork can engage the upper carriage bar. Raise
Check that the bottom of the fork is not worn (4, the carriage to move the lower hook through the fork
Figure 14). removal notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage. En-
2. Replace any damaged or broken parts that are gage the lock pin with a notch in the upper carriage
used to keep the forks locked in position. bar.

Adjust

NOTE: During the adjustment of the forks, the heel

of the forks should not be touching the ground.

The forks are connected to the carriage by hooks and

lock pins. See Figure 13 and Figure 15. The lock
pins are installed through the top fork hooks and fit
into slots in the top carriage bar. If pin does not re-
main engaged in carriage slot, replace with new pin.
Adjust the forks as far apart as possible for maxi-
mum support of the load. Hook forks will slide along
the carriage bars to adjust for the load to be lifted.
Raise the lock pin in each fork to slide the fork on
the carriage bar. Make sure the lock pin is engaged
in the carriage bar to lock the fork in position after
the width adjustment is made.

Fork Tip Alignment

Length of Forks 3% Dimension
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.) 1. FORK 5. WEDGE
1524 mm (60 in.) 46 mm (1.81 in.) 2. LOCK PIN 6. KNOB
1830 mm (72 in.) 55 mm (2.17 in.) 3. SPRING 7. LOCK PIN
4. WASHER ASSEMBLY
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH) Figure 15. Fork Lock Pin Assembly
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93
8. FORK REMOVAL NOTCH

Figure 14. Forks Check

24
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

Integral Sideshift Carriage HOW TO MAKE CHECKS WITH ENGINE

RUNNING
Check for cracks, wear and damage. If damaged,
see Mast Repairs, 2 and 3-Stage Masts 4000 SRM
1250 for repair procedures. If necessary, lubricate WARNING
sliding surfaces at grease fittings with multipurpose DO NOT operate a lift truck that needs repairs.
grease shown in the Maintenance Schedule. See Fig- Report the need for repair immediately. If re-
ure 16. 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.

WARNING
FASTEN 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 in NEU-
TRAL. Make the checks carefully.
1. CAPSCREWS
2. LOWER HOOK Indicator Lights, Horn, Fuses, and Relays
3. APRON
4. LOWER BEARING STRIPS If lift truck is equipped with a key switch, turn
5. UPPER BEARING STRIPS key to ON position. If lift truck is equipped with a
6. GREASE FITTINGS Power ON/OFF button, press button to turn system
7. CYLINDER ROD power on. All warning light and indicator lights
8. SNAP RING
9. ROD SCRAPER will light up for two seconds (start check) when
10. ROD BUSHINGS system power is turned ON. See Figure 17. Check
11. SEAL all indicator lights for correct operation as described
12. FIXED FRAME in the Operating Manual. Check the operation of
the horn. Start the engine by turning the key switch
Figure 16. Integral Sideshift Carriage to the Start position, if truck is equipped with a key
switch, or press the engine start button, if lift truck
is equipped with this button. If any indicator lights
do not operate correctly, check the fuses. The fuses
are located in the Power Distribution Module (PDM)
which is under the hood next to the battery on the
right side. See Figure 18.

25
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking (Duramatch Plus 2™ Transmissions)
15 Indicator Light, Water Separator
(Diesel Only)
16 Indicator Light, Cold Start
(Diesel Only)

Figure 17. Warning and Indicator Lights

26
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

NOTE: HOOD REMOVED FOR CLARITY.

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

Figure 18. PDM Showing Fuses and Relays

Service Brakes using the lift truck. Replace the brake oil in
the system if there is dirt or water in the sys-
Brake Oil Level tem.

WARNING Do NOT use "DOT" fluid, only use Dexron III oil
from sealed container to prevent possible dam-
Small amounts of water in the brake system
age to the brake system. Failure to observe the
can cause reduced braking performance if the
above Warning could result in death or serious
water reaches the wheel cylinder areas. Do
injury.
not allow water entry. Ensure that the sealed
reservoir lid is properly replaced. There is an indicator light on the Display Switch
Cluster for the brake oil. The red light is ON when
The brake system has a boosted master cylin-
the key switch is in the START position or the Power
der, braking will be more difficult if the engine
ON/OFF button is pressed, and must go OFF when
is not running.
the engine is running. If the light is on when the en-
Loss of oil from the brake oil reservoir indi- gine is running, the brake fluid oil in the reservoir is
cates a leak. Repair the brake system before too low.

27
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Operation, Check

Check the operation of the service brakes. Push on

the inching/brake pedal. The service brakes must be
applied before the inching/brake pedal reaches the
floor plate. The pedal must stop firmly and must
not move slowly down after the brakes are applied.
The service brakes must apply equally to both drive
wheels. The service brakes must not pull the lift
truck to either side of the direction of travel when
they are applied. The service brakes are 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 the service brakes are adjusted and the
operation of the automatic adjuster mechanism is 1. LOCK BUTTON RELEASE
correct before the parking brake is adjusted. 2. OFF POSITION
3. ON POSITION
Lift trucks with a MONOTROL® pedal. The 4. ADJUSTMENT KNOB
switch energizes the seat warning circuit when hand Figure 19. Parking Brake
lever is released. This switch puts the transmission
in NEUTRAL by de-energizing the direction sole- Engine Oil Pressure
noid. There is also a switch on the left-hand side of
bracket. This switch prevents engine from starting NOTE: The engine will enter shutdown mode after a
unless parking brake is applied. warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
NOTE: Make sure parking brake is released before lift trucks with powertrain protection system. Lift
making adjustment. trucks equipped with a Cummins diesel engine will
1. Turn the adjustment knob to raise the equalized enter the shutdown mode when the engine oil pres-
link and tighten the parking brake cables shown sure is less than 49 kPa (7 psi) on lift trucks with pow-
in Figure 19. Do not tighten the adjustment so ertrain protection system. See the ENGINE SHUT-
that the brake is applied when the lever is re- DOWN procedures in the Operating Manual.
leased. The lever for the parking brake has a There is an indicator light for the engine oil pressure
lock. Use your thumb or finger to release the lock on the Display Switch Cluster. During normal opera-
on the lever when the parking brake is released. tion, the red indicator light will illuminate when the
2. For burnished brakes, test the operation of the key switch is turned to ON, if the truck is equipped
parking brake. The lift truck with a capacity load with a key switch, or when the power ON/OFF but-
must not move when parking brake is applied on ton is pressed, if the truck is equipped with a key-
a 15 percent grade [a slope that increases 1.5 m less option, and will stay illuminated until correct oil
in 10 m (1.5 ft in 10 ft). pressure is obtained, at which time the light will go
off.

28
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily

If the light continues to stay on when engine is run- If coolant is added, use the correct mixture of wa-
ning, the engine oil pressure is low. Stop the engine ter and ethylene glycol shown in the Maintenance
and check the oil level. See Figure 12 for lift truck Schedule.
models S80, 100, 120FT; S80, 100FTBCS; 120FTS;
S120FTPRS) (G004) and Figure 11 and Figure 12 for WARNING
lift truck models H80, 90, 100, 110, 120FT) (N005)
Compressed air can move particles so that they
Do not restart the engine until the low pressure con-
cause injury to the user or to other personnel.
dition has been corrected.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
Cooling System goggles or a face shield to prevent injury to the
eyes.
WARNING
DO NOT remove the radiator cap from the radi- Check the radiator fins. Clean the radiator with com-
ator when the engine is hot. When the radiator pressed air or water as needed. Check for and re-
cap is removed, the pressure is released from move any debris on the radiator core. If the indicator
the system. If the system is hot, the steam and light turns on again after restarting, shut down the
boiling coolant can cause burns. lift truck and do not operate the lift truck until the
problem is corrected.
NOTE: The engine will enter shutdown mode after
a warning buzzer sounds and a 30-second count-
down, if coolant temperature reaches 121 C (250 F)
or above on lift trucks with powertrain protection
system. Lift trucks equipped with a Cummins diesel
engine will enter the shutdown mode when the
coolant temperature reaches 110 C (230 F) or above
on lift trucks with powertrain protection system.
See the ENGINE SHUTDOWN procedures in the
Operating Manual.

There is an indicator light on the Display Switch

Cluster for the coolant temperature. The red light
is on when the key switch is in the START position
or the Power ON/OFF button is pressed, and must
go off when the engine is running. If the light is on
when the engine is running, the coolant and engine
are too hot. Stop the engine and check the coolant
level in the coolant recovery reservoir.

Make sure the coolant level is between the ADD and

FULL marks on the auxiliary coolant reservoir (see 1. FILL CAP
Figure 20). The coolant will expand as it is heated 2. AUXILIARY COOLANT RESERVOIR
and the level in the auxiliary coolant reservoir will 3. FULL MARK
4. ADD MARK
increase. 5. RADIATOR CAP

CAUTION Figure 20. Auxiliary Coolant Reservoir

Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.

29
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248

Steering System Do not try to find hydraulic leaks by putting

hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
WARNING
the pressure.
The lift truck has hydraulic power steering.
The steering can be difficult if the engine is Perform the following checks and inspections:
not running.
1. Check for leaks in the hydraulic system. Check
Make sure the steering system operates smoothly the condition of the hydraulic hoses and tubes.
and provides good steering control. Make sure the
steering column can be adjusted and the gas cylinder NOTE: Some parts of the mast move at different
function is correct. speeds during raising and lowering.

Control Levers and Pedals 2. Slowly raise and lower the mast several times
without a load. Raise the mast to its full height
Check that the control levers for the transmission, at least once. The mast components must raise
mast, and attachment operate as described in Oper- and lower smoothly in the correct sequence. Hose
ating Manual. Check that the pedals operate cor- must track properly during operation.
rectly as described in Operating Manual.
3. The inner weldments and the carriage must
Lift System, Operate lower completely.

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

WARNING The inner weldments and the carriage must raise
When working on or near the mast, see Safety smoothly. Lower the mast. All moving compo-
Procedures When Working Near Mast at the nents must lower smoothly.
end of this section.
5. Lower the load to approximately 0.3 m (1 ft). Tilt
Lower the lift mechanism completely. Never the mast forward and backward. The mast must
allow any person under a raised carriage. Do tilt smoothly and both tilt cylinders must stop
not put any part of your body in or through evenly.
the lift mechanism unless all parts of the mast
6. Check that the controls for the attachment op-
are completely lowered and the engine is
erate the functions of the attachment. See the
STOPPED.
symbols by each of the controls. Make sure all of
If the mast cannot be lowered, use chains on the hydraulic lines are connected correctly and
the mast weldments and carriage so that they do not leak.
cannot move. Make sure the moving parts are
attached to a part that does not move.

30
8000 SRM 1248 First Service After First 100 Hours of Operation

First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL FILTER CUMMINS 4.5L ENGINE OIL FILTER
NOTE: The engine oil filter must also be changed af- Change engine oil filter. See Figure 22. Apply clean
ter the first 100 hours of operation for a newly in- oil to gasket of new filter. Install new filter. Turn fil-
stalled engine. ter until gasket touches, then tighten 1/2 to 3/4 turn
with your hand. Start engine. Check area around oil
Change engine oil filter. See Figure 21. Apply clean filter for leaks.
oil to gasket of new filter. Install new filter. Turn fil-
ter until gasket touches, then tighten 1/2 to 3/4 turn
with your hand. Start engine. Check area around oil
filter for leaks.

NOTE: LEFT SIDE OF ENGINE SHOWN

NOTE: BOTTOM LEFT-HAND SIDE SHOWN
1. OIL FILTER
2. DRAIN PLUG 1. OIL FILTER 2. DRAIN PLUG
3. ENGINE OIL
DIPSTICK Figure 22. Engine Oil Filter Change, Cummins
4. ENGINE OIL FILL 4.5L Diesel
Figure 21. GM 4.3L Engine Filter Oil Change

31
First Service After First 100 Hours of Operation 8000 SRM 1248

HYDRAULIC SYSTEM 5. Start the truck, and allow it to run for 30 seconds.
Check for leaks. Stop engine and check hydraulic
Hydraulic Filter, Replace oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
WARNING the hydraulic oil, see Hydraulic Oil, Replace.
At operating temperature, the hydraulic oil is
HOT. Do not permit the hot oil to touch the skin
and cause a burn.

CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system.

Never operate the hydraulic pump without oil

in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.

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

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

riage. Unscrew and remove filter lid and spring
from head. See Figure 23. Lift the hydraulic fil-
ter element enough to allow the hydraulic oil to
drain.

NOTE: Have container large enough to hold the filter

element and allow for final hydraulic oil draining.

2. Remove the hydraulic filter element and O-ring

from the bowl and place into the container. Cover
the head to prevent any foreign materials from
getting into the hydraulic tank.

3. Lubricate new O-ring with hydraulic oil and in-

stall it on the bottom of the new filter element.
Install the new filter element into the bowl.

4. Install spring and filter lid onto head. 1. LID 6. FITTING

2. SPRING 7. QUAD RING
3. O-RING 8. FILTER ELEMENT
CAUTION 4. CAPSCREW 9. BOWL
Additives may damage the hydraulic system. 5. HEAD
Before using additives, contact your local Hys-
ter dealer. Figure 23. Hydraulic Filter

32
8000 SRM 1248 First Service After First 100 Hours of Operation

TRANSMISSION OIL FILTER, REPLACE

WARNING
At operating temperature, the transmission oil
is HOT. Do not permit the hot oil to touch the
skin and cause a burn.

CAUTION
Do not permit dirt to enter the transmission
when the oil level is checked or the filter is
changed. Dirt can cause damage to the trans-
mission components.

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

NOTE: The transmission oil filter must also be

changed after the first 100 hours of operation for a
newly installed transmission. NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF
NOTE: Before removing the oil filter, make a hole at CLARITY.
the top of the filter and allow five minutes for the oil
1. TRANSMISSION
to drain down into the transmission. See Figure 24. 2. TRANSMISSION DRAIN PLUG
This will reduce the oil that will run out of the filter 3. SPRING
and onto the transmission when the filter is removed. 4. SCREEN
5. TRANSMISSION OIL FILTER
1. Remove and discard transmission oil filter. Ap- 6. TRANSMISSION DIPSTICK
ply clean oil to gasket of new transmission oil fil- 7. TRANSMISSION BREATHER
ter. Install new transmission oil filter and hand
Figure 24. Transmission Oil Filter Change
tighten. See Figure 24.

2. Check oil level at the dipstick tube. If necessary,

add additional oil shown in the Maintenance
Schedule. Check for leaks during operation.

33
Maintenance Procedures Every 250 Hours or 6 months 8000 SRM 1248

Maintenance Procedures Every 250 Hours or 6 months

NOTE: Perform the 8-hour checks prior to performing DRIVE BELT
the procedures in this section.
GM 4.3L Engine
GM 4.3L ENGINE OIL AND FILTER
Fan and Alternator Drive Belt
NOTE: Change the oil filter for the engine at the first
100 hours of operation on new lift trucks. Check drive belt for wear and damage. See Figure 26.
A few small cracks that run across belt are accept-
Change engine oil and engine oil filter. See Fig- able. A belt with cracks that run length of belt or a
ure 25. Use the correct oil according to the Main- belt with missing pieces is not acceptable. See Fig-
tenance Schedule. Apply clean oil to gasket of new ure 27 for the drive belt arrangement.
filter. Install new filter. Turn filter until gasket
touches, then tighten 1/2 to 3/4 turn with your hand.
Start engine. Check area around oil filter for leaks.

1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE

Figure 26. Drive Belt Inspection

NOTE: LEFT SIDE OF ENGINE SHOWN

1. OIL FILTER
2. DRAIN PLUG
3. ENGINE OIL
DIPSTICK
4. ENGINE OIL FILL

Figure 25. GM 4.3L Engine Oil Change

Figure 27. GM 4.3L Drive Belt Arrangement

34
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

Legend for Figure 27

NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING

TENSIONERS.
1. FAN PULLEY
2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY
4. SERPENTINE BELT
5. TENSIONER CENTERING PULLEY
6. ALTERNATOR PULLEY

DRAIN TAR FROM LPG REGULATOR

1. Warm engine to operating temperature.

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

3. Raise the hood.

4. Remove tar drain screw from regulator. Allow tar 1. TAR DRAIN SCREW
to drain from regulator. When tar has completely
drained, install tar drain screw in regulator. See Figure 28. GM LPG Regulator
and Figure 28.

Maintenance Procedures Every 500 Hours or 6 Months

NOTE: Perform the 8-hour and 250-hour checks prior Check the hydraulic oil level when the oil is at operat-
to performing the procedures in this section. ing temperature with the mast in a vertical position,
the carriage lowered, and the engine stopped. See
HYDRAULIC SYSTEM OIL Figure 35. Add hydraulic oil only as needed. If hy-
draulic oil is above the FULL level, the hydraulic oil
WARNING will leak from the breather during operation. The oil
At operating temperature, the hydraulic oil is level indicated by the dipstick is most accurate when
HOT. Do not permit the hot oil to touch the skin the oil temperature is 53 to 93 C (130 to 200 F).
and cause a burn.
HYDRAULIC TANK BREATHER
CAUTION Inspect
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter NOTE: When inspecting the breather, do not remove
is changed. it. The breather element is a non serviceable part. If
it is damaged, replace with a new breather element.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the 1. Raise the hood and remove the right rear side
hydraulic pump without oil will damage the panel See Figure 29.
pump.

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

35
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

3. If necessary, unscrew and replace the breather

if oil has accumulated in the cavity or on the
breather, or if dirt has accumulated at the
breather passages at the bottom of the breather

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

Figure 29.

BATTERY

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

WARNING
Batteries generate explosive fumes. Keep the
1. HOOD/SEAT ASSEMBLY vents in the caps clean. Keep sparks or open
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER flame away from the battery area. Do not
make sparks from the battery connections.
Figure 29. Hydraulic Tank Breather Disconnect the battery ground cable when
doing maintenance.
WARNING Disconnect the negative and positive terminals of the
Compressed air can move particles so that they battery. Using a damp cloth clean the case of the bat-
cause injury to the user or to other personnel. tery. If the terminals are corroded, clean the termi-
Make sure that the path of the compressed air nals with a wire brush. Connect the negative and
is away from all personnel. Wear protective positive cables to their respective terminals.
goggles or a face shield to prevent injury to the
eyes. CUMMINS 4.5L ENGINE OIL AND FILTER
NOTE: Change the oil filter for the engine at the first
CAUTION 100 hours of operation on new lift trucks.
Direct air pressure on the filter element can
cause damage. Direct air pressure away from Change engine oil and engine oil filter. See Fig-
filter element. ure 30. Use the correct oil according to the Main-
tenance Schedule. Apply clean oil to gasket of new
2. Using compressed air, remove any dirt and de- filter. Install new filter. Turn filter until gasket
bris in the frame cavity around the breather. See touches, then tighten 1/2 to 3/4 turn with your hand.
Figure 29. Start engine. Check area around oil filter for leaks.

36
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

2. Disconnect air inlet elbow to access the fuel filter

element. See Figure 31.

3. Disconnect fuel filter sensor connector from the

fuel filter element.

CAUTION
Drain the water/fuel into a container and dis-
pose in accordance with local environmental
regulations.

4. Open the drain valve by turning the valve coun-

terclockwise approximately 3 1/2 turns until
draining occurs. Drain until fuel filter element
is empty.

5. Remove and discard Fuel filter element.

Install
1. Clean the fuel filter head mounting surface and
apply a small amount of diesel fuel to the gasket
on the new fuel filter element. See Figure 31.

2. Before installing the filter element, fill the filter

element with diesel fuel. This method will aid in
bleeding the fuel system.
NOTE: BOTTOM LEFT HAND SIDE.
CAUTION
1. OIL FILTER 2. DRAIN PLUG
Do not overtighten the filter element. Over-
Figure 30. Engine Oil Change Cummins 4.5L tightening the filter element may distort the
Diesel threads.

FUEL/WATER SEPARATOR FILTER 3. Install the new fuel filter element until it con-
tacts the fuel filter head mounting surface.
REPLACEMENT, CUMMINS 4.5L ENGINE Tighten one additional turn.

CAUTION 4. Connect the fuel sensor connector to fuel filter

element
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 5. Connect air inlet elbow hose.
Replace the fuel filter at specified intervals to pre- 6. Open the fuel supply valve.
vent contaminants from adversely affecting the
diesel fuel flow. 7. Prime the fuel system. See Priming the Fuel Sys-
tem (Cummins 4.5L Engine).
Remove
8. Check for fuel leaks.
1. Stop Engine and allow it to cool.

37
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

Figure 31. Cummins 4.5L Engine Fuel System

38
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

Legend for Figure 31

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

PRIMING THE FUEL SYSTEM (CUMMINS personal injury. Wear clothes and protective
4.5L ENGINE) clothing.

Controlled Venting 5. Crank the engine until fuel is expelled from the
loosen fittings. Tighten the injector line fittings
while cranking. The engine should fire.
CAUTION
When using the starting motor to vent the sys- CAUTION
tem, do not engage it for more than 30 seconds,
Disposal of lubricants and fluids must meet lo-
or starter motor damage will occur. Wait 2 min-
cal environmental regulations.
utes before engaging the starter again.
6. Wipe up any fuel that may have spilled and dis-
Controlled venting is provided at the injection pump
pose of the fuel and rags in accordance with local
through the fuel drain manifold. Small amounts of
directives.
air introduced by changing the filters or injection
pump supply line will be vented automatically if the
fuel filter element is changed and filled prior to in-
AIR FILTER
stallation. Check the air filter every 500 hours of operation. See
Figure 32. Very dirty conditions will require a daily
Manual Bleeding inspection and possible installation of a new filter el-
ement.
Manual Bleeding will be required if one of the follow-
ing conditions exist.
• The fuel filter is not filled prior to installation. CAUTION
• The fuel injection pump is replaced. Be careful not to allow dirt to enter the engine
• The high pressure fuel line connections are loos- air intake when inspecting, cleaning, or replac-
ened, or lines are replaced. ing the air filter. A small amount of dirt could
• It is an initial engine start up after an extended cause engine damage.
period of no engine operation.
1. Shut off the engine.
1. Crack open the fuel line to the injector pump. See
Figure 31. 2. Unlatch and remove the cover. To remove filter
element, press and rotate filter element counter-
2. Operate the hand lever until fuel is expelled from clockwise until the filter element is free. See Fig-
the loosened fitting. ure 32.

3. Tighten the fuel line to the injector pump to 3. Gently pull the filter element from the canister.
9 N•m (80 lbf in). See Figure 31. Avoid dislodging contaminants from the filter or
knocking it against the canister.
4. Crack open one of more of the injector lines lo-
cated on the cylinder head. 4. With a clean soft rag, clean the inside surface of
the canister. Be careful not to knock any contam-
WARNING inants into the outlet tube.
The pressure spray released by the fuel injec- 5. Inspect the liner assembly for damage. If dam-
tors can penetrate the skin and cause serious aged, replace the liner assembly.

39
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

6. If removed, install the liner assembly into the NOTE: If the filter element is properly installed the
canister and ensure that the liner assembly is cover will fit easily into the canister. If the cover
properly seated in the canister. It will fit snugly does not fit easily, the filter element is not installed
in the canister. properly.

7. Inspect the filter element for voids, cuts, tears or 9. Install the cover into the canister and ensure the
indentations in the urethane-sealing surfaces. "INLET" arrow is in line with the canister inlet.

8. Install the filter element into the canister. Press 10. Fasten the latches to secure the cover to the can-
and rotate the filter element clockwise until fully ister. Make sure the latches penetrate the slots
engaged in the canister. See Figure 32. in both the canister and the cover.

11. Inspect all clamps for tightness and tighten if

CAUTION necessary, and inspect all hoses for damage, Re-
During cover installation, do not force the place damaged hoses. Inspect the dust evacua-
cover on the canister, to do so will result in tion valve for damage, if damaged, replace the
damage to the filter element, cover, and possi- dust evacuation valve.
bly the canister.

1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY

Figure 32. Air Filter

40
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

DRIVE BELT Legend for Figure 34

Cummins 4.5L Diesel Engine NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD-
JUSTING TENSIONERS.
Fan and Alternator Drive Belt
1. ALTERNATOR PULLEY
Check drive belt for wear and damage. See Figure 33. 2. CAMSHAFT PULLEY
3. WATER PUMP PULLEY
A few small cracks that run across belt are accept- 4. CRANKSHAFT PULLEY
able. A belt with cracks that run length of belt or a 5. TENSIONER CENTERING PULLEY
belt with missing pieces is not acceptable. See Fig-
ure 34 for the drive belt arrangement. CLEAN DEBRIS FROM RADIATOR CORE
Check the radiator core for restrictions and remove
material causing radiator core to be plugged or re-
stricted.

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

Clean with compressed air, adjusted to a maximum

1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE output of 103 kPa (15 psi), and blow debris from core
and fan shroud.
Figure 33. Drive Belt Inspection
TRANSMISSION OIL LEVEL

WARNING
At operating temperature, the transmission oil
is HOT. Do not permit the hot oil to touch the
skin and cause a burn.

CAUTION
Do not permit dirt to enter the transmission
when the oil level is checked or the filter is
changed.

If engine has been running, the engine must be shut

down for one minute or longer prior to checking the
oil level (see Figure 35). 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.

Figure 34. Cummins 4.5L Diesel Engine Drive

Belt Arrangement

41
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK

Figure 35. Transmission and Hydraulic Oil Check

WET BRAKE CENTER BODY OIL LEVEL 1. Remove the center body fill/level plug. See Fig-
CHECK ure 36 for lift truck models S80, 100, 120FT;
S80, 100, 120FTBCS; S120FTPRS (G004) and
Figure 37 for lift truck models H80, 90, 100, 110,
WARNING
120FT (N005).
At operating temperature, the center section
oil is HOT. Do not permit the hot oil to touch 2. Visually check oil level. If necessary, add oil at
the skin and cause a burn. the fill/level port until the oil/fill level port has
overflowed. The Correct oil is shown in the Main-
CAUTION tenance Schedule.
Do not permit dirt to enter the center body 3. Install center body oil/level fill level plug and
when the oil level is checked. Dirt will contam- tighten to 30 to 50 N•m (22 to 37 lbf ft).
inate the oil and cause damage to the center
body of the axle.

42
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER SECTION DRAIN PLUG
4. CENTER SECTION FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER SECTION B. FRONT VIEW SHOWN

Figure 36. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
S80, 100, 120FT; S80, 100FTBCS; S120FTS; PLUGS
S120FTPRS (G004) 3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION

Figure 37. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
H80, 90, 100, 110, 120FT (N005)

43
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

FORKS NOTE: When lubricating the mast mounting/pivot

pins, the load must be removed from the normal
WARNING contact surface to allow grease to properly lubricate
the normal contact surfaces of the mast bushings
Never repair damaged forks. Do not heat, weld,
or bend the forks. Forks are made of special 2. Raise the carriage about 61 cm (2 ft), and tilt the
steel using special methods. Replace damaged mast fully back. Place blocks under the outer
forks as a complete set. mast channels to within 13 mm (0.5 in.) of the
channels See Figure 39.
Measure thickness of forks with a fork arm caliper
(Hyster Part No. 3020387) at a vertical section where 3. Tilt the mast fully forward. See Figure 39.
there is no wear. This thickness is dimension X. Now
measure thickness at heel of fork (see Figure 14). If
the thickness of the heel is not greater than 90% of
dimension X, replace fork.

MAST LUBRICATION

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.

NOTE: The load rollers and sheaves have sealed 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 38.

A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS A. MAST TILTED FULLY BACK
B. MAST TILTED FORWARD
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES 1. BLOCK
3. LOAD ROLLER 2. MAST

Figure 38. Mast Lubrication Figure 39. Blocking the Mast

44
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

4. Lubricate the mast pivot bushings at grease fit- 6. If a sideshift carriage is installed, lubricate slid-
tings on outer mast. See Figure 40 and Figure 41. ing surfaces at grease fittings with multipurpose
Use multipurpose grease shown in the Mainte- grease shown in the Maintenance Schedule. See
nance Schedule. Figure 42.

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

der the channels

1. MAST HANGER BUSHINGS 7. CAPSCREW

2. LUBE FITTINGS 8. NUT
3. MAST BUSHING PLUGS 9. WASHER
4. TILT PIN 10. ROD END BUSHING
5. ROD END 11. TILT CYLINDER ASSEMBLY
6. ANCHOR PIN 12. MAST MOUNTING CAP

Figure 40. Mast Mounting Hanger Lubrication

45
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

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

Figure 41. Pivot Pin Lubrication

Legend for Figure 42
1. CAPSCREWS 6. GREASE FITTINGS
2. LOWER HOOK 7. CYLINDER ROD
3. APRON 8. SNAP RING
4. LOWER BEARING 9. ROD SCRAPER
STRIPS 10. ROD BUSHING
5. UPPER BEARING 11. SEAL
STRIPS 12. FIXED FRAME

Figure 42. Integral Sideshift Carriage

46
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

HEADER HOSE CHECKS NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
tion should not be performed in combination with the
Daily inspection plus; kinked, crushed flattened or 1000 Hour/6 Months Lift Chain Lubrication.
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/re- Lubricate lift chains with SAE 30 engine oil. The best
place hose/components as necessary. procedure is to remove the chains from the lift truck
and soak them in engine oil. Be sure to clean any dirt
LIFT CHAIN LUBRICATION or grease from chains before lubricating. DO NOT
USE STEAM TO CLEAN THE LIFT CHAINS.
WARNING
When working on or near the mast, see Safety
TILT CYLINDER LUBRICATION
Procedures When Working Near Mast in this NOTE: The floor plate must be removed in order to
section. lubricate the rear tilt cylinder lubrication fittings.
Do not repair worn or damaged lift chains. If a Lubricate the tilt cylinder ends. Use multipurpose
lift chain is worn or damaged, both lift chains grease shown in the Maintenance Schedule. There
must be replaced. are four lubrication fittings. See Figure 43.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 3. ANCHOR PIN 5. TILT SPACER
2. RETAINER 4. LUBRICATION FITTING

Figure 43. Tilt Cylinder Lubrication

47
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

MASTER BRAKE CYLINDER ROD END MANUAL HYDRAULIC LEVERS

PIN LUBRICATION LUBRICATION
Lubricate the master brake cylinder rod end pin. Use Lubricate the bushings for the manual hydraulic
engine oil shown in the Maintenance Schedule. See levers. Use spray lubricant as listed in the Mainte-
Figure 44. nance Schedule. See Figure 45.

1. ROD END PIN

2. COTTER PIN (LOCKING)

Figure 44. Master Brake Cylinder Rod End Pin

Lubrication

NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)

Figure 45. Manual Hydraulic Levers

Lubrication

48
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months

BRAKE OIL

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

Replace the brake oil in the system if there is

dirt or water in the system.

CAUTION
Do NOT use "DOT" fluid, only use Dexron III
oil from sealed container to prevent possible
damage to the brake system.

Remove the dash board from the cowl. The brake oil
reservoir is located on the cowl, at the master cylin-
der. See Figure 46. Add brake oil, as necessary. Use
the brake fluid shown in the Maintenance Schedule.

1. RESERVOIR CAP 8. NIPPLE

2. BRAKE OIL 9. MASTER
RESERVOIR CYLINDER
3. RESERVOIR 10. CYLINDRICAL
MOUNTING BLOCK DRAIN
BRACKET PLUG
4. COWL 11. CYLINDRICAL
5. UPPER BRAKE OIL BLOCK
SUPPLY HOSE 12. CYLINDRICAL
6. CYLINDRICAL BLOCK MOUNTING
BLOCK OUTLET BRACKET
FITTING CAPSCREW
7. LOWER BRAKE
OIL SUPPLY HOSE

Figure 46. Brake Oil Reservoir

49
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248

TIE ROD LUBRICATION FOR LIFT TRUCK TIE ROD LUBRICATION FOR LIFT TRUCK
MODELS S80, 100, 120FT; S80, 100FTBCS; MODELS H80, 90, 100, 110, 120FT (N005)
S120FTS; S120FTPRS (G004)
Lubricate the tie rods. Use multipurpose grease
Lubricate the tie rods. Use multipurpose grease shown in the Maintenance Schedule. There is one
shown in the Maintenance Schedule. There is one lubrication fittings on each tie rod. See Figure 48.
lubrication fittings on each tie rod. See Figure 47.

1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE) 1. LUBRICATION FITTING (TIE ROD)
2. LUBRICATION FITTING (SPINDLE)
Figure 47. Tie Rod Lubrication for Lift Truck 3. STEERING AXLE
Models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) Figure 48. Tie Rod Lubrication for Lift Truck
Models H80, 90, 100, 110, 120FT (N005)

50
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months

DIFFERENTIAL AND DRIVE AXLE OIL, Legend for Figure 49

LIFT TRUCK MODELS WITH DRY BRAKES 1. DRIVE AXLE
2. CHECK/FILL PLUG
The differential and drive axle use the same oil sup- 3. DRAIN PLUG
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 49 and Figure 50. If oil is low, add oil shown
in the Maintenance Schedule until the oil level is be-
tween 0 to 10 mm (0 to 0.40 in.) below the bottom
edge of fill hole. Install fill plug and check for leaks.

1. CHECK/FILL PLUG
2. DRAIN PLUG
3. DRIVE AXLE

Figure 50. Drive Axle (Dry Brake) Fluid Fill

for Lift Truck Models H80, 90, 100, 110, 120FT
(N005)

Figure 49. Drive Axle (Dry Brake) Fluid Fill

for Lift Truck Models S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS (G004)

Maintenance Procedures Every 1000 Hours or 6 Months

NOTE: Perform the 8-hour, 250-hour, and 500-hour Additional engine information is available in the fol-
checks prior to performing the procedures in this sec- lowing sections:
tion. • GM Engines, 4.3 Liter V-6 600 SRM 1251
•
VALVE CLEARANCE, CHECK AND
ADJUST IGNITION SYSTEM
The GM 4.3L engine has hydraulic valve lifters and GM 4.3L Engine
does not require valve clearance adjustments during
normal service. The GM 4.3L gasoline and LPG engines have an elec-
tronic control unit (ECU) that controls the ignition
See the Maintenance Schedule for valve clearances. timing. There are no adjustments. Change the spark

51
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248

plugs every 1000 hours. The correct spark plug gap

is 0.9 mm (0.035 in.).

LPG FUEL FILTER ELEMENT REPLACE,

GM 4.3L ENGINE
Remove

WARNING
LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

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

stops.

2. Disconnect negative battery cable.

WARNING
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.
1. BOLT
3. Remove the bolt and seal washer retaining the 2. SEAL WASHER
top section of the fuel filter housing. Discard seal 3. FUEL FILTER HOUSING TOP SECTION
washer. See Figure 51. 4. FUEL FILTER
5. FUEL FILTER O-RING
4. Remove top section of fuel filter housing. 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
5. Remove and discard housing O-ring.
Figure 51. Fuel Filter Removal and Installation
6. Remove fuel filter and fuel filter O-ring.

52
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months

Install IN-LINE FILTER REPLACEMENT,

CUMMINS 4.5L ENGINE
1. Clean and inspect the fuel filter housing for con-
tamination or damage.
CAUTION
2. Install the new fuel filter and fuel filter O-ring. Disposal of lubricants and fluids must meet lo-
See Figure 51. cal environmental regulations.
3. Install new housing O-ring. Replace the fuel filter at specified intervals to pre-
vent contaminants from adversely affecting the
4. Install top section of fuel filter housing.
diesel fuel flow.
5. Install bolt and new seal washer. Tighten bolt to
13 N•m (115 lbf in). Remove

NOTE: Opening the fuel valve too quickly can cause 1. Stop Engine and allow it to cool.
the internal excessive flow valve to close, restricting
2. Close fuel supply valve located on the fuel send-
the flow of fuel. If this happens, close the fuel valve,
ing unit. See Figure 52.
wait a few seconds, and then slowly open the fuel
valve again. This will reset the excess fuel valve.
CAUTION
6. Slowly open the fuel valve on tank. Drain the fuel into a container and dispose in
7. Turn the key to the ON position and back to accordance with local environmental regula-
the OFF position to pressurize the fuel system. tions.
Check for leaks. 3. Loosen clamps and disconnect two fuel lines from
8. Check for leaks at connections by using soapy the in-line fuel filter. Remove and discard the
solution or electronic leak detector. If leaks are in-line fuel filter
detected, make proper repairs.
Install
1. Install in-line fuel filter by connecting the two
fuel lines and tighten clamps. See Figure 52.

2. Open the fuel supply valve.

3. Check for fuel leaks.

53
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248

Figure 52. Cummins 4.5L Engine Fuel System

54
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months

Legend for Figure 52

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

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 53.

LIFT CHAIN LUBRICATION

WARNING
Cleaning 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

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 Pitch Wear Limit
Total Length
the eyes. (The
of 20 Links
Maximum
Remove the lift chains. Clean the lift chains by soak- (Pitch) of New
Length of 20
ing them in a solvent that has a petroleum base for Chain
Links)
at least 30 minutes. Use compressed air, adjusted to
a maximum output of 103 kPa (15 psi), to completely 12.7 mm 254.0 mm 261.6 mm
dry the chains when they are clean. (0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
Lubricate the lift chains by soaking them in 30W en- (0.63 in.) (12.5 in.) (12.9 in.)
gine oil for at least 30 minutes. Remove the chains 19.1 mm 381.0 mm 392.4 mm
from the oil. Hang the chains for one hour so excess (0.75 in.) (15.0 in.) (15.4 in.)
oil will drain from the chains. 25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)

1. CHAIN WEAR SCALE

Figure 53. Lift Chains Check

55
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1248

INTEGRAL SIDESHIFT CARRIAGE, CHECK STEERING AXLE (SPINDLE BEARINGS)

SLIDING SURFACES FOR LIFT TRUCK MODELS S80, 100,
120FT; S80, 100FTBCS; S120FTS;
1. Check the sideshift carriage sliding surfaces,
and if necessary lubricate sliding surface at the S120FTPRS (G004)
grease fittings with multipurpose grease shown Lubricate the spindle bearings on the steering axle.
in the Maintenance Schedule. See Figure 54 There are four lubrication fittings, two on each side of
the steering axle. See Figure 55. Use multipurpose
grease as shown in the Maintenance Schedule.

1. CAPSCREWS 6. GREASE FITTINGS

2. LOWER HOOK 7. CYLINDER ROD
3. APRON 8. SNAP RING
4. LOWER BEARING 9. ROD SCRAPER
STRIPS 10. ROD BUSHING
5. UPPER BEARING 11. SEAL
STRIPS 12. FIXED FRAME

Figure 54. Integral Sideshift Carriage

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

Figure 55. Lubricate Spindle Bearings for Lift

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

56
8000 SRM 1248 Maintenance Procedures Every 1000 Hours or 6 Months

STEERING AXLE (SPINDLE BEARINGS) CONTROL LEVERS AND PEDALS

FOR LIFT TRUCK MODELS H80, 90, 100,
Lubricate linkages, pedal shafts, control cables
110, 120FT (N005) (throttle, hood, parking brake), and seat rails. Use a
Lubricate the spindle bearings on the steering axle. silicone spray lubricant, Hyster Part No. 328388.
There are four lubrication fittings, two on each side of
the steering axle. See Figure 56. Use multipurpose
INSPECT ENGINE ELECTRICAL SYSTEM,
grease as shown in the Maintenance Schedule. CONNECTORS
When inspecting the electrical system, check the fol-
lowing:

• Check and clean battery connection. Ensure that

connections are tight.
• Check battery for damage or cracks to the case.
Replace if necessary.
• Check positive and negative cables for corrosion,
rubbing, and chaffing. Tighten connections at both
ends.
• Check engine wire harness for rubbing, chaffing,
pinching, and cracks or breaks in the wiring.
• Check engine harness connectors. Check to ensure
connectors are fitted and locked by pushing the
connectors together. Pull on the connector halves
to make sure they are locked.
• Check ignition coil wire and spark plug wires for
hardening, cracking, arching, chaffing, separation,
split boot covers, and proper fit. Replace spark
plugs at the recommended interval as shown in the
Maintenance Schedule.
• Check that all electrical components are securely
mounted and retained to the engine or chassis.
• Check the MIL, charging, and oil pressure lights
1. LUBRICATION FITTING (TIE ROD) for operation by starting the engine and checking
2. LUBRICATION FITTING (SPINDLE BEARINGS) that the light illuminates before turning out.
3. STEERING AXLE

Figure 56. Lubricate Spindle Bearings for Lift

Truck Models H80, 90, 100, 110, 120FT (N005)

57
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and from head. See Figure 57. Lift the hydraulic fil-
1000-hour checks prior to performing the procedures ter element enough to allow the hydraulic oil to
in this section. drain.

HYDRAULIC SYSTEM NOTE: Have container large enough to hold the filter
element and allow for final hydraulic oil draining.
Hydraulic Filter, Replace
2. Remove the hydraulic filter element and O-ring
from the bowl and place into the container. Cover
WARNING the head to prevent any foreign materials from
At operating temperature, the hydraulic oil is getting into the hydraulic tank.
HOT. Do not permit the hot oil to touch the skin
and cause a burn. 3. Lubricate new O-ring with hydraulic oil and in-
stall it on the bottom of the new filter element.
Install the new filter element into the bowl.
CAUTION
Do not permit dirt to enter the hydraulic sys- 4. Install spring and filter lid onto head.
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to the com-
CAUTION
ponents of the hydraulic system.
Additives may damage the hydraulic system.
Never operate the hydraulic pump without oil Before using additives, contact your local Hys-
in the hydraulic system. The operation of the ter dealer.
hydraulic pump without oil will damage the
pump. 5. 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
CAUTION shown in the Maintenance Schedule. To change
Disposal of lubricants and fluids must meet lo- the hydraulic oil, see Hydraulic Oil, Replace.
cal environmental regulations.

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

riage. Unscrew and remove filter lid and spring

58
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

2. Unscrew and remove old hydraulic tank

breather, and replace with new hydraulic tank
breather.

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

Figure 58.

1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER

Figure 58. Hydraulic Tank Breather

IGNITION SYSTEM; DISTRIBUTOR CAP,

ROTOR, AND SPARK PLUG WIRES
NOTE: Make sure the key is in the OFF position and
the negative battery cable has been removed from the
1. LID 5. HEAD battery before removing the ignition system.
2. SPRING 6. FITTING
3. O-RING 7. QUAD RING Remove and discard spark plug wire assembly, coil
4. CAPSCREW 8. FILTER ELEMENT
9. BOWL wire, spark plugs, distributor cap, and rotor. For
procedures see High Voltage Switch (HVS) Igni-
Figure 57. Hydraulic Filter tion, GM 4.3L EPA Compliant Engines 2200 SRM
1097 for Spark Plug Wire Remove/Install, Distribu-
Hydraulic Tank Breather, Replace tor Cap Removal/Installation, and Rotor Disassem-
ble, Ignition Coil Wire Removal, and Spark Plug Re-
1. Raise the hood and remove the right rear side placement.
panel. See Figure 58.

59
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

COOLING SYSTEM, GM 4.3L AND as necessary. Connect the hose back on the fit-
CUMMINS 4.5L ENGINES ting at the top of the radiator.

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

Place a container with a minimum capacity of
CAUTION
15.1 liter (15.9 qt) under the radiator drain valve Additives may damage the cooling system. Be-
which could be located on either the lower left or fore using additives, contact your local Hyster
right side of the radiator on the engine side of the dealer.
radiator.
4. Close drain valve. Fill cooling system with the
correct coolant mixture of 50% water and 50%
WARNING ethylene glycol boron-free antifreeze. Fill the
DO NOT remove the radiator cap from the ra- auxiliary reservoir to a level between the ADD
diator when the engine is hot. When the radi- and FULL marks on the reservoir.
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam 5. Install radiator cap. Start engine. Check for
and boiling coolant can cause burns. DO NOT leaks. Add coolant to auxiliary coolant reservoir
remove the cover for the radiator when the en- as needed. Coolant level should be between the
gine is running. ADD and FULL marks on the reservoir.

AIR FILTER ELEMENT

CAUTION
Disposal of lubricants and fluids must meet lo- CAUTION
cal environmental regulations.
Do not allow dirt to enter the engine air intake
2. Open drain valve and remove radiator cap. Drain while changing the air filter element. A small
coolant into the container. Flush cooling sys- amount of dirt can cause damage to the engine.
tem. Check hoses for damage. Replace with new
NOTE: In dirty or dusty environments, change at
hoses, as needed.
1000 hours.
3. Disconnect the hose leading from the auxiliary
Replace the air filter element after 2000 hours.
reservoir to fitting at the top of the radiator un-
Inspect the O-ring on the liner assembly. If the
der the radiator cap, and drain the reservoir into
O-ring is damaged, replace the liner assembly. See
the same container used for the radiator coolant.
Figure 59.
Check the reservoir for contaminants and flush,

Figure 59. Air Filter

60
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

Legend for Figure 59

1. CANISTER 4. FILTER ELEMENT
2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY

OXYGEN SENSOR Legend for Figure 61

Check that the oxygen sensor electrical connector is 1. OXYGEN SENSOR (POST-CATALYTIC)
seated and locked. Check wires for cracks, splits, 2. MUFFLER
3. OXYGEN SENSOR (PRE-CATALYTIC)
chaffing, or burn through. If necessary, repair. See
Figure 60 and Figure 61.
LPG REGULATOR FUEL FILTER, GM
ENGINE
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 62.

1. OXYGEN SENSOR
2. ELECTRICAL CONNECTOR
3. EXHAUST PIPES TO EXHAUST MANIFOLD

Figure 60. Oxygen Sensor Location for Lift

Truck Models H80, 90, 100, 110, 120FT) (N005)
and S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004)

1. LPG REGULATOR 6. PAPER FILTER

2. INLET FITTING 7. RUBBER WASHER
3. O-RING 8. SCREWS
4. PLASTIC CAP 9. OUTLET FITTING
5. FOAM FILTER 10. SCREEN

Figure 62. GM LPG Regulator

Figure 61. Oxygen Sensor (BCS Only) for Lift
Truck Models S80, 100FTBCS (G004)

61
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

4. Remove and discard the plastic cap, foam filter, GASOLINE FUEL INJECTOR, GM ENGINES
paper filter, and rubber washer from the LPG
regulator. For removal and cleaning instructions, see the sec-
tion Gasoline Fuel System, GM 4.3L Engine 900
5. Disconnect the hose from the outlet fitting. Re- SRM 1244..
move three screws and the outlet fitting from the
LPG regulator. Discard the O-ring. FUEL INJECTOR, CUMMINS 4.5L ENGINE
6. Remove and discard the screen from the LPG reg- For removal and cleaning instructions for lift truck
ulator. models H80, 90, 100, 110, 120FT) (N005) equipped
with the Cummins 4.5L diesel engine. Contact you
Install local Hyster dealer or see Hyster Hypass Online.

1. Install a new screen in the LPG regulator. FORKS

2. Install a new O-ring on the outlet fitting. Using
three screws, install the outlet fitting on the LPG WARNING
regulator. Never repair damaged forks. Do not heat, weld,
cut, drill, or bend the forks. Forks are made
3. Install new rubber washer, paper filter, foam fil- of special steel using special methods. Replace
ter, and plastic cap in the LPG regulator. damaged forks as a set.
4. Install new O-ring on the inlet fitting. Install Check heel and attachment points of forks with a
inlet fitting into the LPG regulator and connect penetrant or by magnetic particle inspection.
hose to the inlet fitting.

5. Open shutoff valve on LPG tank and check for

leaks.

GASOLINE FUEL FILTER

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

2. Remove and discard the fuel filter. See Figure 63.

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.

LPG FUEL INJECTOR, GM ENGINES

For removal and cleaning instructions, see the sec-
tion LPG Fuel System, GM 4.3L Engine 900 SRM 1. FUEL FILTER
1242. 2. FUEL PUMP/SENDER UNIT

Figure 63. Fuel Filter Replacement (GM 4.3L)

62
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

TRANSMISSION OIL AND FILTER (DRY 4. Remove and discard transmission breather.
BRAKE), REPLACE Install new transmission breather and hand
tighten.

WARNING 5. Remove and discard old oil filter. Apply clean oil
At operating temperature, the transmission oil to gasket of new filter. Install new filter and hand
is HOT. Do not permit the hot oil to touch the tighten.
skin and cause a burn.
6. Add oil to transmission at the dipstick tube. The
correct oil is shown in the Maintenance Schedule.
CAUTION
Do not permit dirt to enter the transmission 7. Start and run the engine for approximately 5
when the oil level is checked or the filter is minutes after fill to allow oil to lubricate parts
changed. Dirt can cause damage to the trans- within the transmission and wet brake portion
mission components. of the drive axle center section. With the truck
in the ON position, See Maintenance Schedule
to add additional oil at the transmission dipstick
CAUTION tube that will need to be added to properly fill the
Disposal of lubricants and fluids must meet lo- wet brake portion of the drive axle center section
cal environmental regulations. and transmission.
NOTE: Change the transmission oil filter at the first
100 hours of operation on new lift trucks. See Fig-
ure 64. Before removing the oil filter, make a hole
at the top of the filter and allow five minutes for the
oil to drain down into the transmission. This will re-
duce the oil that will run out of the filter and onto the
transmission when the filter is removed.

1. The drain plug for the transmission is on the

lower right side of the cover of the transmission,
toward the rear of the lift truck. Remove drain
plug, spring, and screen. See Figure 64. Drain oil
into a container. when oil is completely drained,
install drain plug.

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures. NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF
Compressed air can move particles so they CLARITY.
cause injury to the user or to other personnel.
Make sure the path of the compressed air is 1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
away from all personnel. Wear protective gog- 3. SPRING
gles or a face shield to prevent injury to the 4. SCREEN
eyes. 5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
2. Clean screen with cleaning solvent, and dry with 7. TRANSMISSION BREATHER
compressed air, adjusted to a maximum output
of 103 kPa (15 psi). Figure 64. Transmission Oil Change

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

spring, and drain plug.

63
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

8. Turn the key to the OFF position and check for toward the rear of the lift truck. Remove drain
leaks and check oil level. plug, spring, and screen. See Figure 65. Drain oil
into a container, once oil is completely drained,
9. Turn the key to the OFF position and check oil reinstall drain plug.
level. If necessary, top off oil.
2. Remove planetary carrier housing drain plug and
TRANSMISSION AND WET BRAKE fill/level plug. Drain oil into a suitable container.
PLANETARY CARRIER HOUSING OIL When oil is completely drained, reinstall drain
CHANGE plug and fill/level plug. Tighten to 30 to 50 N•m
(22 to 37 lbf ft). For lift truck models S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS
WARNING (G004) see Figure 66. For lift truck models H80,
The oil used for the wet brake drive axle or 90, 100, 110, 120FT (N005) see Figure 67.
transmission should not be contaminated. If ei-
ther the wet brake planetary carrier housings
and/or transmission oil becomes contaminated,
the oil must be drained and replaced with new
oil.

WARNING
At operating temperature, the transmission
and wet brake planetary carrier housing oil
is HOT. Do not permit the hot oil to touch the
skin and cause a burn.

CAUTION
Do not permit dirt to enter the transmission or
wet brake planetary carrier housing when the
oil level is checked or the filter is changed. Dirt
will contaminate the oil and cause damage to
the transmission and wet brake planetary car-
rier housing components.

CAUTION NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR CLARITY.
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
NOTE: Change the transmission oil filter at the first 3. SPRING
100 hours of operation on new lift trucks. See Fig- 4. SCREEN
ure 65. Before removing the oil filter, make a hole 5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
at the top of the filter and allow five minutes for the 7. TRANSMISSION BREATHER
oil to drain down into the transmission. This will re-
duce the oil that will run out of the filter and onto the Figure 65. Transmission Oil Change
transmission when the filter is removed.

1. The drain plug for the transmission is on the

lower right side of the cover of the transmission,

64
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

3. Clean screen with cleaning solvent, and dry with

compressed air, adjusted to a maximum output
of 103 kPa (15 psi).

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

spring, and drain plug.

A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER BODY DRAIN PLUG
4. CENTER BODY FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER BODY

Figure 66. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004)
A. REAR VIEW SHOWN
B. FRONT VIEW SHOWN
WARNING
Cleaning solvents can be flammable and toxic 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
and can cause skin irritation. When using 2. PLANETARY CARRIER HOUSING DRAIN
cleaning solvents, always follow the solvent PLUGS
manufacturer’s recommended safety proce- 3. CENTER BODY FILL/LEVEL PLUG
dures. 4. CENTER BODY DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH)
Compressed air can move particles so they 6. PLANETARY CARRIER HOUSING (LH)
cause injury to the user or to other personnel. 7. CENTER BODY
Make sure the path of the compressed air is Figure 67. Wet Brake Drive Axle Drain and
away from all personnel. Wear protective gog- Fill/Level Plug Location for Lift Truck Models
gles or a face shield to prevent injury to the H80, 90, 100, 110, 120FT (N005)
eyes.

65
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

5. Remove and discard transmission breather.

Install new transmission breather and hand CAUTION
tighten. Before adding oil, ensure the truck is parked
and on level ground.
6. Remove and discard old oil filter. Apply clean oil
to gasket of new filter. Install new filter and hand 2. Add oil at the fill/level port for the center body
tighten. until the oil/fill level port has overflowed. The
correct oil is shown in the Maintenance Sched-
7. Add oil to transmission at the dipstick tube. The ule. For lift truck models S80, 100, 120FT; S80,
correct oil is shown in the Maintenance Schedule. 100FTBCS; S120FTS; S120FTPRS (G004) see
Figure 66. For lift truck models H80, 90, 100,
8. Start and run the engine for approximately 5
110, 120FT (N005) see Figure 67.
minutes after fill to allow oil to lubricate parts
within the transmission and wet brake planetary 3. Install oil fill/level plug. Tighten to 30 to 50 N•m
carrier housings. With the truck in the ON po- (22 to 37 lbf ft).
sition, See Maintenance Schedule to add addi-
tional oil at the transmission dipstick tube that BRAKE OIL (MASTER CYLINDER),
will need to be added to properly fill the plane- CHANGE
tary carrier housings and transmission. For lift
truck models S80, 100, 120FT; S80, 100FTBCS; 1. Remove the dashboard from the cowl.
S120FTS; S120FTPRS (G004) see Figure 66. For
lift truck models H80, 90, 100, 110, 120FT (N005)
CAUTION
see Figure 67.
Disposal of lubricants and fluids must meet lo-
9. Turn the key to the OFF position and check for cal environmental regulations.
leaks and check oil level.
2. Remove the brake oil reservoir from the bracket
WET BRAKE CENTER SECTION OIL on the cowl. See Figure 68.
CHANGE
WARNING
Remove Small amounts of water in the brake system
can cause reduced braking performance if the
1. Remove the center body fill/level plug. Remov- water reaches the wheel cylinder areas. Do
ing the fill/level plug will allow the oil to drain not allow water entry. Ensure that the sealed
at a faster rate. For lift truck models S80, 100, reservoir lid is properly replaced.
120FT; S80, 100FTBCS; S120FTS; S120FTPRS
(G004) see Figure 66. For lift truck models H80,
90, 100, 110, 120FT (N005) see Figure 67. CAUTION
Do NOT use "DOT" fluid, only use Dexron III
2. Place and empty container under the center body oil from a sealed container to prevent possible
drain plug. damage to the brake system.
3. Remove the center body drain plug, and wait un- 3. Remove the brake oil reservoir cover and cylin-
til oil has drained completely. drical block drain plug. Pour the oil into a
suitable container with a 0.35 liter (0.74 pt)
Install minimum capacity. Install the cylindrical block
drain plug. Refill the reservoir with clean oil
1. Install drain plug for the center body. Tighten to
from a sealed container and install the cover on
30 to 50 N•m (22 to 37 lbf ft). For lift truck mod-
the reservoir. The correct oil is shown in the
els S80, 100, 120FT; S80, 100FTBCS; S120FTS;
Maintenance Schedule.
S120FTPRS (G004), see Figure 66. For lift truck
models H80, 90, 100, 110, 120FT (N005), see Fig- 4. Install the reservoir into the bracket located on
ure 67. the cowl.

66
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually

3. Loosen the bleed screw at the wheel cylinder one

turn so that the used brake oil can be removed
from the brake system. Slowly push the brake
pedal and hold it at the end of its stroke. Close
the bleed screw. Release the brake pedal.

NOTE: The new brake oil will be easily recognized, as

the color will be more clear than the used oil which
will be darker.

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

brake oil in the container.

5. Check the level of the brake oil in the reservoir

for the master cylinder during the procedure.
Make sure to keep the brake oil at the correct
level.

6. Repeat the procedure for the other wheel 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 1.0 mm (0.040 in.). If the brake
linings are worn thinner than the specification, re-
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR place the brake linings. See the section Brake Sys-
3. RESERVOIR MOUNTING BRACKET tem 1800 SRM 1247 for the removal and installation
4. COWL procedures of the drive wheels and brake drums. If
5. UPPER BRAKE OIL SUPPLY HOSE the brake linings or brake shoes are worn or dam-
6. CYLINDRICAL BLOCK OUTLET FITTING aged, they must be replaced. Brake shoes must be
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE replaced in complete sets. Inspect brake drums for
9. MASTER CYLINDER cracks or damage. Replace any damaged parts.
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET WARNING
CAPSCREW Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings
Figure 68. Brake Oil Change is a cancer or lung disease hazard. Do not
create dust! Do not clean brake parts with
BRAKE OIL (DRY BRAKE), REMOVE compressed air or by brushing. Follow the
Perform the following procedure to remove used cleaning procedure in this section. When the
brake oil from the remainder of the brake system. brake drums are removed, do not create dust.

1. Ensure that the master cylinder reservoir is Do not sand, grind, chisel, hammer, or change
filled with brake oil. linings in any way that will create dust. Any
changes to brake linings must be done in a re-
NOTE: This procedure cannot be performed by one stricted area with special ventilation. Protec-
person. tive clothing and a respirator must be used.

2. Put one end of a rubber hose on the bleed screw

of the wheel cylinder. Put the other end of the
hose into a empty container.

67
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248

Brake cleaning procedures are as follows:

CAUTION
Do not use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
of brake parts. Do not permit oil or grease in
the brake fluid or on the brake linings.

1. Do not release brake lining dust from brake lin-

ings 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. 1. DRIVE AXLE
2. CHECK/FILL PLUG
4. Any cleaning cloths that will be washed must be 3. DRAIN PLUG
cleaned so that fibers are not released into the Figure 69. Drive Axle (Dry Brake) Fluid Fill
air. for Lift Truck Models S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS (G004)
DIFFERENTIAL (DRY BRAKE)
NOTE: Additional information on the differential can
be found in the section Drive Axle and Differential
Assembly Repair, (Dry Brake) 1400 SRM 1245.

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

Drive Tires in this manual.

2. The differential and drive axle use the same oil

supply. Place a container with a minimum capac-
ity of 5 liter (5.3 qt) under the differential. Re-
move the drain plug located in the bottom of the
differential and drain the oil from the differential
completely. Install the drain plug.

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

housing. Add oil shown in the Maintenance
Schedule until the oil level is at the lower edge of
the fill hole. Install fill plug and rotate the drive
wheels in order to get oil pumped into the axle. 1. CHECK/FILL PLUG
Remove the fill plug and check the oil level. Add 2. DRAIN PLUG
oil, as necessary. Install the fill plug and check 3. DRIVE AXLE
for leaks. See Figure 69 and Figure 70.
Figure 70. Drive Axle (Dry Brake) Fluid Fill
for Lift Truck Models H80, 90, 100, 110, 120FT
(N005)

68
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years

TEST LPG/GAS REGULATOR PRESSURE • Check the exhaust manifold at the cylinder head
for leaks. Ensure that all bolts and shields are in
For more information regarding the Test LPG/GAS place.
Regulator Pressure, see the section LPG Fuel Sys- • Check exhaust pipe fasteners to manifold for leaks
tem, GM 4.3L Engine 900 SRM 1242. and Gaso- to ensure they are tight. Repair if necessary.
line Fuel System, GM 4.3L Engine 900 SRM 1244. • Check all exhaust pipe extension connectors for
leaks and tighten, if necessary.
CHECK THROTTLE SHAFT FOR STICKING • Visually inspect converter for correct muffler
mounting and tail pipe mounting.
Check Throttle body return action to ensure throttle
• Check for any leaks at the inlet and outlet of the
shaft is not sticking. Repair if necessary.
converter.
INSPECT EXHAUST MANIFOLD AND
PIPING FOR LEAKS
To check the exhaust manifold and piping for leaks,
perform the following:

Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000- NOTE: Replace the hydraulic oil filter at the same
hour, and 2000-hour checks prior to performing the time the oil is changed.
procedures in this section.
1. Place a container with a minimum capacity of
HYDRAULIC OIL, REPLACE 39.4 liter (42 qt) under the drain plug at the
bottom of the hydraulic tank. To drain the oil,
remove the drain plug from the bottom of the
WARNING hydraulic tank. See Figure 71. When the tank
At operating temperature the hydraulic oil is is empty, inspect the inside of the tank for any
HOT. Do not permit the hot oil to touch the skin foreign matter or possible fungus. If necessary,
and cause a burn. clean the inside of the tank in accordance with
the instructions found in the section Frame 100
CAUTION SRM 1243. When either the inspection or the
Do not permit dirt to enter the hydraulic sys- cleaning of the tank is completed, install the
tem when the oil level is checked or the filter drain plug in the bottom of the hydraulic tank.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. CAUTION
Never operate the hydraulic pump without oil Additives may damage the hydraulic system.
in the hydraulic system. The operation of the Before using additives, contact your local Hys-
hydraulic pump without oil will damage the ter dealer.
pump. 2. Fill hydraulic tank with oil specified in the Main-
tenance Schedule.
CAUTION
3. When the oil level is correct, operate system and
Disposal of lubricants and fluids must meet lo-
check for leaks.
cal environmental regulations.

NOTE: Heavy-duty or contaminated applications will

require hydraulic oil change at 2000 hours.

69
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248

1. HYDRAULIC TANK 2. DRAIN PLUG

Figure 71. Hydraulic Oil Change

VALVE CLEARANCE, CHECK AND during normal service. Check the valve clearance
ADJUST FOR CUMMINS 4.5L DIESEL and make adjustments as needed. See the Mainte-
ENGINE nance Schedule for valve clearances.

The Cummins 4.5L engine has hydraulic valve lifters

and does not require valve clearance adjustments

70
8000 SRM 1248 Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast

The following procedures must be used when inspect- OR
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re- 2. If parts of the mast must be in a raised position,
moving the mast. See the correct Service Manual sec- install a safety chain to restrain the moving parts
tion for the specific mast being repaired. of the mast. Connect moving parts to a part that
does not move. Follow these procedures:

WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances
between parts are small. Serious injury or b. Raise mast to align bottom crossmember
death can result if part of the body is hit by of weldment that moves in outer weldment
parts of the mast or the carriage. with a crossmember on outer weldment.
On the two-stage and free-lift mast, the
• Never put any part of the body into or under moving part is the inner weldment. On
the mast or carriage unless all parts of the the three-stage mast, it is the intermediate
mast are completely lowered or a safety chain weldment. See Figure 72.
is installed. Also make sure that the power is
off and the key is removed. Put a DO NOT OP- c. Use a 3/8-in. minimum safety chain with a
ERATE tag in the operator’s compartment. hook to fasten the crossmembers together so
• Be careful of the forks. When the mast is the movable member cannot lower. Put the
raised, the forks can be at a height to cause hook on the back side of the mast. Make sure
an injury. the hook is completely engaged with a link in
• DO NOT climb on the mast or lift truck at any the chain. Make sure the safety chain does
time. Use a ladder or personnel lift to work not touch lift chains or chain sheaves, tubes,
on the mast. hoses, fittings, or other parts on the mast.
• DO NOT use blocks to support the mast weld- d. Lower the mast until there is tension in the
ments nor to restrain their movement. safety chain and the free-lift cylinder (free-
• Mast repairs require disassembly and re- lift, three-stage, and four-stage masts only)
moval of parts and can require removal of is completely retracted. If running, stop en-
the mast or carriage. Follow the repair pro- gine. Apply parking brake. Install a DO
cedures in the correct Service Manual for NOT REMOVE tag on the safety chain(s).
the mast.
e. Install another safety chain (3/8-in. mini-
NOTE: If there is no power to lower the mast on lift mum) between the top or bottom crossmem-
trucks equipped with Electronic Hydraulic System, ber of the carriage and a crossmember on the
there is an emergency load lowering valve located outer weldment.
on the hoist/lower valve section of the main control
valve. See the Operating Manual for the proce- 3. Apply parking brake. After lowering or restrain-
dures to lower a load using the emergency load low- ing the mast, shut off power and remove key. Put
ering valve. a DO NOT OPERATE tag in the operator’s com-
partment.
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.

71
Safety Procedures When Working Near Mast 8000 SRM 1248

Figure 72. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

72
8000 SRM 1248 Fuel Filter Water Removal

Legend for Figure 72

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST

Fuel Filter Water Removal

NOTE: The following procedure only pertains to lift
trucks equipped with Cummins 4.5L diesel engines.

1. Shut off the engine.

NOTE: The drain valve is located on the bottom of

fuel filter element.

2. To access the fuel filter element and drain valve,

remove the air inlet elbow. See Figure 73.

CAUTION
Drain water/fuel into a container and dispose
in accordance with local environmental regu-
lations.

3. Turn the drain valve counterclockwise approx-

imately 3 1/2 turns. Drain fuel filter until clear
fuel is visible.

CAUTION
Do not overtighten when closing the drain 1. AIR INLET ELBOW
valve. Overtightening can damage the threads. 2. FUEL FILTER ELEMENT
3. DRAIN VALVE
Close the drain valve by lifting and turning clock-
wise until it is hand-tight. Figure 73. Cummins 4.5L Engine Fuel Filter
Drain valve location

73
Hood Latch Check 8000 SRM 1248

Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is
The hood, hood latch, and latch striker must be fully closed after two clicks of the latch.
correctly adjusted for the correct operation of
the operator restraint system. 4. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center
1. Install hood latch on frame of hood. See Fig- of hood latch. Open hood and tighten capscrews
ure 74. Tighten capscrews so that hood latch can for latch.
still move when hood is closed.
5. Check operation of hood latch. Have an operator
2. Install latch striker in highest slot position. sit in the seat. Make sure hood is fully closed
Check that latch striker is in center of jaws of (two clicks). Also check that hood touches rubber
hood latch when hood closes. bumper. If necessary, repeat Step 4.

1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME

Figure 74. Hood Latch Check

74
8000 SRM 1248 Lift Chain Adjustments

Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.

Never allow anyone under a raised carriage.

Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.

Do not try to find hydraulic leaks by putting

your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.

During test procedures for the hydraulic sys-

1. MAST
tem, fasten the load to the carriage with chains 2. CARRIAGE
to prevent it from falling. Keep all personnel 3. FORK
away from the lift truck during the tests. 4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE THE FLOOR LEVEL.
When lift chains are correctly adjusted:
• Tension will be the same on each chain of chain Figure 75. Lift Chain Adjustments With Forks
set. Check tension by pushing on both chains at Installed
the same time.
• Chain length will be correct.
• Chains must travel freely through complete cycle.

NOTE: When chain adjustments are complete, make

sure the threads on the nuts of the chain anchors
are completely engaged. Make sure all adjustment is
not removed from the chain anchors. Chain anchors
must be able to move on their mounting.

1. When adjusting lift chains on forklift trucks

equipped with the forks installed, go to Step 2.
If forklift truck is equipped with an attachment
without forks, go to Step 3.

NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and the mast is in the vertical position.

2. Adjust chain anchors which support the carriage 1. MAST

2. CARRIAGE
until bottom of the fork heel is 6 ±3 mm (0.24 3. DISTANCE FROM FLOOR TO LOWER
±0.12 in.) above floor level. See Figure 75. CARRIAGE BAR
3. Adjust chain anchors which support carriage un- Figure 76. Lift Chain Adjustment Without
til the bottom of lower carriage bar is above the Forks Installed
floor level as shown in Table 2. See Figure 76.

75
Jump-Starting the Lift Truck 8000 SRM 1248

In Table 2, the masts are divided by class. Each Table 2. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)

Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK

CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by push- touching.
ing or towing lift truck.

If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these DO NOT try to start the engine by pushing or
procedures carefully when connecting the jumper towing the lift truck. Damage to the hydraulic
cables: system can occur if engine is started by push-
ing or towing lift truck.
1. Disconnect the negative battery terminal of the
lift truck being started. 1. Always connect positive jumper cable to positive
terminal of discharged battery and negative
2. Always connect positive jumper cable to positive jumper cable to negative terminal.
terminal of discharged battery and negative
jumper cable to negative terminal. 2. Always connect jumper cable, that is the ground
cable, last.
3. Always connect jumper cable, that is the ground
cable, last. 3. Always connect jumper cables to discharged lift
truck battery before connecting them to the fully-
4. Always connect jumper cables to discharged bat- charged lift truck battery.
tery before connecting them to booster battery.

76
8000 SRM 1248 Overhead Guard Changes

Welding Repairs
warning. Should work be performed, utilize
WARNING good industrial hygiene practices including
Welding can cause a fire or an explosion. Al- removal of all paint (prime and finish coats) to
ways follow the instructions in the Frame sec- the metal around the area to be welded, local
tion if a fuel or hydraulic tank must be welded. ventilation, and/or supplied-air respiratory
Make sure there is no fuel, oil, or grease near protection.
the weld area. Make sure there is good venti-
lation in the area where the welding must be
done. CAUTION
When an arc welder is used, always disconnect
Do not heat, weld, or bend forks. Forks are the ground cable from the battery in the lift
made of special steel using special methods. truck. This action will prevent damage to the
The strength of the overhead guard can be re- alternator or the battery.
duced by welding or heating. Get information
from your dealer for Hyster lift trucks before Connect the ground clamp for the arc welder as
welding on a mast. close as possible to the weld area. This action
will prevent damage to a bearing from the large
Forklift frames and components may be current from the welder.
painted with a catalyzed paint such as
polyurethane or a two-part primer. Weld- Some repairs require welding. If an acetylene or arc
ing, burning, or other heat sufficient to cause welder is used, make sure procedures in previous
thermal decomposition of the paint may re- WARNING and CAUTION are done.
lease isocyanates. These chemicals are allergic
sensitizers to the skin and respiratory tract See the American National Standard Safety in Weld-
and overexposure may occur without odor ing and Cutting, AWS Z 49.1 - 1999.

Overhead Guard Changes

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

77
Wheel and Tire Replacement 8000 SRM 1248

Wheel and Tire Replacement

GENERAL 2. Remove wheel nuts and remove wheel from lift
truck. Lift truck wheels are heavy.
The S series lift trucks have solid rubber tires (often
called cushion tires) that are pressed onto the rim. Remove and Install Tire on Wheel
The H series lift trucks have pneumatic tires or solid
rubber tires that look like pneumatic tires. These NOTE: Make sure the tires are installed on the
variations in tires also cause a variation in the types wheels so that the outside edges of the tire and
of wheels and the disassembly and assembly proce- wheel are as shown in Figure 77. Also, check the
dures. Nameplate of the lift truck for the correct tire size
and tread width.
SOLID RUBBER TIRE, CHANGE
1. The correct tools, equipment, and a press ring
(S SERIES)
must be used for each size of wheel. Use a press
NOTE: to push wheel from rim and tire. The capacity of
the press must be approximately 355 to 1779 kN
Solid rubber tires made from softer or harder ma- (80,000 to 400,000 lbf). For the tire sizes, see the
terial can be installed as optional equipment. The Nameplate.
tread on the sold rubber tires can be either smooth
or it can have lugs. Do not mix types of tires or tread 2. When the drive wheels are installed on the lift
on lift truck. See Figure 77. truck, tighten wheel nuts to a torque value of 618
to 680 N•m (456 to 502 lbf ft).
WARNING 3. The steering wheels are fastened to the spindle
The type of solid rubber tire is shown on the of the steering axle with a large castle nut. Make
Nameplate. Make sure the Nameplate is cor- sure inner and outer bearings are correctly lu-
rect for the type of tires on the lift truck. The bricated with grease. Install inner bearing
12000 lb.. capacity solid rubber tired fork lift assembly and wheel on spindle. Install outer
must be equipped with high load capacity bearing cone and castle nut. Tighten castle nut
steering tires. up to 203 N•m (150 lbf ft) while rotating hub
in both directions to properly seat the bearings,
Wheels must be changed and tires repaired by loosen the castle nut until wheel hub turns freely
trained personnel only. with no end play. Tighten castle nut to 34 N•m
(25 lbf ft). If the cotter pin cannot be installed,
Always wear safety glasses.
loosen the castle nut to the first position where
1. Raise lift truck as described in How to Put Lift the cotter pin can be installed. Install cap for
Truck on Blocks in this manual. bearings.

78
8000 SRM 1248 Wheel and Tire Replacement

A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER 2. WHEEL 3. OVERHANG
TIRE

Figure 77. Tires and Wheels for S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)
Lift Trucks

PNEUMATIC TIRE WITH TUBE, REPAIR Deflate tire completely before removing the
wheel from the lift truck. If dual wheels are
Remove Wheels From Lift Truck used, deflate both tires. Air pressure in the
tires can cause the tire and rim parts to ex-
WARNING plode, causing serious injury or death.
A solid rubber tire that is the same shape as Always wear safety glasses.
a pneumatic tire can be installed on a three-
piece or four-piece wheel for a pneumatic tire. Never loosen the nuts that hold the inner and
DO NOT make changes in the parts of the rim if outer wheel halves together when there is air
this type of solid rubber tire is installed instead pressure in the tire.
of a pneumatic tire. Changes to the parts of the
rim can cause a failure of the wheel and cause 1. Put lift truck on blocks as described in How to
an accident. Put Lift Truck on Blocks at the beginning of this
section.
WARNING 2. Remove air from tire. Remove valve core to make
The type of tire and the tire pressure (pneu- sure all air is out of inner tube. Push a wire
matic tires) are shown on the nameplate. Make through valve stem to make sure valve stem does
sure the nameplate is correct for the type of not have a restriction.
tires on the lift truck.
3. Remove wheel nuts and remove wheel and tire
WARNING from lift truck. Lift truck tires and wheels are
heavy.
Wheels must be changed and tires repaired by
trained personnel only.

79
Wheel and Tire Replacement 8000 SRM 1248

Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Fig-
ure 78. There are several types of wheels used on
this series of lift trucks.

A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT

Figure 78. Types of Pneumatic Wheels

Remove Tire From Two-Piece Wheel

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

Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.

STEP 1.
Remove nuts that fasten wheel rims together.

80
8000 SRM 1248 Wheel and Tire Replacement

STEP 2.
Loosen tire bead from wheel rim.

STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.

Remove Tire From Three- and Four-Piece Wheels

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

Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.

STEP 1.
Loosen tire bead from side flange.

81
Wheel and Tire Replacement 8000 SRM 1248

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

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

STEP 4.
Remove wheel from tire.

Install Wheel in Tire parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
WARNING not touch. The clearance at the ends of the lock
ring will be approximately 13 to 25 mm (0.5 to
Damage to the tire and wheel assembly and in-
1.0 in.) after it is installed. If the clearance is
jury or death can occur if you do not do the fol-
wrong, the wrong part has been used.
lowing procedures:
• Clean and inspect all parts of the wheel be- 1. Clean and inspect all parts of wheel. Paint any
fore installing the tire. parts that have rust or corrosion.
• DO NOT use any damaged or repaired wheel
parts. 2. Install new inner tube in tire. Used tubes and
• Make sure all parts of the wheel are the cor- flaps can cause tire failure.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or 3. Apply a rubber lubricant or a soap solution to the
manufacturers of wheels. tire bead and tube.
• DO NOT mix types of tires, type of tire tread,
4. Install new tire flap.
or wheel assemblies of different manufactur-
ers on any one lift truck. 5. Make sure rim is the correct size for tire. Lubri-
cate part of wheel that contacts bead and flap.
Do not use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put

82
8000 SRM 1248 Wheel and Tire Replacement

6. Install the three-piece or four piece wheel in the

CAUTION tire a shown in Install Three-Piece or Four-Piece
Do not use pneumatic-shaped, solid tires on Wheel in Tire.
two-piece bolt together drive wheels. Spinning
may occur. 7. Install the two-piece wheel in the tire as shown
in Install Tire on Two-Piece Wheel.

Install Three-Piece or Four-Piece Wheel in Tire

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

Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.

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

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

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

83
Wheel and Tire Replacement 8000 SRM 1248

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

Install Tire on Two-Piece Wheel

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

Install Two-Piece Wheel in Tire

STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.

84
8000 SRM 1248 Wheel and Tire Replacement

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

ADD AIR TO PNEUMATIC TIRES WITH adjustments. The clearance at the ends of the
TUBE lock ring will be approximately 13 to 25 mm (0.5
to 1.0 in.) when the tire has the correct air pres-
sure.
WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire.

Do not sit or stand by the safety cage. Do not

use a hammer to try and correct the position of
the side flange or lock ring when the tire has
air pressure greater than 20 kPa (3 psi).

1. Put tire in a safety cage.

2. Add 20 kPa (3 psi) of air pressure to tire. See

Figure 79.
Figure 79. Add Air to Tires
3. Check that all wheel parts are correctly installed.
Hit lock ring lightly to make sure it is in the seat. Install the Wheels

4. If installation is correct, add air pressure to tire Install wheel on the hub. Tighten nuts in a cross
to the specified pressure. pattern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 618 to 680 N•m
5. Check that all wheel parts are correctly installed. (456 to 502 lbf ft) for steer wheel nuts. If the wheels
If installation is not correct, remove all air pres- are the two-piece rims, make sure nuts that fasten
sure from tire. Remove valve core to make sure rim halves together are toward brake drum when
all air pressure has been removed and then make they are installed.

85
Wheel and Tire Replacement 8000 SRM 1248

Dual Drive Wheels, Install

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

1. Install inner wheel on hub. If the wheels are

the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
they are installed.

2. Install wheel adapter spacers on the inner wheel

studs and tighten spacers to 100 to 125 N•m (74
to 92 lbf ft). Install the dual hub assembly and
inner wheel nuts on the spacers and tighten the
wheel nuts to 450 to 500 N•m (332 to 369 lbf ft).
See Figure 80.

3. Install outer wheel on dual hub assembly.

Tighten nuts to a torque value of 450 to 500 N•m
(332 to 369 lbf ft). If the wheels are the two-piece
rims, make sure nuts that fasten rim halves
together are toward brake drum when they are
installed.

4. Install the valve extension bracket and tighten

the attaching nut to 8 N•m (70 lbf in). Install 1. TIRE 5. WHEEL ADAPTER
the valve extension hose into the bracket. See 2. DUAL HUB SPACER
Figure 80. ASSEMBLY 6. VALVE EXTENSION
3. WHEEL NUT 7. BRACKET
4. WHEEL

Figure 80. Dual Drive Wheels Installation

86
8000 SRM 1248 Wheel and Tire Replacement

PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be
Remove Wheels From Lift Truck used with a tube.

The main component of a TBS is a special rubber

WARNING
ring that fits inside the tire between the tire beads
Wheels must be changed and tires repaired by to ensure the air tightness of the existing wheel and
trained personnel only. the tubeless tire assembly. See Figure 78.
Deflate tire completely before removing the 1. Put lift truck on blocks as described in How to
wheel from the lift truck. If dual wheels are Put Lift Truck on Blocks at beginning of this sec-
used, deflate both tires. Air pressure in tires tion.
can cause the tire and rim parts to explode
causing serious injury or death. 2. Remove the valve cap and core to remove all air
from the tire.
Always wear safety glasses.
3. Remove the wheel nuts and remove the wheel
Never loosen the nuts that hold the inner and and tire from the lift truck. Lift truck tires and
outer wheels halves together when there is air wheels are heavy.
pressure in the tire.

Remove Tire From Wheel

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

Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause injury.

NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 78.

STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.

87
Wheel and Tire Replacement 8000 SRM 1248

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

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

STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel only)
from the tire and wheel assembly.

STEP 5.
Push the TBS toward the inside of the tire to remove
it.

88
8000 SRM 1248 Wheel and Tire Replacement

Install Tire on Wheel

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

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

WARNING
Do not lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids
can cause an explosion during inflation or use.

STEP 1.
Clean interior and exterior bead of the tire. Lubri-
cate tire beads and the inside of the tire, up to the
tire shoulders. Apply lubricant to the entire under-
side of the TBS.

NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve.

One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve
slot. The valve hole that is not used should be sealed with a small plastic plug.

STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and remov-
ing the lubricated valve several times. If a three- or
four-piece wheel is being used, remove the valve. If
a two-piece wheel is being used, leave valve in valve
hole.

If the TBS has two-valve holes, lubricate the plastic

plug and insert into valve hole that will not be used.

89
Wheel and Tire Replacement 8000 SRM 1248

STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in the
TBS.

STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.

Line up the valve hole in the TBS with the valve slot
in the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.

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

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

90
8000 SRM 1248 Wheel and Tire Replacement

STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.

Push down on the press to depress the tire beads un-

til locking ring groove is fully exposed.

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

STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mal-
let to ensure all components are correctly sealed. Re-
move the press from wheel and tire assembly.

Add Air to Pneumatic Tubeless Tire

WARNING
Add air pressure to tires only in safety cage.
Inspect safety cage for damage before use.
When air pressure is added, use a chuck that
fastens onto valve stem. Make sure there is
enough hose to permit operator to stand away
from safety cage when air pressure is added to
tire.

Do not sit or stand by safety cage.

1. Put tire in safety cage. See Figure 81.

2. Add air to tire to the recommended air pressure

that is shown on the Nameplate. Install valve Figure 81. Add Air to Tires
cap to ensure air stays in the tire.

91
Wheel and Tire Replacement 8000 SRM 1248

Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
Install wheel on hub. Tighten nuts in a cross pat-
tern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 155 to 175 N•m WARNING
(114 to 129 lbf ft) for steer wheel nuts. If wheels Wheels must be changed and tires repaired by
are two-piece rims, make sure nuts that fasten rim trained personnel only.
halves together are toward brake drum when they
are installed. Always wear safety glasses.

1. Put lift truck on blocks as described in How to

Put Lift Truck on Blocks at the beginning of this
section.

2. Remove wheel nuts and remove wheel and tire

from lift truck. Lift truck tires and wheels are
heavy.

Remove Wheel From Tire

NOTE: When you disassemble the wheels, see Figure 78. There are several types of wheels used on these series
of lift trucks.

WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury. Always wear safety glasses.

STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side flange.

92
8000 SRM 1248 Wheel and Tire Replacement

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

STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.

STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.

93
Wheel and Tire Replacement 8000 SRM 1248

Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 78. There are several types of wheels used on these series
of lift trucks. Do not use a two-piece pneumatic wheel for solid rubber tires.

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

Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not
touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.

CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.

STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.

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

94
8000 SRM 1248 Wheel and Tire Replacement

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

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

95
Adhesives and Sealants 8000 SRM 1248

Adhesives and Sealants

Loctite®
Hyster Part No. Description Size
Part No.
360387 222 Small Screw Threadlock (Purple) 50 ml
318702* 242 Removable Threadlock (Blue) 10 ml
226414* 271 High Strength Threadlock (Red) 10 ml
318996 277 High Viscosity Threadlock (Red) 50 ml
318650 290 Low Viscosity Threadlock (Green) 0.02 oz
251099 290 Low Viscosity Threadlock (Green) 50 ml
355844* 422 SuperBonder® Adhesive 3 ml
350830 515 Gasket Eliminator (Purple) 6 ml
313022* 515 Gasket Eliminator (Purple) 50 ml
273338* 567 Pipe Sealant with Teflon® 50 ml
318705 595 Super Flex® Silicone 100 ml
318701* 609 Retaining Compound 10 ml
341959 680 Retaining Compound 50 ml
226415 Primer T - Aerosol 6 oz
251979 767 Antiseize Compound 1 lb
360053-10 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
318700 Adhesive and Sealant Kit (Contains one each of *
items)
*Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700.
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.

96
 TECHNICAL PUBLICATIONS

8000 SRM 1248 7/07 (3/07)(10/06)(8/06)(6/06)(4/06)(3/06) Printed in U.S.A.