MANUAL DE SERVICIO HYSTER NAFTA GAS Manutencao-Hyster-H40-70FT-Maintenance-Hyster-H40-70FT PDF

PERIODIC
MAINTENANCE
S40-70FT, S55FTS [F187];
H40-70FT [L177]
PART NO. 1580525 8000 SRM 1150

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Serial Number Data ........................................................................................................................................ 1
How to Move Disabled Lift Truck................................................................................................................... 2
How to Tow Lift Truck ................................................................................................................................ 2
How to Put Lift Truck on Blocks .................................................................................................................... 3
How to Raise Drive Tires ............................................................................................................................ 3
How to Raise Steering Tires ....................................................................................................................... 3
How to Clean a Lift Truck............................................................................................................................... 4
Maintenance Schedule......................................................................................................................................... 5
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 30
How to Make Checks With Engine Stopped................................................................................................. 30
Tires and Wheels ....................................................................................................................................... 30
Safety Labels ............................................................................................................................................. 30
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 31
Operator Restraint System....................................................................................................................... 32
Automatic Locking Retractor (ALR) .................................................................................................... 32
Emergency Locking Retractor (ELR) ................................................................................................... 32
Adjust Seat - Full Suspension .............................................................................................................. 32
Adjust Seat - Internal Suspension ....................................................................................................... 34
Hood and Seat Latches ............................................................................................................................. 35
Engine Compartment................................................................................................................................ 35
Paper Application ...................................................................................................................................... 35
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ 36
Hydraulic Hoses ........................................................................................................................................ 36
Coolant Hoses ............................................................................................................................................ 36
Steering Column Gas Cylinder................................................................................................................. 36
Transmission ............................................................................................................................................. 36
Hydraulic System Oil ................................................................................................................................ 36
Engine Oil .................................................................................................................................................. 37
Air Filter .................................................................................................................................................... 43
Forks .......................................................................................................................................................... 43
Remove .................................................................................................................................................. 43
Inspect ................................................................................................................................................... 45
Install..................................................................................................................................................... 45
Adjust..................................................................................................................................................... 45
How to Make Checks With Engine Running................................................................................................ 46
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 46
Service Brakes ........................................................................................................................................... 48
Brake Fluid Level ................................................................................................................................. 48
Operation, Check .................................................................................................................................. 49
Parking Brake ........................................................................................................................................... 49
Engine Oil Pressure .................................................................................................................................. 49
Cooling System .......................................................................................................................................... 50
Steering System ........................................................................................................................................ 51
Control Levers and Pedals ........................................................................................................................ 51
Lift System, Operate ................................................................................................................................. 51
First Service After First 100 Hours of Operation ............................................................................................ 51
Mazda and GM Engine Oil and Oil Filter.................................................................................................... 51
Yanmar Engine Oil and Oil Filter ................................................................................................................ 52
Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 53
Mazda and GM Engine Oil and Oil Filter.................................................................................................... 53
©2013 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Drive Belt ....................................................................................................................................................... 54
Mazda 2.0L and 2.2L Engines .................................................................................................................. 54
Fan and Alternator Drive Belt ............................................................................................................. 54
GM 2.4L Engine ........................................................................................................................................ 54
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) .............................. 55
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only).................................. 56
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 57
Hydraulic System Oil .................................................................................................................................... 57
Hydraulic Tank Breather .............................................................................................................................. 57
Inspect........................................................................................................................................................ 57
Battery ........................................................................................................................................................... 58
Yanmar Engine Oil and Oil Filter ................................................................................................................ 58
Drive Belt ....................................................................................................................................................... 58
Yanmar Diesel Engine............................................................................................................................... 58
PCV Valve ...................................................................................................................................................... 59
Clean Debris From Radiator Core ................................................................................................................ 59
Transmission Oil Level ................................................................................................................................. 59
Wet Brake Planetary Housing Oil Level Check........................................................................................... 61
Forks............................................................................................................................................................... 63
Mast Lubrication ........................................................................................................................................... 63
Header Hose Checks...................................................................................................................................... 66
Lift Chain Lubrication .................................................................................................................................. 66
Tilt Cylinder Lubrication .............................................................................................................................. 67
Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 68
Manual Hydraulic Levers Lubrication ......................................................................................................... 69
Brake Fluid .................................................................................................................................................... 69
Tie Rod Lubrication (H40-70FT)................................................................................................................... 70
Differential and Drive Axle Oil (Dry Brake) ................................................................................................ 71
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 72
Valve Clearance, Check and Adjust.............................................................................................................. 72
Ignition System.............................................................................................................................................. 72
GM 2.4L Engine ........................................................................................................................................ 72
Mazda 2.0L and 2.2L Engines .................................................................................................................. 72
LPG Fuel Filter Element Replace, GM 2.4L Engine ................................................................................... 72
Remove....................................................................................................................................................... 72
Install ......................................................................................................................................................... 72
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant
Engines) ......................................................................................................................................................... 73
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only ............................................... 74
Remove....................................................................................................................................................... 74
Clean/Inspect ............................................................................................................................................. 74
Install ......................................................................................................................................................... 74
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only ............................... 75
Remove and Replace ................................................................................................................................. 75
Fuel Filter Replacement, Yanmar Engine.................................................................................................... 76
Priming the Fuel System (Yanmar).............................................................................................................. 77
Lift Chains Wear Check ................................................................................................................................ 78
Lift Chain Lubrication .................................................................................................................................. 78
Integral Sideshift Carriage, Check Bearings ............................................................................................... 79
ii
Periodic Maintenance Table of Contents

Integral Sideshift Carriage, Check Lower Mounting Hooks ....................................................................... 79
Steering Axle.................................................................................................................................................. 80
Control Levers and Pedals ............................................................................................................................ 80
Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 81
Hydraulic System .......................................................................................................................................... 81
Hydraulic Filter, Replace .......................................................................................................................... 81
Hydraulic Tank Breather, Replace ........................................................................................................... 82
Air Filter ........................................................................................................................................................ 83
PCV Valve ...................................................................................................................................................... 84
Oxygen Sensor .............................................................................................................................................. 85
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ........... 86
Remove and Replace ................................................................................................................................. 86
LPG Regulator Fuel Filter, GM Engines...................................................................................................... 87
Remove....................................................................................................................................................... 87
Install ......................................................................................................................................................... 87
Gasoline Fuel Filter....................................................................................................................................... 88
Remove and Replace for Lift Trucks Equipped with GFI ....................................................................... 88
Timing Belt .................................................................................................................................................... 89
Mazda Engines .......................................................................................................................................... 89
GM 2.4L Engine ........................................................................................................................................ 89
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ......................... 89
Gasoline Fuel Injector, Mazda Engines........................................................................................................ 89
LPG Fuel Injector, GM Engines.................................................................................................................... 89
Gasoline Fuel Injector, GM Engines ............................................................................................................. 89
Fuel Injector, Yanmar Engines ..................................................................................................................... 89
Forks............................................................................................................................................................... 89
Integral Sideshift Carriage ........................................................................................................................... 89
Bearings, Replace ...................................................................................................................................... 89
Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 89
Iron Transmission Housing ...................................................................................................................... 89
Aluminum Transmission Housing ........................................................................................................... 90
Remove .................................................................................................................................................. 90
Clean and Inspect ................................................................................................................................. 94
Install..................................................................................................................................................... 94
Transmission Oil Change, Wet Brake Drive Axle ....................................................................................... 95
Iron Transmission Housing ...................................................................................................................... 95
Aluminum Transmission Housing ........................................................................................................... 96
Wet Brake Axle Center Section and Planetary Housing, Oil Change ........................................................ 99
Brake Fluid (Master Cylinder), Change..................................................................................................... 103
Brake Fluid (Dry Brake), Remove .............................................................................................................. 104
Service Brakes (Dry Brake) ........................................................................................................................ 104
Differential (Dry Brake) .............................................................................................................................. 105
Maintenance Procedures Every 4000 Hours or 2 Years................................................................................. 106
Hydraulic Oil, Replace ................................................................................................................................ 106
Cooling System ............................................................................................................................................ 106
Safety Procedures When Working Near Mast................................................................................................ 108
Hood Latch Check ............................................................................................................................................ 110
Lift Chain Adjustments ................................................................................................................................... 111
Jump-Starting the Lift Truck.......................................................................................................................... 112
Jump-Starting Using a Battery Charger ................................................................................................... 112
Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................. 112
iii
Table of Contents Periodic Maintenance

Welding Repairs ............................................................................................................................................... 113
Overhead Guard Changes ............................................................................................................................... 113
Wheel and Tire Replacement .......................................................................................................................... 113
General ......................................................................................................................................................... 113
Solid Rubber Tire, Change (S Series) ......................................................................................................... 113
Remove and Install Tire on Wheel ......................................................................................................... 114
Pneumatic Tire With Tube, Repair............................................................................................................. 115
Remove Wheels From Lift Truck............................................................................................................ 115
Remove Tire From Wheel ....................................................................................................................... 115
Remove Tire From Two-Piece Wheel ................................................................................................. 116
Remove Tire From Three- and Four-Piece Wheels ........................................................................... 117
Install Wheel in Tire ............................................................................................................................... 118
Install Three-Piece or Four-Piece Wheel in Tire ............................................................................... 118
Install Tire on Two-Piece Wheel ........................................................................................................ 120
Install Two-Piece Wheel in Tire ......................................................................................................... 120
Add Air to Pneumatic Tires With Tube...................................................................................................... 121
Install the Wheels ................................................................................................................................... 121
Dual Drive Wheels, Install ..................................................................................................................... 121
Pneumatic Tubeless Tire, Repair................................................................................................................ 122
Remove Wheels From Lift Truck............................................................................................................ 122
Install Tire on Wheel .............................................................................................................................. 124
Add Air to Pneumatic Tubeless Tire ...................................................................................................... 127
Wheels, Install......................................................................................................................................... 127
Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... 127
Install Tire on Wheel .............................................................................................................................. 129
Adhesives and Sealants ................................................................................................................................... 131
This section is for the following models:
S40-70FT, S55FTS [F187];

H40-70FT [L177]
iv
8000 SRM 1150 General
General
in the Maintenance Schedule for the following condi-
WARNING tions:
DO NOT make repairs or adjustments unless • The lift truck is used more than eight hours per
you have both authorization and training. Re- day.
pairs and adjustments that are not correct can • The lift truck must work in dirty operating condi-
make a dangerous operating condition. tions.
• Poor ground conditions.
WARNING • Intensive usage at high performance levels or
DO NOT operate a lift truck that needs repairs. other abnormal conditions will require more fre-
Report the need for repairs immediately. If re- quent servicing.
pair is necessary, put a DO NOT OPERATE tag Your dealer for Hyster lift trucks has the equipment
in the operator’s area. Remove the key from and trained service personnel to do a complete pro-
the key switch. gram of inspection, lubrication, and maintenance. A
regular program of inspection, lubrication, and main-
CAUTION tenance will help your lift truck provide more effi-
Disposal of lubricants and fluids must meet lo- cient performance and operate for a longer period of
cal environmental regulations. time.
This section contains a Maintenance Schedule and Some users have service personnel and equipment
the instructions for maintenance and inspection. to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service man-
The Maintenance Schedule has time intervals for in- uals are available from your dealer for Hyster lift
spection, lubrication, and maintenance of your lift trucks to help users who do their own maintenance.
truck. The service intervals are provided in both op-
erating hours recorded on the lift truck hourmeter SERIAL NUMBER DATA
and in calendar time. The recommendation is to use
the interval that comes first. The serial number for the lift truck is on the Name-
plate. It is also on the right side of the frame, under
The recommendations for the time intervals provided the floor plate.
is for eight hours of operation per day. The time inter-
vals must be decreased from the recommendations
1
General 8000 SRM 1150
HOW TO MOVE DISABLED LIFT TRUCK from surface. Install chain around a mast cross-
member and carriage to prevent carriage and
How to Tow Lift Truck mast channels from moving.
4. If another lift truck is used to tow the disabled lift

WARNING
truck, that lift truck must have an equal or larger
Use extra caution when towing a lift truck if capacity than the disabled lift truck. Install ap-
any of the following conditions exist: proximately 1/2 of a capacity load on forks of lift
• Brakes do not operate correctly. truck that is being used to tow disabled lift truck.
• Steering does not operate correctly. This 1/2 capacity load will increase traction of lift
• Tires are damaged. truck. Keep load as low as possible.
• Traction conditions are bad.
• The lift truck must be towed on a slope. 5. Use a towing link made of steel that fastens to
tow pins in counterweights of both lift trucks.
If the engine cannot run, there is no power Slowly and carefully remove the slack out of the
available for the hydraulic steering system towing link. See Figure 1.
and the service brakes. This condition can
make the lift truck difficult to steer and stop.
If the lift truck uses power from the engine to
help apply the brakes, the application of the
brakes will be more difficult. Poor traction can
cause the disabled lift truck or towing vehicle
to slide. A slope will also make the lift truck
more difficult to stop.
Never lift and move a disabled lift truck unless

the disabled lift truck MUST be moved and
cannot be towed. A lift truck used to move
a disabled lift truck MUST have a capacity
rating equal to or greater than the weight of
the disabled lift truck. The capacity of the lift
truck used to move a disabled lift truck must
have a load center equal to half the width of
the disabled lift truck. See the Nameplate of
the disabled lift truck for the approximate
total weight. The forks must extend the full
width of the disabled lift truck. Put the weight
center of the disabled lift truck on load center
of the forks. Be careful to not damage the
underside of the lift truck.
1. The towed lift truck must have an operator.
2. Tow truck slowly.

1. STEEL TOW LINK 2. TOW PIN
3. Using a lift truck or a lifting device that could
be attached to the mast (I.E. come-a-long), raise Figure 1. Towing the Lift Truck
carriage and forks approximately 30 cm (12 in.)
2
8000 SRM 1150 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 lift
blocks under the mast assembly so the lift
truck is equipped with these type of lifting eyes, the
truck cannot fall forward.
lift truck can be lifted and blocks installed.
The surface must be solid, even, and level when
1. Apply parking brake. Put blocks on both sides
the lift truck is put on blocks. Make sure any
(front and back) of drive tires to prevent move-
blocks used to support the lift truck are solid,
ment of lift truck. See Figure 2.
one-piece units.
2. Use hydraulic jack to raise steering tires. Make
CAUTION sure jack has a capacity of at least 2/3 of total
These lift trucks are equipped with cowl lifting weight of lift truck as shown on the Nameplate.
eyes. The cowl lifting eyes are to be used to 3. Put jack under steering axle or frame to raise
lift the front of the lift truck only. Lifting more lift truck. Put blocks under frame to support lift
than the front of the lift truck with the cowl truck.
lifting eyes will damage the cowl section.
1. Put blocks on each side (front and back) of steer-

ing tires to prevent movement of lift truck. See
Figure 2.
3
General 8000 SRM 1150
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
HOW TO CLEAN A LIFT TRUCK refer to Paper Application section in the applicable
Operating Manual and to available Service Gram/
WARNING Bulletin for more detail.
Engine, exhaust system components and other If it becomes necessary to clean the fork lift, follow
components are hot to the touch. Be sure lift the guidelines listed below.
truck components are cool before starting in-
spection and cleaning, or personal injury may 1. Assure truck components are cool before starting
occur. the cleaning procedure.
2. Disconnect the battery. If an electric truck, re-

WARNING
move the traction battery.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 3. Remove accumulated debris using a compressed
Make sure that the path of the compressed air air line and nozzle.
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the 4. Lightly spray a non-corrosive cleaning agent onto
eyes. the areas to be cleaned. This will help loosen
grime, so close contact direct spraying will not be
necessary.
CAUTION
Units may be washed with a non-heated pres- 5. Be sure to avoid directing the spray into electri-
sure washer. Steam cleaning is not recom- cal panel compartment. Ensure overspray does
mended in most instances, as condensation not come in contact with electrical components;
may form in electrical components causing do not spray water directly at electrical compo-
damage or erratic behavior. nents, wiring connectors or electrical enclosures.
Even sealed connectors may allow water egress
NOTE: Lift trucks used in paper applications may under pressure or if connector is damaged.
need cleaning beyond what is described here. Please
4
8000 SRM 1150 Maintenance Schedule
6. Avoid spraying in areas containing electrical 8. DO NOT pressure wash the battery. Do not use
components such as: hot water. For cleaning traction batteries, refer
• Floor Plates to the Battery section of the Service Manual.
• Battery Compartment
• Dash/cowl assembly 9. DO NOT pressure wash lift chains, sheaves or
• Armrests with electrical components load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
7. Clean the battery compartment by using a clean section in the Service Manual for proper clean-
cloth to wash the battery with water. Dry with ing procedures.
compressed air. Care should be taken to keep
moisture at a minimum as some units have a 10. After cleaning, immediately start and run the lift
traction or hydraulic motor directly below the truck to dry out components.
battery compartment.
Maintenance Schedule
NOTE: The lift trucks shown in Figure 3 through The lift truck shown in Figure 11 represents H40-
Figure 10 and Figure 12 through Figure 16 repre- 70FT (L177) lift trucks only.
sent S40-70FT, S55FTS (F187) lift trucks, H40-70FT
(L177) are similar.
5
Maintenance Schedule 8000 SRM 1150
Figure 3. GM 2.4L Gas Trucks (Prior to Jan. 2011)
6
Figure 4. GM 2.4L LPG Trucks (Prior to Jan. 2011)
7
Figure 5. Mazda 2.0L and 2.2L Gas Trucks (Except 2007 Emission Compliant Engines)
8
Figure 6. Mazda 2.0L and 2.2L LPG Trucks (Except 2007 Emission Compliant Engines)
9
Figure 7. Mazda 2.0L and 2.2L Gas Trucks (2007 Emission Compliant Engines Only)
10
Figure 8. Mazda 2.0L and 2.2L LPG Trucks (2007 Emission Compliant Engines Only)
11
Figure 9. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
12
Figure 10. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
13
Figure 11. Yanmar 2.6L and 3.3L Diesel Trucks (Prior to Jan. 2011)
14
Figure 12. GM 2.4L Gas Trucks with Aluminum Case Transmission (After January, 2011)
15
Figure 13. GM 2.4L LPG Trucks with Aluminum Case Transmission (After January, 2011)
16
Figure 14. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (After January,
2011)
17
Figure 15. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (After January,
2011)
18
Figure 16. Yanmar 2.6L and 3.3L Diesel Trucks (After January, 2011)
19
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 500 1000 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 hr/ hr/ hr/ 1 yr 2 yr Quantity
day 6 mo 6 mo 6 mo
27 Tires X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
30, Mast, Carriage, Header X Check Condition See Parts Manual
31 Hoses, Lift Chains, and Lubrication
Attachment
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat Latches X Check Condition
and Operation
Engine Compartment X Remove
Combustible
Materials
See NOTE 5
Paper Application: X Check Condition
Engine Compartment, Clean as
Truck Components, Required
Exhaust Wraps, Replace as
Radiator, Radiator Required
Screen if equipped, See NOTE 10
Belly Pan if equipped
Check for Leaks - Fuel, X Check for Leaks
Oil, Water See NOTE 1
Hydraulic Hoses X Check Condition See Parts Manual
13 Coolant Hoses X Check Condition See Parts Manual
18 Fuel Tank (Gas) CIL 40.5 liter 85 Octane Gasoline
S40-70FT, S55FTS (10.7 gal) Minimum
(F187)
18 Fuel Tank (Gas) CIL 52 liter (13.7 gal) 85 Octane Gasoline
H40-70FT (L177) Minimum
18 Fuel Tank (LPG) CIL 29.9 liter LPG - HD 5, HD 10
(7.9 gal)
15.2 kg (33.5 lb)
18 Fuel Tank (Diesel) CIL 52 liter (13.7 gal) Diesel No. 2
H40-70FT (L177)
Horn, Lights, Alarms X Check Operation
1 Service Brakes X Check Operation
25 Parking Brake X Check Operation
Steering Controls and X Check Condition
Steering Column Gas and Operation
Cylinder
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
20
Table 1. Maintenance Schedule (Continued)
day 6 mo 6 mo 6 mo
24 Transmission X Check for Leaks
24 Transmission X Check Operation
3 Hydraulic Oil X X C 30.1 liter (32 qt) ISO VG 46
S40-70FT, S55FTS See NOTE 2, Hydraulic Oil
(F187) NOTE 3 and 15°C (5°F) and
NOTE 16. Above
3 Hydraulic Oil X X C 39.8 liter (42 qt) ISO VG 46
H40-70FT (L177) See NOTE 2, Hydraulic Oil
NOTE 3 and 15°C (5°F) and
NOTE 16. Above
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
See NOTE 16.
10 Hydraulic Tank X C Inspect and See Parts Manual
Breather Replace as
Required
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 3.9 liter (4.1 qt) 7°C (20°F)
Mazda CIL See NOTE 4 and and Below
2.0L Engine NOTE 5. SAE 5W-20
(Gas/LPG) 16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Mazda 2.2L CIL See NOTE 4 and and Below
Engine NOTE 5. SAE 5W-20
(Gas/LPG) 16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
21
day 6 mo 6 mo 6 mo
GM 2.4L Engine CIL See NOTE 4 and and Below
(Gas/LPG) NOTE 5. SAE 5W-20
16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
21 Engine Oil Filter C 1 Filter See Parts Manual
Mazda 2.0L See NOTE 4
and 2.2L and GM and NOTE 5.
2.4L Engines
(Gasoline)
9 Engine Oil X C 10.2 liter 20°C (68°F)
Yanmar 2.6L CIL (10.8 qt) and Over
and 3.3L See NOTE 4 SAE 40
Engine and NOTE 5. 10 to 30°C (50 to 86°F)
(Diesel) SAE 30
0 to 20°C (32 to 68°F)
SAE 20
16 to 40°C
(3 to 103°F)
SAE 15W-40
20 to 30°C
( 4 to 86°F)
SAE 10W-30
10 to 10°C
(14 to 50°F)
SAE 20W
20 to 10°C
( 4 to 50°F)
SAE 10W
21 Engine Oil Filter C 1 Filter See Parts Manual
Yanmar 2.6L See NOTE 4
and 3.3L and NOTE 5.
(Diesel)
20 Air Filter CIL C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 13.
20 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 13.
22
day 6 mo 6 mo 6 mo
16 Drive Belt X Check for Wear
Mazda 2.0L and Damage.
and 2.2L Adjust as
(Gas/LPG) Needed.
GM 2.4L Engines and Damage.
(Gas/LPG) No adjustment
needed.
Yanmar 2.6L and and Damage.
3.3L Engines Adjust as
(Diesel) Needed.
LPG Regulator X Drain Tar See
Mazda 2.0L NOTE 5.
and 2.2L Engines
Engine Idle Speed X See NOTE 5. 800 ±25 rpm
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
Engine Governed Speed X See NOTE 5. 2700 ±25 rpm
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
LPG Regulator GM X Drain Tar See
2.4L Engine NOTE 5.
GM 2.4L
(Gas/LPG)
GM 2.4L
(Gas/LPG)
Yanmar 2.6L
and 3.3L
(Diesel)
Yanmar 2.6L
(Diesel)
Yanmar 3.3L
(Diesel)
17 PCV Valve X C Replace as See Parts Manual
Necessary
See NOTE 14.
23
day 6 mo 6 mo 6 mo
Oxygen Sensor X Check Indicator Light
4 Valve Adjustment X Adjust as Intake
Mazda 2.0L Required 0.15 mm (0.006 in.)
and 2.2L Engines Cold
(Gas/LPG) Exhaust
0.35 mm (0.014 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Yanmar 2.6L Required 0.20 mm (0.008 in.)
and 3.3L Cold
Diesel Engines Exhaust
0.20 mm (0.008 in.)
Cold
Timing X Adjust as 6°±1° BTDC
Mazda 2.0L Required (Orange Mark)
and 2.2L Engines
(Gas)
Timing X Adjust as 6°±1° BTDC
Mazda 2.0L Required (Orange Mark)
and 2.2L Engines
(LPG)
19 LPG Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L Engines
(2007 Emission
Compliant Engines
Only)
LPG Fuel Regulator C 1 Filter See Parts Manual
Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emis-
sion Compliant En-
gines)
19 LPG Fuel Injector C 1 Filter See Parts Manual
Vapor Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emis-
sion Compliant En-
gines)
19 Fuel Filter, LPG C 1 Filter See Parts Manual
GM 2.4L Engines
24
day 6 mo 6 mo 6 mo
19 Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L (Except
2007 Emission Com-
pliant Engines) and
GM 2.4L Engines
(Gasoline)
19 Fuel Filter C 1 Filter See Parts Manual
Mazda 2.0L
and 2.2L Engines
(2007 Emission
Compliant Engines
Only )
(Gasoline)
19 Fuel Water Separator C 1 Filter See Parts Manual
Yanmar 2.6L
and 3.3L Engines
(Diesel)
19 In-line Fuel Filter C 1 Filter See Parts Manual
Yanmar 2.6L and
3.3L Engines
(Diesel)
15 Timing Belt C Replace See Parts Manual
See NOTE 7.
22 Fuel Injector 1 Injector Check and Clean
Mazda 2.0L See NOTE 8. If Required
and 2.2L Engines
(LPG, Except 2007
Emission Compliant
Engines)
22 Fuel Injectors 4 Injectors Check and Replace
See NOTE 8. If Required
Mazda 2.0L
and 2.2L Engines
(Gas)
5 Spark Plugs C Check See Parts Manual
Mazda 2.0L Plug Wires 0.8 ±0.1 mm (0.031
and 2.2L Engines 4 Plugs ±0.004 in.)
(Gas/LPG)
22 Fuel Injectors X 4 Injectors Check and Replace
GM 2.4L Engines If Required
Gas/LPG
5 Spark Plugs C Check See Parts Manual
GM 2.4L Engines Plug Wires 0.8 to 0.9 mm
(Gas/LPG) 4 Plugs (0.032 to 0.035 in.)
25
day 6 mo 6 mo 6 mo
22 Fuel Injectors X 4 Injectors Check and Replace
Yanmar 2.6L If Required
and 3.3L Engine
(Diesel)
12, Cooling System X C 11.0 liter See NOTE 15
14 Mazda 2.0L CIL (11.6 qt)
and 2.2L Engines
(Serpentine
and Square
Wave)
14 Mazda 2.0L CIL (11.2 qt)
and 2.2L Engines
(Square Wave
w/Air Oil
Cooler)
14 GM 2.4L Engine CIL (11.2 qt)
14 Yanmar 2.6L CIL (12.1 qt)
and 3.3L Engines
Clean Debris From X See NOTE 5
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brakes- Iron JDM J20C
Case
Dry Brakes- Alu- JDM J20C
minum Case
23 Transmission Oil Filter C 1 Filter See Parts Manual
See NOTE 4.
28 Forks X X X Check Condition
29 Mast L Lubricate Multipurpose Grease
Sliding Surfaces As Required See NOTE 9.
and Load Roller Sur- See NOTE 11.
faces
29 Header Hoses X Check Condition
30 Lift Chains L X, L Lube as SAE 30W
Required. Check Engine Oil
for Wear
30 Lift Chains X Check SAE 30W
Lubrication Engine Oil
See NOTE 12.
26
day 6 mo 6 mo 6 mo
Mast X L Lube as Multipurpose Grease
Sideshift Required See NOTE 9.
Carriage 2 Fittings
Integral Sideshift L Lube as Multipurpose Grease
Carriage Required See NOTE 9.
Fork 2 Fittings
Positioner See NOTE 5.
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 9.
Mast L X C Lube as Multipurpose Grease
Integral Required See NOTE 9.
Sideshift 2 Fittings 2.5 mm (3/32 in.) is
Carriage 4 Bearings minimum thickness
(Upper/Lower
Bearings)
Mast X Check for Wear 0.76 mm (0.03 in.)
Integral and Clearance. Minimum Wear
Sideshift See NOTE 2 and Limit.
Carriage NOTE 5
(Lower Mounting
Hooks)
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 9.
Brake Master Cylinder L SAE 10W-30
Rod End Pin API SM
ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
26 Brake Fluid CIL X C 0.25 liter SAE J-1703
Master Cylinder (0.53 pt) DOT-3
Dry Brakes
26 Brake Oil CIL X C 0.35 liter Dexron III from
Master Cylinder (0.74 pt) Sealed Container
Wet Brakes
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rod Ends H40- See NOTE 9.
70FT (L177)
King Pin See NOTE 9.
H40-70FT (L177)
27
day 6 mo 6 mo 6 mo
Spindle See NOTE 9.
Bearings S40-70FT,
S55FTS (F187)
2 Pedals, Levers, Seat L Lubricate as Hyster Part No.
Rails, Cables, Hinges, Necessary 328388
Linkages, Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
Dry Brakes Thickness Minimum
32 Differential and Drive X C 5.0 liter (5.3 qt) SAE 80W-90 or
Axle Oil 85W-140
Dry Brakes
S40-70FT, S55FTS
(F187)
32 Differential and Drive X C 6.5 liter (6.9 qt) SAE 80W-90 or
Axle Oil 85W-140
Dry Brakes
H40-70FT (L177)
Wet Brakes- Iron JDM J20C
Case
H40-70FT (L177)
Wet Brakes- Alu- JDM J20C
minum Case
H40-70FT (L177)
32 Wet Brake Axle X C 0.5 liter (0.5 qt) SAE 80W/90
Planetary Housing
Oil, Left Side
32 Wet Brake Axle X C 2.0 liter (2.1 qt) SAE 80W/90
Planetary Housing
Oil, Right Side
32 Wet Brake Axle, Center X C 1.0 liter (1.1 qt) John Deere JDM
Section Oil J20C
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours
of operation.
28
day 6 mo 6 mo 6 mo
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications in-
volving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based on
an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Replace timing belt on Mazda engines every 3500 hours. Use only hour interval.
NOTE 8: Check fuel injectors at 5000 hours or 7 years.
NOTE 9: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 10: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should
be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and
steam clean as necessary.
NOTE 11: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 12: Lubricate at first sign of visible surface rust.
NOTE 13: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every
2000 Hours or Annually to change air filter element.
NOTE 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled water or deionized water.
NOTE 16: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures
1900 SRM 1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or
highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less
frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
29
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1150
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE damaged rims. Check for loose or missing hardware.
STOPPED Remove any wire, strapping, or other material that
is wrapped around the axle. See Figure 17.
WARNING Safety Labels
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE WARNING
tag in the operator’s area. If the lift truck is Safety labels are installed on the lift truck to
equipped with a key switch, remove the key provide information about operation and pos-
from the key switch. sible hazards. It is important that all safety la-
bels are installed on the lift truck and can be
Put lift truck on a level surface. Lower carriage read.
and forks, stop the engine, and apply parking brake.
Open hood and check for leaks and conditions that Check that all safety labels are installed in the cor-
are not normal. Clean any oil or fuel spills. Ensure rect location on lift truck. See the Parts Manual,
all surfaces are free of oils, lubricants, fuel, and or- Model Description section in the Operating Man-
ganic dust or fibers (paper, wood, cotton, agricultural ual or section Frame 100 SRM 1120 for correct lo-
grass/grain, etc.). cation of safety labels. See Parts Manual for part
numbers of the safety labels.
Tires and Wheels
Check tires for damage. Check tread and remove any
objects that will cause damage. Check for bent or
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 17. Tire Check
30
8000 SRM 1150 Maintenance Procedures Every 8 Hours or Daily
Mast, Carriage, Lift Chains, Header Hoses, 6. Check that lift chains are correctly lubricated.
Attachment Use SAE 30W engine oil as necessary to lubricate
lift chains.
WARNING 7. Inspect lift chains for cracks or broken links, and
Lower the lift mechanism completely. Never worn or turned pins. See Figure 18.
allow any person under a raised carriage. DO
NOT put any part of your body in or through 8. Inspect chain anchors and pins for cracks and
the lift mechanism unless all parts of the mast damage.
are completely lowered and the engine is
STOPPED. DO NOT try to correct the align- 9. Make sure lift chains are adjusted so that they
ment of the fork tips by bending the forks or have equal tension. Adjustments or replace-
adding shims. Never repair damaged forks by ment of the lift chains must be done by au-
heating or welding. Forks are made of special thorized personnel.
steel using special procedures. If either fork is
damaged, replace the forks as a set.
1. Inspect welds on mast and carriage for cracks.

Make sure that capscrews and nuts are tight.
2. Inspect channels for wear in areas where the

rollers travel. Inspect rollers for wear or dam-
age.
3. Inspect load backrest extension for cracks and

damage.
4. If lift truck is equipped with an integral sideshift

carriage or attachment, inspect the parts for
cracks and wear. Make sure the parts that fas-
ten the integral sideshift carriage or attachment
to carriage are in good condition.
5. Visually inspect hoses/fittings for hydraulic

leaks; hose cover for cuts, cracks or exposed re- 1. WORN PIN 5. LOOSE LEAVES
inforcement; defective/broken clamping devices 2. CRACKS 6. TURNED PIN
or sheaves; proper tracking during operation. 3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
Adjust/repair/replace hose/components as nec-
essary. See Mast Repairs, 2-, 3-, and 4-Stage Figure 18. Lift Chain Check
Masts 4000 SRM 1148 for quick disconnect pro-
cedures.
31
Operator Restraint System seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
NOTE: The seat belt can be either black or red. when it is pulled with a sudden jerk, replace the
seat belt assembly.
The seat belt, hip restraint, seat, hood, and hood
• With the hood in the open position, make sure the
latch are all part of the operator restraint system.
seat belt will not pull from the retractor assembly.
Each item must be checked to make sure it is fas-
If the seat belt can be pulled from the retractor,
tened correctly, functions correctly, and is in good
with the hood in the open position, replace the seat
condition. See Figure 19.
belt assembly.
Automatic Locking Retractor (ALR)
Adjust Seat - Full Suspension
NOTE: S40-70FT, S55FTS (F187) lift trucks produced
Seat Position Adjustment (Standard Seat)
before November 2005 are equipped with the ALR
• Fore and aft adjustment - It is recommended that
type seat belts.
the seat be adjusted so that the thigh is horizon-
The seat belt must fasten securely. Make sure the tal to the ground in order to achieve the best er-
seat belt extends and retracts smoothly and is not gonomic position. See Figure 19.
frayed or torn. If the seat belt is damaged or does not
Seat Position Adjustment (Swivel Seat)
operate properly, it must be replaced. See Figure 19.
• The seat swivels 12 degrees to the right to allow the
Emergency Locking Retractor (ELR) operator a more ergonomic position when driving
in reverse.
NOTE: Lift trucks produced after November 2005 • The seat swivels 5 degrees to the left to allow an
are equipped with the Emergency Locking Retractor easier exit of the truck.
(ELR) style seat belt. • The neutral position is shown in Figure 19.
When the ELR style seat belt is properly buckled Seat Adjustment for Operator Weight
across the operator, the belt will permit slight op-
erator repositioning without activating the locking
CAUTION
mechanism. If truck tips, travels off a dock, or comes
to a sudden stop, the locking mechanism will be acti- A major cause for high Whole Body Vibration is
vated and hold the operator’s lower torso in the seat. caused by the operator not adjusting the seat to
his/her weight.
A seat belt that is damaged, worn, or does not op-
erate properly will not provide protection when it is NOTE: It is important to adjust the weight setting for
needed. The end of the belt must fasten correctly in each operator.
the latch. The seat belt must be in good condition.
NOTE: The seat is designed for maximum weight of
Replace the seat belt if damage or wear is seen. See
135 kg (298 lb).
Figure 19.
• The target is for the "ride indicator" to fall between
NOTE: The following seat belt operation checks must
the arrows when the operator sits upright in the
be performed three times before replacing the seat
seat with the feet positioned on the pedals. This
belt assembly.
ensures that the operator is set at the midpoint of
• With the hood closed and in the locked position, the 80 mm (3.15 in.) suspension.
pull the seat belt slowly from the retractor assem- • The handle can be turned as shown to increase or
bly. Make sure the seat belt pulls out and retracts decrease the weight resistance. Pull handle out be-
smoothly. If the seat belt cannot be pulled from the fore turning. As the handle is turned the "stiffness"
retractor assembly or the belt will not retract, re- of the suspension can be felt to increase or decrease
place the seat belt assembly. on which way the handle is turned.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
32
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR AND
SWIVEL SEAT
1. LATCH STRIKER 8. SEAT BELT
2. HOOD LATCH 9. SEAT
3. FORWARD/BACKWARD ADJUSTMENT 10. HIP RESTRAINT
4. HOOD 11. HOOD HINGE
5. OPERATOR WEIGHT ADJUSTMENT 12. SWIVEL ADJUSTMENT
6. SEAT RAIL 13. BACKREST ANGLE ADJUSTMENT
7. ARM REST
Figure 19. Hood, Standard Seat, and Swivel Seat Check
33
Adjust Seat - Internal Suspension NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
Seat Position Adjustment (Swivel Seat)
• The seat swivels 10.5 degrees to the right to allow • The target is for the "ride indicator" to fall between
the operator a more ergonomic position when driv- the arrows when the operator sits upright in the
ing in reverse. seat with the feet positioned on the pedals. This
• The seat swivels 5 degrees to the left to allow an ensures that the operator is set at the midpoint of
easier exit of the truck. the 40 mm (1.57 in.) suspension.
• The neutral position is shown in Figure 20. • The weight adjustment knob can be turned left or
right to increase or decrease the weight resistance.
Seat Adjustment for Operator Weight As the weight adjustment knob is turned the "stiff-
ness" of the suspension can be felt to increase or de-
CAUTION crease on which way the weight adjustment knob
is turned.
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
NOTE: It is important to adjust the weight setting for

each operator.
NOTE: OPTIONAL SWIVEL SEAT SHOWN.

A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT
1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Figure 20. Seat Adjustment
34
Hood and Seat Latches

WARNING
Make sure seat rails and latch striker are not loose. Compressed air can move particles so that they
Seat rails must lock tightly in position, but move cause injury to the user or to other personnel.
freely when unlocked. See Figure 19. Seat rails must Make sure that the path of the compressed air
be correctly fastened to the hood and the hood fas- is away from all personnel. Wear protective
tened to hinges on frame. Try to lift the hood to make goggles or a face shield to prevent injury to the
sure it is fastened correctly and will not move. If ad- eyes.
justment is required, go to Hood Latch Check.
Engine Compartment CAUTION

Air pressure, nozzle or extension tube may
Check for the presence of any combustible material cause damage to exhaust wraps and radiator
such as paper, leaves, etc. Remove any combustible fins. Assure that air pressure, nozzle or exten-
materials. sion tube does not damage exhaust wraps or
radiator fins.
Paper Application
Paper removal can generally be accomplished using a
Vehicles used in paper applications require regular compressed air line and nozzle. An extension may be
inspection and cleaning to minimize the risk of fire. helpful to access hard to reach places. Remove floor
This should be done at least once every eight hours plates and side covers for better access to engine com-
or more frequently depending upon operating en- partment. Open or removed belly pan, if equipped.
vironment. The paper application option will help Clean components with compressed air. Take care
limit the contact of paper or tissue scraps to hot to maintain the integrity of the exhaust wraps when
surfaces under the hood, but frequent maintenance cleaning with compressed air and use caution to not
is required. force debris into openings. Check the condition of ex-
haust wraps for wear, proper fit, contamination with
WARNING oil or antifreeze, gaps in coverage, failed fasteners
and replace as necessary. Do not reuse wraps if they
Engine and exhaust system components are
have been removed for some other service operation.
hot to touch. Be sure lift truck components are
cool before starting inspection and cleaning or
personal injury may occur. WARNING
Be careful when cleaning with steam. Steam
Ensure truck engine cools properly by allowing it to can cause serious burns. Wear protective cloth-
idle for several minutes. Shutting truck down while ing, gloves, and eye protection. Never expose
hot will not allow engine to cool quickly due to the your skin to steam.
loss of coolant circulation. The heat trapped under
the hood may actually increase engine temperature If compressed air did not adequately remove debris,
because of no heat transfer through the radiator. steam clean to remove any persistent accumulation
With engine off and lift truck components cooled, of material or oil. Protect electrical components from
check and clean the radiator and if equipped, radi- moisture when steam cleaning. Do not spray exhaust
ator screen. Check engine manifold, exhaust pipes, wraps directly with high pressure steam. Allow lift
muffler and catalytic converter for paper scraps. truck to air dry before returning to work in a con-
Clean as required. Check and clean engine compart- taminated environment. Paper dust and scraps will
ment components, transmission, fan shroud, belly adhere to wet surfaces.
pan if equipped, and inside frame ledges to avoid
paper, dust and oil accumulation. Check axle and Check the condition of exhaust wraps for wear,
cowl openings for paper buildup and bailing wire. proper fit, contamination with oil or antifreeze, gaps
Remove any debris. in coverage, failed fasteners and replace as neces-
sary. Do not reuse wraps if they have been removed
for some other service operation.
35
Fuel, Oil, and Coolant Leaks, Check
WARNING
All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame
to check the fuel level or to check for leaks in
the fuel system. If there is a leak in the fuel sys-
tem, extra care must be used during the repair.
DO NOT operate the lift truck until a leak is re-
paired.
Make a visual check for leaks on and under the lift

truck. If possible, find and report leaks to mainte-
nance for repair. Leaks often indicate a need for re-
pair of damaged or worn components. Leaks in the
LPG fuel system are usually not visible unless ice
1. TILT LEVER 2. GAS CYLINDER
is present. There is however, usually a strong odor.
Fuel leaks MUST be repaired IMMEDIATELY. Figure 21. Steering Column Gas Cylinder and
Tilt Lever
Check fuel system for leaks and the condition of
parts. When fuel is added to lift truck, see section
Hydraulic System Oil
HOW TO ADD FUEL TO THE LIFT TRUCK in the
Operating Manual.
WARNING
Also check the condition of radiator or heater hoses At operating temperature, the hydraulic oil is
that are not leaking. Soft or cracked hoses need to be HOT. DO NOT permit the hot oil to touch the
replaced before a major leak occurs. skin and cause a burn.
Hydraulic Hoses
CAUTION
Check condition of hydraulic hoses for serviceabil- DO NOT permit dirt to enter the hydraulic sys-
ity by inspecting for cracks or other obvious dam- tem when the oil level is checked or the filter
age. Check to ensure that the hydraulic hoses are is changed.
not leaking. If any hose is leaking, report it to main-
tenance for repair. Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
Coolant Hoses hydraulic pump without oil will damage the
pump.
Check condition of coolant hoses for serviceability by
inspecting for cracks or other obvious damage. Check After engine has stopped, wait one minute before
to ensure that the coolant hoses are not leaking. If checking the oil level. Keep hydraulic oil at the cor-
any hose is leaking, report it to maintenance for re- rect level as indicated on dipstick. Use correct oil as
pair. shown in the Maintenance Schedule.
Steering Column Gas Cylinder Check hydraulic system for leaks and damaged or
loose components. Heavy-duty or high-temperature
Make sure the gas cylinder for steering column oper- operations can require more frequent checks.
ates correctly. The cylinder must NOT allow column
to move unless tilt lever is released. See Figure 21.
Transmission
Check transmission for leaks and damaged or loose
components. Heavy-duty or high temperature oper-
ations can require more frequent checks.
36
Engine Oil
After engine has stopped, wait one minute before
checking oil level. Keep oil at correct level as indi-
cated on the dipstick. Use the correct oil as shown in
the Maintenance Schedule.
See Figure 22 for lift trucks equipped with a Yanmar

2.6L and 3.3L diesel engine.
See Figure 23 for lift trucks equipped with GM en-

gine.
See Figure 24 for lift trucks equipped with a Mazda

engine (except 2007 emission compliant engines).

engine (2007 emission compliant engines).
There is an indicator light for the engine oil pressure

on the Display Switch Cluster. During normal opera-
tion, the red indicator light will illuminate when the
key switch is turned to ON, if the truck is equipped
with a key switch, or when the Power ON/OFF but-
ton is pressed, if the truck is equipped with a Power
ON/OFF option, and will stay illuminated until cor-
rect oil pressure is obtained, at which time the light
will go OFF.
1. BATTERY
If the light continues to stay on when engine is run- 2. AUXILIARY COOLANT RESERVOIR
3. RADIATOR CAP
ning, the engine oil pressure is low. Stop the engine 4. DRIVE BELT
and check the oil level. Do not restart the engine un- 5. AIR FILTER
til the low pressure condition has been corrected. 6. ENGINE OIL FILTER
7. DIPSTICK ENGINE OIL
8. FUEL FILTER
9. FUEL INJECTOR
10. ENGINE OIL FILL
Figure 22. Yanmar 2.6L and 3.3L Diesel Engine

Maintenance Points
37
Figure 23. GM Engine Maintenance Points
38
Legend for Figure 23

A. GAS ENGINE B. LPG ENGINE
1. DIPSTICK ENGINE OIL 7. AIR FILTER
2. BATTERY 8. FUEL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. ENGINE OIL FILTER
4. RADIATOR CAP 10. PCV VALVE
5. ENGINE OIL FILL 11. SPARK PLUGS
6. DRIVE BELT 12. FUEL INJECTOR
39
Figure 24. Mazda Engine Maintenance Points (Except 2007 Emission Compliant Engines)
40

A. GAS ENGINE B. LPG ENGINE
6. DRIVE BELT 12. FUEL INJECTOR
41
Figure 25. Mazda Engine Maintenance Points (2007 Emission Compliant Engines Only)
42

A. LPG ENGINE B. GAS ENGINE
6. DRIVE BELT 12. FUEL INJECTORS (GAS ONLY)
Air Filter NOTE: If lift truck is equipped with a fork positioner

attachment, perform Step 1 and Step 2. If lift truck
The air filter canister should not be opened until an is not equipped with a fork positioner attachment, go
air filter element replacement is required. An air to Step 4.
filter element replacement is required when one of
the following occurs: NOTE: Depending on the size and configuration of
• The optional air flow restriction indicator light on the forks installed on the lift trucks equipped with
the dash illuminates. a fork positioner, there may be a spacer bar between
• If equipped, the manual air flow indicator is red. the inner and outer fork carriers. See Figure 26.
• The specified number of hours has passed since the
last filter element replacement. 1. Lower the carriage and remove four capscrews
from inner fork carriers. Remove inner fork car-
DO NOT operate lift truck until the air filter element riers from integral sideshift carriage. See Fig-
has been replaced. ure 27.
Forks
NOTE: Forks must be removed or installed by trained
personnel only.
The identification of a fork describes how the fork is

connected to the carriage. These lift trucks have hook
forks.
Remove
WARNING
DO NOT try to move a fork without a lifting
device. Each hook fork for these lift trucks can 1. OUTER FORK CARRIER
weigh 45 to 115 kg (99 to 253 lb). 2. CAPSCREW
3. SPACER BAR*
4. INNER FORK CARRIER
CAUTION
*SPACER BAR USED ON 977 mm (38.5 in.) AND
Remove fork latch pins if adding a fork posi- 1067 mm (42 in.) CLASS II CARRIAGES.
tioner attachment. Damage to forks and other
carriage components can occur if fork latch Figure 26. Fork Carrier Spacer Bar
pins are not removed prior to using attach-
ment.
NOTE: Forks are to be replaced only in sets and not

individually.
43
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. SIDESHIFT CARRIAGE ASSEMBLY
Figure 27. Fork Removal, Lift Trucks Equipped With Fork Positioner Attachment
2. Slide fork to fork removal notch in bottom bar of

carriage. See Figure 27.
3. Lower fork onto blocks so bottom hook of fork

moves through the fork removal notch. Lower
carriage further so top hook of the fork is disen-
gaged from top carriage bar. Move carriage away
from fork or use a lifting device to move fork away
from carriage. See Figure 28.
4. A fork can be removed from the carriage for re-

placement of the fork or other maintenance. Lift
lock pin and slide a hook fork to the fork removal
notch on carriage. See Figure 28 and Figure 29.
Lower fork onto blocks so that the bottom hook of
the fork moves through fork removal notch. See
Figure 29. Lower carriage further so that the top
hook of fork is disengaged from the top carriage
bar. Move carriage away from the fork, or use
1. CARRIAGE BARS 3. BLOCKS
a lifting device to move fork away from the car- 2. HOOK FORK
riage.
Figure 28. Hook Fork Removal
44
Inspect Install
1. Inspect forks for cracks and wear. Check that the

fork tips are aligned as shown in Figure 29.
WARNING
DO NOT try to move a fork without a lifting
2. Check that the bottom of fork is not worn. See device. Each hook fork for these lift trucks can
Figure 29, item 4. weigh 45 to 115 kg (99 to 253 lb).
3. Replace any damaged or broken parts that are

used to keep the forks locked in position. CAUTION
Remove fork latch pins if adding a fork posi-
tioner attachment. Damage to forks and other
carriage components can occur if fork latch
pins are not removed prior to using attach-
ment.
NOTE: Forks are to be replaced only in sets and not

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

tioner, go to Step 1. If lift truck is equipped with fork
positioner, go to Step 2.
1. Move the fork and carriage so that the top

hook on the fork can engage the upper carriage
bar. Raise the carriage to move the lower hook
through the fork removal notch. Slide the fork on
the carriage so that both upper and lower hooks
engage the carriage. Engage the lock pin with a
notch in the upper carriage bar. See Figure 30.
2. If lift truck is equipped with a fork positioner

attachment, install inner fork carriers using
four capscrews. Tighten capscrews to 35 N•m
(25 lbf ft). See Figure 27.
Fork Tip Alignment
Adjust
Length of Forks 3% Dimension
NOTE: During the adjustment of the forks, the heel
915 mm (36 in.) 27 mm (1.10 in.) of the forks should not be touching the ground.
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.) NOTE: The information below applies to lift trucks
1372 mm (54 in.) 41 mm (1.61 in.) NOT equipped with fork positioner attachment.
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.) The forks are connected to the carriage by hooks and
lock pins. See Figure 28 and Figure 30. Lock pins are
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF installed through the top fork hooks and fit into slots
FORK LENGTH) in the top carriage bar. If pin does not remain en-
2. CRACKS gaged in carriage slot, replace with new pin. Adjust
3. LATCH DAMAGE forks as far apart as possible for maximum support
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X) of the load. Hook forks will slide along carriage bars
5. CARRIAGE to adjust for the load to be lifted. Raise the lock pin in
6. LOAD BACKREST EXTENSION each fork to slide the fork on the carriage bar. Make
7. MAXIMUM ANGLE 93° sure lock pin is engaged in the carriage bar to lock
8. FORK REMOVAL NOTCH fork in position after the width adjustment is made.
Figure 29. Forks Check
45
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.
Indicator Lights, Horn, Fuses, and Relays

If lift truck is equipped with a key switch, turn
1. FORK 5. WEDGE key to ON position. If lift truck is equipped with a
2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN Power ON/OFF button, press button to turn system
4. WASHER ASSEMBLY power ON. All warning lights and indicator lights
will light up for two seconds (start check) when
Figure 30. Fork Lock Pin Assembly system power is turned ON. See Figure 31. Check
all indicator lights for correct operation as described
HOW TO MAKE CHECKS WITH ENGINE in the Operating Manual. Check the operation of
RUNNING the horn. Start the engine by turning the key switch
to the Start position, if truck is equipped with a key
WARNING switch, or press the engine start button, if lift truck
is equipped with this button. If any indicator lights
DO NOT operate a lift truck that needs repairs.
do not operate correctly, stop the engine and check
Report the need for repair immediately. If re-
the fuses. The fuses are located in the Power Distri-
pair is necessary, put a DO NOT OPERATE tag
bution Module (PDM) which is under the hood and
in the operator’s area. If lift truck is equipped
next to the battery on the right side. See Figure 32.
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
46
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator
14 Indicator Light, 1st Gear Locking (Duramatch Plus 2 Transmissions)
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 31. Warning and Indicator Lights
47
NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE) 20. SEMICONDUCTOR TRANSZORB
Figure 32. PDM Showing Fuses and Relays
Service Brakes On lift trucks with dry brake drive axles, only
use SAE J-1703 (DOT 3) brake fluid in the mas-
Brake Fluid Level ter cylinder.
WARNING WARNING
Small amounts of water in the brake system If the brake system has a power assist (or
can cause reduced braking performance if the boosted master cylinder), braking will be more
water reaches the wheel cylinder areas. DO difficult if the engine is not running.
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced. Loss of fluid from the brake fluid reservoir in-
dicates a leak. Repair the brake system before
On lift trucks with wet brake drive axles, only using the lift truck. Replace the brake fluid in
use Dexron III oil from sealed container in the the system if there is dirt or water in the sys-
master cylinder. tem.
48
There is an indicator light on the Display Switch 2. For burnished brakes, test the operation of the
Cluster for the brake fluid. The red light is ON parking brake. The lift truck with a capacity load
when the key switch is in the START position or must not move when parking brake is applied on
the Power ON/OFF button is pressed, and must go a 15 percent grade [a slope that increases 1.5 m
OFF when the engine is running. If the light is on in 10 m (1.5 ft in 10 ft)].
when the engine is running, the brake fluid level in
the reservoir is too low.
Operation, Check
Check the operation of the service brakes. Push on

the inching/brake pedal. The service brakes must be
applied before the inching/brake pedal reaches the
floor plate. The pedal must stop firmly and must
not move slowly down after the brakes are applied.
The service brakes must apply equally to both drive
wheels. The service brakes must not pull the lift
truck to either side of the direction of travel when
they are applied. The service brakes are automat-
ically adjusted when the transmission is in reverse
and the lift truck is moving and the brakes are firmly
applied. Full application of the inching/brake pedal
applies the service brakes and puts the transmission
in NEUTRAL.
Lift trucks with a MONOTROL® pedal. When

the inching/brake pedal is fully applied, a switch in
the starting circuit is closed so that the engine can be
started.
Parking Brake
1. LOCK BUTTON RELEASE
Make sure service brakes are adjusted and the oper- 2. OFF POSITION
3. ON POSITION
ation of the automatic adjuster mechanism is correct 4. ADJUSTMENT KNOB
before parking brake is adjusted.
Figure 33. Parking Brake
Lift trucks with a MONOTROL® pedal. The
switch energizes the seat warning circuit when hand Engine Oil Pressure
lever is released. This switch puts the transmis-
sion in NEUTRAL by de-energizing the direction NOTE: The engine will enter shutdown mode after a
solenoid. There is also a switch on the left side of warning buzzer sounds and a 30 second countdown,
bracket. This switch prevents engine from starting if engine oil pressure is less than 34.5 kPa (5 psi) on
unless parking brake is applied. lift trucks equipped with a Mazda engine and power-
train protection system. Lift trucks equipped with a
NOTE: Make sure parking brake is released before Yanmar diesel engine will enter the shutdown mode
making adjustment. when the engine oil pressure is less than 49 kPa
(7 psi) on lift trucks with powertrain protection
1. Turn adjustment knob to raise the equalized link
system. See the Engine Shutdown procedures in
and tighten parking brake cables shown in Fig-
the Operating Manual.
ure 33. DO NOT tighten the adjustment so that
brake is applied when the lever is released. The There is an indicator light for the engine oil pressure
lever for the parking brake has a lock. Use your on the Display Switch Cluster. During normal opera-
thumb or finger to release lock on lever when tion, the red indicator light will illuminate when the
parking brake is released. key switch is turned to ON, if the truck is equipped
49
with a key switch, or when the power ON/OFF but- and the level in the auxiliary coolant reservoir will
ton is pressed, if the truck is equipped with this op- increase.
tion, and will stay illuminated until correct oil pres-
sure is obtained, at which time the light will go off. CAUTION
If the light continues to stay on when engine is run- Additives may damage the cooling system. Be-
ning, the engine oil pressure is low. Stop the engine fore using additives, contact your local Hyster
and check the oil level. Do not restart the engine un- dealer.
til the low pressure condition has been corrected.
If coolant is added, see Maintenance Schedule for cor-
See Figure 22 for lift trucks equipped with a Yanmar rect solution.
2.6L and 3.3L diesel engine.
WARNING
See Figure 23 for lift trucks equipped with GM en-
gine.
cause injury to the user or to other personnel.
See Figure 24 for lift trucks equipped with a Mazda Make sure that the path of the compressed air
engine (except 2007 emission compliant engines). is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
See Figure 25 for lift trucks equipped with a Mazda eyes.
Check the radiator fins. Turn engine OFF and clean
Cooling System the radiator with compressed air or water as needed.
Check for and remove any debris on the radiator core.
If the indicator light turns on again after restarting,
WARNING shut down the lift truck and do not operate the lift
DO NOT remove the radiator cap from the radi- truck until the problem is corrected.
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown,
if coolant temperature reaches 121°C (250°F) or
above on lift trucks with powertrain protection sys-
tem and a Mazda engine. Lift trucks equipped with
a Yanmar diesel engine will enter shutdown mode
when coolant temperature reaches 110°C (230°F)
or above on lift trucks with powertrain protection
system. See ENGINE SHUTDOWN procedures in
the Operating Manual.
There is an indicator light on the Display Switch

Cluster for the coolant temperature. The red light
is on when key switch is in the START position or
the Power ON/OFF button is pressed, and must go
off when the engine is running. If light is on when
engine is running, the coolant and engine are too hot. 1. FILL CAP
Stop engine and check coolant level in the coolant 2. AUXILIARY COOLANT RESERVOIR
recovery reservoir. 3. FULL MARK
4. ADD MARK
Make sure coolant level is between the ADD and 5. RADIATOR CAP
FULL marks on the auxiliary coolant reservoir. See
Figure 34. Auxiliary Coolant Reservoir
Figure 34. The coolant will expand as it is heated
50
8000 SRM 1150 First Service After First 100 Hours of Operation
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. Turn engine OFF and check for leaks in the
Make sure steering system operates smoothly and hydraulic system. Check condition of hydraulic
provides good steering control. Make sure steering hoses and tubes.
column can be adjusted and the gas cylinder function
is correct. NOTE: Some parts of the mast move at different
speeds during raising and lowering.
Control Levers and Pedals
2. Slowly raise and lower mast several times with-
Check that control levers for the transmission, mast, out a load. Raise mast to its full height at least
and attachment operate as described in Operating once. The mast components must raise and lower
Manual. Check that pedals operate correctly as de- smoothly in the correct sequence. Hose must
scribed in Operating Manual. track properly during operation.
Lift System, Operate 3. The inner weldments and the carriage must
lower completely.
WARNING 4. Raise the mast 1 m (3 ft) with a capacity load.

When working on or near the mast, see Safety The inner weldments and the carriage must raise
Procedures When Working Near Mast at the smoothly. Lower the mast. All moving compo-
end of this section. nents must lower smoothly.
Lower the lift mechanism completely. Never 5. Lower the load to approximately 0.3 m (1 ft). Tilt
allow any person under a raised carriage. DO mast forward and backward. The mast must
NOT put any part of your body in or through tilt smoothly and both tilt cylinders must stop
the lift mechanism unless all parts of the mast evenly.
are completely lowered and the engine is
6. Check that the controls for the attachment op-
STOPPED.
erate the functions of the attachment. See the
If the mast cannot be lowered, use chains on symbols by each of the controls. Make sure all of
the mast weldments and carriage so that they the hydraulic lines are connected correctly and
cannot move. Make sure the moving parts are do not leak.
attached to a part that does not move.
First Service After First 100 Hours of Operation

MAZDA AND GM ENGINE OIL AND OIL your hand. Fill engine with oil as specified in Main-
FILTER tenance Schedule, until full mark reached on the dip-
stick. Start engine. Check area around oil filter for
NOTE: The engine oil and oil filter must also be leaks, shut engine off and check oil dipstick, if low
changed after the first 100 hours of operation for a add oil. See Figure 35.
newly installed engine.
Change engine oil and oil filter. Apply clean oil to

gasket of new filter. Install new filter. Turn filter un-
til gasket touches, then tighten 1/2 to 3/4 turn with
51
First Service After First 100 Hours of Operation 8000 SRM 1150
NOTE: BOTTOM VIEW OF ENGINE SHOWN.

A. MAZDA B. GM
1. OIL FILTER 2. DRAIN PLUG
Figure 35. Engine Oil Change
YANMAR ENGINE OIL AND OIL FILTER

Change engine oil and oil filter. Apply clean oil to
gasket of new filter. Install new filter. Turn filter un-
til gasket touches, then tighten 1/2 to 3/4 turn with
your hand. Fill engine with oil as specified in Main-
tenance Schedule, until full mark reached on the dip-
stick. Start engine. Check area around oil filter for
leaks, shut engine off and check oil dipstick, if low
add oil. See Figure 36.

Figure 36. Engine Oil Change Yanmar Diesel
52
8000 SRM 1150 Maintenance Procedures Every 250 Hours or 6 Months
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform 8-hour checks prior to performing Change engine oil and engine oil filter. Use correct oil
procedures in this section. according to Maintenance Schedule. Apply clean oil
to gasket of new filter. Install new filter. Turn filter
MAZDA AND GM ENGINE OIL AND OIL until gasket touches, then tighten 1/2 to 3/4 turn with
FILTER your hand. Start engine. Check area around oil filter
for leaks. See Figure 37.
NOTE: Change oil and oil filter for engine at first 100
hours of operation on new lift trucks.

A. MAZDA B. GM
Figure 37. Engine Oil Change
53
Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1150
DRIVE BELT GM 2.4L Engine

Mazda 2.0L and 2.2L Engines Fan and Alternator Drive Belt
Fan and Alternator Drive Belt Check drive belt for fan and alternator for wear and
damage. See Figure 39. The belt tensioner on GM
Check drive belt for fan and alternator for wear and 2.4L engine is a nonadjustable, self-tensioning device
damage. with two positions: tension applied and tension re-
lieved. Adjustments are not needed.
Check tension by pushing on drive belt to check de-
flection. When pressure is 98 N (22 lbf), correct de-
flection is approximately 7 to 8 mm (0.3 in.). Loosen
alternator support bracket to adjust tension of belt.
See Figure 38.
1. BELT
2. DRIVE TOOL SLOT
3. SELF-ADJUSTING TENSIONER
Figure 39. GM 2.4L Engine Drive Belt

1. CHECK TENSION HERE
2. ALTERNATOR SUPPORT BRACKET
Figure 38. Drive Belts Check and Adjustment,

Mazda Engines
54
DRAIN TAR FROM LPG REGULATOR

(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES)
NOTE: For 2007 Mazda Emission Compliant Engines
go to Drain Tar From LPG Regulator (2007 Mazda
Emission Compliant Engines Only).
1. Warm engine to operating temperature.
2. Shut fuel valve off and run engine until engine

runs out of fuel and stops.
3. Raise hood.
4. Remove tar drain screw from regulator. Allow tar

to drain from regulator. When tar has completely
drained, install tar drain screw in regulator. See
Figure 40 and Figure 41.
1. TAR DRAIN SCREW
Figure 41. GM LPG Regulator
1. TAR DRAIN SCREW
Figure 40. Mazda LPG Regulator
55
DRAIN TAR FROM LPG REGULATOR (2007 10. Install EPR assembly, see LPG Fuel System,
MAZDA EMISSION COMPLIANT ENGINES Mazda 2.0L and 2.2L Emission Compliant
ONLY) Engines 900 SRM 1326.
NOTE: The following procedures are for 2007 Mazda

Emission Compliant Engines Only.
NOTE: Draining the LPG regulator when engine is

warm will help the oils to flow freely from the regu-
lator.
1. Warm engine to operating temperature.
2. Close fuel valve on tank and run engine until it

runs out of fuel and stops. Try to restart engine
2-3 times until it no longer starts.
3. Turn the key to the OFF position.
4. Raise hood and disconnect negative battery ca-

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

tem, Mazda 2.0L and 2.2L Emission Compli-
ant Engines 900 SRM 1326.
6. Remove the retaining pin in the fuel temperature

sensor and remove from the electronic pressure
regulator (EPR). See Figure 42.
7. Using a suitable container, rotate the EPR 90° so 1. FUEL TEMPERATURE SENSOR
that the outlet fitting is pointing down and drain 2. RETAINING PIN
the EPR. 3. ELECTRONIC PRESSURE REGULATOR (EPR)
8. Inspect and remove any tar or debris from the Figure 42. 2007 Mazda Emission Compliant
secondary chamber. EPR Assembly
9. Install fuel temperature sensor and retaining

pin. See Figure 42.
56

NOTE: Perform the 8-hour and 250-hour checks prior
WARNING
to performing the procedures in this section.
HYDRAULIC SYSTEM OIL cause injury to the user or to other personnel.
Make sure that the path of the compressed air
WARNING goggles or a face shield to prevent injury to the
At operating temperature, the hydraulic oil is eyes.
HOT. DO NOT permit the hot oil to touch the
skin and cause a burn.
CAUTION
CAUTION Direct air pressure on the filter element can
cause damage. Direct air pressure away from
DO NOT permit dirt to enter the hydraulic sys-
filter element.
tem when the oil level is checked or the filter
is changed. 1. Using compressed air, remove any dirt and de-
bris in the frame cavity around the breather. See
Never operate the hydraulic pump without oil
Figure 43.
hydraulic pump without oil will damage the 2. Replace the breather if oil has accumulated in
pump. the cavity or on the breather, or if dirt has accu-
mulated at the breather passages at the bottom
CAUTION of the breather.
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
Check the hydraulic oil level when the oil is at operat-

ing temperature with the mast in a vertical position,
the carriage lowered, and the engine stopped.
See Figure 47 for lift trucks equipped with iron trans-

mission housing.
See Figure 48 for lift trucks equipped with aluminum

transmission housing.
Add hydraulic oil only as needed. If hydraulic oil

is above the FULL level, the hydraulic oil will leak
from the breather during operation. The oil level in-
dicated by the dipstick is most accurate when the oil
temperature is 53 to 93°C (130 to 200°F).
HYDRAULIC TANK BREATHER

1. HOOD/SEAT ASSEMBLY
Inspect 2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
NOTE: When inspecting the breather, do not remove
it. The breather element is a non serviceable part. If Figure 43. Hydraulic Tank Breather
it is damaged, replace with a new breather element.
57
BATTERY
WARNING
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
the area. Use a solution of sodium bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
Wear eye protection.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. DO NOT NOTE: BOTTOM VIEW OF ENGINE SHOWN.
make sparks from the battery connections.
Disconnect the battery ground cable when 1. OIL FILTER 2. DRAIN PLUG
doing maintenance.
Figure 44. Engine Oil Change Yanmar Diesel
Disconnect the negative and positive terminals of the
battery. Using a damp cloth clean the case of the bat- DRIVE BELT
tery. If the terminals are corroded, clean the termi-
nals with a wire brush. Connect the negative and Yanmar Diesel Engine
positive cables to their respective terminals. Fan and Alternator Drive Belt
YANMAR ENGINE OIL AND OIL FILTER NOTE: The drive belt tension may be checked at any
of the three positions A, B, or C shown in Figure 45
NOTE: Change the oil and oil filter for the engine at which ever is most easily accessible.
the first 100 hours of operation on new lift trucks.
Check the drive belt for the fan and alternator for
Change engine oil and engine oil filter. See Mainte- wear and damage. Check tension by pushing on drive
nance Schedule for correct oil type and amount. Ap- belt with a force of 98 N (22 lbf) to check deflection
ply clean oil to gasket of new filter. Install new filter. at any one of three possible positions. See Figure 45.
Turn filter until gasket touches, then tighten 1/2 to Check Table 2 for the correct deflection of the V-belt.
3/4 turn with your hand. Start engine. Check area Loosen alternator support bracket bolt to adjust ten-
around oil filter for leaks. Figure 44. sion of belt. See Figure 46. When the tension of
the V-belt is correct, tighten the alternator support
bracket bolt, and check the belt tension again.
Table 2. V-Belt Deflection Table
Used V-Belt Tension New V-Belt Tension

A B C A B C
10-13 mm 7-10 mm 8-13 mm 8-11 mm (0.3125- 5-8 mm (0.1875- 7-11 mm
(0.375-0.5 in.) (0.250-0.375 in.) (0.3125-0.5 in.) 0.4375 in.) 0.3125 in.) (0.250-0.4375 in.)
58
PCV VALVE
Remove the PCV Valve (positive crankcase ventila-
tion valve) from the valve cover. Check the operation
of the PCV Valve by shaking the PCV Valve and lis-
ten for the check ball rattling inside. If the check ball
does not rattle, replace the PCV Valve.
See Figure 23 for lift trucks equipped with a GM en-

gine.


CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and remove
material causing radiator core to be plugged or re-
stricted.
WARNING
Figure 45. Yanmar Diesel Engine Drive Belt is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean with compressed air, adjusted to a maximum

output of 103 kPa (15 psi), and blow debris from core
and fan shroud.
TRANSMISSION OIL LEVEL
WARNING
At operating temperature, the transmission oil
is HOT. DO NOT permit the hot oil to touch the
CAUTION
DO NOT permit dirt to enter the transmission
when the oil level is checked or the filter is
changed.
1. SUPPORT 3. PRY BAR NOTE: Transmission oil temperature should be at

BRACKET BOLT least 50°C (120°F) when checking oil level.
2. ALTERNATOR
If engine has been running, the engine must be shut
Figure 46. Yanmar Diesel Engine Drive Belt down for one minute or longer prior to checking the
Adjustment oil level.
59
See Figure 47 for lift trucks equipped with iron trans- If the transmission oil is low, add oil to transmission
mission housing. at the dipstick tube at the correct level as indicated
on the dipstick. Use the correct oil as shown in the
See Figure 48 for lift trucks equipped with aluminum Maintenance Schedule.
transmission housing.
NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 47. Transmission and Hydraulic Oil Check
Figure 48. Transmission and Hydraulic Oil Check
60
NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
WET BRAKE PLANETARY HOUSING OIL 1. Remove the planetary housing fill/level plugs
LEVEL CHECK and O-rings. See Figure 49.
2. Visually check oil level. If necessary, add oil at

WARNING the right fill/level port for the right planetary
At operating temperature, the transmission housing and at the left fill/level port for the
and wet brake planetary carrier housing oil is left planetary housing until the oil/level port
HOT. DO NOT permit the hot oil to touch the has overflowed. The correct oil is shown in the
skin and cause a burn. Maintenance Schedule or Figure 50.
3. Install the planetary housing fill/level plug and

CAUTION
O-rings and tighten to 40 N•m (29.5 lbf ft).
DO NOT permit dirt to enter the center body
when the oil level is checked. Dirt will contam-
inate the oil and cause damage to the center
body of the axle.
1. RIGHT PLANETARY HOUSING 4. FILL/LEVEL PLUG

2. LEFT PLANETARY HOUSING 5. CENTER SECTION
3. O-RING
Figure 49. Planetary Housings Fill/Level Plugs
61
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY SECTION - USE SAE 80W/90
C. CENTER HOUSING (BRAKE COOLING CHAMBER) - USE JDM J20C
1. OIL FILL/LEVEL PLUG 3. COOLING OIL INLET PORT
2. OIL BREATHER
Figure 50. Oil Application Diagram
62
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 spe- 2. Raise carriage about 61 cm (2 ft), and tilt the
cial steel using special methods. Replace dam- mast fully back. Place blocks under the outer
aged forks as a complete set. mast channels to within 13 mm (0.5 in.) of the
channels. See Figure 52.
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 52.
there is no wear. This thickness is dimension X. Now
measure thickness at heel of fork (see Figure 29). If
the thickness of the heel is not greater than 90% of
dimension X, replace fork.
MAST LUBRICATION
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 51.
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 2. MAST
3. LOAD ROLLER
Figure 52. Blocking the Mast
Figure 51. Mast Lubrication
63
4. Tilt mast fully back. Remove the blocks from un- shown in the Maintenance Schedule. See Fig-
der the channels. ure 53 and Figure 54.
5. If a integral sideshift carriage is installed, lu- 6. If a fork positioner is installed, lubricate slid-
bricate sliding surfaces at grease fittings with ing surfaces at lube fittings with multipurpose
multipurpose grease shown in the Maintenance grease shown in the Maintenance Schedule. See
Schedule. See Figure 55 Figure 56.
Lubricate the mast pivot bushings at grease fit-

tings on outer mast. Use multipurpose grease
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 53. Mast Mounting Hanger Lubrication
64
1. OUTER MAST 3. LUBRICATION FITTING

2. MAST PIVOT BUSHING
Figure 54. Pivot Pin Lubrication

1. UPPER BEARINGS
2. LOWER HOOKS
3. LOAD ROLLER
4. SNAP RING
5. SIDESHIFT CYLINDER
6. LOWER BEARINGS
7. SHIMS
8. INNER CARRIAGE
9. LUBE FITTINGS
10. OUTER FRAME
Figure 55. Integral Sideshift Carriage
65
1. LUBE FITTING, SIDESHIFT CARRIAGE 4. UPPER FORK POSITIONER CYLINDER

2. LUBE FITTING, FORK POSITIONER 5. LOWER FORK POSITIONER CYLINDER
3. FORK CARRIER 6. SIDESHIFT CYLINDER
Figure 56. Fork Positioner Lubrication
HEADER HOSE CHECKS DO NOT repair worn or damaged lift chains. If

a lift chain is worn or damaged, both lift chains
Daily inspection plus; kinked, crushed, flattened or must be replaced.
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/re- NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
place hose/components as necessary. See Mast Re- tion should not be performed in combination with the
pairs, 2-, 3-, and 4-Stage Masts 4000 SRM 1148 1000 Hour/6 Months Lift Chain Lubrication.
for quick disconnect procedures.
Lubricate lift chains with SAE 30W engine oil. The
LIFT CHAIN LUBRICATION best procedure is to remove the chains from the lift
truck and soak them in engine oil. Be sure to clean
any dirt or grease from chains before lubricating. DO
WARNING
NOT USE STEAM TO CLEAN THE LIFT CHAINS.
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
66
TILT CYLINDER LUBRICATION Lubricate the tilt cylinder ends. Use multipurpose
grease shown in the Maintenance Schedule. There
NOTE: The floor plate must be removed in order to are four lubrication fittings. See Figure 57.
lubricate the rear tilt cylinder lubrication fittings.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. LUBRICATION FITTING
2. RETAINER 5. TILT SPACER
3. ANCHOR PIN
Figure 57. Tilt Cylinder Lubrication
67
MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION
Lubricate the master brake cylinder rod end pin. Use
engine oil as shown in the Maintenance Schedule.
See Figure 58 and Figure 59.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 59. Master Brake Cylinder Rod End Pin

Lubrication (Wet Brake)
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 58. Master Brake Cylinder Rod End Pin

Lubrication (Dry Brake)
68
MANUAL HYDRAULIC LEVERS On lift trucks with wet brake drive axles, only
LUBRICATION use Dexron III oil from sealed container in the
master cylinder.
Lubricate the bushings for the manual hydraulic
levers. Use spray lubricant as listed in the Mainte- Replace the brake oil in the system if there is
nance Schedule. See Figure 60. dirt or water in the system.
On lift trucks with dry brake drive axles, only

ter cylinder.
Remove the dash board from the cowl. The brake

fluid reservoir is located on the cowl, at the mas-
ter cylinder. Add brake fluid, as necessary. Use the
brake fluid shown in the Maintenance Schedule. See
Figure 61 and Figure 62.
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 60. Manual Hydraulic Levers

Lubrication
BRAKE FLUID
1. BRAKE FLUID RESERVOIR
WARNING 2. MOUNTING BRACKET
Small amounts of water in the brake system 3. COWL
can cause reduced braking performance if the
water reaches the wheel cylinder areas. DO Figure 61. Brake Fluid Reservoir (Dry Brakes)
reservoir lid is properly replaced.
69
TIE ROD LUBRICATION (H40-70FT)

Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There are two
lubrication fittings on each tie rod. See Figure 63.
1. AXLE
2. LUBRICATION FITTING
Figure 63. Tie Rod Lubrication

1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 62. Brake Oil Change (Wet Brakes)
70
DIFFERENTIAL AND DRIVE AXLE OIL

(DRY BRAKE)
The differential and drive axle use the same oil sup-
ply. The oil level must be between 0 to 10 mm (0 to
0.40 in.) below the bottom edge of fill hole. The fill
hole for checking the oil level is on the front of the
differential housing. Remove fill plug and check fluid
level by sticking a finger into the fill hole to feel if the
fluid level is at the bottom edge of the fill hole. See
Figure 64. If oil is low, add oil shown in the Main-
tenance Schedule until the oil level is between 0 to
10 mm (0 to 0.40 in.) below the bottom edge of fill
hole. Install fill plug and check for leaks.
1. DRIVE AXLE 3. DRAIN PLUG

2. CHECK/FILL PLUG
Figure 64. Drive Axle Fluid Fill
71

NOTE: Perform the 8-hour, 250-hour, and 500-hour LPG FUEL FILTER ELEMENT REPLACE,
checks prior to performing the procedures in this sec- GM 2.4L ENGINE
tion.
Remove
VALVE CLEARANCE, CHECK AND
ADJUST WARNING
The GM 2.4L engine has hydraulic valve lifters and LPG can cause an explosion. DO NOT permit
does not require valve clearance adjustments dur- any sparks or open flames in the work area.
ing normal service. Check the valve clearance on
1. Close fuel valve on tank. Run engine until it
Mazda and Yanmar engines and make adjustments
stops.
as needed. See the Maintenance Schedule for valve
clearances. 2. Disconnect negative battery cable.
Additional engine information is available in the fol-
lowing sections: WARNING
• GM Engine Repair, GM 2.4 Liter Engine 600 A small amount of fuel may still be present in
SRM 1121 the fuel line. Use gloves to prevent burns and
• Mazda Engine, 2.0L and 2.2L 600 SRM 1122 wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
IGNITION SYSTEM check to make sure the manual valve is fully
closed.
GM 2.4L Engine
3. Remove the bolt and seal washer retaining the
The GM 2.4L gasoline and LPG engines have an elec- top section of the fuel filter housing. Discard seal
tronic control unit (ECU) that controls the ignition washer. See Figure 65.
timing. There are no adjustments. Change the spark
plugs every 1000 hours. The correct spark plug gap 4. Remove top section of fuel filter housing.
is 0.8 to 0.9 mm (0.032 to 0.035 in.).
5. Remove and discard housing O-ring.
Mazda 2.0L and 2.2L Engines 6. Remove fuel filter and fuel filter O-ring.
The Mazda 2.0L and 2.2L engines have an electronic
ignition system. Change the spark plugs and check Install
the timing every 1000 hours. The correct spark plug 1. Clean and inspect the fuel filter housing for con-
gap is 0.8 ±0.1 mm (0.031 ±0.004 in.). tamination or damage.
The correct timing for the Mazda 2.0L and 2.2L en- 2. Install the new fuel filter and fuel filter O-ring.
gines is as follows: See Figure 65.
• Gasoline = 6° ±1° BTDC at 800 ±25 rpm (Orange
mark) 3. Install new housing O-ring.
• LPG = 6° ±1° BTDC at 800 ±25 rpm (Orange mark)
For all Mazda engines except 2007 emission compli- 4. Install top section of fuel filter housing.
ant engines, see Electrical System, Mazda 2.0L
and 2.2L 2200 SRM 1143. For 2007 Mazda emission 5. Install bolt and new seal washer. Tighten bolt to
compliant engines, see Electrical System, Mazda 13 N•m (115 lbf in).
2.0L and 2.2L Emission Compliant Engines 2200
SRM 1327.
72
8. Check for leaks at connections by using soapy

solution or electronic leak detector. If leaks are
detected, make proper repairs.
LPG VAPOR FUEL FILTER REPLACE,

MAZDA ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
WARNING
LPG can cause an explosion. DO NOT permit
any sparks or open flames in the work area.
Remove and install a new LPG vapor fuel filter ele-

ment as follows:
1. Close fuel valve on tank. Run engine until all fuel

is gone and engine stops.
2. Disconnect negative battery cable.
3. Slowly loosen all hose fittings to filter. Let any

fuel drain from fittings before disassembling fil-
ter unit.
4. Remove capscrews and filter cover.

1. BOLT
2. SEAL WASHER 5. Remove O-ring, filter element, and spring. Dis-
3. FUEL FILTER HOUSING TOP SECTION card spring, filter element, and O-ring. See Fig-
4. FUEL FILTER ure 66.
5. FUEL FILTER O-RING
6. HOUSING O-RING 6. Install new spring, new filter element, and new
7. FUEL FILTER HOUSING BOTTOM SECTION O-ring.
Figure 65. Fuel Filter Removal and Installation 7. Install filter cover to filter body with capscrews.
NOTE: Opening the fuel valve too quickly can cause Tighten hose fittings.
the internal excessive flow valve to close, restricting NOTE: Leaks are normally indicated by a buildup of
the flow of fuel. If this happens, close the fuel valve, frost around a loose fitting. A leak may also be dis-
wait a few seconds, and then slowly open the fuel covered by using soapy water.
valve again. This will reset the excess fuel valve.
8. Open fuel valve on LPG tank and check for leaks.
6. Slowly open the fuel valve on tank. If leaks are found, tighten fittings.
7. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.
73
1. BOLT*
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
1. FILTER BODY 4. FILTER ELEMENT 5. FUEL FILTER O-RING
2. SPRING 5. FILTER COVER 6. HOUSING O-RING
3. O-RING 6. CAPSCREW 7. FUEL FILTER HOUSING BOTTOM SECTION*
8. LOW PRESSURE SWITCH
Figure 66. Mazda LPG Vapor Fuel Filter
*NOT SERVICED SEPARATELY
LPG FUEL FILTER REPLACE, MAZDA 2007
EMISSION COMPLIANT ENGINES ONLY Figure 67. Mazda 2007 Emission Compliant
Fuel Filter Removal/Installation
Remove
5. Remove and discard housing O-ring.
WARNING 6. Remove and discard fuel filter and fuel filter

LPG can cause an explosion. DO NOT permit O-ring.
any sparks or open flames in the work area.
Clean/Inspect
1. Close fuel valve on tank and run engine until it
runs out of fuel and stops. Try to restart engine 1. Clean and inspect the fuel filter housing top sec-
2-3 times until it no longer starts. tion for contamination or damage. If damaged,
replace the housing.
2. Disconnect negative battery cable.
2. Clean and inspect the fuel filter housing bottom
section for contamination or damage. If dam-
WARNING aged, replace the housing.
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and Install
wear eye protection. If liquid fuel continues
to flow from the connections when loosened, 1. Install the new fuel filter and fuel filter O-ring.
check to make sure the manual valve is fully See Figure 67.
closed.
2. Install new housing O-ring.
3. Remove the bolt and seal washer from the fuel
filter housing top section. Discard seal washer. 3. Install fuel filter housing top section onto fuel
See Figure 67. filter housing bottom section.
4. Remove fuel filter housing top section from fuel 4. Install bolt and new seal washer. Tighten bolt to
filter housing bottom section. 13 N•m (115 lbf in).
74
NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.
5. Slowly open the fuel valve on tank.
6. Connect the negative battery cable.
7. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.
8. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.
GASOLINE FUEL FILTER REPLACEMENT,

MAZDA 2007 EMISSION COMPLIANT
ENGINES ONLY
Remove and Replace
1. Raise the hood and disconnect the negative ter-
minal of the battery. 1. SCHRADER VALVE
2. FUEL FILTER
2. Remove and discard the fuel filter. See Figure 68. 3. FUEL PUMP/SENDER UNIT
3. Install the new fuel filter and tighten the clamp Figure 68. Fuel Filter Replacement, Mazda
screws to 2.45 to 2.77 N•m (22 to 25 lbf in). 2007 Emission Compliant Engines Only
4. Connect the negative terminal of the battery and

close the hood.
75
FUEL FILTER REPLACEMENT, YANMAR

ENGINE
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
Replace the fuel filter at specified intervals to pre-

vent contaminants from adversely affecting the
diesel fuel flow.
NOTE: See Figure 69 for all steps in the following

procedure.
1. Stop the engine and allow it to cool.
2. Close all fuel cocks in the line.
NOTE: Tag connectors prior to disconnecting to aid

in reconnecting.
3. Disconnect fuel filter sensor connector.
4. Place an approved container under the fuel filter.
5. Open the drain plug to drain fuel from the fuel

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

Wipe up any spilled fuel immediately.
7. Remove the drain plug from the fuel filter. Dis-

card the O-ring.
8. Remove the fuel filter sensor from the fuel filter

element and discard the O-ring.
9. Remove the inline fuel filter from the inlet nip-

ple that goes to the fuel injection pump. See Fig-
ure 70.
1. FUEL FILTER ASSEMBLY
10. Dispose of the fuel, fuel filters, and O-ring in ac- 2. FUEL FILTER ELEMENT
cordance with local directives. 3. FUEL FILTER SENSOR CONNECTOR
4. FUEL FILTER HEAD
11. Install the new inline fuel filter into the inlet nip- 5. O-RING
6. DRAIN PLUG
ple. 7. FUEL FILTER SENSOR
8. INLINE FUEL FILTER
12. Install the fuel filter sensor assembly in the new 9. INLET NIPPLE
fuel filter using the new O-ring supplied with the
fuel filter. Figure 69. Yanmar Fuel Filter Replacement
76
PRIMING THE FUEL SYSTEM (YANMAR)

1. Place an approved container under the air bleed
port. See Figure 71.
2. Loosen the air bleed port 2 or 3 turns.
CAUTION
NEVER use the starter motor to crank the en-
gine in order to prime the fuel system. This
may cause the starter to overheat and damage
the coils and/or the ring gear.
3. Operate the fuel priming pump until the fuel

coming out of the air bleed port is free of bubbles.
See Figure 71.
4. Tighten the air bleed port.
5. Wipe up any fuel that may have spilled, and dis-

pose of the fuel and rags in accordance with local
1. INLINE FUEL FILTER
2. FUEL LINE directives.
3. WATER SEPARATOR/FUEL FILTER
4. FUEL SUPPLY VALVE
Figure 70. In-Line Fuel Filter Replacement
13. Install the new O-ring on the drain plug, and in-
stall the drain plug on the new fuel filter element.
Hand tighten only.
14. Clean the fuel filter head mounting surface and

apply a small amount of diesel fuel to the gasket
on the new fuel filter element.
15. Install the new fuel filter element until it con-

tacts the fuel filter head mounting surface.
Tighten one additional turn.
16. Open all the fuel cocks in the fuel line.
17. Reconnect the fuel filter sensor connector.
18. Prime the fuel system. See Priming the Fuel Sys-
tem (Yanmar).
19. Check for fuel leaks.
1. AIR BLEED PORT

2. FUEL PRIMING PUMP
Figure 71. Priming the Fuel System
77
LIFT CHAINS WEAR CHECK

If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re-
placed. Measure chain for wear where it moves over
sheaves. Using a chain scale, (Hyster P/N 871796)
check lift chains as shown in Figure 72.
LIFT CHAIN LUBRICATION
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

goggles or a face shield to prevent injury to Pitch Wear Limit
the eyes. Total Length
(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 72. Lift Chains Check
78
INTEGRAL SIDESHIFT CARRIAGE, CHECK Legend for Figure 73

BEARINGS 1. UPPER BEARING
2. LOWER HOOK
1. Lower carriage completely and remove forks. 3. LOAD ROLLER
4. SNAP RING
2. Remove backrest and the lower mounting hooks 5. SIDESHIFT CYLINDER
from sideshift carriage. See Figure 73. 6. LOWER BEARING
7. SHIMS
3. Use a lifting device with a capacity of at least 8. INNER CARRIAGE
450 kg (1000 lb) to lift outer frame away from 9. LUBE FITTING
inner carriage. 10. OUTER FRAME
4. Clean bearing areas. Inspect sideshift bearings INTEGRAL SIDESHIFT CARRIAGE, CHECK
for wear as follows: LOWER MOUNTING HOOKS
a. If either upper bearing is worn to less than Inspect the lower mounting hooks for wear. Replace
2.5 mm (3/32 in.) thickness, replace both up- the hooks if they are worn beyond the wear limit.
per bearings by driving upper bearings out of The wear limit clearance range is 0.76 mm (0.03 in.)
carriage bar. minimum and 1.52 mm (0.06 in.) maximum. See A
in Figure 74.
b. If either lower bearing is worn to less than
2.5 mm (3/32 in.) thickness, replace both
lower bearings by prying lower bearings from
lower carriage bar.
A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND

1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
Figure 73. Integral Sideshift Carriage
Figure 74. Lower Mounting Hooks Wear Limit
and Clearance Adjustment
79
STEERING AXLE
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side of
the steering axle. See Figure 75. Use multipurpose
grease as shown in the Maintenance Schedule.
CONTROL LEVERS AND PEDALS

Lubricate linkages, pedal shafts, control cables
(throttle, hood, parking brake), and seat rails. Use a
silicone spray lubricant, Hyster Part No. 328388.
A. S40-70FT, S55FTS (F187)

B. H40-70FT (L177)
1. STEERING AXLE
2. LUBRICATION FITTING
Figure 75. Lubricate Spindle Bearings
80
8000 SRM 1150 Maintenance Procedures Every 2000 Hours or Annually
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and 5. Remove and discard O-ring from top of bowl. See
1000-hour checks prior to performing the procedures Figure 76.
in this section.
6. Remove and discard quad ring from head. See
HYDRAULIC SYSTEM Figure 76.
Hydraulic Filter, Replace 7. Clean housing and cover plate as necessary.
8. Inspect filter housing, especially sealing sur-

WARNING faces, for damage. Replace if damaged.
At operating temperature, the hydraulic oil is
9. Inspect dipstick plug. Replace O-ring and plug
HOT. DO NOT permit the hot oil to touch the
as necessary.
10. Lubricate sealing surfaces on filter housing and
CAUTION cover plate with clean hydraulic oil.
DO NOT permit dirt to enter the hydraulic sys-
11. Lubricate new quad ring with clean hydraulic oil
tem when the oil level is checked or the filter
and install onto head. See Figure 76.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. 12. Lubricate new O-ring with clean hydraulic oil
and install onto top of bowl. See Figure 76.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the 13. Lubricate new O-ring with clean hydraulic oil
hydraulic pump without oil will damage the and install on bottom of new filter element. See
pump. Figure 76.
14. Install new filter element into bowl as noted dur-

CAUTION ing removal. See Figure 76.
cal environmental regulations. 15. Lubricate new O-ring with clean hydraulic oil
and install on lid. See Figure 76.
1. Put lift truck on a level surface and lower car-
riage. 16. Install spring and lid onto head. See Figure 76.
Hand tighten lid.
2. Unscrew and remove lid and spring from head.
Remove and discard O-ring from lid. See Fig-
ure 76. CAUTION
Additives may damage the hydraulic system.
NOTE: Have container large enough to hold the filter Before using additives, contact your local Hys-
element and allow for final hydraulic oil draining. ter dealer.
NOTE: Note placement of filter element and handle 17. Start the truck, and allow it to run for 30 seconds.
prior to removal to aid in installation. Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
3. Remove filter element and O-ring from bowl and
shown in the Maintenance Schedule. To change
place in container. Cover head to prevent any
the hydraulic oil, see Hydraulic Oil, Replace.
foreign material from getting into the hydraulic
tank. See Figure 76.
4. After filter element has drained, discard filter el-

ement and O-ring.
81
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1150
Hydraulic Tank Breather, Replace

1. Raise the hood and remove the right rear side
panel. See Figure 77.
2. Unscrew and remove old hydraulic tank

breather, and replace with new hydraulic tank
breather.
3. Install right rear side panel and close hood. See

Figure 77.
1. HOOD/SEAT ASSEMBLY
2. RIGHT REAR SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 77. Hydraulic Tank Breather
1. O-RING 6. FILTER ELEMENT

2. SPRING 7. BOWL
3. LID 8. DIPSTICK PLUG
4. HEAD 9. FILTER HOUSING
5. QUAD RING 10. COVER PLATE
Figure 76. Hydraulic Filter
82
AIR FILTER 3. Gently pull the filter element from the canister.
Avoid dislodging contaminants from the element
The air filter canister should not be opened until an or knocking it against the canister.
air filter element replacement is required. An air
filter element replacement is required when one of 4. With a clean, soft rag, clean the inside surface
the following occurs: of the canister. Remove liner assembly to make
• The optional air flow restriction indicator light on cleaning easier. Clean well around the locking
the dash illuminates. tabs that retain the element. Clean tabs make
• The optional manual air flow indicator button pops new filter element installation easier. Be careful
up. not to knock any contaminants into the outlet
• The specified number of hours has passed since the tube to the engine.
last filter element replacement.
5. Inspect liner and O-ring assembly for damage. If
damaged, replace liner and O-ring assembly.
CAUTION
DO NOT to allow dirt to enter the engine air 6. Install liner assembly into canister by pushing
intake when replacing the air filter element. A in. Make sure liner assembly is properly seated
small amount of dirt could cause engine dam- in the canister. It will fit snugly into and be cen-
age. tered in the canister.
1. Shut off engine. Never open air filter canister or If your air filter assembly is equipped with a sec-
remove filter element with engine running. ondary element in place of the liner assembly, re-
place the secondary element with every 2 to 3 pri-
2. Unlatch and remove cover. To remove filter el- mary element replacements.
ement, press and rotate filter element counter-
clockwise about 1/8 turn until the filter element 7. Inspect the new filter element for voids, cuts,
is free. To assist removal, gently move the end tears or indentations in the urethane-sealing
back and forth to help break the seal. See Fig- surfaces. Do not use if damage is detected.
ure 78.
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 78. Air Filter
83
NOTE: If the filter element is properly installed, the

CAUTION cover will fit easily into the canister with no gap be-
The element must be properly installed to en- tween the cover and the canister. If cover does not
sure adequate engine protection. An improp- fit easily, the filter element is not installed properly.
erly installed element may allow dirt and dust Do not use a cover that is bent, damaged, or missing
to enter and damage the engine. latches.
NOTE: Proper element installation is required to al- 9. Install cover into the canister and ensure the IN-
low the cover to be installed correctly. Never reinstall LET arrow is in line with the canister inlet.
a used element. Never install a damaged element.
Always use a Hyster-approved filter element. NOTE: Do not use latches to pull cover down against
the canister. If cover does not fit completely against
8. Install the new filter element into the canister. the canister with no gaps, the element is not installed
Press and rotate the filter element 1/8 turn clock- correctly.
wise until fully engaged in the canister. See Fig-
ure 79. 10. Fasten the latches to secure the cover to the can-
ister. Make sure the latches penetrate the slots
in both the canister and the cover.
11. Inspect the entire air intake system for leaks.

Inspect all clamps for tightness and tighten if
necessary. Inspect all hoses for damage. Re-
place damaged hoses. Inspect the dust evacua-
tion valve for damage. If damaged, replace the
dust evacuation valve.
PCV VALVE
Install a new PCV valve.
1. PUSH IN 2. TWIST TO LOCK See Figure 23 for lift trucks equipped with a GM en-
gine.
Figure 79. Air Filter Label
CAUTION
During cover installation, DO NOT force the See Figure 25 for lift trucks equipped with a Mazda
cover on the canister. To do so will result in engine (2007 emission compliant engines).
damage to the filter element, cover, and possi-
bly the canister.
84
OXYGEN SENSOR
NOTE: The 2007 Mazda emission compliant engines
are equipped with Pre and Post Catalytic Converter
Oxygen Sensors.
Check that the oxygen sensor electrical connector is

seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair.
See Figure 80 for lift trucks equipped with a GM or

Mazda engine.

engine (2007 Mazda emission compliant engines).
A. MAZDA EXHAUST SYSTEM

B. GM EXHAUST SYSTEM
1. OXYGEN SENSOR 3. MANIFOLD
2. EXHAUST PIPE
Figure 80. Oxygen Sensor
85
1. MUFFLER 4. EXHAUST PIPE (EXHAUST MANIFOLD TO

2. POST-CATALYTIC CONVERTER OXYGEN CATALYTIC CONVERTER)
SENSOR 5. EXHAUST PIPE (CATALYTIC CONVERTER TO
3. PRE-CATALYTIC CONVERTER OXYGEN MUFFLER)
SENSOR 6. CATALYTIC CONVERTER
Figure 81. Oxygen Sensors for 2007 Mazda Emission Compliant Engines
LPG REGULATOR FUEL FILTER, MAZDA

ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
Remove and Replace
1. Close shutoff valve on tank. Run engine until it
stops.
2. Remove six capscrews, fuel filter cover, and two

filter elements. Discard filter elements. See Fig-
ure 82.
3. Install two new filter elements and six capscrews

on fuel filter cover. Tighten six capscrews to 6.4
to 7.9 N•m (57 to 70 lbf in).
1. FILTER ELEMENTS 3. FUEL FILTER

2. CAPSCREWS COVER
Figure 82. Mazda LPG Regulator Fuel Filter
86
LPG REGULATOR FUEL FILTER, GM 5. Open shutoff valve on LPG tank and check for
ENGINES leaks.
Remove
1. Close shutoff valve on tank. Run engine until it
stops.
2. Disconnect the hose from the inlet fitting.
3. Remove the inlet fitting from the LPG regulator.

Discard the O-ring. See Figure 83.
4. Remove and discard the plastic cap, foam filter,

paper filter, and rubber washer from the LPG
regulator.
5. Disconnect the hose from the outlet fitting. Re-

move three screws and the outlet fitting from the
LPG regulator. Discard the O-ring.
6. Remove and discard the screen from the LPG reg-

ulator.
Install
1. Install a new screen in the LPG regulator.
2. Install a new O-ring on the outlet fitting. Using 1. LPG REGULATOR 6. PAPER FILTER
2. INLET FITTING 7. RUBBER WASHER
three screws, install the outlet fitting on the LPG 3. O-RING 8. SCREWS
regulator. 4. PLASTIC CAP 9. OUTLET FITTING
5. FOAM FILTER 10. SCREEN
3. Install new rubber washer, paper filter, foam fil-
ter, and plastic cap in the LPG regulator. Figure 83. GM LPG Regulator
4. Install new O-ring on the inlet fitting. Install

inlet fitting into the LPG regulator and connect
hose to the inlet fitting.
87
GASOLINE FUEL FILTER

Remove and Replace for Lift Trucks
Equipped with GFI
1. Raise the hood and disconnect the negative ter-
minal of the battery.
2. Remove and discard the fuel filter. See Figure 84.
3. Install the new fuel filter and tighten the clamp

screws to 2.45 to 2.77 N•m (22 to 25 lbf in).
4. Connect the negative terminal of the battery and

close the hood.
A. MAZDA (EXCEPT 2007 EMISSION COMPLIANT

ENGINES)
B. GM 2.4L
1. FUEL FILTER
2. FUEL TANK
3. FUEL PUMP/SENDER UNIT
Figure 84. Fuel Filter Replacement
88
TIMING BELT FORKS

Mazda Engines WARNING
Change timing belt after 3500 hours of operation. Never repair damaged forks. DO NOT heat,
The cover for the timing belt must be removed for weld, cut, drill, or bend the forks. Forks are
checks and adjustments. See the section Mazda En- made of special steel using special methods.
gine, 2.0L and 2.2L 600 SRM 1122 for more infor- Replace damaged forks as a set.
mation.
Check heel and attachment points of forks with a
penetrant or by magnetic particle inspection.
GM 2.4L Engine
The cover for the timing belt must be removed for INTEGRAL SIDESHIFT CARRIAGE
checks and adjustments. See the section GM Engine
Repair, GM 2.4 Liter Engine 600 SRM 1121 for Bearings, Replace
more information.
Replace all four bearings regardless of wear. See sec-
tion, Maintenance Procedures Every 1000 Hours or
LPG FUEL INJECTOR, MAZDA ENGINES 6 Months for the procedure.
(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES) TRANSMISSION OIL AND FILTER (DRY
BRAKE), REPLACE
For removal and cleaning instructions, see the sec-
tion LPG Fuel System, Mazda 2.0L and 2.2L En-
Iron Transmission Housing
gines 900 SRM 1125.
GASOLINE FUEL INJECTOR, MAZDA WARNING

ENGINES At operating temperature, the transmission oil
For removal and cleaning instructions, see the sec- skin and cause a burn.
tion Gasoline Fuel System, Mazda 2.0L and 2.2L
900 SRM 1127 for all Mazda engines except 2007
emission compliant engines. For 2007 emission com-
CAUTION
pliant engines, see the section Gasoline Fuel Sys- DO NOT permit dirt to enter the transmission
tem, Mazda 2.0L and 2.2L Emission Compliant when the oil level is checked or the filter is
Engines 900 SRM 1325. changed. Dirt can cause damage to the trans-
mission components.
LPG FUEL INJECTOR, GM ENGINES
CAUTION
For removal and cleaning instructions, see the sec-
tion LPG Fuel System, GM 2.4L Engine 900 SRM Disposal of lubricants and fluids must meet lo-
1124. cal environmental regulations.
NOTE: Change the transmission oil filter at the first

GASOLINE FUEL INJECTOR, GM ENGINES 500 hours of operation on new lift trucks. Before re-
For removal and cleaning instructions, see the sec- moving the oil filter, make a hole at the top of the
tion Gasoline Fuel System, GM 2.4L Engine 900 filter and allow five minutes for the oil to drain down
SRM 1126. into the transmission. This will reduce the oil that
will run out of the filter and onto the transmission
FUEL INJECTOR, YANMAR ENGINES when the filter is removed.
For removal and cleaning instructions, see the sec- NOTE: The drain plug for the transmission is on the
tion Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L lower right side of the cover of the transmission, to-
600 SRM 1205. ward the rear of the lift truck.
89
1. Remove drain plug, spring, and screen. Drain oil 3. When oil has drained, first install screen, then
into a container. spring, and transmission drain plug.
4. Remove and discard transmission breather.

Install new transmission breather and hand
tighten.
5. Remove and discard old transmission oil filter.

Apply clean oil to gasket of new transmission oil
filter. Install new filter and hand tighten.
6. Add oil to transmission at the dipstick tube. The

correct oil is shown in the Maintenance Schedule.
7. Start and run the engine for approximately five

minutes after fill to allow oil to lubricate parts
within the transmission.
NOTE: Transmission oil temperature should be at

least 50°C (120°F) when checking oil level.
8. Turn the key to the OFF position, check for leaks,

and check oil level. Top off oil, if necessary.
NOTE: ALL MAJOR COMPONENTS AND FRAME Aluminum Transmission Housing

COMPONENTS REMOVED FOR THE SAKE OF
Remove
CLARITY.
1. TRANSMISSION WARNING
2. TRANSMISSION DRAIN PLUG
3. SPRING At operating temperature, the transmission oil
4. SCREEN is HOT. DO NOT permit the hot oil to touch the
5. TRANSMISSION OIL FILTER skin and cause a burn.
6. TRANSMISSION DIPSTICK
7. TRANSMISSION BREATHER
CAUTION
Figure 85. Transmission Oil Change DO NOT permit dirt to enter the transmission
WARNING changed. Dirt can cause damage to the trans-
mission components.
cleaning solvents, always follow the solvent CAUTION
manufacturer’s recommended safety proce- Disposal of lubricants and fluids must meet lo-
dures. cal environmental regulations.
Compressed air can move particles so they NOTE: Change the transmission oil filter at the first
cause injury to the user or to other personnel. 500 hours of operation on new lift trucks.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog- 1. Remove drain plug. When oil is completely
gles or a face shield to prevent injury to the drained, install drain plug.
eyes.
See Figure 86 for lift trucks equipped with an
2. Clean screen with cleaning solvent, and dry with aluminum gear drive manufactured before Jan-
compressed air, adjusted to the maximum output uary, 2011.
of 103 kPa (15 psi).
90
See Figure 87 for lift trucks equipped with an See Figure 86 for lift trucks equipped with an
aluminum gear drive manufactured after Jan- aluminum gear drive manufactured before Jan-
uary, 2011. uary, 2011.
aluminum gear drive manufactured after July, aluminum gear drive manufactured after Jan-
2013. uary, 2011.
aluminum gear drive manufactured after July, aluminum gear drive manufactured after July,
2013. 2013.
2. Remove capscrews washers, charge pump, and See Figure 89 for lift trucks equipped with an
charge pump gasket. Discard gasket. aluminum gear drive manufactured after July,
2013.
aluminum gear drive manufactured before Jan- 5. Remove and discard transmission oil filter.
uary, 2011.
See Figure 87 for lift trucks equipped with an aluminum gear drive manufactured before Jan-
aluminum gear drive manufactured after Jan- uary, 2011.
uary, 2011.
See Figure 88 for lift trucks equipped with an aluminum gear drive manufactured after Jan-
aluminum gear drive manufactured after July, uary, 2011.
2013.
See Figure 89 for lift trucks equipped with an aluminum gear drive manufactured after July,
aluminum gear drive manufactured after July, 2013.
2013.
3. Remove suction screen spring and suction screen. aluminum gear drive manufactured after July,
2013.
aluminum gear drive manufactured before Jan- 6. Remove and discard transmission breather.
uary, 2011.
See Figure 87 for lift trucks equipped with an aluminum gear drive manufactured before Jan-
aluminum gear drive manufactured after Jan- uary, 2011.
uary, 2011.
See Figure 88 for lift trucks equipped with an aluminum gear drive manufactured after Jan-
aluminum gear drive manufactured after July, uary, 2011.
2013.
See Figure 89 for lift trucks equipped with an aluminum gear drive manufactured after July,
aluminum gear drive manufactured after July, 2013.
2013.
4. Remove flange head capscrews and hydraulic aluminum gear drive manufactured after July,
gear pump. 2013.
91
1. TRANSMISSION 1. TRANSMISSION
2. TRANSMISSION OIL FILTER 2. TRANSMISSION OIL FILTER
3. TRANSMISSION DIPSTICK 3. TRANSMISSION DIPSTICK
4. TRANSMISSION BREATHER 4. TRANSMISSION BREATHER
5. TRANSMISSION DRAIN PLUG 5. TRANSMISSION DRAIN PLUG
6. SUCTION SCREEN 6. SUCTION SCREEN
7. SUCTION SCREEN SPRING 7. SUCTION SCREEN SPRING
8. CHARGE PUMP GASKET 8. CHARGE PUMP GASKET
9. CHARGE PUMP 9. CHARGE PUMP
10. WASHER 10. WASHER
11. CAPSCREW 11. CAPSCREW
12. FLANGE HEAD CAPSCREW 12. FLANGE HEAD CAPSCREW
13. HYDRAULIC GEAR PUMP 13. HYDRAULIC GEAR PUMP
Figure 86. Transmission Oil Filter Change - Figure 87. Transmission Oil Filter Change -
Aluminum Gear Drive (Prior to January, 2011) Aluminum Chain Drive (After January, 2011)
92
1. TRANSMISSION
2. TRANSMISSION OIL FILTER 1. TRANSMISSION
3. TRANSMISSION DIPSTICK 2. TRANSMISSION OIL FILTER
4. TRANSMISSION BREATHER 3. TRANSMISSION DIPSTICK
5. TRANSMISSION DRAIN PLUG 4. TRANSMISSION BREATHER
6. SUCTION SCREEN 5. TRANSMISSION DRAIN PLUG
7. SUCTION SCREEN SPRING 6. SUCTION SCREEN
8. CHARGE PUMP GASKET 7. SUCTION SCREEN SPRING
9. CHARGE PUMP 8. CHARGE PUMP GASKET
10. WASHER 9. CHARGE PUMP
11. CAPSCREW 10. WASHER
12. FLANGE HEAD CAPSCREW 11. CAPSCREW
13. HYDRAULIC GEAR PUMP 12. FLANGE HEAD CAPSCREW
13. HYDRAULIC GEAR PUMP
Figure 88. Transmission Oil Filter Change -
Aluminum Gear Drive (After July, 2013) Figure 89. Transmission Oil Filter Change -
Aluminum Chain Drive (After July, 2013)
93
Clean and Inspect See Figure 86 for lift trucks equipped with an
aluminum gear drive manufactured before Jan-
uary, 2011.
WARNING
Cleaning solvents can be flammable and toxic See Figure 87 for lift trucks equipped with an
and can cause skin irritation. When using aluminum gear drive manufactured after Jan-
cleaning solvents, always follow the solvent uary, 2011.
manufacturer’s recommended safety proce-
dures. See Figure 88 for lift trucks equipped with an
aluminum gear drive manufactured after July,
Compressed air can move particles so they 2013.
Make sure the path of the compressed air is See Figure 89 for lift trucks equipped with an
away from all personnel. Wear protective gog- aluminum gear drive manufactured after July,
gles or a face shield to prevent injury to the 2013.
eyes.
3. Using seven washers and seven capscrews in-
1. Clean suction screen spring and suction screen stall new charge pump gasket and charge pump.
with cleaning solvent and dry with compressed Tighten capscrews to 19 N•m (168 lbf in).
air. Inspect spring and screen for damage. Re-
place if damaged. See Figure 86 for lift trucks equipped with an
aluminum gear drive manufactured before Jan-
2. Wipe exterior surfaces of transmission housing, uary, 2011.
hydraulic gear pump and charge pump with sol-
vent soaked clot and dry with a lint-free cloth. See Figure 87 for lift trucks equipped with an
Inspect housing and pumps for damage. Replace aluminum gear drive manufactured after Jan-
if damaged. uary, 2011.
3. Clean metal threaded components with solvent See Figure 88 for lift trucks equipped with an
and dry with compressed air. Clean plastic aluminum gear drive manufactured after July,
threaded components with warm soapy water 2013.
and dry with a lint-free cloth. Inspect compo- See Figure 89 for lift trucks equipped with an
nents for damage. Replace if damaged. aluminum gear drive manufactured after July,
Install 2013.
1. Install new transmission breather. 4. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of

sealant to either hydraulic gear pump or trans-
See Figure 86 for lift trucks equipped with an mission housing face. Hold pump in the correct
aluminum gear drive manufactured before Jan- position on the transmission. Install flange head
uary, 2011. capscrews into pump and transmission housing.
Tighten capscrews to 38 N•m (28 lbf ft).
aluminum gear drive manufactured after Jan- See Figure 86 for lift trucks equipped with an
uary, 2011. aluminum gear drive manufactured before Jan-
uary, 2011.
aluminum gear drive manufactured after July, See Figure 87 for lift trucks equipped with an
2013. aluminum gear drive manufactured after Jan-
uary, 2011.
aluminum gear drive manufactured after July, See Figure 88 for lift trucks equipped with an
2013. aluminum gear drive manufactured after July,
2013.
2. Install suction screen and suction screen spring.
94

aluminum gear drive manufactured after July, CAUTION
2013. Disposal of lubricants and fluids must meet lo-
5. Apply clean oil to gasket of new transmission oil
filter and install filter onto transmission. NOTE: Change the transmission oil filter at the first
500 hours of operation on new lift trucks. Before re-
See Figure 86 for lift trucks equipped with an moving the oil filter, make a hole at the top of the
aluminum gear drive manufactured before Jan- filter and allow five minutes for the oil to drain down
uary, 2011. into the transmission. This will reduce the oil that
will run out of the filter and onto the transmission
when the filter is removed.
aluminum gear drive manufactured after Jan-
uary, 2011. NOTE: The drain plug for the transmission is on the
lower right side of the cover of the transmission, to-
ward the rear of the lift truck.
2013. 1. Remove drain plug, spring, and screen. Drain oil
into a container. See Figure 90.
2013.
6. Add oil to transmission at dipstick tube. The cor-

rect oil is shown in the Maintenance Schedule.
7. Start and run engine for approximately five min-

utes after fill to allow oil to lubricate parts within
transmission.

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

check oil level. Top off oil, if necessary.
TRANSMISSION OIL CHANGE, WET

BRAKE DRIVE AXLE
Iron Transmission Housing
WARNING NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR THE SAKE OF
At operating temperature, the transmission oil
CLARITY.
skin and cause a burn. 1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
3. SPRING
CAUTION 4. SCREEN
DO NOT permit dirt to enter the transmission 5. TRANSMISSION OIL FILTER
when the oil level is checked or the filter is 6. TRANSMISSION DIPSTICK
changed. Dirt can cause damage to the trans- 7. TRANSMISSION BREATHER
mission components. Figure 90. Transmission Oil Change
95
contaminated, the oil must be drained and re-

WARNING placed with new oil.
cleaning solvents, always follow the solvent
WARNING
manufacturer’s recommended safety proce- At operating temperature, the transmission oil
dures. is HOT. DO NOT permit the hot oil to touch the
cause injury to the user or to other personnel. CAUTION
DO NOT permit dirt to enter the transmission
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
changed. Dirt will contaminate the oil and
eyes.
cause damage to the transmission and wet
2. Clean screen with cleaning solvent, and dry with brake planetary carrier housing components.
compressed air, adjusted to the maximum output
of 103 kPa (15 psi). CAUTION
3. When oil has drained, first install screen, then Disposal of lubricants and fluids must meet lo-
spring, and transmission drain plug. See Fig- cal environmental regulations.
ure 90.
NOTE: Change the transmission oil filter at the first
4. Remove and discard transmission breather. 500 hours of operation on new lift trucks.
Install new transmission breather and hand
1. Place a container under transmission. Remove
tighten. See Figure 90.
transmission temperature sensor to drain oil.
5. Remove and discard old transmission oil filter. See Figure 91. When oil is completely drained,
Apply clean oil to gasket of new transmission oil install transmission temperature sensor.
filter. Install new filter and hand tighten. See
2. Using clamp pliers, slide two clamps toward mid-
Figure 90.
dle of brake cooling hose. See Figure 92.
6. Add oil to transmission at the dipstick tube. The
3. Remove brake cooling hose from wet brake drive
axle and transmission assembly. See Figure 92.
7. Start and run the engine for approximately five
4. Remove capscrews, washers, charge pump, and
charge pump gasket. Discard gasket. See Fig-
within the transmission.
ure 91.
5. Remove suction screen spring and suction screen.
See Figure 91.
8. Turn the key to the OFF position, check for leaks,
6. Remove flange head capscrews and hydraulic
and check oil level. Top off oil, if necessary.
gear pump. See Figure 91.
Aluminum Transmission Housing 7. Remove and discard transmission oil filter. See
Figure 91.
WARNING
8. Remove and discard transmission breather. See
The oil used for the transmission should not be Figure 91.
contaminated. If the transmission oil becomes
96
1. TRANSMISSION 8. CHARGE PUMP

2. TRANSMISSION OIL FILTER 9. WASHER
3. TRANSMISSION DIPSTICK 10. CAPSCREW
4. TRANSMISSION BREATHER 11. FLANGE HEAD CAPSCREW
5. SUCTION SCREEN SPRING 12. HYDRAULIC GEAR PUMP
6. SUCTION SCREEN 13. TRANSMISSION TEMPERATURE SENSOR
7. CHARGE PUMP GASKET
Figure 91. Transmission Oil Change - Aluminum Housing
97
1. WET BRAKE DRIVE AXLE 3. BRAKE COOLING HOSE

2. CLAMP 4. TRANSMISSION ASSEMBLY
Figure 92. Brake Cooling Line Remove/Install
9. Drain oil from left planetary housing as de- away from all personnel. Wear protective gog-
scribed below: gles or a face shield to prevent injury to the
a. Place container under left planetary housing. eyes.
b. Remove drain plug from housing. See Fig-
ure 94. Remove and discard O-ring from 10. Clean screen with cleaning solvent, and dry with
drain plug. compressed air, adjusted to a maximum output
c. Remove fill/level plug from housing. Re- of 103 kPa (15 psi).
moving fill/level plug allows oil to drain at a
11. Install new transmission breather. See Fig-
faster rate. See Figure 93.
ure 91.
d. Drain oil into container. When oil has com-
pletely drained, install new O-ring on drain 12. Install suction screen and suction screen spring.
plug then install drain plug in housing. See Figure 91.
Tighten drain plug to 40 N•m (29.5 lbf ft).
13. Using seven washers and seven capscrews in-
WARNING stall new charge pump gasket and charge pump.
See Figure 91. Tighten capscrews to 19 N•m
(168 lbf in).
cleaning solvents, always follow the solvent 14. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of
manufacturer’s recommended safety proce- sealant to either hydraulic gear pump or trans-
dures. mission housing face. Hold pump in the correct
position on the transmission. Install flange head
capscrews into pump and transmission housing.
See Figure 91. Tighten capscrews to 38 N•m
(28 lbf ft).
98
15. Apply clean oil to gasket of new transmission oil fill/level plug will allow the oil to drain at a
filter. Install oil filter and hand tighten. See faster rate. See Figure 93.
Figure 91.
2. Place an empty container under the center sec-
16. Install brake cooling hose to wet brake drive axle tion drain plug and under the right and left plan-
and transmission assembly. See Figure 92. etary housing drain plugs.
17. Using clamp pliers, slide hose clamps into posi- 3. Remove drain plugs and wait until oil has
tion on each end of brake cooling hose to secure drained completely. Remove and discard O-rings
cooling hose in proper position. See Figure 92. from drain plugs. See Figure 94.
18. Add transmission oil to transmission at the dip- 4. Install new O-rings on drain plugs. Install
stick tube. The correct oil and volume is shown drain plugs. Tighten the drain plugs to 40 N•m
in the Maintenance Schedule. (29.5 lbf ft).

least 50°C (120°F) when checking oil level. CAUTION
Before adding oil, ensure the truck is parked
19. Start and run the engine for approximately five and on level ground.
within the transmission. Add transmission oil to 5. Add oil at the fill/level port for the right and left
transmission at the dipstick tube as needed. planetary housing until the oil/fill level port has
overflowed. The correct oil is shown in the Main-
20. Turn the key to the OFF position and check for tenance Schedule or Figure 95.
leaks and check oil level.
6. Install new O-ring on planetary fill/level plugs.
WET BRAKE AXLE CENTER SECTION Install fill/level plugs.
AND PLANETARY HOUSING, OIL CHANGE 7. The center section (cooling chamber) will fill with
1. Remove the planetary housing fill/level plugs fluid automatically as it circulates through and
and O-rings. Discard O-rings. Removing the back to the transmission.
99
1. RIGHT PLANETARY HOUSING 4. FILL/LEVEL PLUG

2. LEFT PLANETARY HOUSING 5. CENTER SECTION (COOLING CHAMBER)
3. O-RING
Figure 93. Planetary Housings Fill/Level Plugs
100
1. LEFT PLANETARY HOUSING 4. CENTER SECTION (COOLING CHAMBER)

2. O-RING 5. RIGHT PLANETARY HOUSING
3. DRAIN PLUG
Figure 94. Center Section and Planetary Housings Drain Plugs
101
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY HOUSING - USE SAE 80W/90
C. CENTER SECTION (COOLING HOUSING) - USE JDM J20C
1. OIL FILL/LEVEL PLUG 3. COOLING OIL INLET PORT
2. OIL BREATHER
Figure 95. Oil Application Diagram
102
BRAKE FLUID (MASTER CYLINDER),

CHANGE
WARNING
Small amounts of water in the brake system
can cause reduced braking performance if the
water reaches the wheel cylinder areas. DO
reservoir lid is properly replaced.
On lift trucks with wet brake drive axles, only

use Dexron III oil from sealed container in the
master cylinder.
On lift trucks with dry brake drive axles, only

ter cylinder.
1. Remove dashboard from cowl.
CAUTION
2. Remove brake fluid reservoir from bracket on

cowl. See Figure 96 and Figure 97.
3. Remove the brake oil reservoir cover and cylin-

drical block drain plug. Pour the fluid into a suit-
able container with a 0.25 liter (0.53 pt) mini-
mum capacity. Install the cylindrical block drain
plug. Refill reservoir with clean oil from a sealed
container and install cover on the reservoir. The
4. Install reservoir into bracket located on cowl.
1. BRAKE FLUID RESERVOIR

2. MOUNTING BRACKET
3. COWL
Figure 96. Brake Fluid Change (Dry Brake)
103
3. Loosen special fitting at wheel cylinder one turn

so that used brake fluid can be removed from
brake system. Slowly push brake pedal and hold
it at the end of its stroke. Close special fitting.
Release brake pedal.
NOTE: New brake fluid will be easily recognized, as

the color will be more clear than the used fluid, which
will be darker.
4. Repeat Step 1 through Step 3 until there is new

brake fluid in the container.
5. Check level of brake fluid in reservoir for master

cylinder during the procedure. Make sure to keep
brake fluid at the correct level.
6. Repeat the procedure for the other wheel cylin-

der.
SERVICE BRAKES (DRY BRAKE)

Check brake lining and parts of the brake assembly
for wear or damage. The minimum acceptable brake
lining thickness is 1.0 mm (0.040 in.). If brake linings
are worn thinner than the specification, replace the
brake linings. See section Brake System 1800 SRM
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR 1135 for the removal and installation procedures of
3. RESERVOIR MOUNTING BRACKET the drive wheels and brake drums. If the brake lin-
4. COWL ings or brake shoes are worn or damaged, they must
5. UPPER BRAKE OIL SUPPLY HOSE be replaced. Brake shoes must be replaced in com-
6. CYLINDRICAL BLOCK OUTLET FITTING plete sets. Inspect brake drums for cracks or dam-
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE age. Replace any damaged parts.
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
WARNING
12. CYLINDRICAL BLOCK MOUNTING BRACKET Brake linings can contain dangerous fibers.
CAPSCREW Breathing the dust from these brake linings
is a cancer or lung disease hazard. DO NOT
Figure 97. Brake Oil Change (Wet Brakes) create dust! DO NOT clean brake parts with
compressed air or by brushing. Follow the
BRAKE FLUID (DRY BRAKE), REMOVE cleaning procedure in this section. When the
Perform the following procedure to remove used brake drums are removed, DO NOT create
brake fluid from the remainder of the brake system. dust.
1. Ensure that the master cylinder reservoir is DO NOT sand, grind, chisel, hammer, or change
filled with brake fluid. linings in any way that will create dust. Any
changes to brake linings must be done in a re-
2. Put one end of a rubber hose on the special fitting stricted area with special ventilation. Protec-
of the wheel cylinder. Put the other end of the tive clothing and a respirator must be used.
hose into a empty container.
104
Brake cleaning procedures are as follows: 3. The fill hole is on the front of the differential
housing. Add oil shown in the Maintenance
Schedule until oil level is at the lower edge of
CAUTION
the fill hole. Install fill plug and rotate the drive
DO NOT use an oil solvent to clean the wheel wheels in order to get oil pumped into the axle.
cylinder. Use a solvent approved for cleaning Remove the fill plug and check the oil level. Add
of brake parts. DO NOT permit oil or grease in oil, as necessary. Install fill plug and check for
the brake fluid or on the brake linings. leaks. See Figure 98.
1. DO NOT release brake lining dust from brake
linings into the air when brake drum is removed.
2. Use a solvent approved for cleaning of brake

parts to wet lining dust. Follow the instructions
and cautions of the manufacturer for the use of
the solvent. If a solvent spray is used, do not
create brake lining dust with the spray.
3. When the brake lining dust is wet, clean parts.

Put any cloth or towels in a plastic bag or an
airtight container while they are still wet. Put
a DANGEROUS FIBERS warning label on the
plastic bag or airtight container.
4. Any cleaning cloths that will be washed must be

cleaned so that fibers are not released into the
air.
DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential can
be found in the section Drive Axle and Differential
Assembly Repair 1400 SRM 1132 or Drive Axle
and Differential Assembly Repair, (Dry Brake)
1400 SRM 1214.
1. Place lift truck on blocks. See How to Raise Drive

Tires in this manual.
2. The differential and drive axle use the same oil

supply. Place a container with a minimum capac-
ity of 5 liter (5.3 qt) under the differential. Re- 1. DRIVE AXLE 3. DRAIN PLUG
move drain plug located in the bottom of the dif- 2. CHECK/FILL PLUG
ferential and drain oil from the differential com-
pletely. Install drain plug. Figure 98. Drive Axle Fluid Fill
105
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1150
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000-
hour, and 2000-hour checks prior to performing the
CAUTION
procedures in this section. Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
HYDRAULIC OIL, REPLACE ter dealer.
2. Fill hydraulic tank with oil specified in the Main-

WARNING tenance Schedule.
At operating temperature the hydraulic oil is
HOT. DO NOT permit the hot oil to touch the 3. When oil level is correct, operate system and
skin and cause a burn. check for leaks.
COOLING SYSTEM
CAUTION
DO NOT permit dirt to enter the hydraulic sys- 1. Put lift truck on a level surface. Stop engine.
tem when the oil level is checked or the filter Place a container with a minimum capacity of
is changed. Dirt can cause damage to the com- 30.1 liter (32 qt) under the radiator drain valve
ponents of the hydraulic system. which could be located on either the lower left or
right side of the radiator on the engine side of the
Never operate the hydraulic pump without oil radiator.
hydraulic pump without oil will damage the
WARNING
pump.
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
CAUTION ator cap is removed, the pressure is released
Disposal of lubricants and fluids must meet lo- from the system. If the system is hot, the steam
cal environmental regulations. and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the en-
NOTE: Heavy-duty or contaminated applications will gine is running.
require hydraulic oil change at 2000 hours.
NOTE: Replace the hydraulic oil filter at the same CAUTION

time the oil is changed. Disposal of lubricants and fluids must meet lo-
1. Replace hydraulic oil as described below:
2. Open drain valve and remove radiator cap. Drain
a. Place a container with a minimum capacity coolant into the container. Flush cooling sys-
of 30.1 liter (32 qt) under the drain plug at tem. Check hoses for damage. Replace with new
the bottom of the hydraulic tank. To drain hoses, as needed.
the oil, remove drain plug from the bottom of
the hydraulic tank. See Figure 99. 3. Disconnect the hose leading from the auxiliary
reservoir to fitting at the top of the radiator un-
b. When tank is empty, inspect the inside of the der the radiator cap, and drain the reservoir into
tank for any foreign matter or possible fun- the same container used for the radiator coolant.
gus. If necessary, clean the inside of the tank Check the reservoir for contaminants and flush,
in accordance with the instructions found in as necessary. Connect the hose back on the fit-
section Frame 100 SRM 1120. ting at the top of the radiator.
c. When either the inspection or the cleaning
of the tank is completed, install drain plug
in the bottom of the hydraulic tank. Tighten
drain plug to 38 N•m (28 lbf ft).
106
8000 SRM 1150 Maintenance Procedures Every 4000 Hours or 2 Years
the auxiliary reservoir to a level between the

CAUTION ADD and FULL marks on the reservoir.
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster 5. Install radiator cap. Start engine. Check for
dealer. leaks. Add coolant to auxiliary coolant reservoir
as needed. Coolant level should be between the
4. Close drain valve. Fill cooling system, use Ethy- ADD and FULL marks on the reservoir.
lene Glycol Boron-free Antifreeze. Purchase a
pre-diluted 50/50 solution; or mix 50% concen-
trate with 50% distilled or deionized water. Fill
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 99. Hydraulic Oil Change
107
Safety Procedures When Working Near Mast 8000 SRM 1150
Safety Procedures When Working Near Mast

The following 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 100.
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 lowing 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.
108
8000 SRM 1150 Safety Procedures When Working Near Mast
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
Figure 100. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
109

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PERIODIC

PART NO. 1580525 8000 SRM 1150

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2013 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

S40-70FT, S55FTS [F187];

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

Never lift and move a disabled lift truck unless

1. The towed lift truck must have an operator.

2. Tow truck slowly.

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

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

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

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

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

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 17. Tire Check

1. Inspect welds on mast and carriage for cracks.

2. Inspect channels for wear in areas where the

3. Inspect load backrest extension for cracks and

4. If lift truck is equipped with an integral sideshift

5. Visually inspect hoses/fittings for hydraulic

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

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

NOTE: It is important to adjust the weight setting for

NOTE: OPTIONAL SWIVEL SEAT SHOWN.

Figure 20. Seat Adjustment

Hood and Seat Latches

Engine Compartment CAUTION

Fuel, Oil, and Coolant Leaks, Check

Make a visual check for leaks on and under the lift

See Figure 22 for lift trucks equipped with a Yanmar

See Figure 23 for lift trucks equipped with GM en-

See Figure 24 for lift trucks equipped with a Mazda

See Figure 25 for lift trucks equipped with a Mazda

There is an indicator light for the engine oil pressure

Figure 22. Yanmar 2.6L and 3.3L Diesel Engine

Figure 23. GM Engine Maintenance Points

Legend for Figure 23

Legend for Figure 24

Legend for Figure 25

Air Filter NOTE: If lift truck is equipped with a fork positioner

The identification of a fork describes how the fork is

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

1. OUTER FORK CARRIER 5. FORK POSITIONER