MANUAL DE MANTENIMIENTO - Hyster-110FT-S80 PDF

PERIODIC
MAINTENANCE
S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS [G004];
H80, 90, 100, 110, 120FT [N005, P005]
PART NO. 1624742 8000 SRM 1248

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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................................................................................................................... 1
How to Tow Lift Truck ................................................................................................................................ 1
How to Put Lift Truck on Blocks .................................................................................................................... 3
How to Raise Drive Tires ............................................................................................................................ 3
How to Raise Steering Tires ....................................................................................................................... 3
How to Clean a Lift Truck............................................................................................................................... 4
Maintenance Schedule....................................................................................................................................... 11
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 21
How to Make Checks With Engine Stopped................................................................................................. 21
Tires and Wheels ....................................................................................................................................... 21
Safety Labels ............................................................................................................................................. 22
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 22
Operator Restraint System....................................................................................................................... 23
Emergency Locking Retractor (ELR) ................................................................................................... 23
Adjust Seat - Full Suspension .............................................................................................................. 24
Adjust Seat - Internal Suspension ....................................................................................................... 25
Hood and Seat Latches ............................................................................................................................. 26
Engine Compartment................................................................................................................................ 26
Paper Application ...................................................................................................................................... 26
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................ 27
Hydraulic Hoses ........................................................................................................................................ 27
Coolant Hoses ............................................................................................................................................ 27
Steering Column Gas Cylinder................................................................................................................. 27
Transmission ............................................................................................................................................. 28
Hydraulic System Oil ................................................................................................................................ 28
Engine Oil .................................................................................................................................................. 28
Air Filter .................................................................................................................................................... 32
Forks .......................................................................................................................................................... 32
Remove .................................................................................................................................................. 32
Inspect ................................................................................................................................................... 33
Install..................................................................................................................................................... 33
Adjust..................................................................................................................................................... 34
Integral Sideshift Carriage....................................................................................................................... 34
How to Make Checks With Engine Running................................................................................................ 35
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 35
Service Brakes ........................................................................................................................................... 37
Brake Oil Level ..................................................................................................................................... 37
Operation, Check .................................................................................................................................. 38
Parking Brake ........................................................................................................................................... 38
Engine Oil Pressure .................................................................................................................................. 38
Cooling System .......................................................................................................................................... 39
Steering System ........................................................................................................................................ 39
Control Levers and Pedals ........................................................................................................................ 40
Lift System, Operate ................................................................................................................................. 40
First Service After First 100 Hours of Operation ............................................................................................ 41
GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 41
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. 41
Maintenance Procedures Every 250 Hours or 6 Months ................................................................................. 42
GM 4.3L Engine Oil and Oil Filter ............................................................................................................... 42
©2011 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Drive Belt ....................................................................................................................................................... 42
GM 4.3L Engine ........................................................................................................................................ 42
Fan and Alternator Drive Belt ............................................................................................................. 42
Drain Tar From LPG Regulator.................................................................................................................... 43
Drain Tar From LPG Converter ................................................................................................................... 43
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 44
Hydraulic System Oil .................................................................................................................................... 44
Hydraulic Tank Breather .............................................................................................................................. 44
Inspect........................................................................................................................................................ 44
Battery ........................................................................................................................................................... 45
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter............................................................................. 45
Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ................................... 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) .................................................................... 48
Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ............................................................. 49
Controlled Venting .................................................................................................................................... 49
Manual Bleeding ....................................................................................................................................... 49
Drive Belt ....................................................................................................................................................... 50
Cummins 4.5L and QSB 3.3L Diesel Engine........................................................................................... 50
Fan and Alternator Drive Belt ............................................................................................................. 50
Clean Debris From Radiator Core ................................................................................................................ 51
Transmission Oil Level ................................................................................................................................. 51
Wet Brake Center Body Oil Level Check ..................................................................................................... 52
Forks............................................................................................................................................................... 54
Mast Lubrication ........................................................................................................................................... 54
Header Hose Checks...................................................................................................................................... 56
Lift Chain Lubrication .................................................................................................................................. 57
Tilt Cylinder Lubrication .............................................................................................................................. 57
Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 58
Manual Hydraulic Levers Lubrication ......................................................................................................... 58
Brake Oil ........................................................................................................................................................ 59
Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004)........................................................................................................................................ 59
Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005) ................................. 60
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ 60
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 61
Valve Clearance, Check and Adjust.............................................................................................................. 61
Ignition System.............................................................................................................................................. 61
GM 4.3L Engine ........................................................................................................................................ 61
LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... 61
Remove....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... 62
Remove....................................................................................................................................................... 62
Install ......................................................................................................................................................... 62
Lift Chains Wear Check ................................................................................................................................ 64
Lift Chain Lubrication .................................................................................................................................. 64
Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... 64
Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) ...................................................................................................................... 65
ii
Periodic Maintenance Table of Contents

Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90, 100, 110, 120FT (N005, P005)............ 65
Control Levers and Pedals ............................................................................................................................ 66
Inspect Engine Electrical System, Connectors ............................................................................................ 66
Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 66
Hydraulic System .......................................................................................................................................... 66
Hydraulic Filter, Replace .......................................................................................................................... 66
Hydraulic Tank Breather, Replace ........................................................................................................... 67
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires ................................................................ 67
Cooling System, GM 4.3L and Cummins 4.5L and QSB 3.3L Engines ...................................................... 68
Air Filter ........................................................................................................................................................ 68
Oxygen Sensor GM 4.3L LPG Engines Equipped with GFI Installed........................................................ 70
LPG Regulator Fuel Filter, GM 4.3L Engines Equipped With GFI Installed............................................ 71
Remove....................................................................................................................................................... 71
Install ......................................................................................................................................................... 71
Gasoline Fuel Filter....................................................................................................................................... 71
Remove and Replace ................................................................................................................................. 71
LPG Fuel Injector, GM 4.3L Engines Equipped With GFI Installed.......................................................... 72
Gasoline Fuel Injector, GM Engines ............................................................................................................. 72
Fuel Injector, Cummins 4.5L and QSB 3.3L Engine ................................................................................... 72
Forks............................................................................................................................................................... 72
Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 72
Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... 73
Wet Brake Center Section Oil Change ......................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Brake Oil (Master Cylinder), Change........................................................................................................... 76
Brake Oil (Dry Brake), Remove .................................................................................................................... 77
Service Brakes (Dry Brake) .......................................................................................................................... 78
Differential (Dry Brake) ................................................................................................................................ 78
Test LPG/GAS Regulator Pressure............................................................................................................... 79
Check Throttle Shaft for Sticking................................................................................................................. 79
Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... 79
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. 79
Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 81
Hydraulic Oil, Replace .................................................................................................................................. 81
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... 82
Weld Inspection.............................................................................................................................................. 84
Safety Procedures When Working Near Mast.................................................................................................. 87
Fuel Filter Water Removal ................................................................................................................................ 89
Hood Latch Check .............................................................................................................................................. 90
Lift Chain Adjustments ..................................................................................................................................... 91
Jump-Starting the Lift Truck............................................................................................................................ 92
Jump-Starting Using a Battery Charger ..................................................................................................... 92
Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... 92
Welding Repairs ................................................................................................................................................. 93
Overhead Guard Changes ................................................................................................................................. 93
Wheel and Tire Replacement ............................................................................................................................ 94
General ........................................................................................................................................................... 94
Solid Rubber Tire, Change (S Series) ........................................................................................................... 94
Remove and Install Tire on Wheel ........................................................................................................... 94
Pneumatic Tire With Tube, Repair............................................................................................................... 95
iii
Table of Contents Periodic Maintenance

Remove Wheels From Lift Truck.............................................................................................................. 95
Remove Tire From Wheel ......................................................................................................................... 96
Remove Tire From Two-Piece Wheel ................................................................................................... 96
Remove Tire From Three- and Four-Piece Wheels ............................................................................. 97
Install Wheel in Tire ................................................................................................................................. 98
Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. 99
Install Tire on Two-Piece Wheel ........................................................................................................ 100
Install Two-Piece Wheel in Tire ......................................................................................................... 100
Add Air to Pneumatic Tires With Tube...................................................................................................... 101
Install the Wheels ................................................................................................................................... 101
Dual Drive Wheels, Install ..................................................................................................................... 102
Pneumatic Tubeless Tire, Repair................................................................................................................ 103
Remove Wheels From Lift Truck............................................................................................................ 103
Remove Tire From Wheel ....................................................................................................................... 103
Install Tire on Wheel .............................................................................................................................. 105
Add Air to Pneumatic Tubeless Tire ...................................................................................................... 107
Wheels, Install......................................................................................................................................... 108
Solid Rubber Tires on Pneumatic Wheels, Change ................................................................................... 108
Remove Wheel From Tire ....................................................................................................................... 108
Install Tire on Wheel .............................................................................................................................. 110
Adhesives and Sealants ................................................................................................................................... 112
This section is for the following models:
S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS [G004];

H80, 90, 100, 110, 120FT [N005, P005]
iv
8000 SRM 1248 General
General
shown in the Maintenance Schedule. Service Man-
WARNING uals are available from your dealer for Hyster lift
DO NOT make repairs or adjustments unless trucks to help users who do their own maintenance.
you have both authorization and training. Re-
pairs and adjustments that are not correct can SERIAL NUMBER DATA
make a dangerous operating condition.
The serial number for the lift truck is on the name-
plate. It is also on the right side of the frame, under
WARNING the floor plate.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If re- HOW TO MOVE DISABLED LIFT TRUCK
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from How to Tow Lift Truck
the key switch.
WARNING
CAUTION Use extra caution when towing a lift truck if
Disposal of lubricants and fluids must meet lo- any of the following conditions exist:
cal environmental regulations. • Brakes do not operate correctly.
• Steering does not operate correctly.
This section contains a Maintenance Schedule and • Tires are damaged.
the instructions for maintenance and inspection. • Traction conditions are bad.
• The lift truck must be towed on a slope.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift If the engine cannot run, there is no power
truck. The service intervals are given in both oper- available for the hydraulic steering system
ating hours recorded on the lift truck hourmeter and and the service brakes. This condition can
in calendar time. The recommendation is to use the make the lift truck difficult to steer and stop.
interval that comes first. If the lift truck uses power from the engine to
help apply the brakes, the application of the
The recommendations for the time intervals given for
brakes will be more difficult. Poor traction can
eight hours of operation per day. The time intervals
cause the disabled lift truck or towing vehicle
must be decreased from the recommendations in the
to slide. A slope will also make the lift truck
Maintenance Schedule for the following conditions:
more difficult to stop.
• The lift truck is used more than eight hours per
day. Never lift and move a disabled lift truck unless
• The lift truck must work in dirty operating condi- the disabled lift truck MUST be moved and
tions. cannot be towed. A lift truck used to move
• Poor ground conditions. a disabled lift truck MUST have a capacity
• Intensive usage at high performance levels or rating equal to or greater than the weight of
other abnormal conditions will require more fre- the disabled lift truck. The capacity of the lift
quent servicing. truck used to move a disabled lift truck must
have a load center equal to half the width of
Your dealer for Hyster lift trucks has the equipment
the disabled lift truck. See the nameplate of
and trained service personnel to do a complete pro-
the disabled lift truck for the approximate
gram of inspection, lubrication, and maintenance. A
total weight. The forks must extend the full
regular program of inspection, lubrication, and main-
width of the disabled lift truck. Put the weight
tenance will help your lift truck provide more effi-
center of the disabled lift truck on load center
cient performance and operate for a longer period of
of the forks. Be careful to not damage the
time.
underside of the lift truck.
Some users have service personnel and equipment
1. The towed lift truck must have an operator.
to do the inspection, lubrication, and maintenance
2. Tow truck slowly.
1
General 8000 SRM 1248
3. Using a lift truck or a lifting device that could towing link made of steel that fastens to the tow
be attached to the mast (I.E. come-a-long), raise pins in the counterweights of both lift trucks. See
carriage and forks approximately 30 cm (12 in.) Figure 1. Slowly and carefully remove the slack
from surface. Install chain around a mast cross- out of the towing link.
member and the carriage to prevent carriage and
mast channels from moving. 6. If lift trucks are equipped with a leaded counter-
weight without a tow pin (see Figure 1), use a
4. If another lift truck is used to tow the disabled lift towing link made of steel that fastens to the two
truck, that lift truck must have an equal or larger center grill bars of both lift trucks. Slowly and
capacity than the disabled lift truck. Install ap- carefully remove the slack out of the towing link.
proximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck. Lift truck models that are equipped with a leaded
This 1/2 capacity load will increase traction of lift counterweight, that are covered in this SRM are
truck. Keep load as low as possible. S80FTBCS, S100FTBCS, S120FTS, and S120FT-
PRS (G004).
5. If lift trucks are equipped with a tow pin in the
counterweight (standard counterweight), use a
A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)

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

ing tires to prevent movement of lift truck. See
Figure 2.
3
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
6. Avoid spraying in areas containing electrical 8. DO NOT pressure wash the battery. Do not use
components such as: hot water. For cleaning traction batteries, refer
• Floor Plates to the Battery section of the Service Manual.
• Battery Compartment
• Dash/cowl assembly 9. DO NOT pressure wash lift chains, sheaves or
• Armrests with electrical components load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
7. Clean the battery compartment by using a clean section in the Service Manual for proper clean-
cloth to wash the battery with water. Dry with ing procedures.
compressed air. Care should be taken to keep
moisture at a minimum as some units have a 10. After cleaning, immediately start and run the lift
traction or hydraulic motor directly below the truck to dry out components.
battery compartment.
5
Figure 3. GM 4.3L LPG Trucks With GFI Installed
6
Figure 4. GM 4.3L LPG Trucks With PSI Installed
7
Figure 5. GM 4.3 Gasoline Trucks
8
Figure 6. Cummins 4.5L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (N005)
9
Figure 7. Cummins QSB 3.3L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (P005)
10
8000 SRM 1248 Maintenance Schedule
Maintenance Schedule
NOTE: The lift trucks shown in Figure 3, Figure 4, NOTE: The 250-hour, 500-hour, and 1000-hour/6-
and Figure 5 represent SSE 100, 120FT; S80, 100FT- month maintenance services are performed either at
BCS; S120FTS, and S120FTPRS (G004) lift trucks. the specified hours or at 6 months whichever occurs
first.
NOTE: The lift trucks shown in Figure 3, Figure 4,
Figure 5, Figure 6, and Figure 7 represent H80, 90,
100, 110, 120FT (N005, P005) lift trucks.
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
25 Tires and Wheels X Check See Nameplate
Condition
Safety Labels X Replace as See Parts Manual

Necessary
28, Mast, Carriage, X Check See Parts Manual
29 Header Hoses, Condition and
Lift Chains, Lubrication
Attachment
Seat Belt, Hip X Check
Restraints, and Condition and
Seat Rails Operation
Hood and Seat X Check
Latches Condition and
Operation
Engine X Remove
Compartment Combustible
Materials
See NOTE 5.
Paper Application: X Check
Engine Condition
Compartment, Clean as
Truck Components, Required
Exhaust Wraps, Replace as
Radiator, Radiator Required
Screen if equipped, See NOTE 8.
Belly Pan if
equipped
Check for Leaks - X Check
Fuel, Oil, Water for Leaks
See NOTE 1.
Hydraulic Hoses X Check See Parts Manual
Condition
13 Coolant Hoses X Check See Parts Manual
Condition
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
11
Maintenance Schedule 8000 SRM 1248
Table 1. Maintenance Schedule (Continued)
16 Fuel Tank (LPG) CIL 15.1 - 20.4 kg LPG - HD 5, HD 10
(33.5 - 45.0 lb)
Full
16 Fuel Tank CIL 44.7 liter 86 Octane - Gasoline
GM 4.3L (11.8 gal) Minimum
(Gasoline)
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
U.S. Only
16 Fuel Tank (Short CIL 79 liter 86 Octane Minimum
Wheel Base) (20.8 gal)
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005, P005)
U.S. Only
16 Fuel Tank (Long CIL 100.3 liter 86 Octane Minimum
GM 4.3L
(Gasoline)
H80, 90, 100, 110,
120FT (N005, P005)
U.S. Only
16 Fuel Tank (Short CIL 79 liter Diesel No. 2
Cummins 4.5L and
QSB 3.3L (Diesel)
H80, 90, 100, 110,
120FT (N005, P005)
16 Fuel Tank (Long CIL 100.3 liter Diesel No. 2
Cummins 4.5L and
QSB 3.3L (Diesel)
H80, 90, 100, 110,
120FT (N005, P005)
Horn, Lights, X Check
Alarms, Fuses, Operation
and Relays
1 Service Brakes X Check
Operation
23 Parking Brake X Check
Operation
12
Steering Controls X Check
and Steering Condition and
Column Gas Operation
Cylinder
22 Transmission X Check for John Deere
Leaks JDM J20C
22 Transmission X Check
Operation
3 Hydraulic Oil X X C 39.4 liter ISO VG 46
GM 4.3L [S80, (41.6 qt) Hydraulic Oil
100, 120FT]; See NOTE 2 15°C (5°F) and
S80, 100FTBCS, and NOTE 3. Above
S120FTS;
S120FTPRS (G004)
(Short Wheel Base) (65.5 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 15°C (5°F) and
120FT (N005, P005) and NOTE 3 Above
(Long Wheel Base) (82.4 qt) Hydraulic Oil
H80, 90, 100, 110, See NOTE 2 15°C (5°F) and
120FT (N005, P005) and NOTE 3 Above
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
10 Hydraulic Tank X C Inspect and See Parts Manual

Breather Replace as
Required
See NOTE 5.
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 4.7 liter (5.0 qt) 7°C (20°F)
GM 4.3L Engine CIL See NOTE 4 and Below
(Gasoline/LPG) and 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
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L Engine See NOTE 4
and NOTE 5.
13
9 Engine Oil X C 13.0 liter 0°C (32°F)
Cummins 4.5L CIL (13.7 qt) and Below
Engine (Diesel) See NOTE 4 SAE 0W-30
and NOTE 5. 25 to 20°C
( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
15°C (5°F)
and Above
SAE 5W-40
or 15W-40
API CH-4 or CI-4
9 Engine Oil X C 7.5 liter (8 qt) 0°C (32°F)
Cummins CIL See NOTE 4 and Below
QSB 3.3L and NOTE 5. SAE 0W-30
Engine (Diesel) 25 to 20°C
( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
15°C (5°F)
and Above
SAE 5W-40
or 15W-40
API CH-4 or CI-4
19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins 4.5L See NOTE 4
and QSB 3.3L and NOTE 5.
(Diesel)
18 Air Filter CIL C 1 Filter See Parts Manual
(with premium See NOTE 5,
monitoring) NOTE 6, and
NOTE 12.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
14
Engine Oil CIL Check Oil GM Engine
Pressure Pressure 207 to 380 kPa
(30 to 55 psi)
Cummins 4.5L
Diesel Engine
at High Idle
207 kPa (30 psi)
at Low Idle
69 kPa (10 psi)
Cummins QSB
3.3L Diesel Engine
49 kPa (7 psi)
Minimum
15 Drive Belt X Check for Wear
GM Engine and Damage.
No Adjustment
Needed.
See NOTE 5.
15 Drive Belt X Check for Wear
Cummins 4.5L and Damage.
and QSB 3.3L No Adjustment
(Diesel) Needed.
See NOTE 5.
LPG Regulator X Drain Tar
GM 4.3L Engine See NOTE 5.
With GFI Installed
33 LPG Converter X Drain Tar
4.3L LPG Engine See NOTE 5.
With PSI Installed
Engine Idle Speed X 750 ±25 rpm
GM 4.3L
(Gasoline/LPG)
Engine Governed X 2400 ±25 rpm
Speed
GM 4.3L
(Gasoline/LPG)
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature
Cummins 4.5L Less than
(Diesel) 77°C (170°F)
Hot Engine Temperature
Cummins 4.5L Greater than
(Diesel) 77°C (170°F)
15
Speed (No Load)
Cummins 4.5L
Diesel
PCV Valve X Replace as See Parts Manual
GM 4.3L En- Necessary
gine with GFI In- See NOTE 14
stalled
Cold Engine Temperature
Cummins QSB Less than 30°C
3.3L (Diesel) (86°F)
Hot Engine Temperature
Cummins QSB Greater than
3.3L (Diesel) 30°C (86°F)
Speed
Cummins QSB
3.3L (Diesel)
Oxygen Sensor X Replace as
GM 4.3L Engine CIL Necessary
With GFI Installed
4 Valve Adjustment Not Adjustable
GM 4.3L Engine
4 Valve Adjustment X Adjust as Intake
Cummins 4.5L Required 0.254 mm (0.010 in.)
Diesel Engines Cold
Exhaust
0.508 mm (0.020 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Cummins QSB Required 0.35 mm (0.014 in.)
3.3L Diesel See NOTE 13. Cold
Engines Exhaust
0.50 mm (0.02 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
17 Fuel Filter C 1 Filter See Parts Manual
Gasoline (GM)
17 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain Water
Cummins 4.5L from Filter as
and QSB 3.3L Required
Diesel Engine
16
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins 4.5L
Diesel Engine
17 Final Fuel Filter C 1 Filter See Parts Manual
Cummins QSB
3.3L Diesel
Engine
20 Fuel Injectors X Check and
GM 4.3L Gas Replace If
Required
6 Injectors
20 Fuel Injectors X Check and
GM 4.3L LPG Replace If
With GFI In- Required
stalled 6 Injectors
5 Spark Plugs C Check See NOTE 9.
GM 4.3L Engine Plug Wires
6 Plugs
12, Cooling System X C 15.1 liter See NOTE 15.
14 GM 4.3L CIL (15.9 qt)
Engine
14 Cummins 4.5L CIL (14.2 qt)
Diesel Engine
14 Cummins QSB CIL (11 qt)
3.3L Diesel
Engine
Clean Debris From X See NOTE 5.
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brake JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check
Condition
26 Fork Latches L Lubricate as Multipurpose
Necessary Grease
See NOTE 7.
Lift System, X Check
Operate Operation
17
27 Mast L Lubricate Multipurpose
Sliding Surfaces as Required Grease
and Load Roller See NOTE 10 See NOTE 7.
Surfaces and NOTE 11.
27 Header Hoses X Check
Condition
28 Lift Chains X Check SAE 30W
Lubrication. Engine Oil
See NOTE 11.
28 Lift Chains L L, X Check for Wear. SAE 30W
Lube as Engine Oil
Required.
Mast L 2 Fittings Multipurpose
Pivots Grease
See NOTE 7.
Mast X L X Lube as Multipurpose
Integral Required. Grease
Sideshift 8 Fittings See NOTE 7
Carriage 4 Bearing
Sliding Surfaces Strips
Tilt Cylinder Ends L 4 Fittings Multipurpose

Grease
See NOTE 7
Brake Master L SAE 10W-30
Cylinder Rod End API SM
Pin ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
24 Brake Oil CIL X C 0.35 liter Dexron III from
(Master Cylinder) (0.74 pt) Sealed Container
11 Steering Axle L 4 Fittings Multipurpose
Spindle Bear- Grease
ings See NOTE 7.
Tie Rods Grease
[S80, 100, See NOTE 7.
120FT;] S80,
100FTBCS;
S120FTS;
S120FTPRS
(G004)
18
Tie Rods Grease
H80, 90, 100, See NOTE 7.
110, 120FT
(N005, P005)
2 Pedals, Levers, L Lubricate as Use Silicone Spray
Seat Rails, Cables, Necessary Hyster Part No.
Hinges, Linkages, 328388
Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
(Dry Brake) Thickness Minimum
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Hyster Part
Number 328388)
30 Differential and X C 6.0 liter (6.3 qt) SAE 80W-90 or
Drive Axle Oil 85W-140
(Dry Brake)
7/30 Transmission X C 28.8 liter John Deere
and Wet Brake (30.4 qt) JDM J20C
Planetary Carrier
Housing Oil
S80FT, FTBCS
(G004)
Planetary Carrier
Housing Oil
S100FT, FTBCS
S120FT, FTS,
FTPRS (G004)
Planetary Carrier
Housing Oil
H80, 90, 100, 110,
120FT) (N005,
P005)
30 Wet Brake Center X C 2.0 liter (2.1 qt) SAE 80W/90
Section Oil
[S80, 100, 120FT;]
S80, 100FTBCS;
S120FTS;
S120FTPRS (G004)
30 Wet Brake Center X C 2.0 liter (2.1 qt) SAE 80W-90
Section Oil
H80, 90, 100, 110,
120FT (N005, P005)
19
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel
Lines, and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure
Lock-Off Closing
Test LPG/GAS X
Regulator Pressure
Check X
Air Induction
System for Leaks
Check X
Manifold for
Vacuum Leaks
Check X
Throttle Shaft for
Sticking
Check X
Injectors and Rails
for leaks
Inspect X
Exhaust Manifolds
and Piping for
Leaks
Inspect X
Catalyst Inlet
and Outlet
31 Ignition System C Replace
Distributor, Rotor,
and Spark Plug
Wires
Inspect Muffler X Replace as
Inlet and Outlet Required
Mast and Carriage X Inspect Dye Penetrant
with Paper Roll See NOTE 16
Clamp
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
20
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours
of operation - see 2000 Hr/1 Yr service procedures.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications in-
volving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based on
an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should
be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and
steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000 SRM 1249 for spark plug gap and type of spark plugs to use.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate at first sign of visible surface rust.
NOTE 12: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every
2000 Hours or Annually to change air filter element.
NOTE 13: Initial valve adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at 2000-
hour/2-year intervals, whichever comes first.
NOTE 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled or deionized water.
NOTE 16: Inspect after an impact likely to cause damage. In large diameter paper-roll production applications, inspect at
first 4000 hours with subsequent inspection at 2000 hour intervals. At your request, your Hyster dealer will advise you
of the appropriate service intervals based on an application survey.
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE conditions that are not normal. Clean any oil or fuel
STOPPED spills. Ensure all surfaces are free of oils, lubricants,
fuel, and organic dust or fibers (paper, wood, cotton,
agricultural grass/grain, etc.).
WARNING
DO NOT operate a lift truck that needs repairs. Tires and Wheels
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE Check the tires for damage. See Figure 8. Check the
tag in the operator’s area. If the lift truck is tread and remove any objects that will cause damage.
equipped with a key switch, remove the key Check for bent or damaged rims. Check for loose or
from the key switch. missing hardware. Remove any wire, strapping, or
other material that is wrapped around the axle.
Put the lift truck on a level surface. Lower the car-
riage and forks, stop the engine, and apply the park-
ing brake. Open the hood and check for leaks and
21
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 8. Tire Check
Safety Labels 1. Inspect the welds on the mast and carriage for
cracks. Make sure that the capscrews and nuts
are tight.
WARNING
Safety labels are installed on the lift truck to 2. Inspect the channels for wear in the areas where
give information about operation and possible the rollers travel. Inspect the rollers for wear or
hazards. It is important that all safety labels damage.
are installed on the lift truck and can be read.
3. Inspect the load backrest extension for cracks
Check that all safety labels are installed in the cor- and damage.
rect location on the lift truck. See the Parts Man-
ual, Model Description section in the Operating 4. If the lift truck is equipped with an integral
Manual or the section Frame 100 SRM 1243 for the sideshift carriage or attachment, inspect the
correct location of the safety labels. See the Parts parts for cracks and wear. Make sure the parts
Manual for the part numbers of the safety labels. that fasten the integral sideshift carriage or
attachment to the carriage are in good condition.
Mast, Carriage, Lift Chains, Header Hoses,
5. Visually inspect hoses/fittings for hydraulic
Attachment leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
WARNING or sheaves; proper tracking during operation.
Lower the lift mechanism completely. Never Adjust/repair/replace hose/components as neces-
allow any person under a raised carriage. DO sary. See Mast Repairs, 2- and 3-Stage Masts
NOT put any part of your body in or through 4000 SRM 1250 for quick disconnect procedures.
the lift mechanism unless all parts of the mast
are completely lowered and the engine is 6. Check that the lift chains are correctly lubri-
STOPPED. DO NOT try to correct the align- cated. Use SAE 30 engine oil as necessary to
ment of the fork tips by bending the forks or lubricate the lift chains.
adding shims. Never repair damaged forks by
7. Inspect the lift chains for cracks or broken links,
heating or welding. Forks are made of special
and worn or turned pins. See Figure 9.
steel using special procedures. If either fork is
damaged, replace the forks as a set. 8. Inspect the chain anchors and pins for cracks and
damage.
22
9. Make sure the lift chains are adjusted so that The seat belt must be in good condition. Replace the
they have equal tension. Adjustments or re- seat belt if damage or wear is seen. See Figure 10.
placement of the lift chains must be done
by authorized personnel. NOTE: The following seat belt operation checks must
be performed three times before replacing the seat
belt assembly.
• With the hood closed and in the locked position,

pull the seat belt slowly from the retractor assem-
bly. Make sure the seat belt pulls out and retracts
smoothly. If the seat belt cannot be pulled from the
retractor assembly or the belt will not retract, re-
place the seat belt assembly.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
when it is pulled with a sudden jerk, replace the
seat belt assembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
with the hood in the open position, replace the seat
belt assembly.
1. WORN PIN 5. LOOSE LEAVES
2. CRACKS 6. TURNED PIN
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
Figure 9. Lift Chain Check
Operator Restraint System

The seat belt, hip restraint, seat, hood, and hood
latch are all part of the operator restraint system.
See Figure 10. Each item must be checked to make
sure it is fastened correctly, functions correctly, and
is in good condition.
Emergency Locking Retractor (ELR)
NOTE: Lift trucks produced after November 2005

are equipped with the Emergency Locking Retractor
(ELR) style seat belt.
When the ELR style seat belt is properly buckled 1. LATCH STRIKER
across the operator, the belt will permit slight op- 2. HOOD LATCH
erator repositioning without activating the locking 3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD
mechanism. If the truck tips, travels off a dock, or 5. OPERATOR WEIGHT ADJUSTMENT
comes to a sudden stop, the locking mechanism will 6. SEAT RAIL
be activated and hold the operator’s lower torso in 7. ARM REST
the seat. 8. SEAT BELT
9. SEAT
A seat belt that is damaged worn or does not operate 10. HIP RESTRAINT
11. HOOD HINGE
properly will not give protection when it is needed.
The end of the belt must fasten correctly in the latch. Figure 10. Hood and Seat Check
23
to the ground so that the best ergonomic position

is achieved, See Figure 10.
Seat Position Adjustment (Swivel Seat)

• The seat swivels 12 degrees to the right to allow the
operator a more ergonomic position when driving
in reverse.
• The seat swivels 5 degrees to the left to allow as
easier exit of the truck.
• The neutral position is shown in Figure 12.
Seat Adjustment for Operator Weight
CAUTION
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: SWIVEL SEAT IS AN OPTIONAL FEATURE NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT • The target is for the "ride indicator" to fall between
4. SEAT POSITION ADJUSTMENT (SEAT RAIL) the arrows when the operator sits upright in the
5. SEAT BELT seat with the feet positioned on the pedals. This
ensures that the operator is set at the midpoint of
Figure 11. Swivel Seat Controls the 80mm suspension.
• The handle can be turned as shown to increase or
Adjust Seat - Full Suspension
decrease the weight resistance, pull handle out be-
Seat Position Adjustment (Standard Seat) fore turning. As the handle is turned the "stiffness"
• Fore and aft adjustment - It is recommended that of the suspension can be felt to increase or decrease
the seat be adjusted so that the thigh is horizontal on which way the handle is turned.
24
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 12. Seat Adjustment
Adjust Seat - Internal Suspension NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
Seat Position Adjustment (Swivel Seat)
• The seat swivels 10.5 degrees to the right to allow • The target is for the "ride indicator" to fall between
the operator a more ergonomic position when driv- the arrows when the operator sits upright in the
ing in reverse. seat with the feet positioned on the pedals. This
• The seat swivels 5 degrees to the left to allow as ensures that the operator is set at the midpoint of
easier exit of the truck. the 40 mm (1.57 in.) suspension.
• The neutral position is shown in Figure 13. • The weight adjustment knob can be turned left or
right to increase or decrease the weight resistance.
Seat Adjustment for Operator Weight As the weight adjustment knob is turned the "stiff-
ness" of the suspension can be felt to increase or de-
CAUTION crease on which way the weight adjustment knob
A major cause for high Whole Body Vibration is is turned.
caused by the operator not adjusting the seat to
his/her weight.
NOTE: It is important to adjust the weight setting for

each operator.
25
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 13. Seat Adjustment
Hood and Seat Latches WARNING

Make sure the seat rails and latch striker are not Engine and exhaust system components are
loose. The seat rails must lock tightly in position, hot to touch. Be sure lift truck components are
but move freely when unlocked. See Figure 10 and cool before starting inspection and cleaning or
Figure 11. The seat rails must be correctly fastened personal injury may occur.
to the hood and the hood fastened to the hinges on
Ensure the truck engine cools properly by allowing
the frame. Try to lift the hood to make sure it is
it to idle for several minutes. Shutting the truck
fastened correctly and will not move. If adjustment
down while hot will not allow the engine to cool
is required, go to Hood Latch Check.
quickly due to the loss of coolant circulation. The
heat trapped under the hood may actually increase
Engine Compartment
the engine temperature because of no heat transfer
Check for the presence of any combustible material through the radiator. With engine off and lift truck
such as paper, leaves, etc. Remove any combustible components cooled, check and clean the radiator and
materials. if equipped, radiator screen. Check engine manifold,
exhaust pipes, muffler and catalytic converter for
Paper Application paper scraps. Clean as required. Check and clean
the engine compartment components, transmission,
Vehicles used in paper applications require regular fan shroud, belly pan if equipped, and inside frame
inspection and cleaning to minimize the risk of fire. ledges to avoid paper, dust and oil accumulation.
This should be done at least once every 8 hours Check axle and cowl openings for paper buildup and
or more frequently depending upon operating en- bailing wire. Remove any debris.
vironment. The paper application option will help
limit the contact of paper or tissue scraps to hot
surfaces under the hood, but frequent maintenance
is required.
26
Fuel, Oil, and Coolant Leaks, Check

WARNING
cause injury to the user or to other personnel.
WARNING
Make sure that the path of the compressed air All fuels are very flammable and can burn or
is away from all personnel. Wear protective cause an explosion. DO NOT use an open flame
goggles or a face shield to prevent injury to the to check the fuel level or to check for leaks in
eyes. 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-
CAUTION paired.
Air pressure, nozzle or extension tube may
cause damage to exhaust wraps and radiator Make a visual check for leaks on and under the lift
fins. Assure that air pressure, nozzle or exten- truck. If possible, find and report the leak to main-
sion tube does not damage exhaust wraps or tenance for repair. Leaks often indicate a need for
radiator fins. repair of damaged or worn components. Leaks in the
LPG fuel system are usually not visible unless ice
Paper removal can generally be accomplished using a is present. There is however, usually a strong odor.
compressed air line and nozzle. An extension may be Fuel leaks MUST be repaired IMMEDIATELY.
helpful to access hard to reach places. Remove floor
plates and side covers for better access to engine com- Check the fuel system for leaks and the condition of
partment. Open or removed belly pan, if equipped. parts. When fuel is added to the lift truck, see the
Clean components with compressed air. Take care section HOW TO ADD FUEL TO THE LIFT TRUCK
to maintain the integrity of the exhaust wraps when in the Operating Manual.
cleaning with compressed air and use caution to not
force debris into openings. Check the condition of ex- Also check the condition of the radiator or heater
haust wraps for wear, proper fit, contamination with hoses that are not leaking. Soft or cracked hoses need
oil or antifreeze, gaps in coverage, failed fasteners to be replaced before a major leak occurs.
and replace as necessary. Do not reuse wraps if they
have been removed for some other service operation.
Hydraulic Hoses
Check the condition of the hydraulic hoses for ser-
WARNING viceability by inspecting for cracks or other obvious
Be careful when cleaning with steam. Steam damage. Check to insure that the hydraulic hoses
can cause serious burns. Wear protective cloth- are not leaking. If any hose is leaking, report it to
ing, gloves, and eye protection. Never expose maintenance for repair.
your skin to steam.
Coolant Hoses
If compressed air did not adequately remove debris,
steam clean to remove any persistent accumulation Check the condition of the coolant hoses for service-
of material or oil. Protect electrical components from ability by inspecting for cracks or other obvious dam-
moisture when steam cleaning. Do not spray exhaust age. Check to insure that the coolant hoses are not
wraps directly with high pressure steam. Allow lift leaking. If any hose is leaking, report it to mainte-
truck to air dry before returning to work in a con- nance for repair.
taminated environment. Paper dust and scraps will
adhere to wet surfaces. Steering Column Gas Cylinder
Check the condition of exhaust wraps for wear, Make sure the gas cylinder for the steering column
proper fit, contamination with oil or antifreeze, gaps operates correctly. The cylinder must NOT allow the
in coverage, failed fasteners and replace as neces- column to move unless the tilt lever is released. See
sary. Do not reuse wraps if they have been removed Figure 14.
for some other service operation.
27
Never operate the hydraulic pump without oil

in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.
After the engine has stopped, wait one minute before

checking the oil level. Keep the hydraulic oil at the
correct level as indicated on the dipstick. Use the
correct oil as shown in the Maintenance Schedule.
Check the hydraulic system for leaks and damaged or

loose components. Heavy-duty or high-temperature
operations can require more frequent checks.
Engine Oil
1. TILT LEVER 2. GAS CYLINDER WARNING

At operating temperature, the engine oil is
Figure 14. Steering Column Gas Cylinder and
HOT. DO NOT permit the hot oil to touch the
Tilt Lever
skin and cause a burn.
Transmission
CAUTION
Check the transmission for leaks and damaged or DO NOT permit dirt to enter the engine when
loose components. Heavy-duty or high temperature the oil level is checked or the filter is changed.
operations can require more frequent checks.
Never operate the engine without oil. The op-
Hydraulic System Oil eration of the engine without oil will damage
the engine.
WARNING After the engine has stopped, wait one minute before
At operating temperature, the hydraulic oil is checking the oil level. See Figure 15, Figure 16, and
HOT. DO NOT permit the hot oil to touch the Figure 17. Keep the oil at the correct level as indi-
skin and cause a burn. cated on the dipstick. Use the correct oil as shown in
the Maintenance Schedule.
CAUTION
DO NOT permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed.
28
Legend for Figure 15

A. TOP VIEW
B. RIGHT HAND SIDE SHOWN
1. BATTERY
2. AUXILIARY COOLANT RESERVOIR
3. RADIATOR CAP
4. WATER SEPARATOR
5. AIR FILTER
6. LIFT PUMP
7. FUEL INJECTION PUMP
8. ENGINE OIL FILL CAP
9. INLINE FUEL FILTER
10. DIPSTICK ENGINE OIL
11. FUEL INJECTOR
12. DRIVE BELT
Figure 15. Cummins 4.5L Diesel Engine

Maintenance Points for Lift Truck Models H80,
90, 100, 110, 120FT (N005)
29
A. RIGHT SIDE FRONT VIEW B. LEFT SIDE FRONT VIEW

1. DIPSTICK 15. ALTERNATOR
2. TURBOCHARGER 16. ALTERNATOR BELT ADJUSTMENT
3. OIL FILL CAP 17. TEMPERATURE SENDING UNIT
4. AIR INLET HOUSING 18. WATER INLET/THERMOSTAT HOUSING
5. FUEL PRIMER PUMP 19. TURBOCHARGER AIR INLET
6. FUEL/WATER SEPARATOR 20. TURBOCHARGER WASTEGATE
7. ECM 21. TURBOCHARGER EXHAUST
8. FUEL FILTER 22. TURBOCHARGER EXHAUST MANIFOLD
9. STARTER 23. OIL FILTER
10. FUEL RAIL 24. TURBOCHARGER OIL DRAIN LINE
11. ELECTRONIC FUEL PUMP 25. TURBOCHARGER OIL FEEL LINE
12. WATER PUMP 26. OIL PAN
13. CRANK POSITIONING SENSOR 27. OIL PAN DRAIN PLUG
14. CAM POSITIONING SENSOR 28. DRIVE BELT
Figure 16. Cummins QSB 3.3L Diesel Engine Maintenance Points for Lift Truck Models
30
A. GAS ENGINE B. LPG ENGINE

1. DIPSTICK ENGINE OIL 7. AIR FILTER
2. BATTERY 8. FUEL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. ENGINE OIL FILTER
4. RADIATOR CAP 10. SPARK PLUGS
5. ENGINE OIL FILL 11. FUEL INJECTOR
6. DRIVE BELT
Figure 17. GM Engine Maintenance Points With GFI Installed
31
1. DIPSTICK ENGINE OIL 7. AIR FILTER

2. BATTERY 8. ENGINE OIL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. SPARK PLUGS
4. RADIATOR CAP 10. ENGINE LABEL
5. ENGINE OIL FILL 11. LPG CONVERTER
6. DRIVE BELT
Figure 18. GM 4.3L Engine Maintenance Points With PSI Installed
Air Filter The identification of a fork describes how the fork is

connected to the carriage. These lift trucks have hook
The air filter canister should not be opened until an forks.
air filter element replacement is required. An air
filter element replacement is required when one of Remove
the following occurs:
• The optional air flow restriction indicator light on WARNING
the dash illuminates
DO NOT try to move a fork without a lifting
• If equipped, the manual air flow indicator is red
device. Each hook fork for these lift trucks can
• The specified number of hours has passed since the
weigh 45 to 115 kg (99 to 253 lb).
last filter element replacement
NOTE: Forks are to be replaced only in sets and not
Do not operate the lift truck until the air filter ele-
individually.
ment has been replaced.
1. A fork can be removed from the carriage for re-
Forks placement of the fork or other maintenance. Lift
the lock pin and slide a hook fork to the fork re-
NOTE: Forks must be removed or installed by trained
moval notch on the carriage. See Figure 19 and
personnel only.
Figure 20. Lower the fork onto blocks so that the
bottom hook of the fork moves through the fork
removal notch. See Figure 20. Lower the car-
riage further so that the top hook of the fork is
32
disengaged from the top carriage bar. Move the

carriage away from the fork, or use a lifting de-
vice to move the fork away from the carriage.
1. CARRIAGE BARS 3. BLOCKS

2. HOOK FORK
Figure 19. Hook Fork Removal
Inspect
1. Inspect the forks for cracks and wear. Check that Fork Tip Alignment
the fork tips are aligned as shown in Figure 20. Length of Forks 3% Dimension
Check that the bottom of the fork is not worn. See
Figure 20, item 4. 915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
2. Replace any damaged or broken parts that are 1220 mm (48 in.) 37 mm (1.46 in.)
used to keep the forks locked in position. 1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
Install 1830 mm (72 in.) 55 mm (2.17 in.)
Move the fork and carriage so that the top hook on
the fork can engage the upper carriage bar. Raise 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
the carriage to move the lower hook through the fork 2. CRACKS
removal notch. Slide the fork on the carriage so that 3. LATCH DAMAGE
both upper and lower hooks engage the carriage. En- 4. HEEL OF FORK (MUST BE 90% OF
gage the lock pin with a notch in the upper carriage DIMENSION X)
bar. 5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 20. Forks Check
33
Adjust Integral Sideshift Carriage

NOTE: During the adjustment of the forks, the heel Check for cracks, wear and damage. If damaged, see
of the forks should not be touching the ground. Mast Repairs, 2- and 3-Stage Masts 4000 SRM
1250 for repair procedures. If necessary, lubricate
The forks are connected to the carriage by hooks and sliding surfaces at grease fittings with multipurpose
lock pins. See Figure 19 and Figure 21. The lock grease shown in the Maintenance Schedule. See Fig-
pins are installed through the top fork hooks and fit ure 22.
into slots in the top carriage bar. If pin does not re-
main engaged in carriage slot, replace with new pin.
Adjust the forks as far apart as possible for maxi-
mum support of the load. Hook forks will slide along
the carriage bars to adjust for the load to be lifted.
Raise the lock pin in each fork to slide the fork on
the carriage bar. Make sure the lock pin is engaged
in the carriage bar to lock the fork in position after
the width adjustment is made.
1. CAPSCREWS
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
1. FORK 5. WEDGE 8. SNAP RING
2. LOCK PIN 6. KNOB 9. ROD SCRAPER
3. SPRING 7. LOCK PIN 10. ROD BUSHINGS
4. WASHER ASSEMBLY 11. SEAL
12. FIXED FRAME
Figure 21. Fork Lock Pin Assembly
Figure 22. Integral Sideshift Carriage
34
HOW TO MAKE CHECKS WITH ENGINE the parking brake and put the transmission in NEU-
RUNNING TRAL. Make the checks carefully.
Indicator Lights, Horn, Fuses, and Relays

WARNING
DO NOT operate a lift truck that needs repairs. If lift truck is equipped with a key switch, turn
Report the need for repair immediately. If re- key to ON position. If lift truck is equipped with a
pair is necessary, put a DO NOT OPERATE tag Power ON/OFF button, press button to turn system
in the operator’s area. If lift truck is equipped power on. All warning light and indicator lights will
with a key switch, remove the key. light up for two seconds (start check) when system
power is turned ON. See Figure 23. Check all in-
WARNING dicator lights for correct operation as described in
the Operating Manual. Check the operation of the
FASTEN YOUR SEAT BELT! The seat belt is in-
horn. Start the engine by turning the key switch to
stalled to help the operator stay on the truck if
the Start position, if truck is equipped with a key
the lift truck tips over. IT CAN ONLY HELP IF
switch, or press the engine start button, if lift truck
IT IS FASTENED.
is equipped with this button. If any indicator lights
Make sure that the area around the lift truck is clear do not operate correctly, check the fuses. The fuses
before starting the engine or making any checks of are located in the Power Distribution Module (PDM)
the operation. Be careful when making the checks. which is under the hood next to the battery on the
If the lift truck is stationary during a check, apply right side. See Figure 24.
35
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking (Duramatch Plus 2™ Transmissions)
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 23. Warning and Indicator Lights
36
NOTE: HOOD REMOVED FOR CLARITY.

1. 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)
Figure 24. PDM Showing Fuses and Relays
Service Brakes using the lift truck. Replace the brake oil in
the system if there is dirt or water in the sys-
Brake Oil Level tem.
WARNING DO NOT use "DOT" fluid, only use Dexron III oil
from sealed container to prevent possible dam-
Small amounts of water in the brake system
age to the brake system. Failure to observe the
can cause reduced braking performance if the
above Warning could result in death or serious
water reaches the wheel cylinder areas. DO
injury.
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced. There is an indicator light on the Display Switch
Cluster for the brake oil. The red light is ON when
The brake system has a boosted master cylin-
the key switch is in the START position or the Power
der, braking will be more difficult if the engine
ON/OFF button is pressed, and must go OFF when
is not running.
the engine is running. If the light is on when the
Loss of oil from the brake oil reservoir indi- engine is running, the brake fluid oil in the reservoir
cates a leak. Repair the brake system before is too low.
37
Operation, Check
Check the operation of the service brakes. Push on

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

the inching/brake pedal is fully applied, a switch in
the starting circuit is closed so that the engine can be
started.
Parking Brake
Make sure the service brakes are adjusted and the
operation of the automatic adjuster mechanism is 1. LOCK BUTTON RELEASE
correct before the parking brake is adjusted. 2. OFF POSITION
3. ON POSITION
Lift trucks with a MONOTROL® pedal. The 4. ADJUSTMENT KNOB
switch energizes the seat warning circuit when hand Figure 25. Parking Brake
lever is released. This switch puts the transmission
in NEUTRAL by de-energizing the direction sole- Engine Oil Pressure
noid. There is also a switch on the left-hand side of
bracket. This switch prevents engine from starting NOTE: The engine will enter shutdown mode after a
unless parking brake is applied. warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
NOTE: Make sure parking brake is released before lift trucks with powertrain protection system. Lift
making adjustment. trucks equipped with a Cummins diesel engine will
1. Turn the adjustment knob to raise the equalized enter the shutdown mode when the engine oil pres-
link and tighten the parking brake cables shown sure is less than 49 kPa (7 psi) on lift trucks with pow-
in Figure 25. Do not tighten the adjustment so ertrain protection system. See the Engine Shut-
that the brake is applied when the lever is re- down procedures in the Operating Manual.
leased. The lever for the parking brake has a There is an indicator light for the engine oil pressure
lock. Use your thumb or finger to release the lock on the Display Switch Cluster. During normal opera-
on the lever when the parking brake is released. tion, the red indicator light will illuminate when the
2. For burnished brakes, test the operation of the key switch is turned to ON, if the truck is equipped
parking brake. The lift truck with a capacity load with a key switch, or when the power ON/OFF but-
must not move when parking brake is applied on ton is pressed, if the truck is equipped with a key-
a 15 percent grade [a slope that increases 1.5 m less option, and will stay illuminated until correct oil
in 10 m (1.5 ft in 10 ft)]. pressure is obtained, at which time the light will go
off.
38
If the light continues to stay on when engine is run-

ning, the engine oil pressure is low. Stop the engine WARNING
and check the oil level. See Figure 17 for lift truck Compressed air can move particles so that they
models S80, 100, 120FT; S80, 100FTBCS; 120FTS; cause injury to the user or to other personnel.
S120FTPRS) (G004) and Figure 15, Figure 16, and Make sure that the path of the compressed air
Figure 17 for lift truck models H80, 90, 100, 110, is away from all personnel. Wear protective
120FT) (N005, P005) Do not restart the engine un- goggles or a face shield to prevent injury to the
til the low pressure condition has been corrected. eyes.
Cooling System Check the radiator fins. Clean the radiator with com-
pressed air or water as needed. Check for and re-
move any debris on the radiator core. If the indicator
WARNING light turns on again after restarting, shut down the
DO NOT remove the radiator cap from the radi- lift truck and do not operate the lift truck until the
ator when the engine is hot. When the radiator problem is corrected.
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown if
coolant temperature reaches 118°C (245°F) or above
for GM 4.3L lift trucks with powertrain protection
system. Lift trucks equipped with a Cummins 4.5L
or QSB 3.3L diesel engine will enter the shutdown
mode when the coolant temperature reaches 114°C
(238°F) or above on lift trucks with powertrain pro-
tection system. See the Engine Shutdown proce-
dures in the Operating Manual.
There is an indicator light on the Display Switch

Cluster for the coolant temperature. The red light
is on when the key switch is in the START position
or the Power ON/OFF button is pressed, and must
go off when the engine is running. If the light is on
when the engine is running, the coolant and engine
are too hot. Stop the engine and check the coolant
level in the coolant recovery reservoir. 1. FILL CAP
2. FULL HOT MARK
Make sure the coolant level is between the ADD and 3. FULL COLD MARK
FULL marks on the auxiliary coolant reservoir. See 4. ADD COLD MARK
Figure 26. The coolant will expand as it is heated Figure 26. Auxiliary Coolant Reservoir
and the level in the auxiliary coolant reservoir will
increase. Steering System
CAUTION WARNING
Additives may damage the cooling system. Be-
The lift truck has hydraulic power steering.
fore using additives, contact your local Hyster
The steering can be difficult if the engine is
dealer.
not running.
If coolant is added, see Maintenance Schedule for cor-
Make sure the steering system operates smoothly
rect solution.
and provides good steering control. Make sure the
steering column can be adjusted and the gas cylinder
function is correct.
39
Control Levers and Pedals Perform the following checks and inspections:
Check that the control levers for the transmission, 1. Check for leaks in the hydraulic system. Check
mast, and attachment operate as described in Oper- the condition of the hydraulic hoses and tubes.
ating Manual. Check that the pedals operate cor-
rectly as described in Operating Manual. NOTE: Some parts of the mast move at different
speeds during raising and lowering.
Lift System, Operate
2. Slowly raise and lower the mast several times
without a load. Raise the mast to its full height
WARNING at least once. The mast components must raise
When working on or near the mast, see Safety and lower smoothly in the correct sequence. Hose
Procedures When Working Near Mast at the must track properly during operation.
end of this section.
3. The inner weldments and the carriage must
Lower the lift mechanism completely. Never lower completely.
allow any person under a raised carriage. DO
NOT put any part of your body in or through 4. Raise the mast 1 m (3 ft) with a capacity load.
the lift mechanism unless all parts of the mast The inner weldments and the carriage must raise
are completely lowered and the engine is smoothly. Lower the mast. All moving compo-
STOPPED. nents must lower smoothly.
If the mast cannot be lowered, use chains on 5. Lower the load to approximately 0.3 m (1 ft). Tilt
the mast weldments and carriage so that they the mast forward and backward. The mast must
cannot move. Make sure the moving parts are tilt smoothly and both tilt cylinders must stop
attached to a part that does not move. evenly.
DO NOT try to find hydraulic leaks by putting 6. Check that the controls for the attachment op-
hands on pressurized hydraulic components. erate the functions of the attachment. See the
Hydraulic oil can be injected into the body by symbols by each of the controls. Make sure all of
the pressure. the hydraulic lines are connected correctly and
do not leak.
40
8000 SRM 1248 First Service After First 100 Hours of Operation
First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL AND OIL FILTER CUMMINS 4.5L AND QSB 3.3L ENGINE
OIL AND OIL FILTER
NOTE: The engine oil and oil filter must also be
changed after the first 100 hours of operation for a Change engine oil and oil filter. See Figure 28. Ap-
newly installed engine. ply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten 1/2 to
Change engine oil and oil filter. See Figure 27. Ap-
3/4 turn with your hand. Fill engine with oil as speci-
ply clean oil to gasket of new filter. Install new fil-
fied in Maintenance Schedule until full mark reached
ter. Turn filter until gasket touches, then tighten 1/2
on the dipstick. Start engine. Check area around oil
to 3/4 turn with your hand. Fill engine with oil as
filter for leaks, shut engine off and check oil dipstick,
specified in Maintenance Schedule, until full mark
if low add oil.
reached on the dipstick. Start engine. Check area
around oil filter for leaks, shut engine off and check
oil dipstick, if low add oil.
NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG-

END FOR GM 4.3L ENGINES EQUIPPED WITH GFI
OR PSI ARE LOCATED IN THE SAME AREA. NOTE: BOTTOM LEFT-HAND SIDE SHOWN
1. OIL FILTER 1. OIL FILTER 2. DRAIN PLUG

2. DRAIN PLUG
3. ENGINE OIL DIPSTICK Figure 28. Engine Oil Filter Change, Cummins
4. ENGINE OIL FILL 4.5L Diesel (Shown)
Figure 27. GM 4.3L Engine Filter Oil Change
41
Maintenance Procedures Every 250 Hours or 6 Months 8000 SRM 1248
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform the 8-hour checks prior to performing DRIVE BELT
the procedures in this section.
GM 4.3L Engine
GM 4.3L ENGINE OIL AND OIL FILTER
Fan and Alternator Drive Belt
NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks. Check drive belt for wear and damage. See Figure 30.
A few small cracks that run across belt are accept-
Change engine oil and engine oil filter. See Fig- able. A belt with cracks that run length of belt or a
ure 29. Use the correct oil according to the Main- belt with missing pieces is not acceptable. See Fig-
tenance Schedule. Apply clean oil to gasket of new ure 31 for the drive belt arrangement.
filter. Install new filter. Turn filter until gasket
touches, then tighten 1/2 to 3/4 turn with your hand.
Start engine. Check area around oil filter for leaks.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 30. Drive Belt Inspection
NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG-

END FOR GM4.3L ENGINES EQUIPPED WITH GFI
OR PSI ARE LOCATED IN THE SAME AREA.
1. OIL FILTER
2. DRAIN PLUG
3. ENGINE OIL DIPSTICK
4. ENGINE OIL FILL
Figure 29. GM 4.3L Engine Oil Change
Figure 31. GM 4.3L Drive Belt Arrangement
42
8000 SRM 1248 Maintenance Procedures Every 250 Hours or 6 Months
Legend for Figure 31 1. Move the lift truck to a well ventilated area, and
ensure no external ignition sources are present.
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING
TENSIONERS. 2. Start the engine.
1. FAN PULLEY 3. Close the valve on the LPG tank.
2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY 4. When the engine runs out of fuel, turn key or
4. SERPENTINE BELT keyless switch to OFF position, and disconnect
5. TENSIONER CENTERING PULLEY
6. ALTERNATOR PULLEY the negative terminal on the battery.
DRAIN TAR FROM LPG REGULATOR CAUTION

1. Warm engine to operating temperature. A small amount of fuel may remain in the fuel
line. To prevent the possibility of burns wear
2. Shut fuel valve off and run engine until the en- gloves and eye protection. If fuel continues to
gine runs out of fuel and stops. flow check to make sure the LPG tank valve is
completely closed.
3. Raise the hood.
5. Disconnect the inlet line and outlet hose from the
4. Remove tar drain screw from regulator. Allow tar LPG converter. See Figure 33.
to drain from regulator. When tar has completely
drained, install tar drain screw in regulator. See 6. Remove the mounting bolts and LPG converter
Figure 32. from the mounting bracket.
1. LPG CONVERTER
2. INLET LINE
3. OUTLET HOSE
4. MOUNTING BOLTS
1. TAR DRAIN SCREW
Figure 33. LPG Converter Removal
Figure 32. GM LPG Regulator
DRAIN TAR FROM LPG CONVERTER

NOTE: The following procedure is to be used on lift
trucks equipped with a GM 4.3L LPG Engine with
PSI installed.
43
8. Using mounting bolts, install the LPG converter

CAUTION on the mounting bracket.
Engine components may be hot. Use gloves
when handling the LPG Converter to prevent 9. Connect the fuel line and outlet hose to the LPG
the possibility of burns. converter. If disconnected, connect the two cool-
ing hoses.
CAUTION 10. Connect the negative terminal on the battery.

Drain the tar into a container and dispose in
accordance with local environmental regula- 11. Open the valve on the LPG tank and check for
tions. leaks on the LPG converter using soapy water or
a leak detector. If any leaks are found, tighten
7. Rotate the LPG converter sightly so that outlet fittings or replace hose clamps as applicable.
opening is pointing toward the container and al-
low tar to drain from LPG converter. If the LPG 12. Start the engine and recheck for leaks at the con-
converter cannot be rotated a sufficient amount verter.
to drain the tar, disconnect the two cooling hoses.

NOTE: Perform the 8-hour and 250-hour checks prior accurate when the oil temperature is 53 to 93°C (130
to performing the procedures in this section. to 200°F).
HYDRAULIC SYSTEM OIL HYDRAULIC TANK BREATHER
WARNING Inspect
At operating temperature, the hydraulic oil is NOTE: When inspecting the breather, do not remove
HOT. DO NOT permit the hot oil to touch the it. The breather element is a non serviceable part. If
skin and cause a burn. it is damaged, replace with a new breather element.
CAUTION 1. Raise the hood and remove the right rear side
panel See Figure 34.
DO NOT permit dirt to enter the hydraulic sys-
is changed. WARNING
Never operate the hydraulic pump without oil cause injury to the user or to other personnel.
in the hydraulic system. The operation of the Make sure that the path of the compressed air
hydraulic pump without oil will damage the is away from all personnel. Wear protective
pump. goggles or a face shield to prevent injury to the
eyes.
CAUTION
Additives may damage the hydraulic system. CAUTION
Before using additives, contact your local Hys- Direct air pressure on the filter element can
ter dealer. cause damage. Direct air pressure away from
Check the hydraulic oil level when the oil is at operat- filter element.
ing temperature with the mast in a vertical position, 2. Using compressed air, remove any dirt and de-
the carriage lowered, and the engine stopped. See bris in the frame cavity around the breather. See
Figure 41 and Figure 42. Add hydraulic oil only as Figure 34.
needed. If hydraulic oil is above the FULL level, the
hydraulic oil will leak from the breather during oper- 3. If necessary, unscrew and replace the breather
ation. The oil level indicated by the dipstick is most if oil has accumulated in the cavity or on the
44
breather, or if dirt has accumulated at the Disconnect the negative and positive terminals of the
breather passages at the bottom of the breather battery. Using a damp cloth clean the case of the bat-
tery. If the terminals are corroded, clean the termi-
4. Install right rear side panel and close hood. See nals with a wire brush. Connect the negative and
Figure 34. positive cables to their respective terminals.
CUMMINS 4.5L AND QSB 3.3L ENGINE

OIL AND OIL FILTER
NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks.
Change engine oil and engine oil filter. See Fig-

ure 35. Use the correct oil according to the Main-
tenance Schedule. Apply clean oil to gasket of new
filter. Install new filter. Turn filter until gasket
touches, then tighten 1/2 to 3/4 turn with your hand.
Start engine. Check area around oil filter for leaks.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 34. Hydraulic Tank Breather
BATTERY
WARNING
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
the area. Use a solution of sodium bicarbon-
ate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
Wear eye protection.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. DO NOT NOTE: BOTTOM LEFT HAND SIDE.
make sparks from the battery connections.
1. OIL FILTER 2. DRAIN PLUG
Disconnect the battery ground cable when
doing maintenance. Figure 35. Engine Oil Change Cummins 4.5L
Diesel (Shown)
45
FUEL/WATER SEPARATOR FILTER Install

REPLACEMENT, CUMMINS 4.5L AND QSB
1. Clean the fuel filter head mounting surface and
3.3L ENGINE apply a small amount of diesel fuel to the gasket
on the new fuel filter element. See Figure 36 and
CAUTION Figure 37.
Disposal of lubricants and fluids must meet lo-
2. Before installing the filter element, fill the filter
cal environmental regulations.
element with diesel fuel. This method will aid in
Replace the fuel filter at specified intervals to pre- bleeding the fuel system.
vent contaminants from adversely affecting the
diesel fuel flow. CAUTION
DO NOT overtighten the filter element. Over-
Remove
tightening the filter element may distort the
1. Stop engine and allow it to cool. threads.
2. Disconnect air inlet elbow to access the fuel filter 3. Install the new fuel filter element until it con-
element. See Figure 36. tacts the fuel filter head mounting surface.
Tighten one additional turn.
3. Disconnect fuel filter sensor connector from the
fuel filter element. 4. Connect the fuel sensor connector to fuel filter
element
CAUTION 5. Connect air inlet elbow hose.
Drain the water/fuel into a container and dis-
pose in accordance with local environmental 6. Open the fuel supply valve.
regulations.
7. Prime the fuel system. See Priming the Fuel Sys-
4. Open the drain valve by turning the valve coun- tem (Cummins 4.5L and QSB 3.3L Engine).
terclockwise approximately 3 1/2 turns until
8. Check for fuel leaks.
draining occurs. Drain until fuel filter element
is empty.
5. Remove and discard fuel filter element.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. IN-LINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
46
Figure 36. Cummins 4.5L Engine Fuel System
47

A. RIGHT VIEW
B. TOP VIEW
1. TURBO
2. HEAD
3. BELL HOUSING
4. FLYWHEEL
5. OIL PAN
6. ENGINE BLOCK
7. ELECTRONIC FUEL PUMP
8. FUEL FILTER
9. WATER OUTLET HOUSING
10. WATER PUMP BELT
11. WATER INLET HOUSING
12. OIL FILL CAP
13. WATERGATE
14. AIR INLET HOUSING
15. OIL DIPSTICK
16. EXHAUST MANIFOLD
17. EXHAUST OUTLET
18. ENGINE ECM
19. STARTER
20. FUEL/WATER SEPARATOR
21. PRIMER PUMP
22. INTAKE MANIFOLD
23. AIR INLET
24. INJECTOR LINE
FINAL FUEL FILTER REPLACEMENT

(CUMMINS QSB 3.3L ENGINE)
CAUTION
Replace the fuel filter at specified intervals to pre-

diesel fuel flow.
1. Close any OEM fuel valves (if applicable) to pre-

vent fuel from draining.
2. Clean the area around the fuel filter head.
CAUTION
Drain the fuel into a container and dispose in
accordance with local environmental regula-
tions.
Figure 37. Cummins QSB 3.3L Engine Fuel
3. Remove the fuel filter.
System
4. Clean the gasket surface.
48
• The fuel injection pump is replaced.

CAUTION • The high pressure fuel line connections are loos-
DO NOT pour fuel directly into the center of ened, or lines are replaced.
the filter, since this will allow unfiltered fuel • It is an initial engine start up after an extended
to enter the system and may cause damage to period of no engine operation.
fuel system components.
If equipped with electronic fuel pump (Cummins
5. Pre-fill new filters, both pressure side and suc- QSB 3.3L), with the accelerator pedal or lever in the
tion side, with clean fuel prior to assembly. Use idle position, turn the key to the ON position. Wait
the clean side block off plug packed with the fil- for the "Wait to Start" light to go out. Start the truck.
ter.
If the engine does not start after 3 attempts, check
6. Lubricate the gasket with clean engine oil. fuel supply system. The lack of blue or white smoke
indicates the lack of fuel being supplied to the engine.
7. Install fuel filter. Tighten filter until gasket con-
tacts filter head surface. Tighten filter an addi- 1. Crack open the fuel line to the injector pump. See
tional 3/4 turn after contact. Figure 36.
8. Start engine and check for leaks around the fuel 2. Operate the hand lever until fuel is expelled from
filter. the loosened fitting.
PRIMING THE FUEL SYSTEM (CUMMINS 3. Tighten the fuel line to the injector pump to
4.5L AND QSB 3.3L ENGINE) 9 N•m (80 lbf in). See Figure 36.
4. Crack open one of more of the injector lines lo-

Controlled Venting cated on the cylinder head.
CAUTION WARNING
When using the starting motor to vent the sys- The pressure spray released by the fuel injec-
tem, DO NOT engage it for more than 30 sec- tors can penetrate the skin and cause serious
onds, or starter motor damage will occur. Wait personal injury. Wear clothes and protective
2 minutes before engaging the starter again. clothing.
Controlled venting is provided at the injection pump 5. Crank the engine until fuel is expelled from the
through the fuel drain manifold. Small amounts of loosen fittings. Tighten the injector line fittings
air introduced by changing the filters or injection while cranking. The engine should fire.
pump supply line will be vented automatically if
the fuel filter element is changed and filled prior to
installation. CAUTION
Manual Bleeding cal environmental regulations.
Manual Bleeding will be required if one of the follow- 6. Wipe up any fuel that may have spilled and dis-
ing conditions exist. pose of the fuel and rags in accordance with local
• The fuel filter is not filled prior to installation. directives.
49
DRIVE BELT Legend for Figure 39
Cummins 4.5L and QSB 3.3L Diesel NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD-
Engine JUSTING TENSIONERS.
1. ALTERNATOR PULLEY
Fan and Alternator Drive Belt 2. CAMSHAFT PULLEY
3. WATER PUMP PULLEY
Check drive belt for wear and damage. See Figure 38. 4. CRANKSHAFT PULLEY
A few small cracks that run across belt are accept- 5. TENSIONER CENTERING PULLEY
able. A belt with cracks that run length of belt or a
belt with missing pieces is not acceptable. See Fig-
ure 39 and Figure 40 for the drive belt arrangement.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 38. Drive Belt Inspection

1. ALTERNATOR BELT ADJUSTMENT BRACKET
2. DRIVE BELT
3. CAMSHAFT PULLEY
4. CRANKSHAFT PULLEY
5. ALTERNATOR PULLEY
Figure 40. Cummins QSB 3.3L Diesel Engine

Drive Belt Arrangement
Figure 39. Cummins 4.5L Diesel Engine Drive

Belt Arrangement
50
CLEAN DEBRIS FROM RADIATOR CORE TRANSMISSION OIL LEVEL

Check the radiator core for restrictions and remove
material causing radiator core to be plugged or re-
WARNING
stricted. At operating temperature, the transmission oil
is HOT. DO NOT permit the hot oil to touch the
WARNING
cause injury to the user or to other personnel. CAUTION
Make sure that the path of the compressed air DO NOT permit dirt to enter the transmission
is away from all personnel. Wear protective when the oil level is checked or the filter is
goggles or a face shield to prevent injury to the changed.
eyes.
NOTE: Transmission oil temperature should be at
Clean with compressed air, adjusted to a maximum least 50°C (120°F) when checking oil level.
output of 103 kPa (15 psi), and blow debris from core
If engine has been running, the engine must be shut
and fan shroud.
down for one minute or longer prior to checking the
oil level. See Figure 41 or Figure 42. If the trans-
mission oil is low, add oil to transmission at the dip-
stick tube at the correct level as indicated on the dip-
stick. Use the correct oil as shown in the Mainte-
nance Schedule.
NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 41. Transmission and Hydraulic Oil Check
51
NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 42. Transmission and Hydraulic Oil Check
WET BRAKE CENTER BODY OIL LEVEL 1. Remove the center body fill/level plug. See Fig-
CHECK ure 43 for lift truck models S80, 100, 120FT;
S80, 100, 120FTBCS; S120FTPRS (G004) and
Figure 44 for lift truck models H80, 90, 100, 110,
WARNING
120FT (N005, P005).
At operating temperature, the center section
oil is HOT. DO NOT permit the hot oil to touch 2. Visually check oil level. If necessary, add oil at
the skin and cause a burn. the fill/level port until the oil/fill level port has
overflowed. The Correct oil is shown in the Main-
CAUTION tenance Schedule.
DO NOT permit dirt to enter the center body 3. Install center body oil/level fill level plug and
when the oil level is checked. Dirt will contam- tighten to 30 to 50 N•m (22 to 37 lbf ft).
inate the oil and cause damage to the center
body of the axle.
52
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER SECTION DRAIN PLUG
4. CENTER SECTION FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER SECTION B. FRONT VIEW SHOWN
Figure 43. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
S80, 100, 120FT; S80, 100FTBCS; S120FTS; PLUGS
S120FTPRS (G004) 3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
Figure 44. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
H80, 90, 100, 110, 120FT (N005, P005)
53
FORKS contact surface to allow grease to properly lubricate

the normal contact surfaces of the mast bushings
WARNING 2. Raise the carriage about 61 cm (2 ft), and tilt the
Never repair damaged forks. DO NOT heat, mast fully back. Place blocks under the outer
weld, or bend the forks. Forks are made of spe- mast channels to within 13 mm (0.5 in.) of the
cial steel using special methods. Replace dam- channels See Figure 46.
aged forks as a complete set.
3. Tilt the mast fully forward. See Figure 46.
Measure thickness of forks with a fork arm caliper
(Hyster Part No. 3020387) at a vertical section where 4. Lubricate the mast pivot bushings at grease fit-
there is no wear. This thickness is dimension X. Now tings on outer mast. See Figure 47 and Figure 48.
measure thickness at heel of fork (see Figure 20). If Use multipurpose grease shown in the Mainte-
the thickness of the heel is not greater than 90% of nance Schedule.
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 45.
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES A. MAST TILTED FULLY BACK
3. LOAD ROLLER B. MAST TILTED FORWARD
Figure 45. Mast Lubrication 1. BLOCK 2. MAST
NOTE: When lubricating the mast mounting/pivot Figure 46. Blocking the Mast
pins, the load must be removed from the normal
54
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 47. Mast Mounting Hanger Lubrication
5. Tilt mast fully back. Remove the blocks from un- grease shown in the Maintenance Schedule. See
der the channels Figure 49.
6. If a sideshift carriage is installed, lubricate slid-

ing surfaces at grease fittings with multipurpose
55
1. OUTER MAST 2. MAST PIVOT BUSHING 3. LUBRICATION FITTING
Figure 48. Pivot Pin Lubrication

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

Daily inspection plus; kinked, crushed, flattened or
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/re-
place hose/components as necessary. See Mast Re-
pairs, 2- and 3-Stage Masts 4000 SRM 1250 for
Figure 49. Integral Sideshift Carriage quick disconnect procedures.
56
LIFT CHAIN LUBRICATION Lubricate lift chains with SAE 30 engine oil. The best
procedure is to remove the chains from the lift truck
WARNING and soak them in engine oil. Be sure to clean any dirt
or grease from chains before lubricating. DO NOT
USE STEAM TO CLEAN THE LIFT CHAINS.
section.
TILT CYLINDER LUBRICATION
DO NOT repair worn or damaged lift chains. If
NOTE: The floor plate must be removed in order to
a lift chain is worn or damaged, both lift chains
lubricate the rear tilt cylinder lubrication fittings.
must be replaced.
Lubricate the tilt cylinder ends. Use multipurpose
NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
grease shown in the Maintenance Schedule. There
tion should not be performed in combination with the
are four lubrication fittings. See Figure 50.
1000 Hour/6 Months Lift Chain Lubrication.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 3. ANCHOR PIN 5. TILT SPACER
2. RETAINER 4. LUBRICATION FITTING
Figure 50. Tilt Cylinder Lubrication
57
MASTER BRAKE CYLINDER ROD END MANUAL HYDRAULIC LEVERS

PIN LUBRICATION LUBRICATION
Lubricate the master brake cylinder rod end pin. Use Lubricate the bushings for the manual hydraulic
engine oil shown in the Maintenance Schedule. See levers. Use spray lubricant as listed in the Mainte-
Figure 51. nance Schedule. See Figure 52.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 51. Master Brake Cylinder Rod End Pin

Lubrication
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 52. Manual Hydraulic Levers

Lubrication
58
BRAKE OIL Legend for Figure 53

1. RESERVOIR CAP
WARNING 2. BRAKE OIL RESERVOIR
Small amounts of water in the brake system 3. RESERVOIR MOUNTING BRACKET
can cause reduced braking performance if the 4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
water reaches the wheel cylinder areas. DO 6. CYLINDRICAL BLOCK OUTLET FITTING
NOT allow water entry. Ensure that the sealed 7. LOWER BRAKE OIL SUPPLY HOSE
reservoir lid is properly replaced. 8. NIPPLE
9. MASTER CYLINDER
Replace the brake oil in the system if there is 10. CYLINDRICAL BLOCK DRAIN PLUG
dirt or water in the system. 11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
CAUTION
DO NOT use "DOT" fluid, only use Dexron III TIE ROD LUBRICATION FOR LIFT TRUCK
oil from sealed container to prevent possible MODELS S80, 100, 120FT; S80, 100FTBCS;
damage to the brake system. S120FTS; S120FTPRS (G004)
Remove the dash board from the cowl. The brake oil Lubricate the tie rods. Use multipurpose grease
reservoir is located on the cowl, at the master cylin- shown in the Maintenance Schedule. There is one
der. See Figure 53. Add brake oil, as necessary. Use lubrication fittings on each tie rod. See Figure 54.
the brake fluid shown in the Maintenance Schedule.
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE)
Figure 54. Tie Rod Lubrication for Lift Truck

Models S80, 100, 120FT; S80, 100FTBCS;
Figure 53. Brake Oil Reservoir S120FTS; S120FTPRS (G004)
59
TIE ROD LUBRICATION FOR LIFT TRUCK

MODELS H80, 90, 100, 110, 120FT (N005,
P005)
Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There is one
lubrication fittings on each tie rod. See Figure 55.
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
Figure 56. Drive Axle (Dry Brake) Fluid Fill

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

2. LUBRICATION FITTING (SPINDLE)
3. STEERING AXLE
Figure 55. Tie Rod Lubrication for Lift Truck

Models H80, 90, 100, 110, 120FT (N005, P005)
DIFFERENTIAL AND DRIVE AXLE OIL,

LIFT TRUCK MODELS WITH DRY BRAKES
The differential and drive axle use the same oil sup-
ply. The oil level must be between 0 to 10 mm (0 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 1. CHECK/FILL PLUG
2. DRAIN PLUG
fluid level is at the bottom edge of the fill hole. See 3. DRIVE AXLE
Figure 56 and Figure 57. If oil is low, add oil shown
in the Maintenance Schedule until the oil level is be- Figure 57. Drive Axle (Dry Brake) Fluid Fill
tween 0 to 10 mm (0 to 0.40 in.) below the bottom for Lift Truck Models H80, 90, 100, 110, 120FT
edge of fill hole. Install fill plug and check for leaks. (N005, P005)
60

NOTE: Perform the 8-hour, 250-hour, and 500-hour
checks prior to performing the procedures in this sec-
tion.
VALVE CLEARANCE, CHECK AND

ADJUST
The GM 4.3L engine has hydraulic valve lifters and
does not require valve clearance adjustments during
normal service.
See the Maintenance Schedule for valve clearances.
Additional engine information is available in the fol-

lowing sections:
• GM Engines, 4.3 Liter V-6 600 SRM 1251
IGNITION SYSTEM
GM 4.3L Engine
The GM 4.3L gasoline and LPG engines have an elec-
tronic control unit (ECU) that controls the ignition
timing. There are no adjustments. Change the spark
plugs every 1000 hours. The correct spark plug gap
is 1.5 mm (0.059 in.).
1. BOLT
2. SEAL WASHER
LPG FUEL FILTER ELEMENT REPLACE, 3. FUEL FILTER HOUSING TOP SECTION
GM 4.3L ENGINE 4. FUEL FILTER
5. FUEL FILTER O-RING
Remove 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
WARNING Figure 58. Fuel Filter Removal and Installation

LPG can cause an explosion. DO NOT permit
any sparks or open flames in the work area. 4. Remove top section of fuel filter housing.
1. Close fuel valve on tank. Run engine until it 5. Remove and discard housing O-ring.
stops. 6. Remove fuel filter and fuel filter O-ring.
2. Disconnect negative battery cable.
Install
WARNING 1. Clean and inspect the fuel filter housing for con-
A small amount of fuel may still be present in tamination or damage.
the fuel line. Use gloves to prevent burns and
2. Install the new fuel filter and fuel filter O-ring.
wear eye protection. If liquid fuel continues
See Figure 58.
to flow from the connections when loosened,
check to make sure the manual valve is fully 3. Install new housing O-ring.
closed.
4. Install top section of fuel filter housing.
3. Remove the bolt and seal washer retaining the
top section of the fuel filter housing. Discard seal 5. Install bolt and new seal washer. Tighten bolt to
washer. See Figure 58. 13 N•m (115 lbf in).
61
NOTE: Opening the fuel valve too quickly can cause Remove
the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve, 1. Stop Engine and allow it to cool.
wait a few seconds, and then slowly open the fuel
2. Close fuel supply valve located on the fuel send-
valve again. This will reset the excess fuel valve.
ing unit. See Figure 59.
6. Slowly open the fuel valve on tank.
CAUTION
7. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system. Drain the fuel into a container and dispose in
Check for leaks. accordance with local environmental regula-
tions.
8. Check for leaks at connections by using soapy
solution or electronic leak detector. If leaks are 3. Loosen clamps and disconnect two fuel lines from
detected, make proper repairs. the inline fuel filter. Remove and discard the in-
line fuel filter
IN-LINE FILTER REPLACEMENT,
Install
CUMMINS 4.5L ENGINE
1. Install inline fuel filter by connecting the two fuel
CAUTION lines and tighten clamps. See Figure 59.
2. Open the fuel supply valve.
3. Check for fuel leaks.
Replace the fuel filter at specified intervals to pre-
diesel fuel flow.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. INLINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
62
Figure 59. Cummins 4.5L Engine Fuel System
63
LIFT CHAINS WEAR CHECK cleaning solvents, always follow the recom-
mendations of the manufacturer.
If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re- Compressed air can move particles so they
placed. Measure chain for wear where it moves over cause injury to the user or to other personnel.
sheaves. Using a chain scale, Hyster P/N 871796 Make sure that the path of the compressed air
check lift chains as shown in Figure 60. is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
the eyes.
Remove the lift chains. Clean the lift chains by soak-

ing them in a solvent that has a petroleum base for
at least 30 minutes. Use compressed air, adjusted to
a maximum output of 103 kPa (15 psi), to completely
dry the chains when they are clean.
Lubricate the lift chains by soaking them in 30W en-

gine oil for at least 30 minutes. Remove the chains
from the oil. Hang the chains for one hour so excess
oil will drain from the chains.
INTEGRAL SIDESHIFT CARRIAGE, CHECK

SLIDING SURFACES
1. Check the sideshift carriage sliding surfaces,
and if necessary lubricate sliding surface at the
grease fittings with multipurpose grease shown
in the Maintenance Schedule. See Figure 61.
Pitch Wear Limit
Total Length
(The
of 20 Links
Maximum
(Pitch) of New
Length of 20
Chain
Links)
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
1. CHAIN WEAR SCALE

1. CAPSCREWS 6. GREASE FITTINGS
Figure 60. Lift Chains Check 2. LOWER HOOK 7. CYLINDER ROD
3. APRON 8. SNAP RING
LIFT CHAIN LUBRICATION 4. LOWER BEARING 9. ROD SCRAPER
STRIPS 10. ROD BUSHING
5. UPPER BEARING 11. SEAL
WARNING STRIPS 12. FIXED FRAME
Cleaning solvents can be flammable and toxic
Figure 61. Integral Sideshift Carriage
and can cause skin irritation. When using
64
STEERING AXLE (SPINDLE BEARINGS) STEERING AXLE (SPINDLE BEARINGS)

FOR LIFT TRUCK MODELS S80, 100, FOR LIFT TRUCK MODELS H80, 90, 100,
120FT; S80, 100FTBCS; S120FTS; 110, 120FT (N005, P005)
S120FTPRS (G004)
Lubricate the spindle bearings on the steering axle.
Lubricate the spindle bearings on the steering axle. There are four lubrication fittings, two on each side of
There are four lubrication fittings, two on each side of the steering axle. See Figure 63. Use multipurpose
the steering axle. See Figure 62. Use multipurpose grease as shown in the Maintenance Schedule.
grease as shown in the Maintenance Schedule.
1. STEERING AXLE
3. LUBRICATION FITTING (SPINDLE BEARINGS) 1. LUBRICATION FITTING (TIE ROD)
2. LUBRICATION FITTING (SPINDLE BEARINGS)
Figure 62. Lubricate Spindle Bearings for Lift 3. STEERING AXLE
Truck Models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) Figure 63. Lubricate Spindle Bearings for Lift
Truck Models H80, 90, 100, 110, 120FT (N005,
P005)
65
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
CONTROL LEVERS AND PEDALS • Check engine wire harness for rubbing, chaffing,
pinching, and cracks or breaks in the wiring.
Lubricate linkages, pedal shafts, control cables • Check engine harness connectors. Check to ensure
(throttle, hood, parking brake), and seat rails. Use a connectors are fitted and locked by pushing the
silicone spray lubricant, Hyster Part No. 328388. connectors together. Pull on the connector halves
to make sure they are locked.
INSPECT ENGINE ELECTRICAL SYSTEM, • Check ignition coil wire and spark plug wires for
CONNECTORS hardening, cracking, arching, chaffing, separation,
split boot covers, and proper fit. Replace spark
When inspecting the electrical system, check the fol- plugs at the recommended interval as shown in the
lowing: Maintenance Schedule.
• Check and clean battery connection. Ensure that • Check that all electrical components are securely
connections are tight. mounted and retained to the engine or chassis.
• Check battery for damage or cracks to the case. • Check the MIL, charging, and oil pressure lights
Replace if necessary. for operation by starting the engine and checking
• Check positive and negative cables for corrosion, that the light illuminates before turning out.
rubbing, and chaffing. Tighten connections at both
ends.
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and and spring from head. See Figure 64. Lift the
1000-hour checks prior to performing the procedures hydraulic filter element enough to allow the hy-
in this section. draulic oil to drain.
HYDRAULIC SYSTEM NOTE: Have container large enough to hold the filter
element and allow for final hydraulic oil draining.
Hydraulic Filter, Replace
2. Remove the hydraulic filter element and O-ring
from the bowl and place into the container. Cover
WARNING the head to prevent any foreign materials from
At operating temperature, the hydraulic oil is getting into the hydraulic tank.
HOT. DO NOT permit the hot oil to touch the
skin and cause a burn. 3. Lubricate new O-ring with hydraulic oil and in-
stall it on the bottom of the new filter element.
Install the new filter element into the bowl.
CAUTION
DO NOT permit dirt to enter the hydraulic sys- 4. Inspect gasket for damage. If damaged, replace.
is changed. Dirt can cause damage to the com- 5. Lubricate gasket with hydraulic oil and seat it
ponents of the hydraulic system. on filter lid and install spring and lid onto head.
Tighten lid to 15 N•m (132.8 lbf in).
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
CAUTION
hydraulic pump without oil will damage the
pump. Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
CAUTION
Disposal of lubricants and fluids must meet lo- 6. Start the truck, and allow it to run for 30 seconds.
cal environmental regulations. Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
1. Put lift truck on a level surface and lower the shown in the Maintenance Schedule. To change
carriage. Unscrew and remove filter lid, gasket, the hydraulic oil, see Hydraulic Oil, Replace.
66
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
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 65.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 65. Hydraulic Tank Breather
IGNITION SYSTEM; DISTRIBUTOR CAP,

ROTOR, AND SPARK PLUG WIRES
NOTE: Make sure the key is in the OFF position and
the negative battery cable has been removed from the
1. LID 6. FITTING battery before removing the ignition system.
2. SPRING 7. QUAD RING
3. O-RING 8. FILTER ELEMENT Remove and discard spark plug wire assembly, coil
4. CAPSCREW 9. BOWL
5. HEAD wire, spark plugs, distributor cap, and rotor. For
procedures see High Voltage Switch (HVS) Igni-
Figure 64. Hydraulic Filter tion, GM 4.3L EPA Compliant Engines and GM
5.7L LPG EPA Compliant Engine 2200 SRM 1097
Hydraulic Tank Breather, Replace for Spark Plug Wire Removal/Installation, Distribu-
tor Cap Removal/Installation, and Rotor Disassem-
1. Raise the hood and remove the right rear side ble, Ignition Coil Wire Removal, and Spark Plug Re-
panel. See Figure 65. placement.
67
COOLING SYSTEM, GM 4.3L AND 4. Close drain valve. Fill cooling system with a
CUMMINS 4.5L AND QSB 3.3L ENGINES solution of ethylene glycol boron-free antifreeze.
See Maintenance Schedule for correct solution.
1. Put lift truck on a level surface. Stop engine. Fill the auxiliary reservoir to a level between the
Place a container with a minimum capacity of ADD and FULL marks on the reservoir.
15.1 liter (15.9 qt) under the radiator drain valve
which could be located on either the lower left or 5. Install radiator cap. Start engine. Check for
right side of the radiator on the engine side of the leaks. Add coolant to auxiliary coolant reservoir
radiator. as needed. Coolant level should be between the
ADD and FULL marks on the reservoir.
WARNING AIR FILTER
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi- The air filter canister should not be opened until an
ator cap is removed, the pressure is released air filter element replacement is required. An air
from the system. If the system is hot, the steam filter element replacement is required when one of
and boiling coolant can cause burns. DO NOT the following occurs:
remove the cover for the radiator when the en- • The optional air flow restriction indicator light on
gine is running. the dash illuminates
• The optional manual air flow indicator button pops
up
CAUTION
• The specified number of hours has passed since the
Disposal of lubricants and fluids must meet lo- last filter element replacement
2. Open drain valve and remove radiator cap. Drain CAUTION

coolant into the container. Flush cooling sys- DO NOT to allow dirt to enter the engine air
tem. Check hoses for damage. Replace with new intake when replacing the air filter element. A
hoses, as needed. small amount of dirt could cause engine dam-
age.
3. Disconnect the hose leading from the auxiliary
reservoir to fitting at the top of the radiator un- 1. Shut off the engine. Never open the air filter can-
der the radiator cap, and drain the reservoir into ister or remove the filter element with the engine
the same container used for the radiator coolant. running.
Check the reservoir for contaminants and flush,
as necessary. Connect the hose back on the fit- 2. Unlatch and remove the cover. To remove filter
ting at the top of the radiator. element, press and rotate filter element counter-
clockwise about 1/8 turn until the filter element
is free. To assist removal, gently move the end
CAUTION
back and forth to help break the seal. See Fig-
Additives may damage the cooling system. Be- ure 66.
fore using additives, contact your local Hyster
dealer.
68
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 66. Air Filter
3. Gently pull the filter element from the canister.

Avoid dislodging contaminants from the element
CAUTION
or knocking it against the canister. The element must be properly installed to en-
sure adequate engine protection. An improp-
4. With a clean, soft rag, clean the inside surface of erly installed element may allow dirt and dust
the canister. Remove the liner assembly to make to enter and damage the engine.
cleaning easier. Clean well around the locking
tabs that retain the element. Clean tabs make NOTE: Proper element installation is required to al-
new filter element installation easier. Be careful low the cover to be installed correctly. Never reinstall
not to knock any contaminants into the outlet a used element. Never install a damaged element.
tube to the engine. Always use a Hyster-approved filter element.
5. Inspect the liner and O-ring assembly for dam- 8. Install the new filter element into the canister.
age. If damaged, replace the liner and O-ring as- Press and rotate the filter element 1/8 turn clock-
sembly. wise until fully engaged in the canister. See Fig-
ure 67.
6. Install the liner assembly into the canister by
pushing in. Make sure the liner assembly is
properly seated in the canister. It will fit snugly
into and be centered in the canister.
If your air filter assembly is equipped with a sec-

ondary element in place of the liner assembly, re-
place the secondary element with every 2 to 3 pri-
mary element replacements.
7. Inspect the new filter element for voids, cuts,

tears or indentations in the urethane-sealing
surfaces. Do not use if damage is detected.
1. PUSH IN 2. TWIST TO LOCK
Figure 67. Air Filter Label
69
CAUTION
During cover installation, DO NOT force the
cover on the canister. To do so will result in
damage to the filter element, cover, and possi-
bly the canister.
NOTE: If the filter element is properly installed, the

cover will fit easily into the canister with no gap be-
tween the cover and the canister. If the cover does not
fit easily, the filter element is not installed properly.
Do not use a cover that is bent, damaged, or missing
latches.
9. Install the cover into the canister and ensure the

INLET arrow is in line with the canister inlet. 1. OXYGEN SENSOR
2. ELECTRICAL CONNECTOR
3. EXHAUST PIPES TO EXHAUST MANIFOLD
NOTE: Do not use the latches to pull the cover down
against the canister. If the cover does not fit com- Figure 68. Oxygen Sensor Location for Lift
pletely against the canister with no gaps, the element Truck Models H80, 90, 100, 110, 120FT) (N005,
is not installed correctly. P005) and S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004)
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.
OXYGEN SENSOR GM 4.3L LPG ENGINES

EQUIPPED WITH GFI INSTALLED
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 68 and Figure 69..
1. OXYGEN SENSOR (POST-CATALYTIC)

2. MUFFLER
3. OXYGEN SENSOR (PRE-CATALYTIC)
Figure 69. Oxygen Sensor (BCS Only) for Lift

Truck Models S80, 100FTBCS (G004)
70
LPG REGULATOR FUEL FILTER, GM Install

4.3L ENGINES EQUIPPED WITH GFI
1. Install a new screen in the LPG regulator.
INSTALLED
2. Install a new O-ring on the outlet fitting. Using
Remove three screws, install the outlet fitting on the LPG
regulator.
1. Close shutoff valve on tank. Run engine until it
stops. 3. Install new rubber washer, paper filter, foam fil-
ter, and plastic cap in the LPG regulator.
2. Disconnect the hose from the inlet fitting.
4. Install new O-ring on the inlet fitting. Install
3. Remove the inlet fitting from the LPG regulator. inlet fitting into the LPG regulator and connect
Discard the O-ring. See Figure 70. hose to the inlet fitting.
5. Open shutoff valve on LPG tank and check for

leaks.
GASOLINE FUEL FILTER

Remove and Replace
1. Raise the hood and disconnect the negative ter-
minal of the battery.
2. Remove and discard the fuel filter. See Figure 71.
3. Install the new fuel filter and tighten the clamp

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

close the hood.
1. LPG REGULATOR 6. PAPER FILTER

2. INLET FITTING 7. RUBBER WASHER
3. O-RING 8. SCREWS
4. PLASTIC CAP 9. OUTLET FITTING
5. FOAM FILTER 10. SCREEN
Figure 70. GM LPG Regulator
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- Figure 71. Fuel Filter Replacement (GM 4.3L)
ulator.
71

CAUTION
1. FUEL FILTER Disposal of lubricants and fluids must meet lo-
2. FUEL PUMP/SENDER UNIT
LPG FUEL INJECTOR, GM 4.3L ENGINES NOTE: Change the transmission oil filter at the first
EQUIPPED WITH GFI INSTALLED 500 hours of operation on new lift trucks. Before re-
moving the oil filter, make a hole at the top of the
For removal and cleaning instructions, see the sec- filter and allow five minutes for the oil to drain down
tion LPG Fuel System, GM 4.3L Engine with GFI into the transmission. This will reduce the oil that
900 SRM 1242. will run out of the filter and onto the transmission
when the filter is removed.
GASOLINE FUEL INJECTOR, GM ENGINES
NOTE: The drain plug for the transmission is on the
For removal and cleaning instructions, see the sec- lower right side of the cover of the transmission, to-
tion Gasoline Fuel System, GM 4.3L Engine 900 ward the rear of the lift truck.
SRM 1244.
1. Remove drain plug, spring, and screen. See Fig-
FUEL INJECTOR, CUMMINS 4.5L AND ure 72. Drain oil into a container.
QSB 3.3L ENGINE
For removal and cleaning instructions for lift truck
models H80, 90, 100, 110, 120FT) (N005, P005)
equipped with the Cummins 4.5L or QSB 3.3L diesel
engine, contact your local Hyster dealer or see Hys-
ter Hypass Online.
FORKS
WARNING
Never repair damaged forks. DO NOT heat,
weld, cut, drill, or bend the forks. Forks are
made of special steel using special methods.
Replace damaged forks as a set.
Check heel and attachment points of forks with a

penetrant or by magnetic particle inspection.
TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACE
NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF
WARNING CLARITY.
At operating temperature, the transmission oil
is HOT. DO NOT permit the hot oil to touch the 1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
skin and cause a burn. 3. SPRING
4. SCREEN
CAUTION 5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
DO NOT permit dirt to enter the transmission 7. TRANSMISSION BREATHER
when the oil level is checked or the filter is
changed. Dirt can cause damage to the trans- Figure 72. Transmission Oil Change
mission components.
72
TRANSMISSION AND WET BRAKE

WARNING
PLANETARY CARRIER HOUSING OIL
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
CHANGE
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- WARNING
dures. The oil used for the wet brake drive axle or
transmission should not be contaminated. If ei-
Compressed air can move particles so they ther the wet brake planetary carrier housings
cause injury to the user or to other personnel. and/or transmission oil becomes contaminated,
Make sure the path of the compressed air is the oil must be drained and replaced with new
away from all personnel. Wear protective gog- oil.
gles or a face shield to prevent injury to the
eyes.
WARNING
2. Clean screen with cleaning solvent, and dry with At operating temperature, the transmission
compressed air, adjusted to a maximum output and wet brake planetary carrier housing oil is
of 103 kPa (15 psi). HOT. DO NOT permit the hot oil to touch the
3. When oil has drained, first install screen, then
spring, and drain plug.
CAUTION
4. Remove and discard transmission breather. DO NOT permit dirt to enter the transmission
Install new transmission breather and hand or wet brake planetary carrier housing when
tighten. the oil level is checked or the filter is changed.
Dirt will contaminate the oil and cause dam-
5. Remove and discard old oil filter. Apply clean oil age to the transmission and wet brake plane-
to gasket of new filter. Install new filter and hand tary carrier housing components.
tighten.
6. Add oil to transmission at the dipstick tube. The CAUTION

correct oil is shown in the Maintenance Schedule. Disposal of lubricants and fluids must meet lo-
least 50°C (120°F) when checking oil level. NOTE: Change the transmission oil filter at the first
500 hours of operation on new lift trucks. See Fig-
7. Start and run the engine for approximately 5 ure 73. Before removing the oil filter, make a hole
minutes after fill to allow oil to lubricate parts at the top of the filter and allow five minutes for the
within the transmission and wet brake portion oil to drain down into the transmission. This will re-
of the drive axle center section. With the truck duce the oil that will run out of the filter and onto the
in the ON position, See Maintenance Schedule transmission when the filter is removed.
to add additional oil at the transmission dipstick
tube that will need to be added to properly fill the 1. The drain plug for the transmission is on the
wet brake portion of the drive axle center section lower right side of the cover of the transmission,
and transmission. toward the rear of the lift truck. Remove drain
plug, spring, and screen. See Figure 73. Drain oil
NOTE: Transmission oil temperature should be at into a container, once oil is completely drained,
least 50°C (120°F) when checking oil level. reinstall drain plug.
8. Turn the key to the OFF position and check for
leaks and check oil level. If necessary, top off oil.
73
Make sure the path of the compressed air is

away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
3. Clean screen with cleaning solvent, and dry with

compressed air, adjusted to a maximum output
of 103 kPa (15 psi).
4. When oil has drained, first install screen, then

spring, and drain plug.
NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR CLARITY.
1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
3. SPRING
4. SCREEN
5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
7. TRANSMISSION BREATHER
Figure 73. Transmission Oil Change
2. Remove planetary carrier housing drain plug and

fill/level plug. Drain oil into a suitable container.
When oil is completely drained, reinstall drain A. REAR VIEW SHOWN
plug and fill/level plug. Tighten to 30 to 50 N•m B. FRONT VIEW SHOWN
(22 to 37 lbf ft). For lift truck models S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
(G004) see Figure 74. For lift truck models H80, 2. PLANETARY CARRIER HOUSING DRAIN
90, 100, 110, 120FT (N005, P005) see Figure 75. PLUGS
3. CENTER BODY DRAIN PLUG
4. CENTER BODY FILL/LEVEL PLUG
WARNING 5. PLANETARY CARRIER HOUSING (RH)
Cleaning solvents can be flammable and toxic 6. PLANETARY CARRIER HOUSING (LH)
and can cause skin irritation. When using 7. CENTER BODY
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
S80, 100, 120FT; S80, 100FTBCS; S120FTS;
Compressed air can move particles so they S120FTPRS (G004)
cause injury to the user or to other personnel.
74
8. Start and run the engine for approximately 5

minutes after fill to allow oil to lubricate parts
within the transmission and wet brake planetary
carrier housings. With the truck in the ON po-
sition, See Maintenance Schedule to add addi-
tional oil at the transmission dipstick tube that
will need to be added to properly fill the plane-
tary carrier housings and transmission. For lift
truck models S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS (G004) see Figure 74. For
lift truck models H80, 90, 100, 110, 120FT (N005,
P005) see Figure 75.

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

leaks and check oil level.
WET BRAKE CENTER SECTION OIL

CHANGE
Remove
1. Remove the center body fill/level plug. Remov-
ing the fill/level plug will allow the oil to drain
at a faster rate. For lift truck models S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS
(G004) see Figure 74. For lift truck models H80,
90, 100, 110, 120FT (N005, P005) see Figure 75.
A. REAR VIEW SHOWN 2. Place and empty container under the center body
B. FRONT VIEW SHOWN drain plug.
1. PLANETARY CARRIER HOUSING FILL/LEVEL 3. Remove the center body drain plug, and wait un-
PLUGS til oil has drained completely.
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER BODY FILL/LEVEL PLUG Install
5. PLANETARY CARRIER HOUSING (RH) 1. Install drain plug for the center body. Tighten to
6. PLANETARY CARRIER HOUSING (LH) 30 to 50 N•m (22 to 37 lbf ft). For lift truck mod-
7. CENTER BODY els S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS (G004), see Figure 74. For lift truck
models H80, 90, 100, 110, 120FT (N005, P005),
see Figure 75.
H80, 90, 100, 110, 120FT (N005, P005)
5. Remove and discard transmission breather. CAUTION

Install new transmission breather and hand Before adding oil, ensure the truck is parked
tighten. and on level ground.
6. Remove and discard old oil filter. Apply clean oil 2. Add oil at the fill/level port for the center body
to gasket of new filter. Install new filter and hand until the oil/fill level port has overflowed. The
tighten. correct oil is shown in the Maintenance Sched-
7. Add oil to transmission at the dipstick tube. The ule or Figure 76. For lift truck models S80, 100,
correct oil is shown in the Maintenance Schedule. 120FT; S80, 100FTBCS; S120FTS; S120FTPRS
75
(G004) see Figure 74. For lift truck models H80, 3. Install oil fill/level plug. Tighten to 30 to 50 N•m
90, 100, 110, 120FT (N005, P005) see Figure 75. (22 to 37 lbf ft).
A. RIGHT PLANETARY CARRIER HOUSING - USE JDM J20C

B. LEFT PLANETARY CARRIER HOUSING - USE JDM J20C
C. CENTER BODY - USE SAE 80W/90
1. PLANETARY FILL/LEVEL PLUGS 5. RIGHT PLANETARY CARRIER HOUSING
2. PLANETARY DRAIN PLUGS 6. LEFT PLANETARY CARRIER HOUSING
3. CENTER BODY FILL/LEVEL PLUG 7. CENTER BODY
Figure 76. Oil Application Diagram
BRAKE OIL (MASTER CYLINDER), CAUTION

CHANGE DO NOT use "DOT" fluid, only use Dexron III
1. Remove the dashboard from the cowl. oil from a sealed container to prevent possible
damage to the brake system.
CAUTION 3. Remove the brake oil reservoir cover and cylin-

Disposal of lubricants and fluids must meet lo- drical block drain plug. Pour the oil into a
cal environmental regulations. suitable container with a 0.35 liter (0.74 pt)
minimum capacity. Install the cylindrical block
2. Remove the brake oil reservoir from the bracket drain plug. Refill the reservoir with clean oil
on the cowl. See Figure 77. from a sealed container and install the cover on
the reservoir. The correct oil is shown in the
WARNING Maintenance Schedule.
Small amounts of water in the brake system 4. Install the reservoir into the bracket located on
can cause reduced braking performance if the the cowl.
water reaches the wheel cylinder areas. DO
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced.
76
BRAKE OIL (DRY BRAKE), REMOVE

Perform the following procedure to remove used
brake oil from the remainder of the brake system.
1. Ensure that the master cylinder reservoir is

filled with brake oil.
NOTE: This procedure cannot be performed by one

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

of the wheel cylinder. Put the other end of the
hose into a empty container.
3. Loosen the bleed screw at the wheel cylinder one

turn so that the used brake oil can be removed
from the brake system. Slowly push the brake
pedal and hold it at the end of its stroke. Close
the bleed screw. Release the brake pedal.
NOTE: The new brake oil will be easily recognized, as

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

brake oil in the container.
1. RESERVOIR CAP 8. NIPPLE
2. BRAKE OIL 9. MASTER 5. Check the level of the brake oil in the reservoir
RESERVOIR CYLINDER for the master cylinder during the procedure.
3. RESERVOIR 10. CYLINDRICAL Make sure to keep the brake oil at the correct
MOUNTING BLOCK DRAIN
BRACKET PLUG level.
4. COWL 11. CYLINDRICAL
5. UPPER BRAKE OIL BLOCK 6. Repeat the procedure for the other wheel cylin-
SUPPLY HOSE 12. CYLINDRICAL der.
6. CYLINDRICAL BLOCK MOUNTING
BLOCK OUTLET BRACKET
FITTING CAPSCREW
7. LOWER BRAKE
OIL SUPPLY HOSE
Figure 77. Brake Oil Change
77
SERVICE BRAKES (DRY BRAKE) 4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
Check brake lining and parts of the brake assembly air.
for wear or damage. The minimum acceptable brake
lining thickness is 1.0 mm (0.040 in.). If the brake DIFFERENTIAL (DRY BRAKE)
linings are worn thinner than the specification, re-
place the brake linings. See the section Brake Sys- NOTE: Additional information on the differential can
tem 1800 SRM 1247 for the removal and installation be found in the section Drive Axle and Differential
procedures of the drive wheels and brake drums. If Assembly Repair, (Dry Brake) 1400 SRM 1245.
the brake linings or brake shoes are worn or dam-
aged, they must be replaced. Brake shoes must be 1. Place the lift truck on blocks. See How to Raise
replaced in complete sets. Inspect brake drums for Drive Tires in this manual.
cracks or damage. Replace any damaged parts.
2. The differential and drive axle use the same oil
supply. Place a container with a minimum capac-
WARNING ity of 5 liter (5.3 qt) under the differential. Re-
Brake linings can contain dangerous fibers. move the drain plug located in the bottom of the
Breathing the dust from these brake linings differential and drain the oil from the differential
is a cancer or lung disease hazard. DO NOT completely. Install the drain plug.
create dust! DO NOT clean brake parts with
compressed air or by brushing. Follow the 3. The fill hole is on the front of the differential
cleaning procedure in this section. When the housing. Add oil shown in the Maintenance
brake drums are removed, DO NOT create Schedule until the oil level is at the lower edge of
dust. the fill hole. Install fill plug and rotate the drive
wheels in order to get oil pumped into the axle.
DO NOT sand, grind, chisel, hammer, or change Remove the fill plug and check the oil level. Add
linings in any way that will create dust. Any oil, as necessary. Install the fill plug and check
changes to brake linings must be done in a re- for leaks. See Figure 78 and Figure 79.
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
Brake cleaning procedures are as follows:
CAUTION
DO NOT use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
of brake parts. DO NOT permit oil or grease in
the brake fluid or on the brake linings.
1. DO NOT release brake lining dust from brake

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 Figure 78. Drive Axle (Dry Brake) Fluid Fill
a DANGEROUS FIBERS warning label on the for Lift Truck Models S80, 100, 120FT; S80,
plastic bag or airtight container. 100FTBCS; S120FTS; S120FTPRS (G004)
78
Legend for Figure 78 • Check all exhaust pipe extension connectors for
leaks and tighten, if necessary.
1. DRIVE AXLE • Visually inspect converter for correct muffler
2. CHECK/FILL PLUG
3. DRAIN PLUG mounting and tail pipe mounting.
• Check for any leaks at the inlet and outlet of the
converter.
VALVE CLEARANCE, CHECK AND

ADJUST FOR CUMMINS QSB 3.3L DIESEL
ENGINE
The Cummins QSB 3.3L engine does not require
valve clearance adjustments during normal service.
See the Maintenance Schedule for valve clearances.
Check the valve clearance and make adjustments as

needed. To adjust the valve clearances do the follow-
ing:
1. Align the TDC mark on the crankshaft pulley

with the engraved mark on the block. See Fig-
ure 80.
2. Adjust ONLY the valves shown in Figure 81, by

1. CHECK/FILL PLUG
2. DRAIN PLUG loosening the locknut with a wrench and adjust-
3. DRIVE AXLE ing the valve clearance using a screwdriver or
Allen wrench.
Figure 79. Drive Axle (Dry Brake) Fluid Fill
for Lift Truck Models H80, 90, 100, 110, 120FT
(N005, P005)
TEST LPG/GAS REGULATOR PRESSURE

For more information regarding the Test LPG/GAS
Regulator Pressure, see the section LPG Fuel Sys-
tem, GM 4.3L Engine with GFI 900 SRM 1242 and
Gasoline Fuel System, GM 4.3L Engine 900 SRM
1244.
CHECK THROTTLE SHAFT FOR STICKING

Check Throttle body return action to ensure throttle
shaft is not sticking. Repair if necessary.
INSPECT EXHAUST MANIFOLD AND

PIPING FOR LEAKS
To check the exhaust manifold and piping for leaks,
1. CRANKSHAFT PULLEY
perform the following: 2. DRIVE BELT
3. ENGRAVE TIMING MARK
• Check the exhaust manifold at the cylinder head
for leaks. Ensure that all bolts and shields are in Figure 80. Cummins QSB 3.3L TDC Mark
place.
• Check exhaust pipe fasteners to manifold for leaks
to ensure they are tight. Repair if necessary.
79
5. Perform Step 2 and Step 3 to adjust ONLY the

valves shown in Figure 83. See the Maintenance
Schedule for valve clearances.
1. EXHAUST VALVE 4. CYLINDER 2

2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4
Figure 81. Cummins Valve Adjustment 2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4
3. Tighten the lock nut to 24 N•m (212 lbf in) and
measure valve lash. Figure 83. Cummins Valve Adjustment
4. Mark the vibration damper and rotate the crank-

shaft 360 degrees. See Figure 82.
1. TIMING PIN
2. VIBRATION DAMPER
Figure 82. Cummins Vibration Damper
80
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000- NOTE: Replace the hydraulic oil filter at the same
hour, and 2000-hour checks prior to performing the time the oil is changed.
procedures in this section.
1. Place a container with a minimum capacity of
HYDRAULIC OIL, REPLACE 39.4 liter (42 qt) under the drain plug at the
bottom of the hydraulic tank. To drain the oil,
remove the drain plug from the bottom of the
WARNING hydraulic tank. See Figure 84. When the tank
At operating temperature the hydraulic oil is is empty, inspect the inside of the tank for any
HOT. DO NOT permit the hot oil to touch the foreign matter or possible fungus. If necessary,
skin and cause a burn. clean the inside of the tank in accordance with
the instructions found in the section Frame 100
CAUTION SRM 1243. When either the inspection or the
DO NOT permit dirt to enter the hydraulic sys- cleaning of the tank is completed, install the
tem when the oil level is checked or the filter drain plug in the bottom of the hydraulic tank.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. CAUTION
Never operate the hydraulic pump without oil Additives may damage the hydraulic system.
in the hydraulic system. The operation of the Before using additives, contact your local Hys-
hydraulic pump without oil will damage the ter dealer.
pump. 2. Fill hydraulic tank with oil specified in the Main-
tenance Schedule.
CAUTION
3. When the oil level is correct, operate system and
check for leaks.
NOTE: Heavy-duty or contaminated applications will

require hydraulic oil change at 2000 hours.
81
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 84. Hydraulic Oil Change
VALVE CLEARANCE, CHECK AND 2. Adjust ONLY the valves shown in Figure 86, by
ADJUST FOR CUMMINS 4.5L DIESEL loosening the lock nut with a wrench and adjust-
ENGINE ing the clearance using a screwdriver or Allen
wrench.
The Cummins 4.5L engine does not require valve
clearance adjustments during normal service. See 3. Tighten the lock nut to 24 N•m (18 lbf in) and
the Maintenance Schedule for valve clearances. measure valve lash.
Check the valve clearance and make adjustments as 4. Remove the timing pin. See Figure 85.
needed. To adjust the valve clearance, do the follow- 5. Mark the vibration damper and rotate the crank-
ing: shaft 360 degrees. See Figure 87.
1. Rotate the engine until it is at TDC for cylinder 6. Perform Step 2 and Step 3 to adjust ONLY the
number one (intake and exhaust valves closed). valves shown in Figure 88.
Insert timing pin. See Figure 85.
82
1. INSERT TIMING PIN HERE

2. FUEL/WATER SEPARATOR FILTER
3. TIMING BELT
Figure 85. Timing Pin Location, Cummins 4.5L Diesel Engine

2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4 1. TIMING PIN
2. VIBRATION DAMPER
Figure 86. Cummins Valve Adjustment
Figure 87. Cummins Vibration Damper
83
the area to be inspected, then applying penetrant and

developer. If a crack is present, it will show up as a
well-defined maroon/red line as the dye penetrant is
drawn out into the white developer coating.
Contact your local Hyster dealer for instructions if

a crack is detected.
1. Carriage inspection: welded joints between cast

insert and top and vertical carriage bars. See
Figure 89.
2. Mast inspection:
2. INTAKE VALVE 5. CYLINDER 3 a. Welded joints of lower crossmember of mast
3. CYLINDER 1 6. CYLINDER 4 outer channel and related gussets. See Fig-
ure 90.
Figure 88. Cummins Valve Adjustment
b. Welded joints around tilt anchor and inter-
WELD INSPECTION mediate cross member. See Figure 90.
Initial inspection is suggested at 4000 hours, with NOTE: The welded boss for tilt lock option is typi-
subsequent inspections at 2000 hour intervals. Re- cally located on right side of mast channel above tilt
moval of carriage from mast is not required, but rec- anchor bracket.
ommended, to perform inspection. Removal of at-
tachment is recommended for access to carriage. c. Right side rail of outer mast channel in area
of welded boss for optional tilt lock rod. See
NOTE: Visual inspection supported by dye penetrant Figure 90.
application is recommended with focus on areas de-
fined below.
NOTE: Dye penetrant checks are made in a three-

step process using a cleaner, penetrant, and devel-
oper. Follow manufacturers instructions for cleaning
84
A. FRONT VIEW B. REAR VIEW

1. WELDS
Figure 89. Carriage Bar Welds for Inspection
85
A. TYPICAL "XM" MAST

B. TYPICAL "FT" MAST
C. WELDED BOSS FOR TILT LOCK OPTION
1. WELDS
Figure 90. Mast Welds for Inspection
86
8000 SRM 1248 Safety Procedures When Working Near Mast
Safety Procedures When Working Near 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 91.
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.
87
Safety Procedures When Working Near Mast 8000 SRM 1248
Figure 91. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
88
8000 SRM 1248 Fuel Filter Water Removal

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

NOTE: The following procedure only pertains to lift
trucks equipped with Cummins 4.5L and QSB 3.3L
diesel engines.
1. Shut off the engine.
NOTE: The drain valve is located on the bottom of

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

remove the air inlet elbow. See Figure 92.
CAUTION
Drain water/fuel into a container and dispose
in accordance with local environmental regu-
lations.
3. Turn the drain valve clockwise approximately

3 1/2 turns. Drain fuel filter until clear fuel is
visible.
CAUTION 1. AIR INLET ELBOW

DO NOT overtighten when closing the drain 2. FUEL FILTER ELEMENT
valve. Overtightening can damage the threads. 3. DRAIN VALVE
4. Close the drain valve by lifting and turning Figure 92. Engine Fuel Filter Drain Valve
clockwise until it is hand-tight. Location (Cummins 4.5L Shown)
89
Hood Latch Check 8000 SRM 1248
Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is
The hood, hood latch, and latch striker must be fully closed after two clicks of the latch.
correctly adjusted for the correct operation of
the operator restraint system. 4. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center
1. Install hood latch on frame of hood. See Fig- of hood latch. Open hood and tighten capscrews
ure 93. Tighten capscrews so that hood latch can for latch.
still move when hood is closed.
5. Check operation of hood latch. Have an operator
2. Install latch striker in highest slot position. sit in the seat. Make sure hood is fully closed
Check that latch striker is in center of jaws of (two clicks). Also check that hood touches rubber
hood latch when hood closes. bumper. If necessary, repeat Step 4.
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME
Figure 93. Hood Latch Check
90
8000 SRM 1248 Lift Chain Adjustments
Lift Chain Adjustments

WARNING
section.
Never allow anyone under a raised carriage.

DO NOT put any part of your body in or
through the lift mechanism unless all parts
of the mast are completely lowered and the
engine is STOPPED.
DO NOT try to find hydraulic leaks by putting

your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.
During test procedures for the hydraulic sys-

1. MAST
tem, fasten the load to the carriage with chains 2. CARRIAGE
to prevent it from falling. Keep all personnel 3. FORK
away from the lift truck during the tests. 4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE THE FLOOR LEVEL.
When lift chains are correctly adjusted:
• Tension will be the same on each chain of chain Figure 94. Lift Chain Adjustments With Forks
set. Check tension by pushing on both chains at Installed
the same time.
• Chain length will be correct.
• Chains must travel freely through complete cycle.
NOTE: When chain adjustments are complete, make

sure the threads on the nuts of the chain anchors
are completely engaged. Make sure all adjustment is
not removed from the chain anchors. Chain anchors
must be able to move on their mounting.
1. When adjusting lift chains on forklift trucks

equipped with the forks installed, go to Step 2.
If forklift truck is equipped with an attachment
without forks, go to Step 3.
NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage 1. MAST

2. CARRIAGE
until bottom of the fork heel is 6 ±3 mm (0.24 3. DISTANCE FROM FLOOR TO LOWER
±0.12 in.) above floor level. See Figure 94. CARRIAGE BAR
3. Adjust chain anchors which support carriage un- Figure 95. Lift Chain Adjustment Without
til the bottom of lower carriage bar is above the Forks Installed
floor level as shown in Table 2. See Figure 95.
91
Jump-Starting the Lift Truck 8000 SRM 1248
In Table 2, the masts are divided by class. Each Table 2. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK
CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by push- touching.
ing or towing lift truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these DO NOT try to start the engine by pushing or
procedures carefully when connecting the jumper towing the lift truck. Damage to the hydraulic
cables: system can occur if engine is started by push-
ing or towing lift truck.
1. Disconnect the negative battery terminal of the
lift truck being started. 1. Always connect positive jumper cable to positive
terminal of discharged battery and negative
2. Always connect positive jumper cable to positive jumper cable to negative terminal.
terminal of discharged battery and negative
jumper cable to negative terminal. 2. Always connect jumper cable, that is the ground
cable, last.
3. Always connect jumper cable, that is the ground
cable, last. 3. Always connect jumper cables to discharged lift
truck battery before connecting them to the fully-
4. Always connect jumper cables to discharged bat- charged lift truck battery.
tery before connecting them to booster battery.
92
8000 SRM 1248 Overhead Guard Changes
Welding Repairs
warning. Should work be performed, utilize
WARNING good industrial hygiene practices including
Welding can cause a fire or an explosion. Al- removal of all paint (prime and finish coats) to
ways follow the instructions in the Frame sec- the metal around the area to be welded, local
tion if a fuel or hydraulic tank must be welded. ventilation, and/or supplied-air respiratory
Make sure there is no fuel, oil, or grease near protection.
the weld area. Make sure there is good venti-
lation in the area where the welding must be
done. CAUTION
When an arc welder is used, always disconnect
DO NOT heat, weld, or bend forks. Forks are the ground cable from the battery in the lift
made of special steel using special methods. truck. This action will prevent damage to the
The strength of the overhead guard can be re- alternator or the battery.
duced by welding or heating. Get information
from your dealer for Hyster lift trucks before Connect the ground clamp for the arc welder as
welding on a mast. close as possible to the weld area. This action
will prevent damage to a bearing from the large
Forklift frames and components may be current from the welder.
painted with a catalyzed paint such as
polyurethane or a two-part primer. Weld- Some repairs require welding. If an acetylene or arc
ing, burning, or other heat sufficient to cause welder is used, make sure procedures in previous
thermal decomposition of the paint may re- WARNING and CAUTION are done.
lease isocyanates. These chemicals are allergic
See the American National Standard Safety in Weld-
sensitizers to the skin and respiratory tract
ing and Cutting, AWS Z 49.1 - 1999.
and overexposure may occur without odor
Overhead Guard Changes

See your dealer for Hyster lift trucks BEFORE
WARNING performing any changes to the overhead
DO NOT weld mounts for lights or accessories guard.
to the legs of the overhead guard. Changes that
are made by welding or by drilling holes that No welding or drilling on legs of overhead guard is
are too big or in the wrong location can reduce permitted as per previous WARNING.
the strength of the overhead guard.
93
Wheel and Tire Replacement 8000 SRM 1248
Wheel and Tire Replacement

GENERAL Wheels must be changed and tires repaired by
trained personnel only.
The S series lift trucks have solid rubber tires (often
called cushion tires) that are pressed onto the rim. Always wear safety glasses.
The H series lift trucks have pneumatic tires or solid
rubber tires that look like pneumatic tires. These 1. Raise lift truck as described in How to Put Lift
variations in tires also cause a variation in the types Truck on Blocks in this manual.
of wheels and the disassembly and assembly proce-
2. Remove wheel nuts and remove wheel from lift
dures.
truck. Lift truck wheels are heavy.
SOLID RUBBER TIRE, CHANGE
Remove and Install Tire on Wheel
(S SERIES)
NOTE: Make sure the tires are installed on the
NOTE: wheels so that the outside edges of the tire and
wheel are as shown in Figure 96. Also, check the
Solid rubber tires made from softer or harder ma-
Nameplate of the lift truck for the correct tire size
terial can be installed as optional equipment. The
and tread width.
tread on the sold rubber tires can be either smooth
or it can have lugs. Do not mix types of tires or tread 1. The correct tools, equipment, and a press ring
on lift truck. See Figure 96. must be used for each size of wheel. Use a press
to push wheel from rim and tire. The capacity of
WARNING the press must be approximately 355 to 1779 kN
The type of solid rubber tire is shown on the (80,000 to 400,000 lbf). For the tire sizes, see the
Nameplate. Make sure the Nameplate is cor- Nameplate.
rect for the type of tires on the lift truck. The
2. When the drive wheels are installed on the lift
12000 lb. capacity solid rubber tired fork lift
truck, tighten wheel nuts to a torque value of 610
must be equipped with high load capacity
to 680 N•m (450 to 502 lbf ft).
steering tires.
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER 2. WHEEL 3. OVERHANG
TIRE
Figure 96. Tires and Wheels for S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS (G004)
Lift Trucks
94
8000 SRM 1248 Wheel and Tire Replacement
3. The steering wheels are fastened to the spindle sure the nameplate is correct for the type of
of the steering axle with a large castle nut. Make tires on the lift truck.
sure inner and outer bearings are correctly lu-
bricated with grease. Install inner bearing WARNING
assembly and wheel on spindle. Install outer
Wheels must be changed and tires repaired by
bearing cone and castle nut. Tighten castle nut
trained personnel only.
up to 203 N•m (150 lbf ft) while rotating hub
in both directions to properly seat the bearings, Deflate tire completely before removing the
loosen the castle nut until wheel hub turns freely wheel from the lift truck. If dual wheels are
with no end play. Tighten castle nut to 34 N•m used, deflate both tires. Air pressure in the
(25 lbf ft). If the cotter pin cannot be installed, tires can cause the tire and rim parts to ex-
loosen the castle nut to the first position where plode, causing serious injury or death.
the cotter pin can be installed. Install cap for
bearings. Always wear safety glasses.
PNEUMATIC TIRE WITH TUBE, REPAIR Never loosen the nuts that hold the inner and
outer wheel halves together when there is air
Remove Wheels From Lift Truck pressure in the tire.
1. Put lift truck on blocks as described in How to

WARNING Put Lift Truck on Blocks at the beginning of this
A solid rubber tire that is the same shape as section.
a pneumatic tire can be installed on a three-
piece or four-piece wheel for a pneumatic tire. 2. Remove air from tire. Remove valve core to make
DO NOT make changes in the parts of the rim if sure all air is out of inner tube. Push a wire
this type of solid rubber tire is installed instead through valve stem to make sure valve stem does
of a pneumatic tire. Changes to the parts of the not have a restriction.
rim can cause a failure of the wheel and cause
an accident. 3. Remove wheel nuts and remove wheel and tire
from lift truck. Lift truck tires and wheels are
heavy.
WARNING
The type of tire and the tire pressure (pneu-
matic tires) are shown on the nameplate. Make
95
Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Fig-
ure 97. There are several types of wheels used on
this series of lift trucks.
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 97. Types of Pneumatic Wheels
Remove Tire From Two-Piece Wheel
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.
STEP 1.
Remove nuts that fasten wheel rims together.
96
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
to cause an injury.
STEP 1.
Loosen tire bead from side flange.
97
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen bead from other side of wheel rim. Remove
valve stem from wheel.
STEP 4.
Remove wheel from tire.
Install Wheel in Tire parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
WARNING not touch. The clearance at the ends of the lock
ring will be approximately 13 to 25 mm (0.5 to
Damage to the tire and wheel assembly and in-
1.0 in.) after it is installed. If the clearance is
jury or death can occur if you do not do the fol-
wrong, the wrong part has been used.
lowing procedures:
• Clean and inspect all parts of the wheel be- 1. Clean and inspect all parts of wheel. Paint any
fore installing the tire. parts that have rust or corrosion.
• DO NOT use any damaged or repaired wheel
parts. 2. Install new inner tube in tire. Used tubes and
• Make sure all parts of the wheel are the cor- flaps can cause tire failure.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or 3. Apply a rubber lubricant or a soap solution to the
manufacturers of wheels. tire bead and tube.
• DO NOT mix types of tires, type of tire tread,
4. Install new tire flap.
or wheel assemblies of different manufactur-
ers on any one lift truck. 5. Make sure rim is the correct size for tire. Lubri-
cate part of wheel that contacts bead and flap.
DO NOT use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
98
6. Install the three-piece or four piece wheel in the

CAUTION tire a shown in Install Three-Piece or Four-Piece
DO NOT use pneumatic-shaped, solid tires on Wheel in Tire.
two-piece bolt together drive wheels. Spinning
may occur. 7. Install the two-piece wheel in the tire as shown
in Install Tire on Two-Piece Wheel.
Install Three-Piece or Four-Piece Wheel in Tire
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause an injury.
STEP 1.
Install inner tube and rubber flap in tire.
STEP 2.
Install wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
STEP 3.
Turn over rim and tire. Put blocks under rim so rim
is 8 to 10 cm (3 to 4 in.) above floor. Install flange
seat (if used) and lock ring.
99
STEP 4.
Put lock ring in the correct position on rim. Add air
pressure to tire as described in Install Wheel in Tire.
Install Tire on Two-Piece Wheel

CAUTION
DO NOT use pneumatic-shaped solid tires on
WARNING two-piece bolt together drive wheels. Spinning
Wheels can explode and cause injury or death may occur.
if the following procedures are not followed:
• Clean and inspect all parts of the wheel be- 1. Clean and inspect all parts of wheel. Paint any
fore installing the tire. parts that have rust or corrosion.
• DO NOT use any damaged or repaired wheel
parts. 2. Install new inner tube in tire. Used tubes and
• Make sure all parts of the wheel are the cor- flaps can cause tire failure.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or WARNING
manufacturers of wheels. DO NOT lubricate the tire bead with antifreeze
• DO NOT mix types of tires, type of tire tread, or petroleum-based liquid. Vapors from these
or wheel assemblies of different manufactur- liquids can cause an explosion during inflation
ers on any one lift truck. or use.
DO NOT use a steel hammer on the wheel. Use 3. Apply a rubber lubricant or a soap solution to tire
a rubber, lead, plastic, or brass hammer to put bead and tube.
parts together. Make sure the side ring is in the
correct position. The ends of the side ring must 4. Install new tire flap.
not touch. The clearance at the ends of the lock
ring will be approximately 13 to 25 mm (0.5 to 5. Make sure rim is the correct size for tire. Lubri-
1.0 in.) after it is installed. If the clearance is cate part of wheel that contacts bead and flap.
wrong, the wrong part has been used.
Install Two-Piece Wheel in Tire
STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
100
STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (130 lbf ft). Add air pressure to tire (see
nameplate).
ADD AIR TO PNEUMATIC TIRES WITH adjustments. The clearance at the ends of the
TUBE lock ring will be approximately 13 to 25 mm (0.5
to 1.0 in.) when the tire has the correct air pres-
sure.
WARNING
Add air pressure to the tires only in a safety Install the Wheels
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck Install wheel on the hub. Tighten nuts in a cross
that fastens onto the valve stem of the inner pattern to a torque value of 610 to 680 N•m (450 to
tube. Make sure there is enough hose to permit 502 lbf ft) for drive wheel nuts and 610 to 680 N•m
the operator to stand away from the safety cage (450 to 502 lbf ft) for steer wheel nuts. If the wheels
when air pressure is added to the tire. are the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
DO NOT sit or stand by the safety cage. DO they are installed.
NOT use a hammer to try and correct the po-
sition of the side flange or lock ring when the
tire has air pressure greater than 20 kPa (3 psi).
1. Put tire in a safety cage.
2. Add 20 kPa (3 psi) of air pressure to tire. See

Figure 98.
3. Check that all wheel parts are correctly installed.

Hit lock ring lightly to make sure it is in the seat.
4. If installation is correct, add air pressure to tire

to the specified pressure.
5. Check that all wheel parts are correctly installed.

If installation is not correct, remove all air pres-
sure from tire. Remove valve core to make sure
all air pressure has been removed and then make Figure 98. Add Air to Tires
101
Dual Drive Wheels, Install

NOTE: Some lift trucks have dual drive wheels. The
following procedures describe the steps to install the
dual sets of wheels.
1. Install inner wheel on hub. If the wheels are

the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
they are installed.
2. Install wheel adapter spacers on the inner wheel

studs and tighten spacers to 100 to 125 N•m (74
to 92 lbf ft). Install the dual hub assembly and
inner wheel nuts on the spacers and tighten the
wheel nuts to 610 to 680 N•m (450 to 502 lbf ft).
See Figure 99.
3. Install outer wheel on dual hub assembly.

Tighten nuts to a torque value of 610 to 680 N•m
(450 to 502 lbf ft). If the wheels are the two-piece
rims, make sure nuts that fasten rim halves
together are toward brake drum when they are
installed.
4. Install the valve extension bracket and tighten

the attaching nut to 8 N•m (70 lbf in). Install 1. TIRE
the valve extension hose into the bracket. See 2. DUAL HUB ASSEMBLY
Figure 99. 3. WHEEL NUT
4. WHEEL
5. WHEEL ADAPTER SPACER
6. VALVE EXTENSION
7. BRACKET
Figure 99. Dual Drive Wheels Installation
102
PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be
Remove Wheels From Lift Truck used with a tube.
The main component of a TBS is a special rubber

WARNING
ring that fits inside the tire between the tire beads
Wheels must be changed and tires repaired by to ensure the air tightness of the existing wheel and
trained personnel only. the tubeless tire assembly. See Figure 97.
Deflate tire completely before removing the 1. Put lift truck on blocks as described in at begin-
wheel from the lift truck. If dual wheels are ning of this section.
used, deflate both tires. Air pressure in tires
can cause the tire and rim parts to explode 2. Remove the valve cap and core to remove all air
causing serious injury or death. from the tire.
Always wear safety glasses. 3. Remove the wheel nuts and remove the wheel
and tire from the lift truck. Lift truck tires and
Never loosen the nuts that hold the inner and wheels are heavy.
outer wheels halves together when there is air
pressure in the tire.
Remove Tire From Wheel
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 97.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.
103
STEP 2.
Put wheel and tire assembly on the press. Position
the feet of the press on the loose flange. Press down
on loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel only)
from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove
it.
104
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liq-
uids can cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubri-
cate tire beads and the inside of the tire, up to the
tire shoulders. Apply lubricant to the entire under-
side of the TBS.
NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve
slot. The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and remov-
ing the lubricated valve several times. If a three- or
four-piece wheel is being used, remove the valve. If
a two-piece wheel is being used, leave valve in valve
hole.
If the TBS has two-valve holes, lubricate the plastic

plug and insert into valve hole that will not be used.
105
STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in the
TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot
in the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
106
STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.
Push down on the press to depress the tire beads un-

til locking ring groove is fully exposed.
STEP 8.
Insert tire tool into the locking ring groove, and a
vise grip on other end. Remove vise grip. Release
the press and check that all component parts are
correctly positioned. Replace the valve core.
STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to ensure all components are correctly sealed. Remove
the press from wheel and tire assembly.
Add Air to Pneumatic Tubeless Tire
WARNING
Add air pressure to tires only in safety cage.
Inspect safety cage for damage before use.
When air pressure is added, use a chuck that
fastens onto valve stem. Make sure there is
enough hose to permit operator to stand away
from safety cage when air pressure is added to
tire.
DO NOT sit or stand by safety cage.
1. Put tire in safety cage. See Figure 100.
2. Add air to tire to the recommended air pressure

that is shown on the Nameplate. Install valve Figure 100. Add Air to Tires
cap to ensure air stays in the tire.
107
Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
Install wheel on hub. Tighten nuts in a cross pat-
tern to a torque value of 610 to 680 N•m (450 to
502 lbf ft) for drive wheel nuts and 610 to 680 N•m WARNING
(450 to 502 lbf ft) for steer wheel nuts. If wheels Wheels must be changed and tires repaired by
are two-piece rims, make sure nuts that fasten rim trained personnel only.
halves together are toward brake drum when they
are installed. Always wear safety glasses.
1. Put lift truck on blocks as described in How to

Put Lift Truck on Blocks at the beginning of this
section.
2. Remove wheel nuts and remove wheel and tire

from lift truck. Lift truck tires and wheels are
heavy.
Remove Wheel From Tire

NOTE: When you disassemble the wheels, see Figure 97. There are several types of wheels used on these series
of lift trucks.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury. Always wear safety glasses.
STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side flange.
108
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
109
Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 97. There are several types of wheels used on these series
of lift trucks. DO NOT use a two-piece pneumatic wheel for solid rubber tires.
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following
procedures.
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not
touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.
110
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side ring,
and lock ring in position on wheel rim. Install cage
on tire. Use press to push tire onto wheel rim so side
flange and lock ring can be installed.
STEP 4.
While the cage is holding the tire on the wheel rim,
install lock ring. Use a tire tool to make sure lock
ring is in the correct position.
111
Adhesives and Sealants 8000 SRM 1248
Adhesives and Sealants

Loctite®
Hyster Part No. Description Size
Part No.
360387 222 Small Screw Threadlock (Purple) 50 ml
318702* 242 Removable Threadlock (Blue) 10 ml
226414* 271 High Strength Threadlock (Red) 10 ml
318996 277 High Viscosity Threadlock (Red) 50 ml
318650 290 Low Viscosity Threadlock (Green) 0.02 oz
251099 290 Low Viscosity Threadlock (Green) 50 ml
355844* 422 SuperBonder® Adhesive 3 ml
350830 515 Gasket Eliminator (Purple) 6 ml
313022* 515 Gasket Eliminator (Purple) 50 ml
273338* 567 Pipe Sealant with Teflon® 50 ml
318705 595 Super Flex® Silicone 100 ml
318701* 609 Retaining Compound 10 ml
341959 680 Retaining Compound 50 ml
226415 Primer T - Aerosol 6 oz
251979 767 Antiseize Compound 1 lb
360053-10 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
318700 Adhesive and Sealant Kit (Contains one each of *
items)
*Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700.
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.
112
TECHNICAL PUBLICATIONS
8000 SRM 1248 8/11 (1/11)(12/10)(8/10)(7/10)(6/10)(2/10)(6/09)(5/08)(10/07)(7/07)(3/07) Printed in U.S.A.

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PERIODIC

PART NO. 1624742 8000 SRM 1248

• 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.

©2011 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

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

A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)

Figure 1. Counterweight Types

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 4.3L LPG Trucks With GFI Installed

Figure 4. GM 4.3L LPG Trucks With PSI Installed

Figure 5. GM 4.3 Gasoline Trucks

Table 1. Maintenance Schedule

Safety Labels X Replace as See Parts Manual

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

10 Hydraulic Tank X C Inspect and See Parts Manual

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)

Tilt Cylinder Ends L 4 Fittings Multipurpose

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 8. Tire Check

• With the hood closed and in the locked position,

Figure 9. Lift Chain Check

Operator Restraint System

Emergency Locking Retractor (ELR)

NOTE: Lift trucks produced after November 2005

to the ground so that the best ergonomic position

Seat Position Adjustment (Swivel Seat)

Seat Adjustment for Operator Weight

NOTE: It is important to adjust the weight setting for

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

Figure 12. Seat Adjustment

NOTE: It is important to adjust the weight setting for

1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER

Figure 13. Seat Adjustment

Hood and Seat Latches WARNING

Fuel, Oil, and Coolant Leaks, Check

Never operate the hydraulic pump without oil

After the engine has stopped, wait one minute before

Check the hydraulic system for leaks and damaged or

1. TILT LEVER 2. GAS CYLINDER WARNING

Legend for Figure 15

Figure 15. Cummins 4.5L Diesel Engine

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

A. GAS ENGINE B. LPG ENGINE

Figure 17. GM Engine Maintenance Points With GFI Installed