PERIODIC

MAINTENANCE
H6.0FT, H7.0FT [H006, J006]

PART NO. 1653227 8000 SRM 1322

 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.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Serial Number Data ............................................................................................................................................ 1
How to Move Disabled Lift Truck .......................................................................................................................2
How to Tow Lift Truck .................................................................................................................................... 2
How to Put Lift Truck on Blocks ........................................................................................................................ 3
How to Raise Drive Tires ................................................................................................................................ 3
How to Raise Steering Tires ........................................................................................................................... 3
How to Clean a Lift Truck .................................................................................................................................. 4
Maintenance Schedule ............................................................................................................................................ 5
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 22
How to Make Checks With Engine Stopped .................................................................................................... 22
Tires and Wheels ........................................................................................................................................... 22
Safety Labels ..................................................................................................................................................23
Mast, Carriage, Lift Chains, Header Hoses, Attachment ........................................................................... 23
Operator Restraint System ........................................................................................................................... 24
Emergency Locking Retractor (ELR) ........................................................................................................24
Adjust Seat - Full Suspension ...................................................................................................................24
Adjust Seat - Internal Suspension ............................................................................................................26
Seat Plate and Seat Rails ..............................................................................................................................26
Engine Compartment .................................................................................................................................... 26
Paper Application .......................................................................................................................................... 26
Fuel, Oil, and Coolant Leaks, Check ............................................................................................................ 27
Hydraulic Hoses .............................................................................................................................................28
Coolant Hoses ................................................................................................................................................ 28
Steering Column Gas Cylinder ..................................................................................................................... 28
Transmission ................................................................................................................................................. 28
Hydraulic System Oil .................................................................................................................................... 28
Engine Oil ...................................................................................................................................................... 30
Air Filter ........................................................................................................................................................ 35
Forks ...............................................................................................................................................................35
Remove ....................................................................................................................................................... 35
Inspect ........................................................................................................................................................ 35
Install ......................................................................................................................................................... 36
Adjust ......................................................................................................................................................... 36
Hang On Sideshift Carriage ......................................................................................................................... 36
How to Make Checks With Engine Running ................................................................................................... 38
Indicator Lights, Horn, Fuses, and Relays .................................................................................................. 38
Service Brakes ............................................................................................................................................... 41
Brake Oil Level .......................................................................................................................................... 41
Operation, Check ....................................................................................................................................... 41
Parking Brake ................................................................................................................................................41
Engine Oil Pressure ...................................................................................................................................... 42
Cooling System .............................................................................................................................................. 42
Steering System .............................................................................................................................................43
Control Levers and Pedals ............................................................................................................................ 43
Lift System, Operate ..................................................................................................................................... 43
Air Filter ........................................................................................................................................................ 44
Fuel/Water Separator Filter, Cummins 4.5L and QSB 3.3L Diesel Engine .............................................. 44
First Service After First 100 Hours of Operation ................................................................................................44
GM 4.3L Engine Oil and Oil Filter ...................................................................................................................44
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter ................................................................................ 45
Maintenance Procedures Every 500 Hours or 1 Year ......................................................................................... 45

©2019 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Hydraulic System Oil ........................................................................................................................................ 45
Hydraulic Tank Breather ..................................................................................................................................47
Inspect ............................................................................................................................................................47
Battery ............................................................................................................................................................... 48
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter ................................................................................ 48
Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine .......................................49
Remove ........................................................................................................................................................... 49
Install ............................................................................................................................................................. 49
Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) ........................................................................ 51
Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ................................................................. 51
Controlled Venting ........................................................................................................................................ 51
Manual Bleeding ............................................................................................................................................51
Low Idle Speed Adjustment, Cummins 4.5L Engine Only ............................................................................. 52
GM 4.3L Engine Oil and Oil Filter ...................................................................................................................52
Drain Tar From LPG Regulator ....................................................................................................................... 53
Drain Tar From LPG Converter ....................................................................................................................... 53
Drive Belt ...........................................................................................................................................................54
Cummins 4.5L and QSB 3.3L Diesel Engine and GM 4.3L Engine ........................................................... 54
Fan and Alternator Drive Belt ..................................................................................................................54
Clean Debris From Radiator Core ....................................................................................................................56
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check ............................................................... 56
Wet Brake Center Body Oil Level Check .........................................................................................................57
Forks .................................................................................................................................................................. 59
Mast Lubrication ............................................................................................................................................... 60
Header Hose Checks ......................................................................................................................................... 64
Lift Chain Lubrication ...................................................................................................................................... 64
Tilt Cylinder Lubrication .................................................................................................................................. 64
Master Brake Cylinder Rod End Pin Lubrication ........................................................................................... 65
Manual Hydraulic Levers Lubrication .............................................................................................................66
Brake Oil ............................................................................................................................................................66
Tie Rod Lubrication ...........................................................................................................................................67
Parking Brake Adjustment ...............................................................................................................................68
Maintenance Procedures Every 1000 Hours or 1 Year ....................................................................................... 69
Valve Clearance, Check and Adjust ................................................................................................................. 69
Ignition System ................................................................................................................................................. 69
GM 4.3L Engine .............................................................................................................................................69
LPG Fuel Filter Element Replace, GM 4.3L Engine .......................................................................................69
Remove ........................................................................................................................................................... 69
Install ............................................................................................................................................................. 70
In-Line Filter Replacement, Cummins 4.5L Engine ....................................................................................... 70
Remove ........................................................................................................................................................... 70
Install ............................................................................................................................................................. 71
Lift Chains Wear Check ....................................................................................................................................72
Lift Chain Lubrication ...................................................................................................................................... 72
Hang On Sideshift Carriage, Check Sliding Surfaces .....................................................................................72
Steering Axle Spindle Bearings ........................................................................................................................76
Control Levers and Pedals ................................................................................................................................ 77
Inspect Engine Electrical System, Connectors ................................................................................................ 77
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change .................................... 78
Parking Brake Lever Lubrication, Wet Brake Axle ........................................................................................ 82
Normal Operating Environment .................................................................................................................. 82
Heavy Duty or Contaminated Environment ................................................................................................83

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Remove ....................................................................................................................................................... 83
Clean and Inspect ...................................................................................................................................... 84
Install ......................................................................................................................................................... 84
Maintenance Procedures Every 2000 Hours or Annually ...................................................................................85
Hydraulic System .............................................................................................................................................. 85
Hydraulic Filter Assembly, Replace ............................................................................................................. 85
Install ............................................................................................................................................................. 86
Hydraulic Tank Breather, Replace ...............................................................................................................87
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires ................................................................... 89
Cooling System Check .......................................................................................................................................89
Air Filter ............................................................................................................................................................ 91
Oxygen Sensor, GM 4.3L Engine Equipped With GFI Installed ....................................................................92
LPG Regulator Fuel Filter, GM 4.3L Engines with GFI Installed .................................................................93
Remove ........................................................................................................................................................... 93
Install ............................................................................................................................................................. 94
LPG Fuel Injector, GM 4.3L Engines with GFI Installed ...............................................................................94
Fuel Injector, Cummins 4.5L and QSB 3.3L Engine .......................................................................................94
Forks .................................................................................................................................................................. 94
Brake Oil (Master Cylinder), Change .............................................................................................................. 95
Test Regulator PressureLPG ............................................................................................................................ 95
Check Throttle Shaft for Sticking .................................................................................................................... 95
Inspect Exhaust Manifold and Piping for Leaks ............................................................................................. 96
Transmission Automatic Clutch Calibration ...................................................................................................96
Brake System Accumulator .............................................................................................................................. 96
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine ................................................. 96
Wheel Bearings ..................................................................................................................................................97
Steer Wheels, Lubrication .............................................................................................................................97
Maintenance Procedures Every 4000 Hours or 2 Years ......................................................................................97
Hydraulic Oil, Replace ...................................................................................................................................... 97
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ..........................................................99
Safety Procedures When Working Near Mast ................................................................................................... 101
Fuel Filter Water Removal ................................................................................................................................. 104
Lift Chain Adjustments ...................................................................................................................................... 104
Jump-Starting the Lift Truck .............................................................................................................................106
Jump-Starting Using a Battery Charger ....................................................................................................... 106
Jump-Starting a Lift Truck Using Another Lift Truck .................................................................................106
Welding Repairs .................................................................................................................................................. 107
Overhead Guard Changes ...................................................................................................................................107
Wheel and Tire Replacement ..............................................................................................................................107
General .............................................................................................................................................................107
Pneumatic Tire With Tube, Repair ................................................................................................................ 107
Remove Wheels From Lift Truck ................................................................................................................107
Remove Tire From Wheel ............................................................................................................................108
Remove Tire From Two-Piece Wheel ......................................................................................................109
Remove Tire From Three- and Four-Piece Wheels ................................................................................110
Install Wheel in Tire ................................................................................................................................... 111
Install Three-Piece or Four-Piece Wheel in Tire ................................................................................... 112
Install Tire on Two-Piece Wheel .............................................................................................................113
Install Two-Piece Wheel in Tire ..............................................................................................................113
Add Air to Pneumatic Tires With Tube ..........................................................................................................114
Install the Wheels ........................................................................................................................................114
Dual Drive Wheels, Install ..........................................................................................................................114

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Pneumatic Tubeless Tire, Repair ................................................................................................................... 116
Remove Wheels From Lift Truck ................................................................................................................116
Remove Tire From Wheel ............................................................................................................................116
Install Tire on Wheel ...................................................................................................................................118
Add Air to Pneumatic Tubeless Tire .......................................................................................................... 121
Wheels, Install ............................................................................................................................................. 121
Solid Rubber Tires on Pneumatic Wheels, Change ....................................................................................... 121
Remove Tire From Wheel ............................................................................................................................121
Install Tire on Wheel ...................................................................................................................................123
Snap-On-Tire, Change .................................................................................................................................... 125
Remove Snap-On-Tire, Solid Tire From Wheel ......................................................................................... 125
Install Snap-On-Tire, Solid Tire on Wheel ................................................................................................ 126
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change ................................................... 127
Remove Easy Mounting Tire From Wheel ................................................................................................. 128
Install Easy Mounting Tire on Wheel ........................................................................................................ 130
Adhesives and Sealants ...................................................................................................................................... 132

This section is for the following models:

H6.0FT, H7.0FT [H006, J006]

iv
8000 SRM 1322 General

General
time intervals must be decreased from the
recommendations in the Maintenance Schedule for
WARNING
the following conditions:
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and • The lift truck is used more than eight hours
adjustments that are not correct can make a per day.
dangerous operating condition. • The lift truck must work in dirty operating
conditions.
• Poor ground conditions.
WARNING • Intensive usage at high performance levels or
DO NOT operate a lift truck that needs repairs. other abnormal conditions will require more
Report the need for repairs immediately. If repair is frequent servicing.
necessary, put a DO NOT OPERATE tag in the Your dealer for Hyster lift trucks has the
operator's area. Remove the key from the key equipment and trained service personnel to do a
switch. complete program of inspection, lubrication, and
maintenance. A regular program of inspection,
lubrication, and maintenance will help your lift
CAUTION truck provide more efficient performance and
Disposal of lubricants and fluids must meet local operate for a longer period of time.
environmental regulations. Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
This section contains a Maintenance Schedule and
shown in the Maintenance Schedule. Service
the instructions for maintenance and inspection.
Manuals are available from your dealer for Hyster
The Maintenance Schedule has time intervals for lift trucks to help users who do their own
inspection, lubrication, and maintenance of your lift maintenance.
truck. The service intervals are provided in both
operating hours recorded on the lift truck SERIAL NUMBER DATA
hourmeter and in calendar time. The
recommendation is to use the interval that comes The serial number for the lift truck is on the
first. Nameplate. It is also on the right side of the frame,
under the floor plate.
The recommendations for the time intervals
provided is for eight hours of operation per day. The

1
General 8000 SRM 1322

HOW TO MOVE DISABLED LIFT TRUCK 2. Tow truck slowly.

How to Tow Lift Truck 3. Using a lift truck or a lifting device that can be
attached to the mast (I.E. come-a-long), raise
carriage and forks approximately 30 cm (12 in.)
WARNING
from surface. Install chain around a mast
Use extra caution when towing a lift truck if any of crossmember and the carriage to prevent
the following conditions exist: carriage and mast channels from moving.
• Brakes do not operate correctly.
• Steering does not operate correctly. 4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or
• Tires are damaged. larger capacity than the disabled lift truck.
• Traction conditions are bad. Install approximately 1/2 of a capacity load on
• The lift truck must be towed on a slope. forks of lift truck that is being used to tow
disabled lift truck. This 1/2 capacity load will
If the engine cannot run, there is no power increase traction of lift truck. Keep load as low
available for the hydraulic steering system and the as possible.
service brakes. This condition can make the lift
truck difficult to steer and stop. If the lift truck 5. Use a towing link made of steel that fastens to
uses power from the engine to help apply the tow pins in counterweights of both lift trucks.
brakes, the application of the brakes will be more Slowly and carefully remove the slack out of
difficult. Poor traction can cause the disabled lift the towing link. See Figure 1.
truck or towing vehicle to slide. A slope will also
make the lift truck more difficult to stop.
Never lift and move a disabled lift truck unless the
disabled lift truck MUST be moved and cannot be
towed. A lift truck used to move a disabled lift
truck MUST have a capacity rating equal to or
greater than the weight of the disabled lift truck.
The capacity of the lift truck used to move a
disabled lift truck must have a load center equal to
half the width of the disabled lift truck. See the
Nameplate of the disabled lift truck for the
approximate total weight. The forks must extend
the full width of the disabled lift truck. Put the
weight center of the disabled lift truck on load
center of the forks. Be careful to not damage the
underside of the lift truck.

CAUTION
To prevent damage to the transmission during
towing, lift the drive wheels off the ground or
disconnect the drive shaft.
1. STEEL TOW LINK
2. TOW PIN

CAUTION Figure 1. Towing the Lift Truck

DO NOT try to start the engine by pushing or
towing the lift truck. Damage to the hydraulic
system can occur if engine is started by pushing
or towing lift truck.

1. The towed lift truck must have an operator.

2
8000 SRM 1322 General

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

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 lift the
front of the lift truck only. Lifting more than the 3. Put jack under steering axle or frame to raise
front of the lift truck with the cowl lifting eyes will lift truck. Put blocks under frame to support lift
damage the cowl section. truck.

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

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

3
General 8000 SRM 1322

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK 1. Assure truck components are cool before
starting the cleaning procedure.

WARNING 2. Disconnect the battery. If an electric truck,

Engine, exhaust system components and other remove the traction battery.
components are hot to the touch. Be sure lift truck
components are cool before starting inspection 3. Remove accumulated debris using a
and cleaning, or personal injury may occur. compressed air line and nozzle.

4. Lightly spray a non-corrosive cleaning agent

onto the areas to be cleaned. This will help
WARNING loosen grime, so close contact direct spraying
Compressed air can move particles so that they will not be necessary.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is 5. Be sure to avoid directing the spray into
away from all personnel. Wear protective goggles electrical panel compartment. Ensure
or a face shield to prevent injury to the eyes. overspray does not come in contact with
electrical components; do not spray water
directly at electrical components, wiring
CAUTION connectors or electrical enclosures. Even sealed
Units may be washed with a non-heated pressure connectors may allow water egress under
washer. Steam cleaning is not recommended in pressure or if connector is damaged.
most instances, as condensation may form in
electrical components causing damage or erratic 6. Avoid spraying in areas containing electrical
behavior. components such as:
• Floor Plates
NOTE: Lift trucks used in paper applications may
• Battery Compartment
need cleaning beyond what is described here. Please
refer to Paper Application section in the applicable • Dash/cowl assembly
Operating Manual and to available Service Gram/ • Armrests with electrical components
Bulletin for more detail.
If it becomes necessary to clean the fork lift, follow
the guidelines listed below.

4
8000 SRM 1322 Maintenance Schedule

7. Clean the battery compartment by using a 9. DO NOT pressure wash lift chains, sheaves or
clean cloth to wash the battery with water. Dry load rollers in the mast assembly. Refer to the
with compressed air. Care should be taken to Chains, Sheaves and Load Rollers maintenance
keep moisture at a minimum as some units section in the Service Manual for proper
have a traction or hydraulic motor directly cleaning procedures.
below the battery compartment.
10. After cleaning, immediately start and run the
8. DO NOT pressure wash the battery. Do not use lift truck to dry out components.
hot water. For cleaning traction batteries, refer
to the Battery section of the Service Manual.

Maintenance Schedule
NOTE: The 500-hour, and 1000-hour/1 year
maintenance services are performed either at the
specified hours or at 1 year whichever occurs first.

5
Maintenance Schedule 8000 SRM 1322

Figure 3. GM 4.3L LPG Trucks With GFI Installed

6
8000 SRM 1322 Maintenance Schedule

Figure 4. GM 4.3L LPG Trucks With PSI Installed

7
Maintenance Schedule 8000 SRM 1322

Figure 5. Cummins 4.5L Diesel Trucks

8
8000 SRM 1322 Maintenance Schedule

Figure 6. Cummins QSB 3.3L Diesel Trucks

9
Maintenance Schedule 8000 SRM 1322

Figure 7. GM 4.3L LPG Trucks, Trucks With Two-Speed Transmission Manufactured After June 2009, or
Three-Speed Transmission Manufactured After October 2009

10
8000 SRM 1322 Maintenance Schedule

Figure 8. Cummins QSB 3.3L Diesel Trucks, Trucks With Two-Speed Transmission Manufactured After
June 2009, or Three-Speed Transmission Manufactured After October 2009

11
Maintenance Schedule 8000 SRM 1322

Table 1. Maintenance Schedule

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
25 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
27, Mast, Carriage, X Check Condition See Parts Manual
28, Header Hoses, Lift and Lubrication
29, Chains, Attachment
38
Seat Belt, Hip X Check Condition
Restraints, and and Operation
Seat Rails
Engine X Remove
Compartment Combustible
Materials
See NOTE 5 and
NOTE 15.
Paper Application: X Check Condition
Engine Clean as
Compartment, Required Replace
Truck Components, as Required
Exhaust Wraps, See NOTE 8 and
Radiator, Radiator NOTE 15.
Screen if equipped,
Belly Pan if
equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1 and
NOTE 15.
Hydraulic Hoses X Check Condition See Parts Manual
See NOTE 15.
13 Coolant Hoses X Check Condition See Parts Manual
See NOTE 15.
16 Fuel Tank CIL Dual Tanks LPG - HD 5, HD 10
LPG (GM 29.9 liter
4.3L) (7.9 gal) Per
Tank
Single Tank
38.8 liter
(10.25 gal)
16 Fuel Tank CIL 74.8 liter Diesel No. 2
Cummins (19.7 gal)
4.5L
and QSB 3.3L
(Diesel)
Horn, Lights, X Check Operation
Alarms, Fuses,
and Relays
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

12
8000 SRM 1322 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
1 Service Brakes X Check Operation
23 Parking Brake X Check Operation
Steering Controls X Check Condition
and Steering and Operation
Column Gas
Cylinder
22 Transmission X Check for Leaks John Deere
See NOTE 15. JDM J20C
NOTE 17
22 Transmission X Check Operation
See NOTE 15.
7 Transmission Oil X Check Oil Level John Deere
See NOTE 15. JDM J20C
NOTE 17
39 Transmission Oil X Check Oil Level John Deere
Breather/Dipstick See NOTE 15. JDM J20C
(Trucks With Two- NOTE 17
Speed Transmission
Manufactured After
June 2009, or
Three-Speed
Transmission
Manufactured After
October 2009)
40 Transmission Oil C 24 liter (25.4 qt) John Deere
See NOTE 15. JDM J20C
NOTE 17
21 Transmission Oil C 1 Filter See Parts Manual
Filter See NOTE 4 and
NOTE 15.
37 Transmission Oil C 1 Breather See See Parts Manual
Breather NOTE 15.
39 Transmission Oil X Check Breather 1 See Parts Manual
Breather/Dipstick Breather See
(Trucks With Two- NOTE 15.
Speed Transmission
Manufactured After
June 2009, or
Three-Speed
Transmission
Manufactured After
October 2009)
22 Transmission X Perform See Calibration
Automatic Clutch Procedures
Calibration 8000SRM1134 for
Calibration Procedures
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

13
Maintenance Schedule 8000 SRM 1322

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
3 Hydraulic Oil X X C 71.5 liter ISO VG 46 Hydraulic
(75.8 qt) Oil
See NOTE 2, -15°C (5°F) and Above
NOTE 3, NOTE 17
NOTE 15 and
NOTE 16.
6 Hydraulic Oil Filter C 1 Filter See See Parts Manual
NOTE 15 and
NOTE 16.
10 Hydraulic Tank X C Inspect and See Parts Manual
Breather Replace as
Required
See NOTE 5 and
NOTE 15.
8 Battery and Cable X Clean See
Terminals NOTE 15.
9, 33 Engine Oil X C 4.7 liter (5.0 qt) -7°C (20°F) and below
Fill/Dip Stick CIL Every See NOTE 4, SAE 5W-20
GM 4.3L 6 mos. NOTE 5, and 16°C (60°F) and below
Engine (LPG) NOTE 15. SAE 5W-30
-18°C (0°F) and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
9, 33 Engine Oil Fill/ X C 13 liter (13.7 qt) 0°C (32°F) and below
Dipstick CIL Every See NOTE 4, SAE 0W-30
Cummins 6 mos. NOTE 5, and -25 to 20°C (-13 to
4.5L NOTE 15. 68°F)
Engine SAE 5W-30
(Diesel) -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, 33 Engine Oil Fill/ X C 7.5 liter (8 qt) 0°C (32°F) and below
Dipstick CIL Every See NOTE 4, SAE 0W-30
Cummins 6 mos. NOTE 5, and -25 to 20°C (-13 to
QSB NOTE 15. 68°F)
3.3L Engine SAE 5W-30
(Diesel) -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
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

14
8000 SRM 1322 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L Every See NOTE 4,
Engine 6 mos. NOTE 5, and
NOTE 15.
19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins Every See NOTE 4,
4.5L 6 mos. NOTE 5, and
and QSB 3.3L NOTE 15.
Diesel Engine
18 Air Filter (With CIL C 1 Filter See Parts Manual
Premium See NOTE 5,
Monitoring) NOTE 6,
NOTE 11, and
NOTE 15.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6,
NOTE 11, and
NOTE 15.
Engine Oil Pressure CIL Check Oil GM Engine
Pressure See 207 to 380 kPa (30 to
NOTE 15. 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)
15 Drive Belt X Check for Wear
GM Engine and Damage.
No Adjustment
Needed.
See NOTE 5 and
NOTE 15.
15 Drive Belt X Check for Wear
Cummins and Damage.
4.5L No Adjustment
and QSB 3.3L needed
(Diesel) See NOTE 5 and
NOTE 15.
32 LPG Regulator X Drain Tar
GM 4.3L See NOTE 5.
Engine With
GFI Installed
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

15
Maintenance Schedule 8000 SRM 1322

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
32 LPG Converter X Drain Tar See Parts Manual
GM 4.3L See NOTE 5
Engine With
PSI Installed
Engine Idle Speed X 750 ±25 rpm
GM 4.3L
(LPG)
Engine Governed X 2400 ±25 rpm
Speed
GM 4.3L
(LPG)
(No Load)
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature
Cummins Less than
4.5L 77°C (170°F)
(Diesel)
Engine Idle Speed X Coolant 800 ±50 rpm
Hot Engine Temperature
Cummins Greater than
4.5L 77°C (170°F)
(Diesel)
Engine Idle Speed X Coolant 1000 ±25 rpm
Cold Engine Temperature
Cummins Less than
QSB 30°C (86°F)
3.3L (Diesel)
Engine Idle Speed X Coolant 800 ±25 rpm
Hot Engine Temperature
Cummins Greater than
QSB 30°C (86°F)
3.3L (Diesel)
Engine Governed X 2250 ±50 rpm
Speed
Cummins
4.5L
(Diesel)
(No Load)
Engine Governed X 2230 ±25 rpm
Speed
Cummins
QSB
3.3L (Diesel)
Oxygen Sensor X Replace As
GM 4.3L Engine CIL Necessary
With GFI Installed
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

16
8000 SRM 1322 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
4 Valve Adjustment Not Adjustable
GM 4.3L Engine See NOTE 15.
4 Valve Adjustment X Adjust as Intake
Cummins Required See 0.254 mm (0.010 in.)
4.5L NOTE 15. Cold
Diesel Exhaust
Engines 0.508 mm (0.020 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Cummins Required. 0.35 mm (0.014 in.)
QSB See NOTE 12 Cold
3.3L Diesel and NOTE 15. Exhaust
Engines 0.50 mm (0.02 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
36 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain water from
Cummins filter as required
4.5L
and QSB 3.3L
Diesel Engine
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 Replace If
LPG With Required
GFI Installed 6 Injectors See
NOTE 15.
20 Fuel Injectors X Check and
Cummins Replace If
4.5L Required
and QSB 3.3L 4 Injectors See
Diesel Engine NOTE 15.
5 Spark Plugs C Change Spark 1.5 mm (0.059 in.)
GM 4.3L Plugs AC41-993
Engine 6 Plugs See
NOTE 15.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

17
Maintenance Schedule 8000 SRM 1322

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
12, Cooling System X C 15.1 liter See NOTE 13
14 GM 4.3L CIL (15.9 qt) See
Engine NOTE 15.
12, Cooling System X C 13.5 liter See NOTE 13
14 Cummins CIL (14.2 qt) See
4.5L NOTE 15.
Diesel Engine
12, Cooling System X C 10.4 liter (11 qt) See NOTE 13
14 Cummins CIL See NOTE 15.
QSB
3.3L Diesel
Engine
Clean Debris From X See NOTE 5 and
Radiator Core NOTE 15.
26 Forks X X X Check Condition
Fork Latches L Lubricate As Multipurpose Grease
Required See NOTE 7.
Lift System, X Check Operation
Operate
27 Mast L Lubricate As Multipurpose Grease
Sliding Required See NOTE 7.
Surfaces See NOTE 9.
and Load
Roller
Surfaces
38 Header Hoses X Check Condition
28 Lift Chains X Check Condition/ Engine Oil
Lube if SAE 30W
Necessary.
See NOTE 10
28 Lift Chains X, L Check for Wear SAE 30W
Lube as Required Engine Oil
28 Lift Chains L Lube as Required Engine Oil
SAE 30W
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast (Before X L X Lube as Required Multipurpose Grease
August, 2012) (2 fittings for See NOTE 7 and
Hang On Upper Bearings) NOTE 14. 1.5 mm
Sideshift and (0.06 in.) Minimum
Carriage (4 Lower Bearing Thickness.
Sliding Strips)
Surfaces Check Bearings
(Upper and For Wear.
Lower
Bearings)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

18
8000 SRM 1322 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
Mast (After August, X L X Lube as Required Multipurpose Grease
2012) (4 fittings for See NOTE 7 and
Hang On Upper Bearings) NOTE 14. 2.5 mm
Sideshift and (0.10 in.) Minimum
Carriage (3 Lower Bearing Thickness.
Sliding Strips)
Surfaces Check Bearings
(Upper and For Wear.
Lower
Bearings)
Mast X L X Lube as Required Multipurpose Grease
Fork 2 Fittings See NOTE 7 and
Positioner NOTE 14.
Mast X L X Lube as Required Multipurpose Grease
Fork 2 Anchors See NOTE 7 and
Positioner NOTE 14.
Cylinder Rod
Anchors
Mast X Check Torque See NOTE 14.
Fork 8 Capscrews
Positioner
Lower Hook
Capscrews
Mast L Lube as Required See NOTE 14.
Fork Carrier
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 7.
Brake Master L SAE 10W-30
Cylinder Rod API SM
End 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
Brake System X Check Pre-charge Pre-charge Pressure
Accumulator Pressure 4 ±0.35 bar (58 ±5 psi)
11 Steering Axle L 4 Fittings Multipurpose Grease
Spindle See NOTE 7.
Bearings
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 7.
41 Wheel Bearings L Check Grease. Multipurpose Grease
Steer Wheels See NOTE 7.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

19
Maintenance Schedule 8000 SRM 1322

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
2 Pedals, Levers, Seat L Lubricate as Use Silicone spray
Rails, Cables, Necessary Hyster Part No.
Hinges, Linkages, 328388
Hood Latch
23 Parking Brake X Adjust as Must Hold a Full
Adjustment Necessary. Capacity Load on a
15% Grade.
23 Parking Brake L Lubricate as Use Silicone spray
Necessary (Hyster Part Number
328388)
30 Wet Brake Drive C Change Oil John Deere
Axle Housing Arm 7.8 liter (8.25 qt) JDM J20C
Oil
(Left
Chamber)
35 Wet Brake Drive C Change Oil John Deere
Axle Housing Arm 7.8 liter (8.25 qt) JDM J20C
Oil
(Right
Chamber)
34 Wet Brake Center X C Change Oil SAE 80W-90
Section Oil 4.6 liter (4.9 qt)
42 Parking Brake X Check and Normal Operating
Levers (Wet Brake Lubricate as Environment: Spray
Axle) Necessary Lubricant (Hyster P/N
4066494) Heavy Duty
or Contaminated
Environment:
Multipurpose Grease
See NOTE 7.
Inspect Engine X See NOTE 15.
Electrical System
Connectors
Inspect Engine X See NOTE 15.
Vacuum, Fuel
Lines, and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure Lock-
Off
Closing
Test LPG X
Regulator Pressure
Check Air X
Induction System
for Leaks
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

20
8000 SRM 1322 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
Check Manifold X
for Vacuum Leaks
Check Throttle X
Shaft for Sticking
Check Injectors X See NOTE 15.
and Rails for Leaks
Inspect X
Exhaust Manifolds
and Piping for
Leaks
Inspect X
Catalyst Inlet
and Outlet
31 Ignition System C Replace See
Distributor Cap, NOTE 15.
Rotor, and Spark
Plug Wires
GM 4.3L
Engine
Inspect Muffler X Replace as
Inlet and Outlet Required
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500
hours of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications
involving 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 applications require regular inspections 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 as necessary.
NOTE 9: Lubricate mast every three months if units has less than 1000 hours.
NOTE 10: Lubricate if dry or at first sign of visible surface rust.
NOTE 11: 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 12: Initial valve adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at 2000-
hour/2-year intervals, whichever comes first.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

21
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Table 1. Maintenance Schedule (Continued)

Ite Item 8 hr/ 500 1000 2000 4000 hr/ Procedure or Specification
m 1 day hr/ hr/ hr/ 2 yr Quantity
No. 1 yr 1 yr 1 yr
NOTE 13: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate
with 50% distilled water or deionized water.
NOTE 14: For lift trucks equipped with Hang On Sideshift Carriage (with or without Fork Positioner) see
Maintenance Procedures Every 500 hours or 1 Year, Mast Lubrication section in this manual.
NOTE 15: Turn lift truck engine OFF prior to performing maintenance or checks in engine compartment.
NOTE 16: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures
1900SRM1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or
highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less
frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
NOTE 17: If lift truck is used in Paper application use ONLY JDM J20C type fluid for both the transmission and
hydraulic system.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE other material wrapped around the axle. See
STOPPED Figure 9.

WARNING
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the
operator's area. If the lift truck is equipped with a
key switch, remove the key from the key switch.
If a lift truck that needs repairs is operated,
damage to lift truck and injury to personnel can
occur.

Put lift truck on a level surface. Lower carriage and 1. CHECK FOR DAMAGE (REMOVE NAILS,
forks, stop engine, and apply parking brake. Open GLASS, AND OTHER OBJECTS FROM THE
both hood door assemblies and check for leaks and TREAD)
conditions that are not normal. Clean any oil or fuel 2. CHECK EDGES FOR WEAR
spills. Ensure all surfaces are free of oils, lubricants, 3. CHECK TIRE PRESSURE
fuel, and organic dust or fibers (paper, wood, cotton,
Figure 9. Tire and Wheel Check
agricultural grass/grain, etc.).

Tires and Wheels

Check tires for damage. Check the tread and
remove any objects that will cause damage. Check
for bent or damaged rims. Check for loose or
missing hardware. Remove any wire, strapping, or

22
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

Safety Labels 6. Visually inspect hoses/fittings for hydraulic

leaks; hose cover for cuts, cracks or exposed
reinforcement; defective/broken clamping
WARNING devices or sheaves; proper tracking during
Safety labels are installed on the lift truck to operation. Adjust/repair/replace hose/
provide information about operation and possible components as necessary. See Mast Repairs,
hazards. It is important that all safety labels are 2- and 3-Stage Masts (S/N A513, A514, A613,
installed on the lift truck and can be read to avoid A614, A702, A703, A704, A705, A706, A707,
damage to lift truck and injury to personnel. A751, A752, B513, B514, B586, B587, B588,
B589, B590, B591, B749, B750, B751, B752,
Check that all safety labels are installed in the B753, B754) 4000SRM1250 for quick
correct location on lift truck. See the Parts disconnect procedures.
Manual, Model Description section in the
Operating Manual or section Frame 7. Check that lift chains are correctly lubricated.
0100SRM1321 for the correct location of the safety Use SAE 30W engine oil as necessary to
labels. See the Parts Manual for the part numbers lubricate lift chains.
of the safety labels.
8. Inspect lift chains for cracks or broken links,
Mast, Carriage, Lift Chains, Header Hoses, and worn or turned pins. See Figure 10.
Attachment 9. Inspect chain anchors and pins for cracks and
damage.
WARNING
To avoid serious injury to personnel, always lower 10. Make sure lift chains are adjusted so that they
the lift mechanism completely. Never allow any have equal tension. Adjustments or
person under a raised carriage. Do not put any replacement of the lift chains must be
part of your body in or through the lift mechanism done by authorized personnel.
unless all parts of the mast are completely lowered
and the engine is STOPPED.
DO NOT operate fork lift without lateral fork stops
in place. Forks may disengage from fork carriage.

1. Inspect welds on the mast and carriage for

cracks. Make sure that the capscrews and nuts
are tight.

2. Inspect carriage to be sure fork stops are in

place. Fork stops prevent forks from laterally
disengaging from the carriage.

3. Inspect channels for wear in areas where

rollers travel. Inspect rollers for wear or
damage.

4. Inspect load backrest extension for cracks and

damage.
1. WORN PIN
5. If lift truck is equipped with a hang on sideshift 2. CRACKS
carriage or attachment, inspect the parts for 3. EDGE WEAR
cracks and wear. Make sure the parts that 4. HOLE WEAR
5. LOOSE LEAVES
fasten the hang on sideshift carriage or 6. TURNED PIN
attachment to the carriage are in good 7. CORROSION
condition.
Figure 10. Lift Chain Check

23
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Operator Restraint System

NOTE: The seat belt can be either black or red.
The seat, seat belt, seat rails, hip restraint, and seat
plate are all part of the operator restraint system.
Each item must be checked to make sure it is
fastened correctly, functions correctly, and is in good
condition. See Figure 11.

Emergency Locking Retractor (ELR)

When the ELR style seat belt is properly buckled
across the operator, the belt will permit slight
operator repositioning without activating the
locking mechanism. If the truck tips, travels off a
dock, or comes to a sudden stop, the locking
mechanism will be activated and hold the operator's
lower torso in the seat.
A seat belt that is damaged, worn, or does not
NOTE: NON-SWIVEL SEAT SHOWN.
operate properly will not provide protection when it
is needed. The end of the belt must fasten correctly 1. FLANGE NUT
in the latch. The seat belt must be in good condition. 2. SEAT PLATE
Replace the seat belt if damage or wear is seen. See 3. FORWARD/BACKWARD ADJUSTMENT
Figure 11. 4. SEAT RAIL
5. SEAT BELT
NOTE: The following seat belt operation checks 6. HIP RESTRAINT
must be performed three times before replacing the 7. OPERATOR WEIGHT ADJUSTMENT
seat belt assembly. 8. SEAT

• Pull the seat belt slowly from the retractor Figure 11. Seat, Seat Rail, Seat Plate, and Seat Belt
assembly. Make sure the seat belt pulls out Check
and retracts smoothly. If the seat belt cannot
be pulled from the retractor assembly or the Adjust Seat - Full Suspension
belt will not retract, replace the seat belt
assembly. Seat Position Adjustment (Swivel Seat)
• Pull the seat belt with a sudden jerk. Make • The seat swivels 12 degrees to the right to
sure the seat belt will not pull from the allow the operator a more ergonomic position
retractor assembly. If the seat belt can be when driving in reverse.
pulled from the retractor, when it is pulled • The seat swivels 5 degrees to the left to allow
with a sudden jerk, replace the seat belt an easier exit of the truck.
assembly.
• The neutral position is shown in Figure 12.

24
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

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: The seat is designed for maximum weight of
135 kg (298 lb).

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

between the arrows when the operator sits
upright in the seat with the feet positioned on
the pedals. This ensures that the operator is
set at the midpoint of the 80 mm (3.15 in.)
suspension.
• The handle can be turned as shown to
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE. increase or decrease the weight resistance.
Pull handle out before turning. As the handle
1. BACKREST ANGLE ADJUSTMENT LEVER is turned, the "stiffness" of the suspension can
2. SWIVEL ADJUSTMENT be felt to increase or decrease on which way
3. OPERATOR WEIGHT ADJUSTMENT the handle is turned.
4. FORWARD/BACKWARD ADJUSTMENT HANDLE
5. SEAT BELT

Figure 12. Swivel Seat Controls

25
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

NOTE: OPTIONAL SWIVEL SEAT SHOWN.

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

Adjust Seat - Internal Suspension the pedals. This ensures that the operator is
set at the midpoint of the 40 mm (1.57 in.)
Seat Position Adjustment (Swivel Seat) suspension.
• The seat swivels 10.5 degrees to the right to • The weight adjustment knob can be turned
allow the operator a more ergonomic position left or right to increase or decrease the weight
when driving in reverse. resistance. As the weight adjustment knob is
• The seat swivels 5 degrees to the left to allow turned the "stiffness" of the suspension can be
an easier exit of the truck. felt to increase or decrease on which way the
weight adjustment knob is turned.
• The neutral position is shown in Figure 13.
Seat Adjustment for Operator Weight Seat Plate and Seat Rails
Make sure the seat rails are not loose. The seat rails
CAUTION must lock tightly in position, but move freely when
unlocked. See Figure 11. The seat rails must be
A major cause for high Whole Body Vibration is
correctly fastened to the seat plate and the seat
caused by the operator not adjusting the seat to
plate must be fastened to the frame.
his/her weight.

NOTE: It is important to adjust the weight setting Engine Compartment

for each operator. Check for the presence of any combustible material
NOTE: The seat is designed for maximum weight of such as paper, leaves, etc. Remove any combustible
135 kg (298 lb). materials.

• The target is for the "ride indicator" to fall Paper Application

between the arrows when the operator sits
upright in the seat with the feet positioned on Vehicles used in paper applications require regular
inspection and cleaning to minimize the risk of fire.

26
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

This should be done at least once every eight hours wraps when cleaning with compressed air and use
or more frequently depending upon operating caution to not force debris into openings.
environment. The paper application option will help
limit the contact of paper or tissue scraps to hot
surfaces under the hooddoors , but frequent WARNING
maintenance is required. Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing,
gloves, and eye protection. Never expose your
WARNING skin to steam.
Engine and exhaust system components are hot to
touch. Be sure lift truck components are cool If compressed air did not adequately remove debris,
before starting inspection and cleaning or steam clean to remove any persistent accumulation
personal injury may occur. of material or oil. Protect electrical components from
moisture when steam cleaning. DO NOT spray
Ensure truck engine cools properly by allowing it to exhaust wraps directly with high pressure steam.
idle for several minutes. Shutting truck down while Allow lift truck to air dry before returning to work
hot will not allow the engine to cool quickly due to in a contaminated environment. Paper dust and
the loss of coolant circulation. The heat trapped scraps will adhere to wet surfaces.
under the hood doors may actually increase the
Check the condition of exhaust wraps for wear,
engine temperature because of no heat transfer
proper fit, contamination with oil or antifreeze, gaps
through the radiator. With engine off and lift truck
in coverage, failed fasteners and replace as
components cooled, check and clean the radiator
necessary. DO NOT reuse wraps if they have been
and if equipped, radiator screen. Check engine
removed for some other service operation.
manifold, exhaust pipes, muffler and catalytic
converter for paper scraps. Clean as required. Check
Fuel, Oil, and Coolant Leaks, Check
and clean the engine compartment components,
transmission, fan shroud, belly pan if equipped, and
inside frame ledges to avoid paper, dust and oil WARNING
accumulation. Check axle and cowl openings for
All fuels are very flammable and can burn or cause
paper buildup and bailing wire. Remove any debris.
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel
WARNING system. If there is a leak in the fuel system, extra
care must be used during the repair. DO NOT
Compressed air can move particles so that they
operate the lift truck until a leak is repaired.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is Make a visual check for leaks on and under the lift
away from all personnel. Wear protective goggles truck. If possible, find and report the leak to
or a face shield to prevent injury to the eyes. maintenance for repair. Leaks often indicate a need
for repair of damaged or worn components. Leaks in
the LPG fuel system are usually not visible unless
CAUTION ice is present. There is however, usually a strong
Air pressure, nozzle or extension tube may cause odor. Fuel leaks MUST be repaired
damage to exhaust wraps and radiator fins. Assure IMMEDIATELY.
that air pressure, nozzle or extension tube does
Check fuel system for leaks and the condition of
not damage exhaust wraps or radiator fins.
parts. When fuel is added to the lift truck, see
Paper removal can generally be accomplished using section How to Add Fuel to the Lift Truck in the
a compressed air line and nozzle. An extension may Operating Manual.
be helpful to access hard to reach places. Remove Also check the condition of the radiator or heater
floor plates and both hood doors for access to engine hoses that are not leaking. Soft or cracked hoses
compartment. Open or remove belly pan, if need to be replaced before a major leak occurs.
equipped. Clean components with compressed air.
Take care to maintain the integrity of the exhaust

27
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Hydraulic Hoses Check the transmission for leaks and damaged or

loose components. Heavy-duty or high temperature
Check condition of hydraulic hoses for serviceability operations can require more frequent checks.
by inspecting for cracks or other obvious damage.
Check to insure that hydraulic hoses are not See Figure 15 for lift truck models equipped with
leaking. If any hose is leaking, report it to two-speed transmission manufactured before June,
maintenance for repair. 2009 or a three-speed transmission manufactured
before October, 2009.
Coolant Hoses See Figure 16 for lift truck models equipped with
Check condition of coolant hoses for serviceability two-speed transmission manufactured after June,
by inspecting for cracks or other obvious damage. 2009 or a three-speed transmission manufactured
Check to insure that the coolant hoses are not after October, 2009.
leaking. If any hose is leaking, report it to
maintenance for repair. Hydraulic System Oil

Steering Column Gas Cylinder

WARNING
Make sure the gas cylinder for the steering column At operating temperature, the hydraulic oil is HOT.
operates correctly. The cylinder must NOT allow the Do not permit the hot oil to touch the skin and
column to move unless the tilt lever is released. See cause a burn.
Figure 14.

CAUTION
Do not permit dirt to enter the hydraulic system
when the oil level is checked or the filter is
changed. Damage to the lift truck and hydraulic
system can occur if dirt enters the hydraulic
system.
Never operate the hydraulic pump without oil in
the hydraulic system. The operation of the
hydraulic pump without oil will damage the pump.

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.
1. TILT LEVER See Figure 15 for lift truck models equipped with
2. GAS CYLINDER
two-speed transmission manufactured before June,
Figure 14. Steering Column Gas Cylinder and Tilt 2009 or a three-speed transmission manufactured
Lever before October, 2009.
See Figure 16 for lift truck models equipped with
Transmission two-speed transmission manufactured after June,
2009 or a three-speed transmission manufactured
NOTE: On lift trucks equipped with two-speed
after October, 2009.
transmission manufactured after June, 2009 or a
three-speed transmission manufactured after Check the hydraulic system for leaks and damaged
October, 2009 the transmission oil dipstick and or loose components. Heavy-duty or high-
transmission oil breather are one unit. See temperature operations can require more frequent
Figure 16. checks.

28
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED BEFORE JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED BEFORE OCTOBER 2009 SHOWN.

1. TRANSMISSION BREATHER 4. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL DIPSTICK 5. HYDRAULIC TANK BREATHER
3. HYDRAULIC OIL FILTER 6. HYDRAULIC DRAIN PLUG

Figure 15. Transmission and Hydraulic Oil Checks

29
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED AFTER OCTOBER 2009 SHOWN.

1. TRANSMISSION OIL DIPSTICK/BREATHER 5. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL FILTER 6. HYDRAULIC TANK
3. HYDRAULIC TANK BREATHER 7. HYDRAULIC OIL DRAIN PLUG
4. HYDRAULIC OIL FILTER 8. TRANSMISSION OIL DRAIN PLUG

Figure 16. Transmission and Hydraulic Oil Checks

Engine Oil After engine has stopped, wait one minute before
checking the oil level.
WARNING See Figure 17 for lift truck models equipped with
At operating temperature, the engine oil is HOT. Do GM 4.3L engine and GFI fuel system.
not permit the hot oil to touch the skin and cause a See Figure 18 for lift truck models equipped with
burn. GM 4.3L engine and PSI fuel system.
See Figure 19 for lift truck models equipped with
Cummins 4.5L diesel engine.
CAUTION
DO NOT permit dirt to enter the engine when the See Figure 20 for lift truck models equipped with
oil level is checked or the filter is changed. Cummins QSB 3.3L diesel engine.
Damage to the engine can occur if dirt enters the
engine.
Never operate the engine without oil. The
operation of the engine without oil will damage the
engine.

30
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

1. BATTERY 8. SPARK PLUGS

2. POWER DISTRIBUTION MODULE (PDM) 9. DRIVE BELT
3. FUEL INJECTOR 10. RADIATOR CAP
4. LPG FUEL FILTER ASSEMBLY 11. AUXILIARY COOLANT RESERVOIR
5. ENGINE OIL FILL 12. AIR FILTER PRECLEANER
6. ENGINE OIL DIPSTICK 13. LPG REGULATOR ASSEMBLY
7. AIR FILTER 14. COOLANT HOSES

Figure 17. GM 4.3L LPG Engine Maintenance Points With GFI Installed

31
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

1. BATTERY 8. DRIVE BELT

2. POWER DISTRIBUTION MODULE (PDM) 9. RADIATOR CAP
3. LPG FUEL FILTER ASSEMBLY 10. AUXILIARY COOLANT RESERVOIR
4. ENGINE OIL FILL 11. AIR FILTER PRECLEANER
5. ENGINE OIL DIPSTICK 12. LPG CONVERTER ASSEMBLY
6. AIR FILTER 13. COOLANT HOSES
7. SPARK PLUGS 14. ENGINE LABEL

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

32
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

Figure 19. Cummins 4.5L Diesel Engine Maintenance Points

33
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Legend for Figure 19.

A. TOP VIEW B. RIGHT SIDE VIEW

1. BATTERY 8. AUXILIARY COOLANT RESERVOIR

2. FUEL INJECTION PUMP 9. RADIATOR CAP
3. FUEL INJECTORS 10. FUEL/WATER SEPARATOR FILTER
4. INLINE FUEL FILTER 11. DRIVE BELT
5. AIR FILTER 12. FUEL TRANSFER PUMP
6. ENGINE OIL DIPSTICK 13. POWER DISTRIBUTION MODULE (PDM)
7. ENGINE OIL CAP 14. SILENCER

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 20. Cummins QSB 3.3L Diesel Engine Maintenance Points

34
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

Air Filter
The air filter canister should not be opened until an
air filter element replacement is required. An air
filter element replacement is required when one of
the following occurs:
• The optional air flow restriction indicator
light on the dash illuminates.
• If equipped, the manual air flow indicator is
red.
• The specified number of hours has passed
since the last filter element replacement.
Do not operate the lift truck until the air filter
element has been replaced.

Forks
NOTE: Forks must be removed or installed by
trained personnel only.
1. CARRIAGE BARS
The identification of a fork describes how the fork is 2. HOOK FORK
connected to the carriage. These lift trucks have 3. BLOCKS
hook forks.
Figure 21. Hook Fork Removal
Remove
Inspect

WARNING WARNING
DO NOT try to move a fork without a lifting device. DO NOT try to correct the alignment of the fork
Each hook fork for these lift trucks can weigh tips by bending the forks or adding shims. Never
66 to 183 kg (145 to 402 lb). repair damaged forks by heating or welding. Forks
are made of special steel using special
NOTE: Forks are to be replaced only in sets and not
procedures. If either fork is damaged, replace the
individually.
forks as a set.
A fork can be removed from the carriage for
replacement of the fork or other maintenance. Lift 1. Inspect the forks for cracks and wear. Check
the lock pin and slide a hook fork to the fork that fork tips are aligned as shown in
removal notch on carriage. See Figure 21 and Figure 22.
Figure 22.
2. Check that the bottom of the fork is not worn.
Lower fork onto blocks so that the bottom hook of
See Figure 22, item 4.
the fork moves through the fork removal notch.
Lower carriage further so that the top hook of the 3. Replace any damaged or broken parts that are
fork is disengaged from the top carriage bar. Move used to keep forks locked in position.
the carriage away from the fork, or use a lifting
device to move the fork away from the carriage. See
Figure 22.

35
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Adjust
NOTE: During the adjustment of the forks, the heel
of the forks should not be touching the ground.
The forks are connected to the carriage by hooks
and lock pins. See Figure 21 and Figure 23. The lock
pins are installed through the top fork hooks and fit
into slots in the top carriage bar. If pin does not
remain engaged in carriage slot, replace with new
pin. Adjust the forks as far apart as possible for
maximum support of the load. Hook forks will slide
along the carriage bars to adjust for the load to be
lifted. Raise the lock pin in each fork to slide the
fork on the carriage bar. Make sure the lock pin is
engaged in the carriage bar to lock the fork in
position after the width adjustment is made.

Fork Tip Alignment

Length of Forks 3% Dimension
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.) 1. FORK
1524 mm (60 in.) 46 mm (1.81 in.) 2. LOCK PIN
3. SPRING
1830 mm (72 in.) 55 mm (2.17 in.) 4. WASHER
5. WEDGE
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF 6. KNOB
FORK LENGTH) 7. LOCK PIN ASSEMBLY
2. CRACKS
3. LATCH DAMAGE Figure 23. Fork Lock Pin Assembly
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE Hang On Sideshift Carriage
6. LOAD BACKREST EXTENSION Check for cracks, wear and damage. If damaged, see
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH Mast Repairs, 2- and 3-Stage Masts (S/N A513,
A514, A613, A614, A702, A703, A704, A705, A706,
Figure 22. Forks Check A707, A751, A752, B513, B514, B586, B587, B588,
B589, B590, B591, B749, B750, B751, B752, B753,
Install B754) 4000SRM1250 for repair procedures. If
necessary, lubricate sliding surfaces (upper
Move fork and carriage so that the top hook on the bearings) at grease fittings and lower bearing strips
fork can engage the upper carriage bar. Raise the with multipurpose grease shown in the
carriage to move the lower hook through the fork Maintenance Schedule. See Figure 24.
removal notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage. If lift truck is equipped with a fork positioner,
Engage the lock pin with a notch in the upper lubricate fork positioner carrier at grease fittings
carriage bar. and the fork cylinder rod anchors with multipurpose
grease shown in the Maintenance Schedule.

36
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

See Figure 24 for fork lift trucks manufactured

before August, 2012.
See Figure 25 for fork lift trucks manufactured after
August, 2012.

1. BACKREST
2. FORK CARRIER RETAINER CAPSCREWS
3. CYLINDER ANCHOR BAR CAPSCREWS
4. CYLINDERS AND HOSES
5. FORKS
6. LOWER HOOKS
7. MOUNTING FLANGE CAPSCREWS
8. BACKREST CAPSCREWS

1. UPPER BEARINGS GREASE FITTINGS Figure 25. Hang On Sideshift Carriage, Fork Lift
2. GREASE FITTINGS FOR FORK POSITIONER Trucks Manufactured After August, 2012
CARRIER AND FORK CYLINDER ROD
ANCHORS
3. FORK POSITIONERS
4. FORK POSITIONER MOUNTING CAPSCREWS
5. LOWER HOOK CAPSCREWS
6. LOWER BEARING STRIPS

Figure 24. Hang On Sideshift Carriage, Fork Lift

Trucks Manufactured Before August, 2012

37
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

HOW TO MAKE CHECKS WITH ENGINE checks of the operation. Be careful when making the
RUNNING checks. If the lift truck is stationary during a check,
apply the parking brake and put the transmission
in NEUTRAL. Make the checks carefully.
WARNING
DO NOT operate a lift truck that needs repairs. Indicator Lights, Horn, Fuses, and Relays
Report the need for repair immediately. If repair is If lift truck is equipped with a key switch, turn key
necessary, put a DO NOT OPERATE tag in the to ON position. If lift truck is equipped with a
operator's area. If lift truck is equipped with a key Power ON/OFF button, press button to turn system
switch, remove the key. power ON. All warning light and indicator lights
If a lift truck that needs repairs is operated, will light up for two seconds (start check) when
damage to lift truck and injury to personnel can system power is turned ON. See Figure 26. Check
occur. all indicator lights for correct operation as described
in the Operating Manual. Check the operation of
the horn. Start the engine by turning the key switch
to the Start position, if truck is equipped with a key
WARNING switch, or press the engine start button, if lift truck
FASTEN YOUR SEAT BELT! The seat belt is is equipped with this button. If any indicator lights
installed to help the operator stay on the truck if do not operate correctly, check the fuses. The fuses
the lift truck tips over. IT CAN ONLY HELP IF IT IS are located in the Power Distribution Module
FASTENED. (PDM), which is located under the floor plates and
mounted on the right side of lift truck frame. See
Make sure that the area around the lift truck is
Figure 27.
clear before starting the engine or making any

38
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

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
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)

Figure 26. Warning and Indicator Lights

39
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Figure 27. PDM Showing Fuses and Relays

40
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

Legend for Figure 27.

NOTE: FLOOR PLATES REMOVED FOR CLARITY.

1. BATTERY 11. SPARE FUEL PUMP RELAY

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

Service Brakes truck to either side of the direction of travel when

they are applied. The service brakes are
Brake Oil Level automatically adjusted when the lift truck is moving
and the brakes are firmly applied. Full application
of the inching/brake pedal applies the service brakes
WARNING and puts the transmission in NEUTRAL.
Small amounts of water in the brake system can
cause reduced braking performance if the water Lift trucks with aMONOTROL® pedal: When
reaches the wheel cylinder areas. DO NOT allow the inching/brake pedal is fully applied, a switch in
water entry. Ensure that the sealed reservoir lid is the starting circuit is closed so that the engine can
properly replaced. be started.
The brake system has a boosted master cylinder, Parking Brake
braking will be more difficult if the engine is not
running and can result in injury to personnel. There is an indicator icon on the display panel for
the parking brake. This icon is illuminated as
Loss of oil from the brake oil reservoir indicates a
describe in the Operating Manual. There is a
leak and can cause damage to the brake system
sensor in the seat that actuates an audible alarm. If
and lift truck. Repair the brake system before
the operator leaves the seat, with system power
using the lift truck. Replace the brake oil in the
OFF, without applying the parking brake, the
system if there is dirt or water in the system.
alarm will sound for 10 seconds until the parking
DO NOT use DOT fluid, only use Dexron III oil from brake is applied or the operator sits back on the
sealed container to prevent possible damage to seat. If system power is ON or the engine is
the brake system. Failure to observe the above running, and the operator leaves the seat, without
Warning could result in death or serious injury. applying the parking brake, the alarm will sound
continuously until parking brake is applied or the
There is an indicator light on the Display Switch operator sits back on the seat.
Cluster for the brake oil. See Figure 26. The red
light is ON when the key switch is in the START Make sure the service brakes operate correctly
position or the Power ON/OFF button is pressed, before checking the operation of the parking brake.
and must go OFF when the engine is running. If the Check the operation of the parking brake. The
light is ON when the engine is running, the brake parking brake, when in good condition and correctly
fluid oil in the reservoir is too low. adjusted, will hold a lift truck with a full capacity
load on a 15% grade [a slope that increases 1.5
meters in 10 meters (1.5 feet increase in 10 feet)]. If
Operation, Check
parking brake requires adjustment, notify service
Check the operation of the service brakes. Push on personnel.
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

41
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1322

Engine Oil Pressure NOTE: The engine will enter shutdown mode after
a warning buzzer sounds and a 30-second
NOTE: The engine will enter shutdown mode after countdown, if coolant temperature reaches
a warning buzzer sounds and a 30-second 121°C (250°F) or above on lift trucks with GM
countdown, if engine oil pressure is less than engine and powertrain protection system. Lift
34.5 kPa (5 psi) on lift trucks with powertrain trucks equipped with a Cummins diesel engine will
protection system and GM engine. Lift trucks enter the shutdown mode when the coolant
equipped with a Cummins QSB 3.3L diesel engine temperature reaches 110°C (230°F) or above on lift
will enter the shutdown mode when the engine oil trucks with powertrain protection system. See the
pressure is less than 49 kPa (7 psi) on lift trucks ENGINE SHUTDOWN procedures in the
with powertrain protection system. Lift trucks Operating Manual.
equipped with a Cummins 4.5L diesel engine will
enter the shutdown mode when the engine oil There is an indicator light on the Display Switch
pressure is less than 69 kPa (10 psi) on lift trucks Cluster for the coolant temperature. The red light is
with powertrain protection system. See the Engine ON when the key switch is in the START position
Shutdown procedures in the Operating Manual. or the Power ON/OFF button is pressed, and must
go OFF when the engine is running. If the light is
There is an indicator light for the engine oil ON when the engine is running, the coolant and
pressure on the Display Switch Cluster. See engine are too hot. Stop the engine and check the
Figure 26. During normal operation, the red coolant level in the auxiliary coolant reservoir. See
indicator light will illuminate when the key switch Figure 26.
is turned to ON, if the truck is equipped with a key
switch, or when the Power ON/OFF button is Make sure the coolant level is between the ADD
pressed, if the truck is equipped with a Power and FULL marks on the auxiliary coolant reservoir.
ON/OFF option, and will stay illuminated until The coolant will expand as it is heated and the level
correct oil pressure is obtained, at which time the in the auxiliary coolant reservoir will increase. See
light will go off. Figure 28.
If the light continues to stay ON when engine is
running, the engine oil pressure is low. Stop the CAUTION
engine and check the oil level. Additives may damage the cooling system. Before
See Figure 17 for lift truck models equipped with using additives, contact your local Hyster dealer.
GM 4.3L engine and GFI fuel system.
If coolant is added, see Maintenance Schedule for
See Figure 18 for lift truck models equipped with correct solution.
GM 4.3L engine and PSI fuel system.
See Figure 19 for lift trucks equipped with
Cummins 4.5L diesel engine. WARNING
Compressed air can move particles so that they
See Figure 20 for lift trucks equipped with cause injury to the user or to other personnel.
Cummins QSB 3.3L diesel engine. Make sure that the path of the compressed air is
Do not restart the engine until the low pressure away from all personnel. Wear protective goggles
condition has been corrected. or a face shield to prevent injury to the eyes.

Cooling System Turn lift truck engine OFF and check the radiator
fins. Clean the radiator with compressed air or
water as needed. Check for and remove any debris
WARNING on the radiator core. If the indicator light turns on
DO NOT remove the radiator cap from the radiator again after restarting, shut down the lift truck and
when the engine is hot. When the radiator cap is do not operate the lift truck until the problem is
removed, the pressure is released from the corrected.
system. If the system is hot, the steam and boiling
coolant can cause burns.

42
8000 SRM 1322 Maintenance Procedures Every 8 Hours or Daily

Lift System, Operate

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast at the end of
this section.
Lower the lift mechanism completely. Never allow
any person under a raised carriage. DO NOT put
any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
Serious injury to personnel can result if lift
mechanism is not lowered completely.
If the mast cannot be lowered, use chains on the
mast weldments and carriage so that they cannot
move. Make sure the moving parts are attached to
a part that does not move.
DO NOT try to find hydraulic leaks by putting
hands on pressurized hydraulic components.
1. RADIATOR CAP Hydraulic oil can be injected into the body by the
2. FILL CAP
3. AUXILIARY COOLANT RESERVOIR pressure and cause serious injury to personnel.
4. ADD MARK
5. FULL COLD MARK Perform the following checks and inspections:
6. FULL HOT MARK
1. Turn lift truck engine OFF and check for leaks
Figure 28. Auxiliary Coolant Reservoir in the hydraulic system. Check the condition of
the hydraulic hoses and tubes.
Steering System
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
WARNING 2. Slowly raise and lower the mast several times
The lift truck has hydraulic power steering. The without a load. Raise mast to its full height at
steering can be difficult if the engine is not least once. The mast components must raise
running. and lower smoothly in the correct sequence.
Hose must track properly during operation.
Make sure the steering system operates smoothly
and provides good steering control. Make sure the
3. The inner weldments and carriage must lower
steering column can be adjusted and the gas
completely.
cylinder function is correct.
4. Raise the mast 1 m (3 ft) with a capacity load.
Control Levers and Pedals The inner weldments and the carriage must
Check that the control levers for the transmission, raise smoothly. Lower the mast. All moving
mast, and attachment operate as described in components must lower smoothly.
Operating Manual. Check that the pedals operate
correctly as described in Operating Manual. 5. Lower the load to approximately 0.3 m (1 ft).
Tilt mast forward and backward. Mast must
tilt smoothly and both tilt cylinders must stop
evenly.

43
First Service After First 100 Hours of Operation 8000 SRM 1322

6. Check that the controls for the attachment Fuel/Water Separator Filter, Cummins 4.5L
operate the functions of the attachment. See and QSB 3.3L Diesel Engine
symbols by each of the controls. Make sure all
hydraulic lines are connected correctly and do This amber indicator light (see Figure 26) will
not leak. illuminate if the sensor on the fuel/water separator
filter indicates that water must be drained from the
Air Filter filter.

There is an indicator light on the Display Switch See Figure 19 for lift trucks equipped with
Cluster (see Figure 26) for the air filter. The amber Cummins 4.5L diesel engine.
light is ON when the key switch is in the START See Figure 20 for lift trucks equipped with
position or the Power ON/OFF button is pressed, Cummins QSB 3.3L diesel engine.
and must go OFF when the engine is running. If the
light is ON when the engine is running, there is a
restriction in the air filter. Turn engine OFF and
remove restriction from air filter. See Figure 29.

1. AIR FILTER COVER

2. RESTRICTION INDICATOR PORT
3. AIR OUTLET
4. DUST DISCHARGE VALVE
5. AIR INLET
6. COVER LATCHES

Figure 29. Air Filter

First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL AND OIL FILTER 2. Check engine oil at the dipstick tube. If
necessary, add additional oil shown in the
NOTE: Turn engine OFF before changing engine oil Maintenance Schedule. Start engine. Check
and filter. area around oil filter for leaks. See Figure 30.
1. Change engine oil and oil filter. 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. Fill engine with oil as
specified in Maintenance Schedule. See
Figure 30.

44
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

3/4 turn with your hand. Fill engine with oil as

specified in Maintenance Schedule. See
Figure 31.

2. Check engine oil at the dipstick tube. If

necessary, add additional oil shown in the
Maintenance Schedule. Start engine. Check
area around oil filter for leaks. See Figure 31.

NOTE: ALL OIL FILL COMPONENTS LISTED IN

LEGEND FOR GM 4.3L 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
NOTE: CUMMINS 4.5L DIESEL ENGINE SHOWN.
Figure 30. GM 4.3L Engine Oil Filter Change CUMMINS QSB 3.3L DIESEL ENGINE SIMILAR.

CUMMINS 4.5L AND QSB 3.3L ENGINE 1. OIL FILTER

2. DRAIN PLUG
OIL AND OIL FILTER 3. OIL DIPSTICK
NOTE: Turn engine OFF before changing engine oil
and filter. Figure 31. Oil Filter Change (Cummins 4.5L
Engine)
1. Change engine oil and oil filter. Apply clean oil
to gasket of new filter. Install new filter. Turn
filter until gasket touches, then tighten 1/2 to

Maintenance Procedures Every 500 Hours or 1 Year

NOTE: Perform the Maintenance Procedures Every HYDRAULIC SYSTEM OIL
8 Hours or Daily prior to performing the procedures
in this section.
WARNING
At operating temperature, the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and
cause a burn.

45
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

Check the hydraulic oil level when the oil is at

operating temperature and with the mast in a
CAUTION
vertical position, the carriage lowered, and the
DO NOT permit dirt to enter the hydraulic system
engine stopped. Add hydraulic oil only as needed. If
when the oil level is checked or the filter is
hydraulic oil is above the FULL level, the hydraulic
changed. Damage to the lift truck and hydraulic
oil will leak from the breather during operation. The
system can occur if dirt enters the hydraulic
oil level indicated by the dipstick is most accurate
system.
when the oil temperature is
Never operate the hydraulic pump without oil in 53 to 93°C (130 to 200°F).
the hydraulic system. The operation of the
See Figure 32 for lift truck models equipped with
hydraulic pump without oil will damage the pump.
two-speed transmission manufactured before June,
2009 or a three-speed transmission manufactured
before October, 2009
CAUTION
Additives may damage the hydraulic system. See Figure 33 for lift truck models equipped with
Before using additives, contact your local Hyster two-speed transmission manufactured after June,
dealer. 2009 or a three-speed transmission manufactured
after October, 2009

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED BEFORE JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED BEFORE OCTOBER 2009 SHOWN.

1. TRANSMISSION BREATHER 4. HYDRAULIC OIL FILL/DIPSTICK

2. TRANSMISSION OIL FILL/DIPSTICK 5. HYDRAULIC TANK BREATHER
3. HYDRAULIC OIL FILTER 6. HYDRAULIC DRAIN PLUG

Figure 32. Transmission and Hydraulic Oil Checks

46
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED AFTER OCTOBER 2009 SHOWN.

1. TRANSMISSION OIL DIPSTICK/BREATHER 5. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL FILTER 6. HYDRAULIC TANK
3. HYDRAULIC TANK BREATHER 7. HYDRAULIC OIL DRAIN PLUG
4. HYDRAULIC OIL FILTER 8. TRANSMISSION OIL DRAIN PLUG

Figure 33. Transmission and Hydraulic Oil Checks

HYDRAULIC TANK BREATHER

Inspect
NOTE: When inspecting the breather, do not
disassemble it. The breather element is a non
serviceable part. If it is damaged, turn engine OFF
and replace with a new breather element.

1. Remove floor mat, front and rear floor plates,

and right side rear cover to access hydraulic
tank breather. See Figure 34.

Figure 34. Side Cover Removal

47
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

Legend for Figure 34. make the acid neutral. Acid in the eyes must be
NOTE: RIGHT SIDE VIEW flushed with water immediately. Wear eye
protection.
1. RIGHT SIDE REAR COVER
2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE WARNING
5. FRONT FLOOR PLATE Batteries generate explosive fumes. Keep the
6. CLIP NUTS vents in the caps clean. Keep sparks or open flame
away from the battery area. DO NOT make sparks
from the battery connections. Disconnect the
WARNING battery ground cable when doing maintenance.
Compressed air can move particles so that they
cause injury to the user or to other personnel. NOTE: Turn engine OFF before working on
Make sure that the path of the compressed air is battery.
away from all personnel. Wear protective goggles Disconnect the negative and positive terminals of
or a face shield to prevent injury to the eyes. the battery. Using a damp cloth clean the case of the
battery. If the terminals are corroded, clean the
terminals with a wire brush. Connect the negative
CAUTION and positive cables to their respective terminals.
Direct air pressure on the filter element can cause
damage. Direct air pressure away from filter CUMMINS 4.5L AND QSB 3.3L ENGINE
element. OIL AND OIL FILTER
2. Using compressed air, remove any dirt and NOTE: Change the oil and oil filter for the engine at
debris in the frame cavity around the breather. the first 100 hours of operation on new lift trucks.
See Figure 32 for lift truck models equipped NOTE: Turn engine OFF before changing engine oil
with two-speed transmission manufactured and filter.
before June, 2009 or a three-speed Change engine oil and engine oil filter. Use the
transmission manufactured before October, correct oil according to the Maintenance Schedule.
2009 Apply clean oil to gasket of new filter. Install new
See Figure 33 for lift truck models equipped filter. Turn filter until gasket touches, then tighten
with two-speed transmission manufactured ½ to 3/4 turn with your hand. Start engine. Check
after June, 2009 or a three-speed transmission area around oil filter for leaks. See Figure 35.
manufactured after October, 2009

3. If necessary, unscrew and replace the breather

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

4. Install right side rear cover, front and rear floor

plates, and floor mat. See Figure 34.

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 bicarbonate (soda) to

48
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

3. Disconnect fuel filter sensor connector from the

fuel filter element.

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

4. Open the drain valve by turning the valve

counterclockwise approximately 3 ½ turns until
draining occurs. Drain until fuel filter element
is empty.

5. Remove and discard Fuel filter element.

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

NOTE: BOTTOM LEFT SIDE ILLUSTRATED. CUM- See Figure 36 for Cummins 4.5L diesel engine
MINS 4.5L ENGINE SHOWN. CUMMINS QSB 3.3L See Figure 37 for Cummins QSB 3.3L diesel
ENGINE SIMILAR. engine

1. OIL FILTER 2. Before installing the filter element, fill the

2. DRAIN PLUG filter element with diesel fuel. This method will
3. OIL DIPSTICK
aid in bleeding the fuel system.
Figure 35. Engine Oil Change Cummins 4.5L Diesel

FUEL/WATER SEPARATOR FILTER CAUTION

REPLACEMENT, CUMMINS 4.5L AND QSB DO NOT overtighten the filter element.
Overtightening the filter element may distort the
3.3L ENGINE threads.

3. Install the new fuel filter element until it

CAUTION contacts the fuel filter head mounting surface.
Disposal of lubricants and fluids must meet local Tighten one additional turn.
environmental regulations.
4. Connect the fuel sensor connector to fuel filter
Replace the fuel filter at specified intervals to element
prevent contaminants from adversely affecting the
diesel fuel flow. 5. Connect air inlet elbow hose.

Remove 6. Open the fuel supply valve.

1. Stop Engine and allow it to cool.
7. Prime the fuel system. See Priming the Fuel
2. Disconnect air inlet elbow to access the fuel System (Cummins 4.5L and QSB 3.3L Engine).
filter element.
8. Check for fuel leaks.
See Figure 36 for Cummins 4.5L diesel engine
See Figure 37 for Cummins QSB 3.3L diesel
engine

49
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

A. RIGHT SIDE VIEW Figure 37. Cummins QSB 3.3L Engine Fuel System
B. FRONT VIEW

1. FUEL FILTER ELEMENT

2. DRAIN VALVE
3. LIFT PUMP
4. FUEL PUMP
5. IN-LINE FUEL FILTER
6. FUEL SUPPLY VALVE
7. FUEL SENDING UNIT
8. FUEL FILTER SENSOR CONNECTOR
9. AIR INLET ELBOW
10. FUEL LINE INJECTOR FITTINGS (4)

Figure 36. Cummins 4.5L Engine Fuel System

50
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

Legend for Figure 37. 5. Pre-fill new filters, both pressure side and
suction side, with clean fuel prior to assembly.
A. RIGHT VIEW B. TOP VIEW Use the clean side block off plug packed with
the filter.
1. TURBO 13. WATERGATE
2. HEAD 14. TURBORCHARGER 6. Lubricate the gasket with clean engine oil.
3. BELL HOUSING AIR INLET
4. FLYWHEEL 15. OIL DIPSTICK
5. OIL PAN 16. EXHAUST MANIFOLD 7. Install fuel filter. Tighten filter until gasket
6. ENGINE BLOCK 17. EXHAUST OUTLET contacts filter head surface. Tighten filter an
7. ELECTRONIC 18. ENGINE ECM additional 3/4 turn after contact.
FUEL PUMP 19. STARTER
8. FUEL FILTER 20. FUEL/WATER 8. Start engine and check for leaks around the
9. WATER OUTLET SEPARATOR
HOUSING 21. PRIMER PUMP fuel filter.
10. WATER PUMP 22. INTAKE MANIFOLD
BELT 23. AIR INLET HOUSING PRIMING THE FUEL SYSTEM (CUMMINS
11. WATER INLET 24. INJECTOR LINE 4.5L AND QSB 3.3L ENGINE)
HOUSING
12. OIL FILL CAP Controlled Venting
FINAL FUEL FILTER REPLACEMENT
(CUMMINS QSB 3.3L ENGINE) CAUTION
When using the starting motor to vent the system,
DO NOT engage it for more than 30 seconds, or
CAUTION starter motor damage will occur. Wait 2 minutes
Disposal of lubricants and fluids must meet local before engaging the starter again.
environmental regulations.
Controlled venting is provided at the injection pump
Replace the fuel filter at specified intervals to through the fuel drain manifold. Small amounts of
prevent contaminants from adversely affecting the air introduced by changing the filters or injection
diesel fuel flow. pump supply line will be vented automatically if the
fuel filter element is changed and filled prior to
1. Close any OEM fuel valves (if applicable) to installation.
prevent fuel from draining.
Manual Bleeding
2. Clean the area around the fuel filter head.
Manual Bleeding will be required if one of the
following conditions exist.
CAUTION • The fuel filter is not filled prior to
Drain the fuel into a container and dispose in installation.
accordance with local environmental regulations. • The fuel injection pump is replaced.
• The high pressure fuel line connections are
3. Remove the fuel filter. See Figure 37.
loosened, or lines are replaced.
4. Clean the gasket surface. • It is an initial engine start up after an
extended period of no engine operation.

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

CAUTION
DO NOT pour fuel directly into the center of the See Figure 36 for Cummins 4.5L diesel engine
filter, since this will allow unfiltered fuel to enter See Figure 37 for Cummins QSB 3.3L diesel
the system and may cause damage to fuel system engine
components.
2. Operate the hand lever until fuel is expelled
from the loosened fitting.

51
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

3. Tighten the fuel line to the injector pump to

9 N•m (80 lbf in).
See Figure 36 for Cummins 4.5L diesel engine
See Figure 37 for Cummins QSB 3.3L diesel
engine

4. Crack open one or more of the injector lines

located on the cylinder head.

WARNING
The pressure spray released by the fuel injectors
can penetrate the skin and cause serious personal
injury. Wear protective clothing.

5. Crank the engine until fuel is expelled from the

loose fittings. If fuel is present at the injectors,
tighten the injector line fittings, and then 1. TPS
crank engine. The engine should start. 2. LOW IDLE STOP
3. TURNBUCKLE NUT
4. TURNBUCKLE
5. CLEVIS
CAUTION 6. LOCK NUT
Disposal of lubricants and fluids must meet local 7. ADJUSTING SCREW (LOW IDLE)
environmental regulations. 8. ROD ENDS

6. Wipe up any fuel that may have spilled and Figure 38. Low Idle and Pull Actuator Adjustment
dispose of the fuel and rags in accordance with Location
local directives.
GM 4.3L ENGINE OIL AND OIL FILTER
LOW IDLE SPEED ADJUSTMENT, NOTE: Change the oil and oil filter for the engine at
CUMMINS 4.5L ENGINE ONLY the first 100 hours of operation on new lift trucks.
NOTE: Turn engine OFF before changing engine oil
CAUTION and filter.
DO NOT attempt to adjust high idle speed limit Change engine oil and engine oil filter. Use the
screws. This may impair the safety and correct oil according to the Maintenance Schedule.
performance of the lift truck and shorten the life of Apply clean oil to gasket of new filter. Install new
the engine. If the high idle speed limit screws filter. Turn filter until gasket touches, then tighten
require adjustment, see your authorized Cummins ½ to 3/4 turn with your hand. Start engine. Check
industrial engine dealer or distributor. area around oil filter for leaks. See Figure 39.
NOTE: Make sure the engine is running prior to
making the low idle adjustment.
1. Loosen lock nut. See Figure 38.

2. Turn the adjustment screw until correct RPM

identified in the Maintenance Schedule has
been set.

3. After the RPM has been set. Use a screw driver

to hold the adjustment screw in place and
tighten lock nut.

52
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

1. TAR DRAIN SCREW

Figure 40. GM LPG Regulator

NOTE: ALL OIL FILL COMPONENTS LISTED IN
LEGEND FOR GM 4.3L ENGINES EQUIPPED WITH
DRAIN TAR FROM LPG CONVERTER
GFI OR PSI ARE LOCATED IN THE SAME AREA.
NOTE: The following procedure is to be used on lift
1. OIL FILTER trucks equipped with a GM 4.3L LPG Engine with
2. DRAIN PLUG PSI installed.
3. ENGINE OIL DIPSTICK
4. ENGINE OIL FILL 1. Move the lift truck to a well ventilated area,
and ensure no external ignition sources are
Figure 39. GM 4.3L Engine Oil Change present.

DRAIN TAR FROM LPG REGULATOR 2. Start the engine.

NOTE: The following procedure is to be used on lift
3. Close the valve on the LPG tank.
trucks equipped with a GM 4.3L LPG Engine with
GFI installed. 4. When the engine runs out of fuel, turn key
1. Warm engine to operating temperature. switch to OFF position, or if equipped, press
Power ON/OFF button OFF, and disconnect
2. Shut fuel valve off and run engine until the the negative terminal on the battery.
engine runs out of fuel and stops.

3. Raise the hood doors. CAUTION

A small amount of fuel may remain in the fuel line.
4. Remove tar drain screw from regulator. Allow To prevent the possibility of burns wear gloves
tar to drain from regulator. When tar has and eye protection. If fuel continues to flow check
completely drained, install tar drain screw in to make sure the LPG tank valve is completely
regulator. See Figure 40. closed.

5. Disconnect the inlet line and outlet hose from

the LPG converter. See Figure 41.

53
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

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

12. Start the engine and recheck for leaks at the

converter.

DRIVE BELT
Cummins 4.5L and QSB 3.3L Diesel
Engine and GM 4.3L Engine
Fan and Alternator Drive Belt
Turn engine OFF and check drive belt for wear and
1. LPG CONVERTER damage. See Figure 42. A few small cracks that run
2. INLET LINE across belt are acceptable. A belt with cracks that
3. OUTLET HOSE run the length of belt or a belt with missing pieces is
4. MOUNTING BOLTS not acceptable. See the following for drive belt
arrangement:
Figure 41. LPG Converter Removal
See Figure 43 for Cummins 4.5L diesel engine
6. Remove the mounting bolts and LPG converter See Figure 44 for Cummins QSB 3.3L diesel engine
from the mounting bracket.
See Figure 45 for GM 4.3L engine

CAUTION
Engine components may be hot. Use gloves when
handling the LPG Converter to prevent the
possibility of burns.

CAUTION
Drain the tar into a container and dispose in
accordance with local environmental regulations.

7. Rotate the LPG converter sightly so that outlet

opening is pointing toward the container and
allow tar to drain from LPG converter. If the 1. ACCEPTABLE CRACKS
LPG converter cannot be rotated a sufficient 2. NOT ACCEPTABLE CRACKS AND DAMAGE
amount to drain the tar, disconnect the two
cooling hoses. Figure 42. Drive Belt Inspection

8. Using mounting bolts, install the LPG

converter on the mounting bracket.

9. Connect the fuel line and outlet hose to the

LPG converter. If disconnected, connect the two
cooling hoses.

10. Connect the negative terminal on the battery.

54
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

NOTE: CUMMINS 4.5L DIESEL ENGINES HAVE 1. ALTERNATOR BELT ADJUSTMENT BRACKET
SELF-ADJUSTING TENSIONERS. NO ADJUST- 2. DRIVE BELT
MENT NEEDED. 3. CAMSHAFT PULLEY
4. CRANKSHAFT PULLEY
5. ALTERNATOR PULLEY
1. ALTERNATOR PULLEY
2. CAMSHAFT PULLEY
3. WATER PUMP PULLEY Figure 44. Cummins QSB 3.3L Diesel Engine Drive
4. CRANKSHAFT PULLEY Belt Arrangement
5. TENSIONER PULLEY

Figure 43. Cummins 4.5L Diesel Engine Drive Belt

Arrangement

55
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

TRANSMISSION OIL, BREATHER, AND

WET BRAKE AXLE OIL LEVEL CHECK

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

CAUTION
DO NOT permit dirt to enter the transmission when
the oil level is checked or the filter is changed and
cause damage to the transmission.

NOTE: The transmission and wet brake drive axle

housing arms share oil. By checking the
transmission oil level and adding oil if necessary,
the oil level in the wet brake drive axle housing
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING
arms is also checked and filled when oil is added.
TENSIONERS. NO ADJUSTMENT NEEDED.
1. If engine has been running, the engine must be
1. FAN PULLEY shut down for one minute or longer prior to
2. WATER PUMP PULLEY checking the oil level. If the transmission oil is
3. CRANKSHAFT PULLEY low, add oil to transmission at the dipstick tube
4. SERPENTINE BELT
5. TENSIONER PULLEY at the correct level as indicated on the dipstick.
6. ALTERNATOR PULLEY Use the correct oil as shown in the
Maintenance Schedule.
Figure 45. GM 4.3L Drive Belt Arrangement
See Figure 32 for lift truck models equipped
with two-speed transmission manufactured
CLEAN DEBRIS FROM RADIATOR CORE before June, 2009 or a three-speed
Turn engine OFF and check the radiator core for transmission manufactured before October,
restrictions and remove material causing radiator 2009
core to be plugged or restricted. See Figure 33 for lift truck models equipped
with two-speed transmission manufactured
after June, 2009 or a three-speed transmission
WARNING
manufactured after October, 2009
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
WARNING
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning
Clean with compressed air, adjusted to a maximum solvents, always follow the recommendations of
output of 103 kPa (15 psi), and blow debris from the manufacturer.
core and fan shroud.

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

56
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

NOTE: The information in Step 2 applies to lift

trucks with a two-speed transmission manufactured
After June 2009, or a three-speed transmission
manufactured After October 2009. On these trucks,
the transmission oil dipstick and breather are one
unit.
2. Check the transmission oil breather. See
Figure 46. If breather is dirty or plugged up,
clean transmission oil breather with a grease
cleaning solvent and use compressed air to dry.
If transmission oil breather is worn or
damaged, replace with new transmission
breather. See Parts Manual.

3. Start and run the engine for approximately one

minutes after adding oil to allow oil to lubricate
parts within the wet brake drive axle housing
arms.

4. Turn lift tuck OFF and let it cool for one

minute. Check oil level at the transmission NOTE: LIFT TRUCKS WITH TWO-SPEED TRANS-
dipstick and add additional oil at the MISSION MANUFACTURED AFTER JUNE 2009, OR
transmission dipstick tube to properly fill the THREE-SPEED TRANSMISSION MANUFACTURED
transmission. The correct oil and quantity AFTER OCTOBER 2009 SHOWN.
needed are shown in the Maintenance
1. TRANSMISSION OIL DRAIN PLUG
Schedule. 2. TRANSMISSION OIL DIPSTICK/BREATHER
3. TRANSMISSION OIL FILL HOLE
4. TRANSMISSION OIL FILTER
5. TRANSMISSION

Figure 46. Transmission Oil Dipstick and Breather

WET BRAKE CENTER BODY OIL LEVEL

CHECK

WARNING
At operating temperature, the center section oil is
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn.

CAUTION
DO NOT permit dirt to enter the center body when
the oil level is checked. Dirt will contaminate the
oil and cause damage to the center body of the
axle.

1. Remove the center body fill plug. See Figure 47.

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

the fill port until the oil/fill level port has
overflowed. The Correct oil is shown in the
Maintenance Schedule or Figure 48.

57
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

3. Install center body fill plug and tighten to

30 to 50 N•m (22 to 37 lbf ft).

1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE

Figure 47. Wet Brake Drive Axle Drain and Fill/Level Plug Location

58
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

A. RIGHT PLANETARY HOUSING - USE JDM J20C

B. LEFT PLANETARY HOUSING - USE JDM J20C
C. CENTER SECTION HOUSING - USE SAE 80W/90

1. HUB FILL/DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG

2. PLANETARY DRAIN PLUG 5. CENTER SECTION DRAIN PLUG
3. PLANETARY FILL PLUG

Figure 48. Oil Application Diagram

FORKS

WARNING
Never repair damaged forks. DO NOT heat, weld,
or bend the forks. Forks are made of special steel
using special methods. Replaced damaged forks
as a complete set.

Measure thickness of forks with a fork arm caliper

(Hyster Part No. 3020387) at a vertical section
where there is no wear. This thickness is dimension
X. Now, measure thickness at heel of fork. If the
thickness of the heel is not greater than 90% of
dimension X, replace fork. See Figure 49.

Figure 49. Forks Check

59
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

Legend for Figure 49. 2. Raise the carriage about 61 cm (2 ft), and tilt
the mast fully back. Place blocks under the
1. TIP ALIGNMENT (MUST BE WITHIN 3% outer mast channels to within 13 mm (0.5 in.)
OF FORK LENGTH) of the channels. See Figure 51.
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF 3. Tilt the mast fully forward. See Figure 51.
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH

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

bearings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller
surfaces along full length of channels as shown
in Figure 50.

A. MAST TILTED FULLY BACK

A. UPPER LOAD ROLLERS B. MAST TILTED FORWARD
B. LOWER LOAD ROLLERS
1. BLOCK
1. LUBRICATE STRIP BEARING SURFACES 2. MAST
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER Figure 51. Blocking the Mast
Figure 50. Mast Lubrication
4. Lubricate the mast pivot bushings at grease
fittings on outer mast. Use multipurpose grease
NOTE: When lubricating the mast mounting/pivot
shown in the Maintenance Schedule. See
pins, the load must be removed from the normal
Figure 52.
contact surface to allow grease to properly lubricate
the normal contact surfaces of the mast bushings.

60
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

1. OUTER MAST 3. LUBRICATION FITTING

2. MAST PIVOT BUSHING

Figure 52. Pivot Pin Lubrication

5. Tilt mast fully back. Remove the blocks from

under the channels

NOTE: Perform Step 6 and Step 7 for lift trucks

manufactured before August, 2012.
6. If a hang on sideshift carriage is installed,
lubricate sliding surfaces (upper bearings) at
grease fittings and lower bearing strips with
multipurpose grease shown in the Maintenance
Schedule. See Figure 53.
If lift truck is equipped with a fork positioner,
lubricate fork positioner carrier at grease
fittings and the fork cylinder rod anchors with
multipurpose grease shown in the Maintenance
Schedule. See Figure 53.

61
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

8. If lift truck is equipped with a hang on sideshift

carriage with fork positioner, lubricate sliding
surfaces (upper bearings) at grease fittings,
fork carrier grease fittings and sideshifter
lower bearings. See Figure 54.

9. Lubricate fork carrier arm as required. Use

graphite dry lube.

10. Check for loose or missing capscrews, worn or

damaged hoses and hydraulic leaks.

11. Inspect frame lower hooks for wear and proper

clearance. Adjust if necessary. See Mast
Repairs, 2- and 3-Stage Masts (S/N A513,
A514, A613, A614, A702, A703, A704, A705,
A706, A707, A751, A752, B513, B514, B586,
B587, B588, B589, B590, B591, B749, B750,
B751, B752, B753, B754) 4000SRM1250 for
adjustment procedures.

12. Tighten fork positioner mounting flange

capscrews to 165 N•m (120 lbf ft). See
1. UPPER BEARINGS GREASE FITTINGS Figure 54.
2. GREASE FITTINGS FOR FORK POSITIONER
CARRIER AND FORK CYLINDER ROD
ANCHORS 13. Tighten fork carrier retainer capscrews to
3. FORK POSITIONERS 66 N•m (50 lbf ft). See Figure 54.
4. FORK POSITIONER MOUNTING CAPSCREWS
5. LOWER HOOK CAPSCREWS 14. Tighten cylinder anchor bar capscrews to
6. LOWER BEARING STRIPS 65 N•m (46 lbf ft). See Figure 54.
Figure 53. Hang On Sideshift Carriage, Fork Lift
15. Tighten fork positioner cylinder rod anchor
Trucks Manufactured Before August, 2012
plugs to 135 N•m (100 lbf ft). See Figure 54.
7. Check the torque for the fork positioner
16. Tighten backrest capscrews to
mounting capscrews, if lift truck is equipped
195 N•m (145 lbf ft). See Figure 54.
with a fork positioner, and lower hook
capscrews on the hang on sideshift carriage. 17. Inspect carrier arm bars and bearings for wear
The torque values for these capscrews are or damage. If bearing thickness is less than
155 to 170 N•m (115 to 125 lbf ft). 2.5 mm (0.10 in.) replace both bearings.
NOTE: Perform Step 8 through Step 17 for lift
trucks manufactured after August, 2012.

62
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

Figure 54. Hang On Sideshift Carriage With Fork Positioner, Fork Lift Trucks Manufactured After August,
2012

63
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

Legend for Figure 54.

A. REAR VIEW

1. BACKREST 6. FORK CARRIER

2. CYLINDERS AND HOSES 7. MOUNTING FLANGE CAPSCREW
3. FORKS 8. FORK CARRIER RETAINER CAPSCREW
4. BACKREST CAPSCREW 9. CYLINDER ANCHOR BAR CAPSCREWS
5. WASHER 10. FRAME-LOWER HOOKS

HEADER HOSE CHECKS DO NOT repair worn or damaged lift chains. If a lift
chain is worn or damaged, both lift chains must be
NOTE: Also inspect header hoses every 8 hours or replaced.
daily.
Inspect for kinked, crushed, flattened, or twisted NOTE: The 500 Hour/1 year Lift Chain Lubrication
hoses; hard, stiff, or charred hoses. Inspect hose should not be performed in combination with the
fittings and for hose slippage and proper hose 1000 Hour/1 year Lift Chain Lubrication.
tensioning. Adjust/repair/replace hose/components Lubricate lift chains with SAE 30W engine oil. The
as necessary. See Mast Repairs, 2- and 3-Stage best procedure is to remove the chains from the lift
Masts (S/N A513, A514, A613, A614, A702, A703, truck and soak them in engine oil. Be sure to clean
A704, A705, A706, A707, A751, A752, B513, B514, any dirt or grease from chains before lubricating.
B586, B587, B588, B589, B590, B591, B749, B750, DO NOT USE STEAM TO CLEAN THE LIFT
B751, B752, B753, B754) 4000SRM1250. CHAINS.

LIFT CHAIN LUBRICATION TILT CYLINDER LUBRICATION

NOTE: The floor plate must be removed in order to
WARNING lubricate the rear tilt cylinder lubrication fittings.
When working on or near the mast, see Safety Lubricate the tilt cylinder ends. Use multipurpose
Procedures When Working Near Mast in this grease shown in the Maintenance Schedule. There
section. are four lubrication fittings. See Figure 55.

64
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 6. MAST END MOUNT

2. LOCK NUT 7. CYLINDER HOSE PORTS
3. ANCHOR PIN 8. ROD END
4. TILT PIN 9. LUBE FITTINGS
5. FRAME END MOUNT

Figure 55. Tilt Cylinder Lubrication

MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION
Lubricate the master brake cylinder rod end pin.
Use lubricant shown in the Maintenance Schedule.
See Figure 56.

65
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

Figure 56. Master Brake Cylinder Rod End Pin

Lubrication

Legend for Figure 56.

1. ROD END PIN NOTE: FOUR FUNCTION LEVERS WITH DETENT

2. COTTER PIN (LOCKING)
SHOWN.
MANUAL HYDRAULIC LEVERS 1. BUSHINGS
LUBRICATION 2. ROD END PIN
3. HYDRAULIC LEVERS
Lubricate the bushings for the manual hydraulic 4. LOCKING RING (COTTER PIN)
levers. Use spray lubricant as listed in the
Maintenance Schedule. See Figure 57. Figure 57. Manual Hydraulic Levers Lubrication

BRAKE OIL

WARNING
Small amounts of water in the brake system can
cause reduced braking performance if the water
reaches the wheel cylinder areas. DO NOT allow
water entry. Ensure that the sealed reservoir lid is
properly replaced.
Replace the brake oil in the system if there is dirt
or water in the system.

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

66
8000 SRM 1322 Maintenance Procedures Every 500 Hours or 1 Year

Remove the dash and kick panel from the cowl. The TIE ROD LUBRICATION
brake oil reservoir is located on the cowl, at the
master cylinder. See Figure 58. Add brake oil, as Lubricate the tie rods. Use multipurpose grease
necessary. Use Dexron III brake oil shown in the shown in the Maintenance Schedule. There are two
Maintenance Schedule. lubrication fittings on each tie rod. See Figure 59.

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

Figure 58. Brake Oil Reservoir

67
Maintenance Procedures Every 500 Hours or 1 Year 8000 SRM 1322

1. SPINDLE BEARINGS LUBE FITTINGS 3. STEERING AXLE

2. TIE RODS LUBE FITTINGS

Figure 59. Tie Rod Lubrication

PARKING BRAKE ADJUSTMENT 2. For burnished brakes, test the operation of the
parking brake. The lift truck with a capacity
Make sure the service brakes are adjusted and the load must not move when parking brake is
operation of the automatic adjuster mechanism is applied on a 15 percent grade [a slope that
correct before the parking brake is adjusted. increases 1.5 m in 10 m (1.5 ft in 10 ft)].
Lift trucks with aMONOTROL® pedal. The
switch energizes the seat warning circuit when
hand lever is released. This switch puts the
transmission in NEUTRAL by de-energizing the
direction solenoid. There is also a switch on the left-
hand side of bracket. This switch prevents engine
from starting unless parking brake is applied.

NOTE: Make sure parking brake is released before

making adjustment.
1. Turn the adjustment knob to raise the
equalized link and tighten the parking brake
cables shown in Figure 60. DO NOT tighten the
adjustment so that the brake is applied when
the lever is released. The lever for the parking
brake has a lock. Use your thumb or finger to
release the lock on the lever when the parking
brake is released.

68
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

Legend for Figure 60.

1. LOCK BUTTON RELEASE

2. OFF POSITION
3. ON POSITION
4. ADJUSTMENT KNOB

Figure 60. Parking Brake

Maintenance Procedures Every 1000 Hours or 1 Year

NOTE: Perform the Maintenance Procedures Every LPG FUEL FILTER ELEMENT REPLACE,
8 Hours or Daily and Maintenance Procedures GM 4.3L ENGINE
Every 500 Hours or 1 Year checks prior to
performing the procedures in this section. Remove

VALVE CLEARANCE, CHECK AND

WARNING
ADJUST LPG can cause an explosion and serious injury to
The GM 4.3L engine has hydraulic valve lifters and personnel. DO NOT permit any sparks or open
does not require valve clearance adjustments during flames in the work area.
normal service. Additional engine information is
available in the following section: GM 4.3L V-6 1. Close fuel valve on tank. Run engine until it
Engines 0600SRM1251. stops.

IGNITION SYSTEM 2. Disconnect negative battery cable.

GM 4.3L Engine
The GM 4.3L LPG engines have an electronic WARNING
control unit (ECU) that controls the ignition timing. A small amount of fuel may still be present in the
There are no adjustments. Turn engine OFF and fuel line. Use gloves to prevent burns and wear
change the spark plugs every 1000 hours. See the eye protection. If liquid fuel continues to flow from
section Capacities and Specifications the connections when loosened, check to make
8000SRM1320 for the correct spark plug gap and sure the manual valve is fully closed.
type of plugs to use.

69
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

3. Remove the bolt and seal washer retaining the 5. Install bolt and new seal washer. Tighten bolt
top section of the fuel filter housing. Discard to 13 N•m (115 lbf in).
seal washer. See Figure 61.
NOTE: Opening the fuel valve too quickly can cause
the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve,
wait a few seconds, and then slowly open the fuel
valve again. This will reset the excess fuel valve.
6. Slowly open the fuel valve on tank.

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

the OFF position to pressurize the fuel system.
Check for leaks.

8. Check for leaks at connections by using soapy

solution or electronic leak detector. If leaks are
detected, make proper repairs.
See LPG Fuel System, GM 4.3L Engine
with GFI 0900SRM1242 for lift trucks
equipped with GFI LPG fuel system
See LPG Fuel System, GM 4.3L Engine
With PSI 0900SRM1556 for lift trucks
equipped with PSI LPG fuel system.

IN-LINE FILTER REPLACEMENT,

CUMMINS 4.5L ENGINE

1. BOLT CAUTION
2. SEAL WASHER Disposal of lubricants and fluids must meet local
3. FUEL FILTER HOUSING TOP SECTION
4. FUEL FILTER environmental regulations.
5. FUEL FILTER O-RING
6. HOUSING O-RING Replace the fuel filter at specified intervals to
7. FUEL FILTER HOUSING BOTTOM SECTION prevent contaminants from adversely affecting the
diesel fuel flow.
Figure 61. LPG Fuel Filter Removal and Installation
Remove
4. Remove top section of fuel filter housing.
1. Stop engine and allow it to cool.
5. Remove and discard housing O-ring.
2. Close fuel supply valve located on the fuel
6. Remove fuel filter and fuel filter O-ring. sending unit. See Figure 62.

Install
1. Clean and inspect the fuel filter housing for
CAUTION
contamination or damage. Drain the fuel into a container and dispose in
accordance with local environmental regulations.
2. Install the new fuel filter and fuel filter O-ring.
3. Loosen clamps and disconnect two fuel lines
See Figure 61.
from the in-line fuel filter. Remove and discard
3. Install new housing O-ring. the in-line fuel filter

4. Install top section of fuel filter housing.

70
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

Install
1. Install in-line fuel filter by connecting the two
fuel lines and tighten clamps. See Figure 62.

2. Open the fuel supply valve.

3. Check for fuel leaks.

A. RIGHT SIDE VIEW B. FRONT VIEW

1. FUEL FILTER 6. FUEL SUPPLY VALVE

ELEMENT 7. FUEL SENDING UNIT
2. DRAIN VALVE 8. FUEL FILTER
3. LIFT PUMP SENSOR
4. FUEL PUMP CONNECTOR
5. IN-LINE FUEL 9. AIR INLET ELBOW
FILTER 10. FUEL LINE INJECTOR
FITTINGS (4)

Figure 62. Cummins 4.5L Engine Fuel System

71
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

LIFT CHAINS WEAR CHECK LIFT CHAIN LUBRICATION

If a section of chain is 3% longer than a similar
section of new chain, the chain is worn and must be
WARNING
replaced. Measure chain for wear where it moves
Cleaning solvents can be flammable and toxic and
over sheaves. Using a chain scale, (Hyster P/N
can cause skin irritation. When using cleaning
871796 ) check lift chains as shown in Figure 63.
solvents, always follow the recommendations of
the manufacturer.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
that the path of the compressed air is away from
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.

Remove the lift chains. Clean the lift chains by

soaking 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
engine 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.

HANG ON SIDESHIFT CARRIAGE, CHECK

SLIDING SURFACES
Pitch Wear Limit 1. Check the sideshift carriage sliding surfaces. If
Total Length necessary, lubricate sliding surfaces (upper
(The
of 20 Links bearings) at grease fittings and lower bearing
Maximum
(Pitch) of strips with multipurpose grease shown in the
Length of 20
New Chain Maintenance Schedule. See Figure 64.
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

Figure 63. Lift Chains Check

72
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

2. If lift truck is equipped with a fork positioner,

lubricate fork positioner carrier at grease
fittings and the fork cylinder rod anchors with
multipurpose grease shown in the Maintenance
Schedule. See Figure 64.

3. Clean the bearing areas. Inspect the hang on

sideshift bearings for wear as follows:

NOTE: Perform Step a and Step b for lift trucks

equipped with hang on sideshift carriage with fork
positioner manufactured before August, 2012.
a. Remove upper bearings from the upper
carriage bar. If any upper bearings are worn
to less than 1.5 mm (0.06 in.) thickness,
replace all upper bearings by driving upper
bearings from upper carriage bar. Install
new upper bearings into upper carriage bar.
See Figure 65.

b. Remove lower bearings from the lower

carriage bar. If any lower bearings are worn
1. UPPER BEARINGS GREASE FITTINGS to less than 1.5 mm (0.06 in.) thickness,
2. GREASE FITTINGS FOR FORK POSITIONER replace all lower bearings by prying lower
CARRIER AND FORK CYLINDER ROD bearings from the lower carriage bar. Install
ANCHORS new lower bearings onto lower carriage bar.
3. FORK POSITIONERS
4. FORK POSITIONER MOUNTING CAPSCREWS See Figure 65.
5. LOWER HOOK CAPSCREWS
6. LOWER BEARING STRIPS

Figure 64. Hang On Sideshift Carriage, Lubricate,

Lift Trucks Manufactured Before August, 2012

73
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

Figure 65. Hang On Sideshift Carriage, Check Bearings, Lift Trucks Manufactured Before August, 2012

74
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

Legend for Figure 65.

A. HANG ON SIDESHIFT CARRIAGE, LIFT TRUCKS MANUFACTURED BEFORE JANUARY, 2011.

B. HANG ON SIDESHIFT CARRIAGE, LIFT TRUCKS MANUFACTURED AFTER JANUARY, 2011.

1. GREASE FITTING 9. LOWER HOOK

2. UPPER BEARING 10. CAPSCREW
3. ANCHOR BRACKET 11. WASHER
4. SIDESHIFT CYLINDER 12. UPPER CARRIAGE BAR
5. CLEVIS PIN 13. PIN
6. COTTER PIN 14. PLUG
7. LOWER BEARING 15. LOWER CARRIAGE BAR
8. NUT

NOTE: Perform Step c and Step d for lift trucks d. Remove lower bearings from the lower
manufactured after August, 2012. carriage bar. If any lower bearings are worn
to less than 2.5 mm (0.10 in.) thickness,
c. Remove upper bearings from the upper
replace all lower bearings by prying lower
carriage bar. If any upper bearings are worn
bearings from the lower carriage bar. Install
to less than 2.5 mm (0.10 in.) thickness,
new lower bearings onto lower carriage bar.
replace all upper bearings by driving upper
bearings from upper carriage bar. Install
new upper bearings into upper carriage bar.
See Figure 66.

75
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

1. UPPER CARRIAGE BAR 7. WASHER

2. LOWER BEARINGS 8. LOWER HOOK
3. RESTRICTOR WASHER 9. CAPSCREW
4. SIDESHIFT CYLINDER 10. GREASE FITTING
5. UPPER BEARING 11. LOWER CARRIAGE BAR
6. ROLL PIN

Figure 66. Hang On Sideshift Carriage, Check Bearings, Lift Trucks Manufactured After August, 2012
Figure

STEERING AXLE SPINDLE BEARINGS of the steering axle. Use multipurpose grease as
shown in the Maintenance Schedule. See Figure 67.
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side

76
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

1. SPINDLE BEARINGS LUBE FITTINGS 3. STEERING AXLE

2. TIE RODS LUBE FITTINGS

Figure 67. Steering Axle Tie Rods and Spindle Bearings

CONTROL LEVERS AND PEDALS • Check engine harness connectors. Check to

ensure connectors are fitted and locked by
Lubricate linkages, pedal shafts, control cables pushing the connectors together. Pull on the
(throttle, hood hinges, parking brake), and seat connector halves to make sure they are
rails. Use a silicone spray lubricant, Hyster Part No. locked.
328388 . • Check ignition coil wire and spark plug wires
for hardening, cracking, arching, chaffing,
INSPECT ENGINE ELECTRICAL SYSTEM, separation, split boot covers, and proper fit.
CONNECTORS Replace spark plugs at the recommended
interval as shown in the Maintenance
NOTE: Turn engine OFF prior to inspecting engine Schedule.
electrical system. • Check that all electrical components are
When inspecting the electrical system, check the securely mounted and retained to the engine
following: or chassis.
• Check the Malfunctioning Indicator Light
• Check and clean battery connection. Ensure (MIL), charging, and oil pressure lights for
that connections are tight. operation by starting the engine and checking
• Check battery for damage or cracks to the that the light illuminates before turning out.
case. Replace if necessary.
• Check positive and negative cables for
corrosion, rubbing, and chaffing. Tighten
connections at both ends.
• Check engine wire harness for rubbing,
chaffing, pinching, and cracks or breaks in
the wiring.

77
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

TRANSMISSION OIL, FILTER, BREATHER

CHANGE AND WET BRAKE DRIVE AXLE
OIL CHANGE

WARNING
At operating temperature, the transmission and
wet brake axle oil is HOT. DO NOT permit the hot
oil to touch the skin and cause a burn.

CAUTION
The oil used for the wet brake drive axle or
transmission should not be contaminated. If either
the wet brake drive axle and/or transmission oil
becomes contaminated, the oil must be drained
and replaced with new oil.

CAUTION
DO NOT permit dirt to enter the transmission or NOTE: LIFT TRUCKS WITH TWO-SPEED TRANS-
wet brake drive axle when the oil level is checked MISSION MANUFACTURED BEFORE JUNE 2009,
or the transmission filter is changed. Dirt will OR THREE-SPEED TRANSMISSION MANUFAC-
contaminate the oil and cause damage to the TURED BEFORE OCTOBER 2009 SHOWN.
transmission and wet brake drive axle NOTE: ALL MAJOR COMPONENTS AND FRAME
components. COMPONENTS REMOVED FOR THE SAKE OF
CLARITY.

1. TRANSMISSION
CAUTION 2. TRANSMISSION BREATHER
Disposal of lubricants and fluids must meet local 3. TRANSMISSION DIPSTICK
environmental regulations. 4. TRANSMISSION OIL FILTER
5. TRANSMISSION DRAIN PLUG
NOTE: Change the transmission oil filter at the
first 500 hours of operation on new lift trucks. Figure 68. Transmission Oil Change
NOTE: Turn engine OFF before changing
transmission oil, filter, and breather.
1. The drain plug for the transmission is located
on the bell housing side of the transmission
sump. Remove drain plug. Drain oil into a
container. Be sure container is large enough to
hold all the oil. See Maintenance Schedule for
transmission oil quantity. Once oil is
completely drained, reinstall drain plug.
See Figure 68 for lift truck models with two-
speed transmission manufactured before June
2009, or three-speed transmission
manufactured before October 2009.
See Figure 69 for lift truck models with two-
speed transmission manufactured after June
2009, or three-speed transmission
manufactured after October 2009.

78
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

2. Remove all drain plugs from the wet brake axle

and drain oil into a container. Be sure
container is large enough to hold all the oil. See
Maintenance Schedule for wet brake axle oil
quantity. When oil has completely drained,
install all drain plugs. Tighten the left and
right chamber drive axle housing arm and
center section drain plugs to
30 to 50 N•m (22 to 37 lbf ft). See Figure 70.

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANS-

MISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED
AFTER OCTOBER 2009 SHOWN.

1. TRANSMISSION OIL DRAIN PLUG

2. TRANSMISSION OIL DIPSTICK/BREATHER
3. TRANSMISSION OIL FILL HOLE
4. TRANSMISSION OIL FILTER
5. TRANSMISSION

Figure 69. Transmission Oil Dipstick and Breather

79
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE

Figure 70. Wet Brake Drive Axle Drain and Fill/Level Plug Location

80
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

A. RIGHT PLANETARY HOUSING - USE JDM J20C

B. LEFT PLANETARY HOUSING - USE JDM J20C
C. CENTER SECTION HOUSING - USE SAE 80W/90

1. HUB FILL/DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG

2. PLANETARY DRAIN PLUG 5. CENTER SECTION DRAIN PLUG
3. PLANETARY FILL PLUG

Figure 71. Oil Application Diagram

3. Remove and discard old transmission oil filter. See Figure 69 for lift truck models with two-
Apply clean oil to gasket of new filter. Install speed transmission manufactured after June
new filter and hand tighten. 2009, or three-speed transmission
manufactured after October 2009.

CAUTION
Before adding oil, ensure the truck is parked and CAUTION
on level ground. DO NOT run the engine for more than two minutes.
Damage to the transmission bearings can occur if
4. Fill wet brake drive axle center section until oil engine runs longer than two minutes and oil level
reaches the fill hole. The correct oil and is not at the full mark.
quantity needed are shown in the Maintenance
Schedule or Figure 71. Install fill plug and 6. Start and run the engine for approximately 1 to
tighten to 48 to 60 N•m (35 to 44 lbf ft). 2 minutes after fill to allow oil to lubricate
parts within the wet brake drive axle housing
5. Add oil to transmission above the FULL mark arms and center section.
on the dipstick tube. The correct oil and
quantity needed is shown in the Maintenance NOTE: Transmission oil temperature should be at
Schedule. least 50°C (120°F) when checking oil level.
See Figure 68 for lift truck models with two-
speed transmission manufactured before June
2009, or three-speed transmission
manufactured before October 2009.

81
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

7. Turn lift tuck OFF. Check oil level at the Normal Operating Environment
transmission dipstick and add additional oil at
the transmission dipstick tube to properly fill 1. Clean area around parking brake lever and
the transmission. The correct oil and quantity thrust bushing to remove dirt and debris. See
needed are shown in the Maintenance Figure 72.
Schedule. See Figure 70.
2. Remove socket head screw and spacer from
8. Repeat Step 5, Step 6, and Step 7 until parking brake lever. See Figure 72.
transmission oil level is at the correct level.
3. Lift parking brake lever approximately
NOTE: Perform Step 9 on lift trucks with two-speed 1 mm (.040 in.) up from thrust lever and away
transmission manufactured Before June 2009, or from drive axle housing. See Figure 72.
three-speed transmission manufactured Before
4. Use spray grease, shown in Maintenance
October 2009.
Schedule, with an extension tube and insert
9. Replace transmission breather with a new tube in space between parking brake lever and
breather. See Figure 68. thrust lever.

PARKING BRAKE LEVER LUBRICATION, 5. Spray a generous amount of grease in space

WET BRAKE AXLE between parking brake lever and thrust lever.
See Figure 72.
Before lubricating the parking brake levers on the
wet brake axle, perform the following: 6. Wait a few minutes to allow solvent to
evaporate. Once solvent has evaporated, spray
1. Block lift truck wheels to prevent lift truck the area a second time.
from moving when parking brake is released.
7. After second application of grease has
2. Have one person sit in the lift truck seat and evaporated, check parking brake lever for free
apply the service brake and release the parking movement.
brake.
8. Install the spacer and socket head screw onto
3. Have another person observe the parking brake parking brake lever. Tighten socket head screw
lever(s) on top of the drive axle while the other to 24 to 26 N•m (17 to 19 lbf ft).
person turns the parking brake adjustment
knob counterclockwise. See Figure 60. The 9. Adjust the parking brake lever(s) using parking
spring on the cable(s) should have enough force brake adjustment screw (see Figure 72). See
to cause the lever(s) to move forward as the Drive Axle and Differential Assembly
parking brake adjustment cable is slackened. Repair 1400SRM1344 for procedures.

4. If lever(s) move freely and lift truck operates in 10. After adjusting parking brake lever(s), adjust
a normal operating environment, go to Normal parking brake. See Maintenance Procedures
Operating Environment. If lever(s) do not move Every 500 Hours or 1 Year for procedures.
or if lift truck operates in a heavy duty or
contaminated environment, go to Heavy Duty
or Contaminated Environment.

82
8000 SRM 1322 Maintenance Procedures Every 1000 Hours or 1 Year

1. SOCKET HEAD SCREW

2. SPACER
3. PARKING BRAKE LEVER
4. THRUST LEVER
5. THRUST BUSHING
6. PARKING BRAKE LEVER ADJUSTMENT SCREW

Figure 72. Lubricate Parking Brake Lever, Normal Operating Environment

Heavy Duty or Contaminated Environment

Remove
1. Clean area around parking brake lever and
thrust bushing to remove dirt and debris. See
Figure 72.

2. Remove parking brake cable from parking

brake lever.

3. Remove socket head screw securing parking

brake lever to thrust lever. See Figure 72.

NOTE: Mark parking brake lever in relation to the

NOTE: CIRCLE INDICATES WHERE TO MARK
thrust lever to help install parking brake lever in
PARKING BRAKE LEVER.
correct position during installation. See Figure 73.
4. Remove spacer and parking brake lever from 1. SPACER
thrust lever. 2. SOCKET HEAD SCREW

Figure 73. Remove Parking Brake Lever

5. Remove socket head screws and thrust bushing

from drive axle. See Figure 74.

83
Maintenance Procedures Every 1000 Hours or 1 Year 8000 SRM 1322

1. SOCKET HEAD SCREW 1. THRUST LEVER

2. THRUST BUSHING 2. APPLY MULTIPURPOSE GREASE HERE
3. THRUST LEVER 3. COVER OPENINGS AND EDGES

Figure 74. Remove Thrust Bushing Figure 76. Inspect and Clean Thrust Lever

6. Remove O-rings from inside and outside of Install

thrust bushing. See Figure 75. 1. Apply thin coat of multipurpose grease (see
Maintenance Schedule) to thrust lever from the
bottom of the spline down to where the O-ring
contacts the thrust lever when the thrust
bushing is installed. See Figure 76.

2. Lubricate new O-ring (inside) with lithium

based grease and install the O-ring inside the
bore on the thrust bushing. See Figure 75.

3. Pack area above the O-ring, inside the bore,

with multipurpose grease, as shown in the
Maintenance Schedule, prior to installing
thrust bushing onto thrust lever. See Figure 75.

4. Lubricate new O-ring (outside) with lithium

1. O-RING (OUTSIDE) based grease and install the O-ring on outside
2. O-RING (INSIDE) of thrust bushing. See Figure 75.
3. BORE (APPLY GREASE HERE)
4. THRUST BUSHING
5. Apply Loctite® 242 to socket head screws and
Figure 75. Remove O-Rings From Thrust Bushing install thrust bushing to drive axle. Tighten
socket head screws to
Clean and Inspect 24 to 26 N•m (17 to 19 lbf ft). See Figure 74.
1. Inspect inside bore of thrust bushing. Remove 6. Install parking brake lever in same position as
any rust or debris. See Figure 75. noted during Remove procedure. See Figure 73.
NOTE: Before removing rust and debris from thrust 7. Install spacer and socket head screw and
lever, cover the opening in the top of the drive axle, secure parking brake lever to thrust lever.
as well as the edges, so that rust and debris do not Tighten socket head screws to
get into the drive axle trumpet arms. 24 to 26 N•m (17 to 19 lbf ft). See Figure 72.
2. Inspect thrust lever and remove any rust or
debris as necessary. See Figure 76.

84
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

8. Attach parking brake cable to parking brake 10. After adjusting parking brake lever(s), adjust
lever. parking brake. See Maintenance Procedures
Every 500 Hours or 1 Year for procedures.
9. Adjust the parking brake lever(s) using parking
brake adjustment screw (see Figure 72). See
Drive Axle and Differential Assembly
Repair 1400SRM1344 for procedures.

Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 500-hour, and 1000-
1. Put lift truck on a level surface and lower the
hour checks prior to performing the procedures in
carriage.
this section.
NOTE: Have a container large enough to hold the
HYDRAULIC SYSTEM hydraulic filter assembly and allow for hydraulic oil
Hydraulic Filter Assembly, Replace draining.
NOTE: Turn lift truck engine OFF before changing
hydraulic oil filter.
WARNING
At operating temperature, the hydraulic oil is HOT. 2. Unscrew and remove lid, spring, and O-ring
DO NOT permit the hot oil to touch the skin and from head. See Figure 77.
cause a burn.
3. Remove filter, seal, O-ring, and bowl from
hydraulic tank and place into container to
drain oil. Cover the head to prevent any foreign
CAUTION materials from getting into the hydraulic tank.
DO NOT permit dirt to enter the hydraulic system
when the oil level is checked or the filter is 4. Remove filter and seal from bowl. See
changed. Dirt can cause damage to the Figure 77.
components of the hydraulic system.
Never operate the hydraulic pump without oil in 5. If present, clean contaminants from inside of
the hydraulic system. The operation of the bowl.
hydraulic pump without oil will damage the pump.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

85
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

1. LID 5. SEAL
2. SPRING 6. BOWL
3. O-RING 7. FITTING
4. FILTER 8. HEAD

Figure 77. Hydraulic Filter Assembly

Install
1. Lubricate new seal with clean hydraulic oil and
CAUTION
install it on bottom of new hydraulic filter. Additives may damage the hydraulic system.
Install new filter into bowl. See Figure 77. Before using additives, contact your local Hyster
dealer.
2. Install hydraulic filter and bowl into hydraulic
tank.

3. Install new O-ring, spring, and lid onto head.

86
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

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

seconds. Check for leaks. Stop engine and check
hydraulic oil level. Add oil, if necessary. Use
hydraulic oil shown in the Maintenance
Schedule. To change the hydraulic oil, see
Hydraulic Oil, Replace.

Hydraulic Tank Breather, Replace

NOTE: Turn lift truck engine OFF before replacing
hydraulic tank breather.

1. Remove floor mat, front and rear floor plates,

and right side rear cover to access the
hydraulic tank breather. See Figure 78.

NOTE: RIGHT SIDE VIEW

1. RIGHT SIDE REAR COVER

2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE
5. FRONT FLOOR PLATE
6. CLIP NUTS

Figure 78. Side Cover Removal

87
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED BEFORE JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED BEFORE OCTOBER 2009 SHOWN.

1. TRANSMISSION BREATHER 4. HYDRAULIC OIL FILL/DIPSTICK

2. TRANSMISSION OIL FILL/DIPSTICK 5. HYDRAULIC TANK BREATHER
3. HYDRAULIC OIL FILTER 6. HYDRAULIC DRAIN PLUG

Figure 79. Hydraulic Tank Breather Location

88
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED AFTER OCTOBER 2009 SHOWN.

1. TRANSMISSION OIL DIPSTICK/BREATHER 5. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL FILTER 6. HYDRAULIC TANK
3. HYDRAULIC TANK BREATHER 7. HYDRAULIC OIL DRAIN PLUG
4. HYDRAULIC OIL FILTER 8. TRANSMISSION OIL DRAIN PLUG

Figure 80. Transmission and Hydraulic Oil Checks

2. Unscrew and remove old hydraulic tank lift truck is equipped with this option, and the
breather, and replace with new hydraulic tank negative battery cable has been removed from the
breather. battery before removing the ignition system.
See Figure 79 for lift truck models with two- Remove and discard spark plug wire assembly, coil
speed transmission manufactured before June wire, spark plugs, distributor cap, and rotor. For
2009, or three-speed transmission procedures see High Voltage Switch (HVS)
manufactured before October 2009. Ignition; GM4.3L EPA Compliant Engines and
GM5.7L LPG EPA Compliant Engine
See Figure 80 for lift truck models with two-
2200SRM1097.
speed transmission manufactured after June
2009, or three-speed transmission
manufactured after October 2009. COOLING SYSTEM CHECK
1. Put lift truck on a level surface. Stop engine.
3. Install right side rear cover, front and rear floor Place a container with a minimum capacity of
plates, and floor mat. See Figure 78. 15.1 liter (15.9 qt) under the radiator drain
valve which could be located on either the lower
IGNITION SYSTEM: DISTRIBUTOR CAP, left or right side of the radiator on the engine
ROTOR, AND SPARK PLUG WIRES side of the radiator.
NOTE: Make sure the key is in the OFF position or
the Power ON/OFF button has been pressed OFF, if

89
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

coolant. Check the reservoir for contaminants

WARNING and flush, as necessary. Connect the hose back
DO NOT remove the radiator cap from the radiator on the fitting at the top of the radiator.
when the engine is hot. When the radiator cap is
removed, the pressure is released from the
system. If the system is hot, the steam and boiling CAUTION
coolant can cause burns. DO NOT remove the Additives may damage the cooling system. Before
cover for the radiator when the engine is running. using additives, contact your local Hyster dealer.

4. Close drain valve. Fill cooling system with the

correct coolant, use Ethylene Glycol Boron-free
CAUTION Antifreeze. Purchase a pre-diluted 50/50
Disposal of lubricants and fluids must meet local
solution; or mix 50% concentrate with 50%
environmental regulations.
distilled water or deionized water. Fill the
2. Open drain valve and remove radiator cap. See auxiliary reservoir to a level between the ADD
Figure 81. Drain coolant into the container. and FULL marks on the reservoir. See
Flush cooling system. Check hoses for damage. Figure 82.
Replace any damaged hoses with new hoses, as
5. Install radiator cap. Start engine. Check for
needed.
leaks. Add coolant to auxiliary coolant reservoir
as needed. Coolant level should be between the
ADD and FULL marks on the reservoir.

NOTE: GM 4.3L ENGINE COOLING SYSTEM AR-

RANGEMENT SHOWN.

1. DRAIN VALVE
2. AUXILIARY RESERVOIR 1. RADIATOR CAP
3. HOSE 2. FILL CAP
4. RADIATOR CAP 3. AUXILIARY COOLANT RESERVOIR
4. ADD MARK
5. FULL COLD MARK
Figure 81. Cooling System Check 6. FULL HOT MARK
3. Disconnect the hose leading from the auxiliary Figure 82. Auxiliary Coolant Reservoir
reservoir to fitting at the top of the radiator
under the radiator cap, and drain the reservoir
into the same container used for the radiator

90
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

AIR FILTER 3. Gently pull filter element from canister. Avoid

dislodging contaminants from the element or
The air filter canister should not be opened until an knocking it against the canister.
air filter element replacement is required. An air
filter element replacement is required when one of 4. With a clean, soft rag, clean the inside surface
the following occurs: of the canister. Remove the liner assembly to
• The optional air flow restriction indicator make cleaning easier. Clean well around the
light on the dash illuminates. locking tabs that retain the element. Clean tabs
• The optional manual air flow indicator button make new filter element installation easier. Be
pops up. careful not to knock any contaminants into the
• The specified number of hours has passed outlet tube to the engine.
since the last filter element replacement.
5. Inspect the liner and O-ring assembly for
damage. If damaged, replace the liner and O-
CAUTION ring assembly.
DO NOT to allow dirt to enter the engine air intake 6. Install the liner assembly into the canister by
when replacing the air filter element. A small pushing in. Make sure the liner assembly is
amount of dirt could cause engine damage. properly seated in the canister. It will fit
snugly into and be centered in the canister.
1. Shut off engine. Never open the air filter
canister or remove filter element with engine If your air filter assembly is equipped with a
running. secondary element in place of the liner
assembly, replace the secondary element with
2. Unlatch and remove the cover. To remove filter every 2 to 3 primary element replacements.
element, press and rotate filter element
counterclockwise about 1/8 turn until the filter 7. Inspect the new filter element for voids, cuts,
element is free. To assist removal, gently move tears or indentations in the urethane-sealing
the end back and forth to help break the seal. surfaces. Do not use if damage is detected.
See Figure 83.

1. CANISTER 4. FILTER ELEMENT

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

Figure 83. Air Filter

91
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

NOTE: If the filter element is properly installed,

CAUTION the cover will fit easily into the canister with no gap
The element must be properly installed to ensure between the cover and the canister. If the cover does
adequate engine protection. An improperly not fit easily, the filter element is not installed
installed element may allow dirt and dust to enter properly. Do not use a cover that is bent, damaged,
and damage the engine. or missing latches.

NOTE: Proper element installation is required to 9. Install cover into the canister and ensure the
allow the cover to be installed correctly. Never INLET arrow is in line with the canister inlet.
reinstall a used element. Never install a damaged
element. Always use a Hyster -approved filter NOTE: Do not use the latches to pull the cover
element. down against the canister. If the cover does not fit
completely against the canister with no gaps, the
8. Install new filter element into canister. Press element is not installed correctly.
and rotate filter element 1/8 turn clockwise
until fully engaged in the canister. See 10. Fasten latches to secure the cover to the
Figure 84. canister. 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.
Replace damaged hoses. Inspect the dust
evacuation valve for damage. If damaged,
replace the dust evacuation valve.

OXYGEN SENSOR, GM 4.3L ENGINE

EQUIPPED WITH GFI INSTALLED
Check that the oxygen sensor electrical connectors
are seated and locked. Check wires for cracks,
splits, chaffing, or burn through and repair if
1. PUSH IN necessary. See Figure 85. If the oxygen sensors need
2. TWIST TO LOCK
to be replaced, see the section Electrical System
Figure 84. Air Filter Label 2200SRM1142 for the procedures.

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 possibly the canister.

92
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD

2. ELECTRICAL CONNECTOR

Figure 85. Oxygen Sensor Check

LPG REGULATOR FUEL FILTER, GM 4.3L 2. Disconnect the hose from the inlet fitting.
ENGINES WITH GFI INSTALLED
3. Remove the inlet fitting from the LPG
Remove regulator. Discard the O-ring. See Figure 86.
1. Close shutoff valve on tank. Run engine until it
stops.

93
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

3. Install new rubber washer, paper filter, foam

filter, and plastic cap in the LPG regulator.

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

inlet fitting into the LPG regulator and connect
hose to the inlet fitting.

5. Open shutoff valve on LPG tank and check for

leaks.

LPG FUEL INJECTOR, GM 4.3L ENGINES

WITH GFI INSTALLED
NOTE: Turn lift truck engine OFF before servicing
the fuel injectors.
For removal and cleaning instructions, see the
section LPG Fuel System, GM 4.3L Engine with
GFI 0900SRM1242.

FUEL INJECTOR, CUMMINS 4.5L AND

QSB 3.3L ENGINE
NOTE: Turn lift truck engine OFF before servicing
the fuel injectors.
1. LPG REGULATOR
2. INLET FITTING For removal and cleaning instructions for lift truck
3. O-RING models equipped with the Cummins 4.5L and QSB
4. PLASTIC CAP 3.3L diesel engines, contact your local HYSTER
5. FOAM FILTER dealer or see Hyster Hypass Online .
6. PAPER FILTER
7. RUBBER WASHER
8. SCREWS FORKS
9. OUTLET FITTING
10. SCREEN
WARNING
Figure 86. GM LPG Regulator Never repair damaged forks. DO NOT heat, weld,
cut, drill, or bend forks. Forks are made of special
4. Remove and discard the plastic cap, foam filter, steel using special methods. Replace damaged
paper filter, and rubber washer from the LPG forks as a set.
regulator.
Check the heel and attachments points of forks with
5. Disconnect the hose from the outlet fitting. a penetrant or by magnetic particle inspection.
Remove three screws and the outlet fitting from
the LPG regulator. Discard the O-ring. Inspect forks for:
• Surface cracks.
6. Remove and discard the screen from the LPG
• Straightness of blade and shank.
regulator.
• Fork angle.
Install • Difference in height of fork tips.
1. Install a new screen in the LPG regulator. • Positioning lock.
• Wear on fork hooks.
2. Install a new O-ring on the outlet fitting. Using
• Legibility of marking.
three screws, install the outlet fitting on the
LPG regulator. If forks need to be replaced, replace as a set.

94
8000 SRM 1322 Maintenance Procedures Every 2000 Hours or Annually

BRAKE OIL (MASTER CYLINDER),

CHANGE WARNING
Small amounts of water in the brake system can
1. Remove the dash and kick panel from the cowl.
cause reduced braking performance if the water
See the section Frame 0100SRM1321 for the
reaches the wheel cylinder areas. DO NOT allow
removal procedures.
water entry. Ensure that the sealed reservoir lid is
properly replaced.
2. Disconnect and cap lower brake oil supply hose
from nipple. See Figure 87.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

4. Remove reservoir cap and cylindrical block

drain plug. Discard O-ring. See Figure 87.
Drain oil from the reservoir and cylindrical
block. Lower brake oil supply hose into a
suitable container.

5. Install cylindrical block drain plug and new O-

ring into cylindrical block. Tighten cylindrical
block drain plug to
90 to 100 N•m (66 to 74 lbf ft).

6. Install the reservoir and cylindrical block onto

their mounting brackets located the cowl. See
Figure 87.

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

7. Fill the reservoir with Dexron III oil until

1. RESERVOIR CAP brake oil flows from the lower brake oil supply
2. BRAKE OIL RESERVOIR hose and connect hose onto nipple. Install
3. RESERVOIR MOUNTING BRACKET
4. COWL reservoir cap.
5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING 8. Bleed the brake lines and axle cylinders. See
7. LOWER BRAKE OIL SUPPLY HOSE the section Brake System - DANA
8. NIPPLE 1800SRM1247 for the procedures.
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK TEST REGULATOR PRESSURELPG
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW For more information regarding the Test LPG/GAS
Regulator Pressure, see the section LPG Fuel
Figure 87. Brake Oil Change System, GM 4.3L Engine with GFI
0900SRM1242. .
3. Remove the reservoir and cylindrical block
from their mounting brackets and remove the CHECK THROTTLE SHAFT FOR STICKING
reservoir and cylindrical block as a unit from
Check Throttle body return action to ensure throttle
the cowl. See Figure 87.
shaft is not sticking. Repair if necessary.

95
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1322

INSPECT EXHAUST MANIFOLD AND 1. Align the TDC mark on the crankshaft pulley
PIPING FOR LEAKS with the engraved mark on the block. See
Figure 88.
To check the exhaust manifold and piping for leaks,
perform the following:

• Check the exhaust manifold at the cylinder

head for leaks. Ensure that all bolts and
shields are in place.
• Check exhaust pipe fasteners to manifold for
leaks to ensure they are tight. Repair if
necessary.
• Check all exhaust pipe extension connectors
for leaks and tighten, if necessary.
• Visually inspect converter for correct muffler
mounting and tail pipe mounting.
• Check for any leaks at the inlet and outlet of
the converter.

TRANSMISSION AUTOMATIC CLUTCH

CALIBRATION
NOTE: Transmission clutch calibration is
performed only on electronic, 3-speed transmissions
(Duramatch and Duramatch Plus transmissions). 1. CRANKSHAFT PULLEY
2. DRIVE BELT
Calibrate the transmission clutches every 2000 3. ENGRAVE TIMING MARK
hours or annually. See the section Calibration
Procedures 8000SRM1134 for the procedures to Figure 88. Cummins QSB 3.3L TDC Mark
calibrate the transmission clutches.
2. Adjust ONLY the valves shown in Figure 89,
by loosening the locknut with a wrench and
BRAKE SYSTEM ACCUMULATOR
adjusting the valve clearance using a
Check the precharge pressure in the brake system screwdriver or Allen wrench.
accumulator. If the precharge pressure is not within
4 ±0.35 bar (58 ±5 psi), recharge the accumulator
with nitrogen gas. See the section Brake System -
DANA 1800SRM1247 for the procedures on
checking the precharge pressure in the accumulator.

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.
NOTE: Turn lift truck engine OFF before checking
and adjusting valve clearance. 1. EXHAUST VALVE
2. INTAKE VALVE
Check the valve clearance and make adjustments as 3. CYLINDER 1
needed. To adjust the valve clearances do the 4. CYLINDER 2
following: 5. CYLINDER 3
6. CYLINDER 4

Figure 89. Cummins Valve Adjustment

96
8000 SRM 1322 Maintenance Procedures Every 4000 Hours or 2 Years

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

measure valve lash.

4. Mark the vibration damper and rotate the

crankshaft 360 degrees. See Figure 90.

1. EXHAUST VALVE
2. INTAKE VALVE
3. CYLINDER 1
4. CYLINDER 2
5. CYLINDER 3
6. CYLINDER 4

Figure 91. Cummins Valve Adjustment

1. TIMING PIN WHEEL BEARINGS

2. VIBRATION DAMPER
Steer Wheels, Lubrication
Figure 90. Cummins Vibration Damper
Lubricate the wheel bearings in the hubs for the
steer wheels with multipurpose grease as shown in
5. Perform Step 2 and Step 3 to adjust ONLY the
the Maintenance Schedule. See Steering Axle
valves shown in Figure 91. See the
1600SRM1133 for the procedures.
Maintenance Schedule for valve clearances.

Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 500-hour, 1000-hour,
and 2000-hour checks prior to performing the CAUTION
procedures in this section.
Disposal of lubricants and fluids must meet local
environmental regulations.
HYDRAULIC OIL, REPLACE
NOTE: Heavy-duty or contaminated applications
WARNING will require hydraulic oil change at 2000 hours.
At operating temperature the hydraulic oil is HOT. NOTE: Replace the hydraulic oil filter at the same
DO NOT permit the hot oil to touch the skin and time the oil is changed.
cause a burn. NOTE: Turn lift truck engine OFF prior to
changing hydraulic oil and filter.
1. Replace the hydraulic oil as described below:
CAUTION
DO NOT permit dirt to enter the hydraulic system a. Place a container with a minimum capacity
when the oil level is checked or the filter is of 60.5 liter (64 qt) under the drain plug at
changed. Dirt can cause damage to the the bottom of the hydraulic tank. To drain
components of the hydraulic system. the oil, remove the drain plug from the
Never operate the hydraulic pump without oil in bottom of the hydraulic tank.
the hydraulic system. The operation of the
hydraulic pump without oil will damage the pump.

97
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1322

See Figure 92 for lift truck models with two-

speed transmission manufactured before CAUTION
June 2009, or three-speed transmission Additives may damage the hydraulic system.
manufactured before October 2009. Before using additives, contact your local Hyster
See Figure 93 for lift truck models with two- dealer.
speed transmission manufactured after June
2009, or three-speed transmission 2. Fill hydraulic tank with oil specified in the
manufactured after October 2009. Maintenance Schedule.

b. When the tank is empty, inspect the inside of 3. When the oil level is correct, operate system
the tank for any foreign matter or possible and check for leaks.
fungus. If necessary, clean the inside of the
tank in accordance with the instructions
found in the section Frame 0100SRM1321.

c. When either the inspection or the cleaning of

the tank is completed, install the drain plug
in the bottom of the hydraulic tank. Tighten
drain plug to 38 N•m (28 lbf ft).

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED BEFORE JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED BEFORE OCTOBER 2009 SHOWN.

1. TRANSMISSION BREATHER 4. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL DIPSTICK 5. HYDRAULIC TANK BREATHER
3. HYDRAULIC OIL FILTER 6. HYDRAULIC DRAIN PLUG

Figure 92. Hydraulic Oil Change

98
8000 SRM 1322 Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED AFTER OCTOBER 2009 SHOWN.

1. TRANSMISSION OIL DIPSTICK/BREATHER 5. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL FILTER 6. HYDRAULIC TANK
3. HYDRAULIC TANK BREATHER 7. HYDRAULIC OIL DRAIN PLUG
4. HYDRAULIC OIL FILTER 8. TRANSMISSION OIL DRAIN PLUG

Figure 93. Transmission and Hydraulic Oil Checks

VALVE CLEARANCE, CHECK AND The Cummins 4.5L engine does not require valve
ADJUST FOR CUMMINS 4.5L DIESEL clearance adjustments during normal service. See
the Maintenance Schedule for valve clearances.
ENGINE
Check the valve clearance and make adjustments as
NOTE: Turn lift truck engine OFF before checking needed. To adjust the valve clearances do the
and adjusting valve clearance. following:

99
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1322

1. INSERT TIMING PIN HERE 3. TIMING BELT

2. FUEL/WATER SEPARATOR FILTER

Figure 94. Timing Pin Location, Cummins 4.5L Diesel Engine

1. Rotate the engine until it is at TDC for cylinder

number one (intake and exhaust valves closed).
Insert timing pin. See Figure 94.

2. Adjust ONLY the valves shown in Figure 95,

by loosening the locknut with a wrench and
adjusting the valve clearance using a
screwdriver or Allen wrench.

1. EXHAUST VALVE
2. INTAKE VALVE
3. CYLINDER 1
4. CYLINDER 2
5. CYLINDER 3
6. CYLINDER 4

Figure 95. Cummins Valve Adjustment

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

measure valve lash.

100
8000 SRM 1322 Safety Procedures When Working Near Mast

4. Remove the timing pin. See Figure 94. 6. Perform Step 2 and Step 3 to adjust ONLY the
valves shown in Figure 97. See the
5. Mark the vibration damper and rotate the Maintenance Schedule for valve clearances.
crankshaft 360 degrees. See Figure 96.

1. EXHAUST VALVE
2. INTAKE VALVE
3. CYLINDER 1
4. CYLINDER 2
1. TIMING PIN 5. CYLINDER 3
2. VIBRATION DAMPER 6. CYLINDER 4
Figure 96. Cummins Vibration Damper Figure 97. Cummins Valve Adjustment

Safety Procedures When Working Near Mast

The following procedures must be used when • DO NOT use blocks to support the mast
inspecting or working near the mast. Additional weldments nor to restrain their movement.
precautions and procedures can be required when • Mast repairs require disassembly and
repairing or removing the mast. See the correct removal of parts and can require removal of
Service Manual section for the specific mast being the mast or carriage. Follow the repair
repaired. procedures in the correct Service Manual for
the mast.

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

WARNING
trucks equipped with Electronic Hydraulic System,
Mast parts are heavy and can move. Distances there is an emergency load lowering valve located
between parts are small. Serious injury or death on the hoist/lower valve section of the main control
can result if part of the body is hit by parts of the valve. See the Operating Manual for the
mast or the carriage. procedures to lower a load using the emergency load
lowering valve.
• Never put any part of the body into or under
the mast or carriage unless all parts of the 1. Lower mast and carriage completely. Push lift/
mast are completely lowered or a safety lower control lever forward and make sure
chain is installed. Also make sure that the there is no movement in the mast. Make sure
power is off and the key is removed. Put a all parts of the mast that move are fully
DO NOT OPERATE tag in the operator's lowered.
compartment.
• Be careful of the forks. When the mast is OR
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.

101
Safety Procedures When Working Near Mast 8000 SRM 1322

2. If parts of the mast must be in a raised the chain. Make sure the safety chain does
position, install a safety chain to restrain the not touch lift chains or chain sheaves, tubes,
moving parts of the mast. Connect moving hoses, fittings, or other parts on the mast.
parts to a part that does not move. Follow these
procedures: d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (free-
a. Put mast in vertical position. lift, three-stage, and four-stage masts only)
is completely retracted. If running, stop
b. Raise mast to align bottom crossmember of engine. Apply parking brake. Install a DO
weldment that moves in outer weldment NOT REMOVE tag on the safety chain(s).
with a crossmember on outer weldment. On
the two-stage and free-lift mast, the moving e. Install another safety chain (3/8-in.
part is the inner weldment. On the three- minimum) between the top or bottom
stage mast, it is the intermediate weldment. crossmember of the carriage and a
See Figure 98 . crossmember on the outer weldment.

c. Use a 3/8-in. minimum safety chain with a 3. Apply parking brake. After lowering or
hook to fasten the crossmembers together so restraining the mast, shut off power and
the movable member cannot lower. Put the remove key. Put a DO NOT OPERATE tag in
hook on the back side of the mast. Make sure the operator's compartment.
the hook is completely engaged with a link in

102
8000 SRM 1322 Safety Procedures When Working Near Mast

Figure 98. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

103
Fuel Filter Water Removal 8000 SRM 1322

Legend for Figure 98.

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 a Cummins 4.5L and QSB CAUTION
3.3L diesel engine. Drain water/fuel into a container and dispose in
accordance with local environmental regulations.
1. Shut engine off.
3. Turn the drain valve counterclockwise
NOTE: The drain valve is located on the bottom of approximately 3 1/2 turns. Drain fuel filter
the fuel filter element. until clear fuel is visible.
2. To access the fuel filter element and drain
valve, remove the air inlet elbow. See
Figure 99. CAUTION
DO NOT overtighten when closing the drain valve.
Overtightening can damage the threads.

Close the drain valve by lifting and turning

clockwise until it is hand-tight.

1. AIR INLET ELBOW

2. FUEL FILTER ELEMENT
3. DRAIN VALVE

Figure 99. Engine Fuel Filter Drain Valve Location

(Cummins 4.5L Shown)

104
8000 SRM 1322 Lift Chain Adjustments

Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
Never allow anyone under a raised carriage. DO
NOT put any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
DO NOT try to find hydraulic leaks by putting your
hand on hydraulic components under pressure.
Hydraulic oil can be injected into the body by the
pressure.
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away 1. MAST
from the lift truck during the tests. 2. CARRIAGE
3. FORK
When lift chains are correctly adjusted: 4. HEEL OF FORK IS
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE
• Tension will be the same on each chain of THE FLOOR LEVEL.
chain set. Check tension by pushing on both
chains at the same time. Figure 100. Lift Chain Adjustments With Forks
• Chain length will be correct. Installed
• Chains must travel freely through complete
cycle. 3. Adjust chain anchors which support carriage
until the bottom of lower carriage bar is above
NOTE: When chain adjustments are complete, the floor level as shown in Table 2. See
make sure threads on nuts of chain anchors are Figure 101.
completely engaged. Make sure all adjustment is
not removed from 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 until bottom of the fork heel is
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above
floor level. See Figure 100.

105
Jump-Starting the Lift Truck 8000 SRM 1322

In Table 2, the masts are divided by class. Each

class is determined by the lifting capability of
the lift cylinders. The Class II mast would have
the lift capability of 2.5-3.5 tons, Class III has
the lift capability of 3.5-4.0 tons, and Class IV
has the lift capability of 4.0-7.0 tons.

Table 2. Carriage Chain Adjustment, Forks Not

Installed
82.5 ±3 mm (3.25
Class II and Class III
±0.12 in.)
133.5 ±3 mm (5.26
Class IV
±0.12 in.)

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR

Figure 101. Lift Chain Adjustment Without Forks

Installed

Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY 4. Always connect jumper cables to discharged
CHARGER battery before connecting them to booster
battery.

CAUTION JUMP-STARTING A LIFT TRUCK USING

DO NOT try to start the engine by pushing or ANOTHER LIFT TRUCK
towing the lift truck. Damage to the hydraulic
system can occur if engine is started by pushing
or towing lift truck.
WARNING
To prevent possible arcing between the two lift
If the battery becomes discharged and requires a trucks, make sure that the lift trucks are not
booster battery to start the engine, follow these touching.
procedures carefully when connecting the jumper
cables.
CAUTION
1. Disconnect the negative battery terminal of the DO NOT try to start the engine by pushing or
lift truck being started. towing the lift truck. Damage to the hydraulic
system can occur if engine is started by pushing
2. Always connect positive jumper cable to or towing lift truck.
positive terminal of discharged battery and
negative jumper cable to negative terminal. 1. Always connect positive jumper cable to
positive terminal of discharged battery and
3. Always connect jumper cable, that is the negative jumper cable to negative terminal.
ground cable, last.
2. Always connect jumper cable, that is the
ground cable, last.

106
8000 SRM 1322 Welding Repairs

3. Always connect jumper cables to discharged lift

truck battery before connecting them to the
fully-charged lift truck battery.

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

Overhead Guard Changes

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

Wheel and Tire Replacement

GENERAL PNEUMATIC TIRE WITH TUBE, REPAIR
The H series lift trucks have pneumatic tires or Remove Wheels From Lift Truck
solid rubber tires that look like pneumatic tires.
These variations in tires also cause a variation in
the types of wheels and the disassembly and WARNING
assembly procedures. A solid rubber tire that is the same shape as a
pneumatic tire can be installed on a three-piece or
four-piece wheel for a pneumatic tire. DO NOT
make changes in the parts of the rim if this type of

107
Wheel and Tire Replacement 8000 SRM 1322

solid rubber tire is installed instead of a pneumatic Lift truck tires and wheels are heavy. Use caution
tire. Changes to the parts of the rim can cause a when removing or installing lift truck tires and
failure of the wheel and cause an accident. wheels or personal injury can occur.

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

Put Lift Truck on Blocks at the beginning of
WARNING
this section.
The type of tire and the tire pressure (pneumatic
tires) are shown on the Nameplate. Make sure the 2. Remove air from tire. Remove valve core to
Nameplate is correct for the type of tires on the lift make sure all air is out of inner tube. Push a
truck. wire through valve stem to make sure valve
stem does not have a restriction.

WARNING 3. Remove wheel nuts and remove wheel and tire

Wheels must be changed and tires repaired by from lift truck.
trained personnel only.
Deflate tire completely before removing the wheel
Remove Tire From Wheel
from the lift truck. If dual wheels are used, deflate NOTE: When you disassemble the wheels, see
both tires. Air pressure in the tires can cause the Figure 102. There are several types of wheels used
tire and rim parts to explode, causing serious on this series of lift trucks.
injury or death.
Always wear safety glasses.
Never loosen the nuts that hold the inner and outer
wheel halves together when there is air pressure in
the tire.

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 102. Types of Pneumatic Wheels

108
8000 SRM 1322 Wheel and Tire Replacement

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.

STEP 2.
Loosen tire bead from wheel rim.

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

109
Wheel and Tire Replacement 8000 SRM 1322

Remove Tire From Three- and Four-Piece Wheels

WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause an injury.

STEP 1.
Loosen tire bead from side flange.

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.

110
8000 SRM 1322 Wheel and Tire Replacement

STEP 4.
Remove wheel from tire.

Install Wheel in Tire 1. Clean and inspect all parts of wheel. Paint any
parts that have rust or corrosion.
WARNING
2. Install new inner tube in tire. Used tubes and
Damage to the tire and wheel assembly and injury flaps can cause tire failure.
or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel WARNING
before installing the tire.
DO NOT lubricate tire bead with antifreeze or
• DO NOT use any damaged or repaired wheel petroleum-based liquid. Vapors from these liquids
parts. can cause an explosion during inflation or use.
• Make sure all parts of the wheel are the
correct parts for that wheel assembly. 3. Apply a rubber lubricant or a soap solution to
• DO NOT mix parts between different types or the tire bead and tube.
manufacturers of wheels.
4. Install new tire flap.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different
manufacturers on any one lift truck. 5. Make sure rim is the correct size for tire.
Lubricate part of wheel that contacts bead and
DO NOT use a steel hammer on the wheel. Use a flap.
rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct 6. Install the three-piece or four piece wheel in
position. The ends of the side ring must not touch. the tire as shown in Install Three-Piece or
The clearance at the ends of the lock ring will be Four-Piece Wheel in Tire.
approximately 13 to 25 mm (0.5 to 1.0 in.) after it is
installed. If the clearance is wrong, the wrong part 7. Install the two-piece wheel in the tire as shown
has been used. in Install Tire on Two-Piece Wheel.

111
Wheel and Tire Replacement 8000 SRM 1322

Install Three-Piece or Four-Piece Wheel in Tire

WARNING
Damage to the 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.

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.

112
8000 SRM 1322 Wheel and Tire Replacement

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
WARNING DO NOT use pneumatic-shaped solid tires on two-
piece bolt together drive wheels. Spinning may
Wheels can explode and cause injury or death if
occur.
the following procedures are not followed:
• Clean and inspect all parts of the wheel 1. Clean and inspect all parts of wheel. Paint any
before 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 flaps can cause tire failure.
correct parts for that wheel assembly.
• DO NOT mix parts between different types or
manufacturers of wheels. WARNING
• DO NOT mix types of tires, type of tire tread, DO NOT lubricate the tire bead with antifreeze or
or wheel assemblies of different petroleum-based liquid. Vapors from these liquids
manufacturers on any one lift truck. can cause an explosion during inflation or use.
DO NOT use a steel hammer on the wheel. Use a 3. Apply a rubber lubricant or a soap solution to
rubber, lead, plastic, or brass hammer to put parts tire bead and tube.
together. Make sure the side ring is in the correct
position. The ends of the side ring must not touch. 4. Install new tire flap.
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 5. Make sure rim is the correct size for tire.
installed. If the clearance is wrong, the wrong part Lubricate part of wheel that contacts bead and
has been used. flap.

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.

113
Wheel and Tire Replacement 8000 SRM 1322

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

TUBE

WARNING
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that
fastens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator
to stand away from the safety cage when air
pressure is added to the tire.
DO NOT sit or stand by the safety cage. DO NOT
use a hammer to try and correct the position of the
side flange or lock ring when the tire has air
pressure greater than 20 kPa (3 psi).
Figure 103. Add Air to Tires
1. Put tire in a safety cage.
Install the Wheels
2. Add 20 kPa (3 psi) of air pressure to tire. See
Figure 103.
WARNING
3. Check that all wheel parts are correctly Lift truck tires and wheels are heavy. Use caution
installed. Hit lock ring lightly to make sure it is when removing and installing lift truck tires and
in the seat. wheels or personal injury can occur.

4. If installation is correct, add air pressure to tire Install wheel on hub. Tighten nuts in a cross
to the specified pressure. pattern to 610 to 680 N•m (450 to 502 lbf ft) for
both drive wheels nuts steer wheels nuts. If the
5. Check that all wheel parts are correctly wheels are the two-piece rims, make sure nuts that
installed. If installation is not correct, remove fasten rim halves together are toward brake drum
all air pressure from tire. Remove valve core to when they are installed.
make sure all air pressure has been removed
and then make adjustments. The clearance at Dual Drive Wheels, Install
the ends of the lock ring will be approximately
13 to 25 mm (0.5 to 1.0 in.) when the tire has
the correct air pressure. WARNING
Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
wheels or personal injury can occur.

114
8000 SRM 1322 Wheel and Tire Replacement

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 500 lbf ft). See
Figure 104.

3. Install outer wheel on dual hub assembly.

Tighten nuts to a torque value of
610 to 680 N•m (450 to 500 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
the valve extension hose into the bracket. See 1. TIRE
Figure 104. 2. DUAL HUB ASSEMBLY
3. WHEEL NUT
4. WHEEL
5. WHEEL ADAPTER SPACER
6. VALVE EXTENSION
7. BRACKET

Figure 104. Dual Drive Wheels Installation

115
Wheel and Tire Replacement 8000 SRM 1322

PNEUMATIC TUBELESS TIRE, REPAIR Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
Remove Wheels From Lift Truck wheels or personal injury can occur.

The Tubeless Bead Seal (TBS) enables tubeless tires

WARNING to be used on wheel rims that were designed to be
Wheels must be changed and tires repaired by used with a tube.
trained personnel only.
The main component of a TBS is a special rubber
Deflate tire completely before removing the wheel ring that fits inside the tire between the tire beads
from the lift truck. If dual wheels are used, deflate to ensure the air tightness of the existing wheel and
both tires. Air pressure in tires can cause the tire the tubeless tire assembly. See Figure 102.
and rim parts to explode causing serious injury or
death. 1. Put lift truck on blocks as described in How to
Put Lift Truck On Blocks at beginning of
Always wear safety glasses.
this section.
Never loosen the nuts that hold the inner and outer
wheels halves together when there is air pressure 2. Remove the valve cap and core to remove all air
in the tire. from the tire.

3. Remove the wheel nuts and remove the wheel

and tire from the lift truck.

Remove Tire From Wheel

WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in
the tires can cause the tire and rim parts to explode causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause injury.

NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see
Figure 102.

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

116
8000 SRM 1322 Wheel and Tire Replacement

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
locking 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.

117
Wheel and Tire Replacement 8000 SRM 1322

Install Tire on Wheel

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

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

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

STEP 1.
Clean interior and exterior bead of the tire.
Lubricate tire beads and the inside of the tire,
up to the tire shoulders. Apply lubricant to the
entire underside of the TBS.

NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to
accommodate the needle valve. If the wheel rim width is greater than 152 mm (6 in.), 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.

118
8000 SRM 1322 Wheel and Tire Replacement

STEP 2.
Apply lubricant to the needle valve and the
valve hole that will be used (see NOTE) by
inserting and removing 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.

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.

119
Wheel and Tire Replacement 8000 SRM 1322

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

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 until 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.

120
8000 SRM 1322 Wheel and Tire Replacement

Add Air to Pneumatic Tubeless Tire Wheels, Install

WARNING WARNING
Add air pressure to tires only in safety cage. Lift truck tires and wheels are heavy. Use caution
Inspect safety cage for damage before use. When when removing and installing lift truck tires and
air pressure is added, use a chuck that fastens wheels or personal injury can occur.
onto valve stem. Make sure there is enough hose
to permit operator to stand away from safety cage Install wheel on hub. Tighten nuts in a cross
when air pressure is added to tire. pattern to 610 to 680 N•m (450 to 500 lbf ft) for
DO NOT sit or stand by safety cage. both drive wheels nuts and steer wheels nuts. If the
wheels are the two-piece rims, make sure nuts that
1. Put tire in safety cage. See Figure 105. fasten rim halves together are toward brake drum
when they are installed.
2. Add air to tire to the recommended air pressure
that is shown on the Nameplate. Install valve SOLID RUBBER TIRES ON PNEUMATIC
cap to ensure air stays in the tire. WHEELS, CHANGE

WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
wheels or personal injury can occur.

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.
Figure 105. Add Air to Tires

Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Figure 102. 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.

121
Wheel and Tire Replacement 8000 SRM 1322

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

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.

122
8000 SRM 1322 Wheel and Tire Replacement

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

Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 102. 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.

123
Wheel and Tire Replacement 8000 SRM 1322

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

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

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.

124
8000 SRM 1322 Wheel and Tire Replacement

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.

SNAP-ON-TIRE, CHANGE 2. Remove wheel nuts and remove wheel and tire
from lift truck. Lift truck tires and wheels are
heavy.
WARNING
NOTE: When you disassemble the wheels, see
Wheels must be changed and tires repaired by
Figure 106. There are several types of wheels used
trained personnel only.
on these series of lift trucks.
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.

Figure 106. Snap-On-Tire and Rim Configurations

Remove Snap-On-Tire, Solid Tire From Wheel

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

125
Wheel and Tire Replacement 8000 SRM 1322

STEP 1.
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 2.
Put cage in position on tire. Use press to push
tire from wheel rim.

Install Snap-On-Tire, Solid Tire on Wheel

NOTE: When you assemble the wheels, see Figure 106. 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
Failure to follow these procedures will cause damage to the tire and wheel assembly and can cause an
injury.
• 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, types of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.

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

126
8000 SRM 1322 Wheel and Tire Replacement

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

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.

EASY MOUNTING STYLE SOLID RUBBER Mounting Style solid rubber tire to be quickly bolted
TIRES ON PNEUMATIC WHEELS, onto the adapter and wheel rim. The adapter is
made up of three separate pieces that are held
CHANGE together by a compression plate. The adapter wraps
The lift trucks covered in this service manual may around the wheel rim, then the tire is put onto the
be equipped with Easy Mounting Style solid rubber adapter, where the adapter locks into the tire
tires, which do not require a press to remove and brackets. When the bolts are installed and tighten,
install the tire onto wheel rim. A specially created the adapter compresses against the wheel rim and
adapter fits over the wheel rim, allowing the Easy holds the tire to wheel rim. See Figure 107.

127
Wheel and Tire Replacement 8000 SRM 1322

1. TIRE 4. COMPRESSION PLATE

2. ADAPTER 5. TIRE BRACKET
3. WHEEL RIM

Figure 107. Easy Mounting Style Solid Rubber Tire Components

Remove Easy Mounting Tire From Wheel

WARNING
Be sure lift truck is secured and on level ground. If jacks are used, be sure they meet the load
requirements of the lift truck. See Nameplate. Failure to do so can result in lift truck rolling away and/or
tipping, which can cause serious personal injury.

CAUTION
DO NOT use a press to remove or install an Easy Mounting Style solid rubber tire. A press will cause
damage to the wheel, tire, and adapter.

If Easy Mounting style solid rubber tires are being installed for the first time, go to sections Easy Mounting
Style Solid Rubber Tires on Pneumatic Wheels, Change or Snap-On-Tire, Change, to remove tire from wheel
rim. Once tire has been removed from wheel rim, go to section Install Easy Mounting Tire on Wheel.
If Easy Mounting Style solid rubber tires are already installed on lift truck, the wheel rim does not have to
be removed from lift truck. In the steps below, the wheel rim is removed from lift truck.

STEP 1.
Put lift truck on blocks as described in How to
Put Lift Truck on Blocks at the beginning of
this manual. If jacks are used in place of blocks,
use only jacks with the correct capacity. See
Nameplate.

128
8000 SRM 1322 Wheel and Tire Replacement

WARNING
When removing bolts and washers from tire, be
sure tire does not slip off rim and cause an injury.

WARNING
Wear safety glasses and protect your hands and
feet when removing and installing Easy Mounting
Style solid rubber tires. Serious injury to
personnel can result if eyes, hands, and feet are
not protected.

STEP 2.
Remove six bolts and washers from tire. 1. CAPSCREW 3. TIRE
2. WASHER

STEP 3.
If tire is difficult to remove from wheel rim, use
a rubber hammer and a driver or drift punch,
and tap lightly in the area indicated by the
arrows in the illustration.

STEP 4.
Remove tire from wheel rim.

129
Wheel and Tire Replacement 8000 SRM 1322

STEP 5.
Pull the adapter off the wheel rim. If adapter is
difficult to remove, insert a suitable tool into
adapter slots and pry off wheel rim.

Install Easy Mounting Tire on Wheel

WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of wheel before installing tire.
• Clean and inspect all parts of the adapter for wear or damage.
• DO NOT use any damaged or repaired wheel or adapter parts.
• Make sure that all parts of wheel are 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, tire, or adapter parts. Use a rubber, lead, plastic, or brass
hammer to put parts together if a hammer is needed.

WARNING
Never use plastic parts beyond their expired service life. Expired parts can fail during usage and lead to
serious injury to personnel. Check the recommended service life date before using parts.

130
8000 SRM 1322 Wheel and Tire Replacement

STEP 1.
Before installing the adapter onto the wheel
assembly, check the recommended service life
date on the adapter to ensure it has not
expired. If date has expired, replace with new
adapter. See Parts Manual.

1. LOCATION OF SERVICE LIFE DATE

2. ADAPTER

WARNING
Wear safety glasses and protect your hands and
feet when removing and installing Easy Mounting
Style solid rubber tires. Serious injury to
personnel can result if eyes, hands, and feet are
not protected.

STEP 2.
Wrap the adapter around the wheel rim. Place
wheel rim on side and check that the adapter
inserts into the wheel rim groove.

1. WHEEL RIM
2. ADAPTER
3. WHEEL RIM GROOVE

131
Wheel and Tire Replacement 8000 SRM 1322

STEP 3.
Place tire onto adapter and wheel rim.

STEP 4.
Insert six bolts and washers into tire and hand
tighten.

STEP 5.
Tighten bolts in a cross pattern to
85 N•m (63 lbf ft) for the drive wheels and
49 N•m (36 lbf ft) for the steer wheels.

132
8000 SRM 1322 Adhesives and Sealants

Adhesives and Sealants

Loctite® Part
Hyster Part No. Description Size
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.

133
 NOTES

134
 TECHNICAL PUBLICATIONS

8000 SRM 1322 5/19 (12/18)(5/18)(10/16)(12/13)(4/13)