Hyster A970 Operating instructions

Hyster A970 (J80XN, J90XN, J100XN, J100XLN,
J110XN, J120XN) Forklift

PERIODIC
MAINTENANCE
J80-120XN, J100XNL [A970]
PART NO. 4040733 8000 SRM 1541

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Serial Number Data ............................................................................................................................................2
Discharging the Capacitors ................................................................................................................................ 2
How to Move Disabled Lift Truck ...................................................................................................................... 3
How to Tow Lift Truck ................................................................................................................................... 3
How to Put Lift Truck on Blocks ........................................................................................................................4
How to Raise Drive Tires ............................................................................................................................... 4
How to Raise Steering Tires ...........................................................................................................................4
How to Clean a Lift Truck ..................................................................................................................................5
Maintenance Schedule ............................................................................................................................................ 6
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 12
How to Make Checks With Key or Keyless Switch OFF ................................................................................ 12
Tires and Wheels .......................................................................................................................................... 12
Forks ..............................................................................................................................................................12
General ......................................................................................................................................................12
Inspect .......................................................................................................................................................12
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments ...........................................14
Safety Labels .................................................................................................................................................15
Steering Column Adjustments .....................................................................................................................15
Tilt Adjust Feature ...................................................................................................................................15
Tilt Memory Feature ................................................................................................................................15
Telescopic Feature ....................................................................................................................................15
Operator Restraint System .......................................................................................................................... 16
Emergency Locking Retractor (ELR) ...........................................................................................................16
Seat Adjustments ..........................................................................................................................................16
Seat Position Adjustment (Standard Seat) .............................................................................................16
Seat Position Adjustment (Swivel Seat) ................................................................................................. 16
Seat Adjustment for Operator Weight .................................................................................................... 17
Battery Restraint System ............................................................................................................................ 19
Hood Latch and Hood Release Handle ........................................................................................................ 20
Manual Hydraulics ...................................................................................................................................20
E-Hydraulics .............................................................................................................................................21
Battery ...........................................................................................................................................................22
Hydraulic System ......................................................................................................................................... 22
How to Make Checks With Key or Keyless Switch ON .................................................................................. 26
Horn, Lights, and Backup Alarm .................................................................................................................26
Motion Alarm ................................................................................................................................................26
Steering System ............................................................................................................................................26
Service Brakes .............................................................................................................................................. 27
Automatic Parking Brake ............................................................................................................................ 27
Hydraulic Control Levers and Pedals ..........................................................................................................27
Direction and Speed Control Pedals ............................................................................................................27
Lift System Operation .................................................................................................................................. 28
Oil Leaks ....................................................................................................................................................... 28
Maintenance Procedures Every 500 Hours or Three Months .............................................................................28
Forks ..................................................................................................................................................................28
Remove .......................................................................................................................................................... 28
Inspect ........................................................................................................................................................... 30
Install ............................................................................................................................................................ 30
Adjustment ....................................................................................................................................................30
Table of Contents
i

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TABLE OF CONTENTS (Continued)
Header Hose Checks ......................................................................................................................................... 31
Mast Lubrication ...............................................................................................................................................32
Brake Fluid Check ............................................................................................................................................ 34
Master Cylinder Oil Check ...........................................................................................................................34
Bleeding the Brake System ..................................................................................................................... 36
Operator Presence System Check .................................................................................................................... 38
Drive Axle Unit Assembly, Gear Oil Level Check ...........................................................................................38
Drive Axle Unit Assembly, Wet Brake Oil Level Check .................................................................................38
Tilt Cylinder Rod End Pins .............................................................................................................................. 40
Lift Chains .........................................................................................................................................................41
Wear Check ...................................................................................................................................................41
Lift Chain Lubrication ......................................................................................................................................42
Fork Pins and Guides ....................................................................................................................................... 42
Check Upper and Lower Bearings, Integral Sideshift Carriage .................................................................... 42
Check Lower Mounting Hook, Integral Sideshift Carriage ............................................................................42
Hydraulic Tank Breather, Check .....................................................................................................................44
Electrical Inspection ......................................................................................................................................... 45
Line Contactor .............................................................................................................................................. 45
Steering Axle .....................................................................................................................................................46
King Pins and Tie Rods, Lubricate ..............................................................................................................46
Other Lubrication ............................................................................................................................................. 46
Hydraulic Control Levers ................................................................................................................................. 46
Cab Heater ........................................................................................................................................................ 46
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................... 47
Hydraulic System ..............................................................................................................................................47
Hydraulic Filter Element, Replace .............................................................................................................. 47
Hydraulic Tank Breather, Change .............................................................................................................. 49
Service Brakes ...................................................................................................................................................49
Master Cylinder Oil, Change ....................................................................................................................... 49
Forks ..................................................................................................................................................................50
Integral Sideshift Carriage, Replace Upper and Lower Bearings ................................................................. 50
Lift Chains .........................................................................................................................................................50
Steer Wheel Bearings, Lubricate ..................................................................................................................... 50
Wheel Bearings ................................................................................................................................................. 50
Steer Wheels, Lubrication ............................................................................................................................50
Maintenance Procedures Every 4000 Hours or Two Years .................................................................................52
Hydraulic Oil Change ....................................................................................................................................... 52
Steering Direction Sensor Inspection .............................................................................................................. 54
Fixed Steering Column .................................................................................................................................54
Telescopic Steering Column ......................................................................................................................... 55
Telescopic Steering Column Lubrication .....................................................................................................56
Drive Axle Unit Assembly, Gear Oil Change .................................................................................................. 57
Drive Axle Unit Assembly, Wet Brake Oil Change .........................................................................................57
Battery Maintenance ............................................................................................................................................ 59
How to Charge Battery .....................................................................................................................................59
Rapid Charge .....................................................................................................................................................60
How to Change Batteries ..................................................................................................................................61
General ..........................................................................................................................................................61
Remove the Battery ......................................................................................................................................62
Manual Hydraulics ...................................................................................................................................62
Table of Contents
ii

TABLE OF CONTENTS (Continued)
E-Hydraulics .............................................................................................................................................64
Install the Battery ........................................................................................................................................ 64
Lift and Tilt System Leak Check ..........................................................................................................................68
Lift Cylinder Leak Check ................................................................................................................................. 68
Tilt Cylinder Leak Check ................................................................................................................................. 68
Safety Procedures When Working Near Mast .....................................................................................................69
WHEN WORKING NEAR THE MAST ALWAYS: ......................................................................................... 69
Lift Chain Adjustments ........................................................................................................................................ 71
Welding Repairs .................................................................................................................................................... 72
Overhead Guard Changes .....................................................................................................................................73
Wheels and Tires ...................................................................................................................................................73
General .............................................................................................................................................................. 73
Pneumatic Tires Repair ....................................................................................................................................73
Remove Wheels From Lift Truck .................................................................................................................73
Remove Tire From Wheel .............................................................................................................................74
Remove Tire From Two-Piece Wheel ...................................................................................................... 75
Remove Tire From Three- and Four-Piece Wheels .................................................................................76
Install Wheel in Tire .....................................................................................................................................77
Install Two-Piece Wheel in Tire .............................................................................................................. 78
Install Three- or Four-Piece Wheel in Tire .............................................................................................79
Add Air to Pneumatic Tires With Tube .......................................................................................................80
Wheels, Install .............................................................................................................................................. 80
Solid Rubber Tires on Pneumatic Wheels, Change .........................................................................................80
Remove Tire From Wheel .............................................................................................................................81
Install Tire on Wheel ....................................................................................................................................82
Wheels, Install .............................................................................................................................................. 84
Dual Drive Wheels, Install ...........................................................................................................................84
This section is for the following models:
(J80-120XN, J100XNL) [A970]
Table of Contents
iii

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

General
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can make a
dangerous operating condition.
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. Remove the key from the key
switch or cover the keyless switch if lift truck is
equipped with one. Disconnect the battery
connector.
DO NOT work under a raised carriage. Lower the
carriage or use a chain to prevent the carriage
and the inner or intermediate weldments from
lowering when doing maintenance. Make sure that
the moving parts are attached to parts that cannot
move.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
CAUTION
Disposal of batteries must meet local
environmental regulations.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance for your
lift truck. The service intervals are provided in both
operating hours recorded on the lift truck
hourmeter, and in calendar time. Use the interval
that occurs first.
The recommendation for the time intervals are for
8 hours of operation per day. The time intervals
must be decreased from the recommendations in
the Maintenance Schedule for the following
conditions:
• The lift truck is used more than eight hours
per day.
• The lift truck must work in dirty operating
conditions.
• Poor ground conditions.
• Intensive usage at high performance levels
or other abnormal conditions will require
more frequent servicing.
Your dealer for Hyster lift trucks will advise you on
the maintenance time intervals based on their
survey of the application.
Your dealer for Hyster lift trucks has the
equipment and trained service personnel to do a
complete program of inspection, lubrication, and
maintenance. A regular program of inspection,
lubrication, and maintenance will help your lift
truck provide more efficient performance and
operate for a longer period of time.
Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service
Manuals are available from your dealer for Hyster
lift trucks to help users who do their own
maintenance.
8000 SRM 1541 General
1

SERIAL NUMBER DATA
The serial number code for the lift truck is on the
Nameplate and stamped into the front face of rear
bulkhead. See Figure 1.
1. SERIAL NUMBER
Figure 1. Stamped Serial Number
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to
discharge before opening any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
property damage.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.
Before performing any tests or adjustments, block
the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can
hold an electrical charge for about 10 seconds
after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge
the capacitor(s) before inspecting or repairing any
component in the drive unit compartment. Make
certain that the battery has been disconnected.
DO NOT short across the motor controller
terminals with a screwdriver or jumper wire.
Make certain the Emergency Disconnect Switch
has not been activated. This will isolate the
controller and prevent the capacitors from
discharging properly. The proper way to
disconnect the battery is by separating the battery
connectors.
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn the key or keyless switch to the OFF
position.
3. Disconnect the battery by separating the
connectors.
4. Block drive wheels to prevent lift truck from
moving.
5. Make sure the Emergency Disconnect Switch
HAS NOT been activated. If the Emergency
Disconnect Switch is activated, rotate the
switch to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
General 8000 SRM 1541
2

HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra care when towing a lift truck if any of
the following conditions exist:
• Brakes DO NOT operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be moved on a steep
grade.
If the hydraulic pump motor, which includes the
steering control functions, does not operate,
steering control of the lift truck can be slow. DO
NOT tow the lift truck if there is no power. Poor
traction can cause the disabled lift truck or towing
vehicle to slide. Steep grades will require
additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift
truck MUST be moved and cannot be towed. The
lift truck used to carry the disabled lift truck MUST
have a rated capacity equal to or greater than the
weight of the disabled lift truck. The capacity
must be for 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 the load center of the forks.
DO NOT damage the underside of the lift truck.
1. The towed lift truck must have an operator.
2. Raise the carriage and forks approximately
300 mm (12 in.) from the surface. Install a
chain to prevent the carriage and mast
channels from moving.
3. Tow with another lift truck of equal or greater
capacity than the disabled lift truck. Install a
load of approximately half-capacity on the forks
of the lift truck that is being used to tow the
disabled lift truck. The half-capacity load will
increase the traction of the lift truck. Keep the
load as low as possible.
4. Use a towing link made of steel that fastens to
the tow pins in the counterweights of both lift
trucks.
5. Remove the floor mat and floor plates. Swing
the Automatic Park Brake valve handle up to
close the Automatic Park Brake valve. Pump
the handle on the hand pump 15 times. The
Automatic Park Brake actuator releases,
disengaging the Automatic Park Brake. See
Figure 2.
6. Tow the lift truck slowly.
1. AUTOMATIC PARKING BRAKE VALVE HANDLE
2. HAND PUMP
3. AUTOMATIC PARKING BRAKE VALVE
Figure 2. Automatic Park Brake Release
8000 SRM 1541 General
3

HOW TO PUT LIFT TRUCK ON BLOCKS
How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, battery,
or counterweight. When the lift truck is put on
blocks, put additional blocks in the following
positions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that
blocks can be installed.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck. See Figure 3.
2. Put the mast in a vertical position. Put a block
under each outer mast channel.
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put additional blocks under the frame behind
the drive tires.
5. If the hydraulic system will not operate, use a
hydraulic jack under the side of the frame near
the front. Make sure that the jack has a
capacity equal to at least half the weight of the
lift truck as shown on the Nameplate.
How to Raise Steering Tires
1. Make sure the Automatic Park Brake is applied
before putting blocks on both sides (front and
back) of the drive tires to prevent movement of
the lift truck. See Figure 3.
2. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at
least 2/3 of the total weight of the lift truck as
shown on the Nameplate.
3. Put the jack under the steering axle or frame to
raise the lift truck. Put blocks under the frame
to support the lift truck.
1. DRIVE TIRES 2. STEERING TIRES
Figure 3. Put Lift Trucks on Blocks
General 8000 SRM 1541
4

HOW TO CLEAN A LIFT TRUCK
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.
CAUTION
Units may be washed with a non-heated pressure
washer. Steam cleaning is not recommended in
most instances, as condensation may form in
electrical components causing damage or erratic
behavior.
NOTE: Lift trucks used in paper applications may
need cleaning beyond what is described here.
Please refer to Paper Application section in the
applicable Operating Manual and to available
Service Gram/Bulletin for more detail.
If it becomes necessary to clean the fork lift, follow
the guidelines listed below.
1. Assure truck components are cool before
starting the cleaning procedure.
2. Disconnect the battery. If an electric truck,
remove the traction battery.
3. Remove accumulated debris using a
compressed air line and nozzle.
4. Lightly spray a non-corrosive cleaning agent
onto the areas to be cleaned. This will help
loosen grime, so close contact direct spraying
will not be necessary.
5. Be sure to avoid directing the spray into
electrical panel compartment. Ensure over-
spray does not come in contact with electrical
components; DO NOT spray water directly at
electrical components, wiring connectors or
electrical enclosures. Even sealed connectors
may allow water egress under pressure or if
connector is damaged.
6. Avoid spraying in areas containing electrical
components such as:
• Floor Plates
• Battery Compartment
• Dash/cowl assembly
• Armrests with electrical components
7. Clean the battery compartment by using a
clean cloth to wash the battery with water. Dry
with compressed air. Care should be taken to
keep moisture at a minimum as some units
have a traction or hydraulic motor directly
below the battery compartment.
8. DO NOT pressure wash the battery. DO NOT
use hot water. For cleaning traction batteries,
refer to the Battery section of the Service
Manual.
9. DO NOT pressure wash lift chains, sheaves or
load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
section in the Service Manual for proper
cleaning procedures.
10. After cleaning, immediately run the lift truck to
dry out components.
8000 SRM 1541 General
5

Maintenance Schedule
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance for your
lift truck. The service intervals are provided in both
operating hours recorded on the lift truck hourme-
ter, and in calendar time. The recommendation is
to use the interval that comes first. The approxi-
mate locations of the items indicated in the Mainte-
nance Schedule are shown in Figure 4.
The Maintenance Schedule has the maximum serv-
ice intervals for usage under normal conditions. In-
spect and lubricate more frequently if the lift truck
operates in dirty, dusty, wet, or difficult conditions.
Figure 4. Maintenance Points
Maintenance Schedule 8000 SRM 1541
6

Table 1. Maintenance Schedule
Item
No.
Item 8 hr/
Daily
500 hr/
3 mo
2000 hr/
1 yr
4000 hr/
2 yr
Procedure or
Quantity
Specification
13 Tires X Check condition.
Automatic Parking
Brake
X
CIL
Check operation. Must hold capacity
load on a 15% grade
[a slope that
increases 1.5 meters
in 10 meters (1.5
feet increase in 10
feet)].
1 Service Brakes X CIL Check operation. See Parts Manual.
5 Brake Fluid
Master Cylinder
Oil
CIL X C 0.18 liter
(0.4 pt) .
Dexron® III
Transmission Fluid
18 Lift Chains X Check condition/
lube if necessary.
See NOTE 3.
SAE 30W engine oil.
19 Drive Unit
Assembly/Wet Brake
X Check for Leaks.
16 Forks X X X Check condition/
replace if
necessary.
Paper Application
Truck
Components
Drip Shield
X Check Condition.
Clean as
Required.
Replace as
Required.
See NOTE 9.
4 Direction and Speed
Control Pedals
X Check operation.
Lubricate as
necessary.
Use multipurpose
grease.
See NOTE 1.
11 Hydraulic Oil
Standard Truck
(Total Capacity)
X C 57 liter (60 qt) .
See NOTE 8.
0 to 48°C
(32 to 118°F)
Hydraulic Oil ISO
VG46.
11 Hydraulic Oil
Cooler/Freezer Truck
(Total Capacity)
X C 57 liter (60 qt)
NOTE 8
-29 to 48°C
(-20 to 118°F)
Hydraulic Oil ISO
VG 32 - VI ≥ 140
(High Viscosity
Index Oil per ISO
11158 L-HV).
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
8000 SRM 1541 Maintenance Schedule
7

Table 1. Maintenance Schedule (Continued)
Item
No.
Item 8 hr/
Daily
500 hr/
3 mo
2000 hr/
1 yr
4000 hr/
2 yr
Procedure or
Quantity
Specification
11 Hydraulic Oil
Sub-zero Construction
(Total Capacity)
X C 57 liter (60 qt)
NOTE 8
-40 to 22°C
(-40 to 71.6°F)
Hydraulic Oil MIL-
H-5606A
Horn, Lights, and
Alarm
X Check operation.
Oil Leaks X Check for leaks.
Safety Labels X Replace as
necessary.
See Parts Manual.
Battery and Battery
Restraint System
X Check condition. See NOTE 4 and
NOTE 12.
Hood Latch and
Release Handle
X, L Lubricate as
Necessary.
Check operation.
See NOTE 11.
Manual Control Lever
Release Latch
X,L Lubricate as
Necessary.
Check operation.
See NOTE 11.
Steering Column Tilt
Memory Lever
X Lubricate as
Necessary.
Check operation.
Use multipurpose
grease.
See NOTE 1.
Operator Restraint
System
X
CIL
Check condition.
Lift System Operation
Check
X Check operation.
Operator Presence
System Check
X Check operation.
20 Pivots (Mast) X L 2 fittings,
lubricate as
required.
Use multipurpose
grease.
See NOTE 1.
14 Mast Sliding Surfaces X L Lubricate as
required.
See NOTE 5.
Use multipurpose
grease.
See NOTE 1.
17 Integral Sideshift
Carriage
X L 2 fittings.
See NOTE 5.
Use multipurpose
grease.
See NOTE 1.
Header Hoses, Hose
Fittings and Clamps
X X Inspect for
kinked,
flattened, stiff, or
charred hoses.
Replace if necessary.
Hydraulic Control
Levers and Pedals
X Check operation.
Steering System X Check operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
Maintenance Schedule 8000 SRM 1541
8

Table 1. Maintenance Schedule (Continued)
Item
No.
Item 8 hr/
Daily
500 hr/
3 mo
2000 hr/
1 yr
4000 hr/
2 yr
Procedure or
Quantity
Specification
19 Drive Axle Unit
Assembly
Gear Oil
X Check oil level.
2.6 liter (2.7 qt)
per chamber.
Use gear oil.
John Deere JDM
J20C
3 Tilt Cylinder Rod End
Pins
X L Use multipurpose
grease.
See NOTE 1.
12 Brake Pedal Linkage
and Shafts
L Lubricate
linkage and
shafts.
See NOTE 2.
Use multipurpose
grease.
See NOTE 1 and
NOTE 11.
18 Lift Chains L Check stretch
and lubricate.
See NOTE 2 and
NOTE 3.
30W Engine Oil
18 Lift Chains X X Check
adjustment and
length.
See NOTE 2.
15 Fork Pins and Guides X L Lubricate as
necessary.
See NOTE 2.
Use multipurpose
grease.
See NOTE 1.
10 Hydraulic Tank
Breather
X C Clean or Replace.
See NOTE 2.
See Parts Manual.
17 Integral Sideshift
Carriage
(Upper/Lower
Bearings)
X Check wear.
4 bearings.
See NOTE 5.
2.5 mm (0.098 in.)
minimum thickness.
17 Integral Sideshift
Carriage
Lower Mounting
Hooks
X Check for Wear
and Clearance.
See NOTE 2.
0.76 mm (0.03 in.)
minimum wear
limit.
8 Contactors X Check condition. See Parts Manual.
See NOTE 12.
6 Steering King Pins L 4 fittings,
lubricate as
required.
See NOTE 2.
Use multipurpose
grease.
See NOTE 1.
7 Steering Tie Rods L 4 fittings,
lubricate as
required.
See NOTE 2.
Use multipurpose
grease.
See NOTE 1.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
8000 SRM 1541 Maintenance Schedule
9

Table 1. Maintenance Schedule (Continued)
Item
No.
Item 8 hr/
Daily
500 hr/
3 mo
2000 hr/
1 yr
4000 hr/
2 yr
Procedure or
Quantity
Specification
Hinges, Levers,
Linkage, Pedals, Seat
Rails, and Latches
L Lubricate as
required.
See NOTE 2.
Use multipurpose
grease.
See NOTE 1 and
NOTE 13.
Hydraulic Control
Levers
L Lubricate as
required.
Use silicone
lubricant spray.
Hyster P/N 328388.
Heater- Air Filter C Replace air
filters. Quantity
of 2.
See Parts Manual.
Heater- Heater
Element
X Clean heater
element.
Use compressed air.
Heater- Operating
Condition
X Check operation
and heater
condition.
17 Integral Side-Shift
Carriage
(Upper/Lower
Bearings)
C Replace bearings/
4 bearings.
2.5 mm (0.098 in.)
minimum thickness.
See Parts Manual.
2 Steer Wheel Bearings L Check grease. Use multipurpose
grease.
See NOTE 1.
9 Hydraulic Oil Filter C 1 filter. See
NOTE 2 and
NOTE 8.
See Parts Manual.
19 Drive Axle Unit
Assembly
Gear Oil
C Change oil.
2.6 liter (2.7 qt)
total both
chambers.
Use gear oil John
Deere JDM J20C.
18 Lift Chains L Remove lift
chains to clean
and lubricate.
30W engine oil.
Steering Position
Sensor
X Check sensor
assembly and
column gear
teeth.
Replace sensor or
column gear as
required.
Telescopic Steering
Column
L Lubricate. Use manual
steering gear grease.
See NOTE 6.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
Maintenance Schedule 8000 SRM 1541
10

Table 1. Maintenance Schedule (Continued)
Item
No.
Item 8 hr/
Daily
500 hr/
3 mo
2000 hr/
1 yr
4000 hr/
2 yr
Procedure or
Quantity
Specification
Automatic Parking
Brake Cable Barrel
L
Automatic Parking
Brake Cable
X Check condition.
Replace as
necessary.
See NOTE 7.
Automatic Parking
Brake Actuator and
Levers
Replace actuator
and levers.
See NOTE 7.
Mast and Carriage
with Paper Roll Clamp
X Inspect.
NOTE 10
Dye Penetrant.
NOTE 1: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 2: 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 dealer will
advise you of the appropriate service intervals based on an application survey.
NOTE 3: Lubricate if dry or at first sign of visible surface rust
NOTE 4: Equalization charge is required approximately each month.
NOTE 5: Maximize life of surface by lubricating every 250 hours for first 1000 hours.
NOTE 6: Multipurpose lithium base grease.
NOTE 7: Replace at 10,000 hours. See Transaxle 1300SRM1539 for procedures.
NOTE 8: 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 9: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire.
This should be done at least once every 8 hours or more frequently depending upon operating environment.
Use compressed air and steam clean as necessary.
NOTE 10: Inspect after an impact likely to cause damage. In large diameter paper-roll production
applications, inspect at first 4000 hours with subsequenct inspection at 2000-hour intervals. At your
request your Hyster dealer will advise you of the appropriate service intervals based on an application
survey.
NOTE 11: Lubricate with anti-seize grease compound for lift trucks equipped with Outdoor Protection/
Wash-down Package.
NOTE 12: Spray electrical connections with rust inhibitor-ignition sealer, after components are properly
tightened, for lift trucks equipped with Outdoor Protection/Wash-down Package.
NOTE 13: Coat all brake linkage pivot points, exposed brake cables, pivot shafts, and bushings with anti-
seize lubricant for lift trucks equipped with Outdoor Protection/Wash-down Package.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
8000 SRM 1541 Maintenance Schedule
11

Maintenance Procedures Every 8 Hours or Daily
WARNING
DO NOT operate a lift truck that needs repairs. Re-
port the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the op-
erator's area. Remove the key from the key switch
or cover the keyless switch.
Inspect the lift truck after every eight hours or
daily before use. Put the lift truck on a level sur-
face. Lower the carriage and forks and turn the key
or keyless switch to the OFF position. Apply the
Automatic Parking Brake (APB). Remove the floor
mat and floor plate and inspect for leaks and condi-
tions that are not normal. Clean any oil spills.
Make sure that lint, dust, paper and other materi-
als are removed from the compartments. Make the
additional checks as described in the following
paragraphs of How to Make Checks With Key or
Keyless Switch OFF and How to Make Checks
With Key or Keyless Switch ON.
HOW TO MAKE CHECKS WITH KEY OR
KEYLESS SWITCH OFF
Tires and Wheels
Inspect the tires for wire, rocks, glass, pieces of
metal, holes, cuts and other damage. Remove any
object that will cause damage. Check for loose or
missing hardware. Remove any wire strapping or
other material that is wrapped around the axle. See
Figure 5.
Forks
General
NOTE: Forks must be removed and installed by
trained personnel.
The identification of a fork describes how the fork is
connected to the carriage. These lift trucks have
hook forks.
Inspect
WARNING
DO NOT try to correct fork tip alignment by bend-
ing the forks or adding shims. Replace bent forks.
Never repair damaged forks by heating or weld-
ing. Forks are made of special steel using special
procedures. Replace damaged forks. Forks are to
be replaced only in sets and not individually.
1. Inspect the forks for cracks and wear. Check
that the fork tips are aligned as shown in Fig-
ure 6.
2. Check that the bottom of the fork is not worn
(item 4 in Figure 6).
3. Replace any damaged or broken parts that are
used to keep the forks locked in position. See
Figure 7.
1. CHECK FOR DAMAGE AND REMOVE NAILS,
GLASS, METAL, AND OTHER OBJECTS FROM
TREAD
2. CHECK EDGES FOR WEAR
3. CHECK TIRE PRESSURE
Figure 5. Tires Check
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1541
12