Hyster E007 H8.00XL User manual

Hyster E007 (H8.00XL H9.00XL H10.00XL H12.00XL
Europe) Forklift

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1
INTRODUCTION
GENERAL
ThissectioncontainsaMAINTENANCESCHEDULE
and the instructions for maintenance and inspection.
The MAINTENANCE SCHEDULE has time intervals
for inspection, lubrication and maintenance of your lift
truck. The recommended time intervals are for eight
hours of operation per day. Shorten the recommended
timeintervalsintheMAINTENANCESCHEDULEfor
the following conditions:
a. If the lift truck is used more than eight hours per
day.
b. If the lift truck must work in dirty operating con-
ditions.
Your dealer for Hyster lift trucks has the equipment and
trained service personnel to do a complete program of
inspection,lubrication,andmaintenance.Aregularpro-
gram of inspection, lubrication, and maintenance will
help your lift truck give more efficient performance and
operate for a longer period of time.
Someusers 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.
WARNING
Do not make repairs or adjustments unlessyou have
both authorization and training. Repairs and ad-
justmentsthatarenotcorrectcanmakeadangerous
operating condition.
WARNING
Donotoperatealifttruckthatneedsrepairs.Report
the need for repairs immediately. If repair is neces-
sary, put a “DO NOT OPERATE” tag in the opera-
tor’s area. Remove the key from the key switch.
CAUTION
Disposal of lubricants and fluids must meet local en-
vironmental regulations.
HOW TO MOVE A DISABLED LIFT TRUCK
NOTE: If there is no air pressure in the brake system,
the parking brake must be manually released. To manu-
ally release the parking brake, use the release bolt at
each air chamber to compress the spring that applies the
brake. Tighten the release bolt (or nut) until the brake is
released.
H8.00–12.00XL (H165–280XL) models: the release
bolt,washerand nut are in areceptacleontheside of the
airchamber.Makesurethereleaseboltis engagedin the
piston before the nut is tightened.
H13.00–16.00XL (H300–360XL) models: the release
bolt is permanently installed in the piston .
WARNING
Use extra care when towing a lift truck if there is a
problem with any of the following:
a. Brakes do not operate correctly.
b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are bad.
e. The lift truck must be towed on a steep grade.
Ifthe engine cannotrun, there is no poweravailable
for the hydraulic steering system and the service
brakes. This condition can make the lift truck diffi-
culttosteerandstop.Poortractioncancausethedis-
abledlifttruckortowingvehicletoslide.Aslopewill
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 capac-
ity of the lift truck used to move a disabled lift truck
musthavealoadcenterequaltohalfthe width of the
disabledlift truck.See thenameplate ofthe disabled
lifttruckfortheapproximatetotalweight.Theforks
must extend the full width of the disabled lift truck.
Puttheweight center of thedisabledlift truck on the
loadcenteroftheforks.Becarefulnottodamagethe
under side of the lift truck.
How to Tow the Lift Truck
1. The towed lift truck must have an operator.

2
2. Tow the lift truck slowly.
3.Raisethecarriageand forks approximately 30 cm (12
inches) from the surface. Install a chain to prevent the
carriage and mast channels from moving.
4. If another lift truck is used to tow the disabled lift
truck, that lift truck must have a weight equal or greater
than the weight of the disabled lift truck. Install an ap-
proximate half–capacity load on the forks of the lift
truck that is being used to tow the disabled lift truck.
This half–capacity load will increase the traction of the
lift truck. Travel with the load as low as possible.
5. Use a towing link made of steel that attaches to the
tow pins in the counterweights of both lift trucks.
HOW TO PUT A LIFT TRUCK ON BLOCKS
WARNING
Thelifttruckmustbeputonblocksforsometypesof
maintenance and repair. The removal of the follow-
ing assemblies will cause large changes in the center
ofgravity:mast,driveaxle,engineandtransmission,
and the counterweight. When the lift truck is put on
blocks, put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle, put
blocks under the counterweight so that the lift
truck can not fall backward.
b. Before removing the counterweight, put blocks
under the mast assembly so that the lift truck can
not fall forward.
The surface must be solid, even, and level when the
lifttruck is puton blocks. Make surethat any blocks
used to support the lift truck are solid, one piece
units. Put a steel plate on top of the block.
NOTE: Some lift trucks have lifting eyes. These lift
pointscanbeusedtoraisethelifttrucksothatblockscan
be installed.
How to Raise the Drive Tires (See FIGURE 1.)
1. Put blocks on each side (front and back) of the steer-
ing tires to prevent movement of the lift truck.
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.Putadditionalblocksundertheframebehindthedrive
tires. Make sure the blocks are under the frame and not
the hydraulic or fuel tanks.
5.Ifthe hydraulic systemwillnotoperate, use ahydrau-
lic 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. See the nameplate.
How to Raise the Steering Tires
(See FIGURE 1.)
1. Apply the parking brake. Put blocks on both sides
(front and back) of the drive tires to prevent movement
of the lift truck.
2. Use a hydraulic jack to raise the steering tires. Put the
jack under the steering axle or frame to raise the lift
truck. 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 blocks under the frame andcounterweight to sup-
port the lift truck. Make sure the blocks are under the
frame and not the hydraulic or fuel tanks.

3
FIGURE 1. PUT A LIFT TRUCK ON BLOCKS
STEERING TIRES DRIVE TIRES 12438
FIGURE 2. MAINTENANCE POINTS (DIESEL ENGINE SHOWN)
12473
12
3
4
5
67891011 1213 14 15 16
17
18192021 22
23 24 25
1
78
26
27
28
2930
31
32
33
3435
25 21
30 10
13
36 11

4
TABLE 1. MAINTENANCE SCHEDULE (Item Numbers Reference FIGURE 2.)
ITEM
NO. ITEM 8
Hr./
Daily
150
Hr./
2 mo.
350
Hr./
2 mo.
1000
Hr./
6 mo.
2000
Hr./
1 yr.
PROCEDURE OR
QUANTITY SPECIFICATION
30 TIRES
TIRE PRESSURE X
XCheck Condition See Nameplate See Parts Manual
1 FORKS X X Check Condition
3MAST, CARRIAGE,
ATTACHMENT XCheck Condition
and Operation
6LIFT CHAINS X X, L
XX
Check Condition
and Lubrication
Check Adjustment
Check Length
Engine Oil
SAFETY LABELS X Replace If
Necessary See Parts Manual
SAFETY BELT
AND SEAT RAILS XCheck Condition
CHECK FOR LEAKS—
FUEL, OIL, COOLANT XCheck for leaks
33 FUEL TANK (Diesel)
LPG (Option) X120 litre (31.7 gal)
(2) 43.5 lb LPG
tanks
Diesel No. 2
LPG — HD–5
24 COOLING SYSTEM X C 26.0 litre (27.5 qt) 50% water with
50% Ethylene Glycol
28 RADIATOR HOSES X Check Condition See Parts Manual
23 DRIVE BELTS X XCheck Condition
Check Tension See Parts Manual
19 PRIMARY FUEL FILTER X C Drain Water See Parts Manual
13 BATTERY
ELECTROLYTE LEVEL X
XClean Check Level See Parts Manual 2 Batteries
15 HYDRAULIC SYSTEM
H8.00–12.00XL
(H165–280XL)
H13.00–16.00XL)
(H300–360XL)
X C 113 litre
(31.7 gallons)
142 litre
(37.5 gallons)
–18°C (0°F) and Above
SAE 10W
API CC or CC/SE/SF/
SG
18 PRE–CLEANER FOR ENGINE
AIR FILTER X Clean See Parts Manual
32 AIR FILTER, ENGINE AND
AIR COMPRESSOR XClean or Replace
(See NOTE 3) See Parts Manual
21
22 ENGINE OIL AND FILTER
Perkins Diesel X C 15.1 litre (16.0 qt) 1 Filter
See NOTES 1 & 2
greater than –18°C (0°F)
SAE 10W–30 API SE/
SG
See Parts Manual
21
22 ENGINE OIL AND FILTER
GM V–8 X C 10 litre (9.5 qt) 1 Filter
See NOTES 1 & 2
API SE/SF
greater than –18°C (0°F)
SAE 10W–30
See Parts Manual
X= Check C=Change L=Lubricate NOTE 1: Change filters after first 100 hours of operation on a new lift truck.
NOTE 2: Change engine oil and filters every 400 hours.
NOTE 3: Very dirty conditions will require a daily clean and check.

5
ITEM
NO. ITEM 8
Hr./
Daily
150
Hr./
2 mo.
350
Hr./
2 mo.
1000
Hr./
6 mo.
2000
Hr./
1 yr.
PROCEDURE OR
QUANTITY SPECIFICATION
17 WINDSHIELD WASHER FLUID X Check Level
HORN, GAUGES, LIGHTS,
ALARMS, AND MIRRORS XCheck Operation
31 TRANSMISSION OIL
HYSTER T–50 X C 28 litre (29 qt) Hyster Part No. 336830
Hyster Part No. 336831
Hyster Part No. 336832
STEERING X Check Operation
9 BRAKES,
SERVICE AND PARKING XXCheck Operation
Check Condition
35 AIR TANK X Drain Moisture
12 DRIVE SHAFT L 3 Fittings Multi–Purpose Grease
See NOTE 4
27
26
STEERING AXLE
TIE RODS
LOWER SPINDLE BEARINGS L
L4 Fittings 2 Fittings
See NOTE 4
Multi–Purpose Grease
Multi–Purpose Grease
10 SHAFT FOR
BRAKE ACTUATORS L2 Fittings Multi–Purpose Grease
See NOTE 4
5DRIVE AXLE AND
DIFFERENTIAL
H8.00–12.00XL
(H165–280 XL)
H13.00–16.00XL
(H300–360XL)
X C
23.7 litre (25.0 qt)
24.6 litre (26 qt)
SAE 85W–140
14 HYDRAULIC TANK
BREATHER X 1
Clean as Necessary See Parts Manual
AIR FILTER, HEATER X 1 Clean
(See NOTE 3) See Parts Manual
25 WHEEL NUTS
DRIVE WHEELS
STEER WHEELS X
XCheck Torque Check Torque 640 to 680 Nm
(470 to 500 lbfft)
11 BRAKE ACTUATOR ARMS X 2
Check Adjustment
8
36
4
2
7
MAST
PIVOTS
SLIDING SURFACES
SIDE SHIFT CARRIAGE
FORK GUIDES
TILT CYLINDER PIVOT PINS
CHAIN ANCHORS
(Top of Mast)
L
L
L
L
L
L
2 Fittings
As Necessary
4 Fittings
As necessary
4 Fittings
2
See NOTE 4
Multi–Purpose Grease
Multi–Purpose Grease
Multi–Purpose Grease
Engine Oil
Multi–Purpose Grease
Multi–Purpose Grease
PEDALS, LEVERS, LINKAGES,
CABLES, HINGES, SEAT RAILS LAs Necessary Engine Oil
X= Check C=Change L=Lubricate NOTE 3: Very dirty conditions will require a daily clean and check.
NOTE 4: Multi–purpose grease with 2–4% molybdenum disulfide.

6
ITEM
NO. ITEM 8
Hr./
Daily
150
Hr./
2 mo.
350
Hr./
2 mo.
1000
Hr./
6 mo.
2000
Hr./
1 yr.
PROCEDURE OR
QUANTITY SPECIFICATION
ENGINE SPEED (DIESEL)
IDLE SPEED
GOVERNED SPEED
ENGINE SPEED (GM V–8)
IDLE SPEED
GOVERNED SPEED
X
X
X
X
Adjust as Necessary
Adjust as Necessary
725 to 775 rpm
2660 to 2760 rpm
725 to 750 rpm
2700 to 2800 rpm
TIMING, INJECTION PUMP X Adjust as Required 23°BTDC Static
TIMING, GM V–8
SPARK PLUGS X
XAdjust as Required (8) Replace as
Necessary
6°to 8°BTDC
Gap = 0.89 mm (0.35 in)
See Parts Manuals
VALVE ADJUSTMENT (DIESEL)
INLET (Cold)
EXHAUST (Cold)
GM V–8
(NO VALVE ADJUSTMENT)
XAdjust as Required 0.20 mm (0.008 in)
0.45 mm (0.018 in)
SPARK PLUGS (GM V–8) C 8 0.89 mm (0.35 in)
See Parts Manual
20 FINAL FUEL FILTERS (DIESEL) C 2 See Parts Manual
FUEL FILTER (LPG) C See Parts Manual
34 TRANSMISSION OIL FILTER C 1 (See NOTE 1) See Parts Manual
16 HYDRAULIC SYSTEM
OIL FILTER C1 (See NOTE 1) See Parts Manual
29 HUB BEARINGS,
STEER WHEELS CAs Necessary Multi–Purpose Grease
See NOTE 4
X= Check C=Change L=Lubricate NOTE 1: Change filters after first 100 hours of operation on a new lift truck.
NOTE 4: Multi–purpose grease with 2–4% molybdenum disulfide.
MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT
(Item Numbers Reference FIGURE 3.)
ITEM
NO. ITEM 150
Hr./
2 mo.
350
Hr./
2 mo.
2000
Hr./
1 yr.
PROCEDURE OR
QUANTITY SPECIFICATION
1SIDE–SHIFT ROLLERS L 8 Fittings Multi–Purpose Grease4
2SIDE–SHIFT CYLINDER PINS L 2 Fittings Multi–Purpose Grease4
3LOCK PINS L 2 Fittings Multi–Purpose Grease4
4BEARING BLOCKS X, L As Necessary Multi–Purpose Grease4
5 ACCUMULATORS X Drain Moisture
6LOCK PIN CYLINDERS L Lubricate Internally See Service Manual
NOTE 4: Multi–purpose grease with 2–4% molybdenum disulfide.X= Check C=Change L=Lubricate

7
FIGURE 3. MAINTENANCE POINTS, EMPTY CONTAINER ATTACHMENT
12698
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY
HOW TO MAKE THE CHECKS WITH THE
ENGINE STOPPED
Put the lift truck on a level surface. Lower the carriage
and forks, stop the engine and apply the parking brake.
Open the hood and check for leaks and conditions that
are not normal. Clean any oil or fuel spills. Make sure
that lint, dust, paper and other materials are removed
from the engine compartment.
Tires and Wheels (See FIGURE 4.)
WARNING
Airpressureintirescancausetireandwheelpartsto
explode.Theexplosionofwheel parts can cause seri-
ous injury or death.
Remove all of the air from the tires before the tires
are removed from the lift truck.
If the air pressure is less than 80% of the correct
pressure, the tire must be removed before air is
added. Put the tire in a safety cage when adding air
pressure to the tire. Follow the procedures under
ADD AIR TO THE TIRES.
When air is added to the tires, a remote air chuck
must be used so that the person adding air can stand
to the side and not in front of the tire.
Keepthe tires atthecorrect airpressure.(Seethe Name-
plate.) Check the air pressure with a gauge when the
tires are cold. If it is necessary to add air to a tire that is
warm, check one of the other tires on the same axle and
add air to the tire that has low pressure so that the air
pressures are equal. The air pressure of warm tires must
alwaysbeequaltoorgreaterthanairpressures specified
for cold tires.
Checkthetiresfordamage.Checkthetreadand remove
any objects that will cause damage. Check for bent or
damaged rims. Check for loose or missing hardware.
Remove any wire, strapping or other material that is
wrapped around the axle.
Make sure the wheel nuts are tight. Tighten the wheel
nuts in a cross pattern (see FIGURE 37.) to the correct

8
torque value shown in the MAINTENANCE SCHED-
ULE.
NOTE: Whenever a wheel is removed, it will be neces-
sary to lubricate the wheel nuts and studs. (See
FIGURE 37.)Puttwodropsofengineoil(orotherlubri-
cant)betweentheflangeandbodyofthewheelnut.Also
put two drops of oil on the threads of the studs.
9447
31
2
1
1. CHECK FOR DAMAGE (REMOVE NAILS,
GLASS AND OTHER OBJECTS FROM
THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK THE TIRE PRESSURE
(PNEUMATIC TIRES)
FIGURE 4. CHECK THE TIRES
CAUTION
When the wheels have been installed check all wheel
nuts after 2 to 5 hours of operation. Tighten the nuts
in a cross pattern to the correct torque value shown
in the MAINTENANCE SCHEDULE table. When
the nuts stay tight after eight hours, the interval for
checking the torque can be extended to 150 hours.
Forks
The identification of a fork is determined by how it is
connected to the carriage. These lift trucks have pin
forks. Pin forks are fastened to the carriage with large
fork pins.
Forks, Adjustment
Alock pin for each fork fits into thetop carriage bar and
a slot in the fork. These lock pins hold the fork in posi-
tion. Adjust the forks as far apart as possible for maxi-
mum support of the load. Make sure the lock pin is en-
gaged in the carriage bar and the fork. The fork must be
locked into position after the adjustment is made.
Forks, Removal
WARNING
Do not try to move a fork without a lifting device.
The forks can weigh up to 370 kg (800 lb) each.
Put the lift truck on a level surface and lower the forks.
Tilt the mast so thattheforkshavestability. Remove the
retainersfortheforkpinsandpushthepinsfromthecar-
riage. Move the lift truck away from the forks.
Forks, Installation
1. Put the forks approximately 1 m (3 ft) in front of the
carriage.
2. Slowly move the lift truck toward the forks until the
fork pins can be installed. Install the fork pins and the
retainers.
3. FORK PIN DAMAGE
4. MUST BE 90% OF
DIMENSION X
5. FORK WEAR
1
5
33
2
11195
FIGURE 5. CHECK THE FORKS
X
4
1. TIP ALIGNMENT
(MUST BE WITHIN 3%
OF FORK LENGTH)
2. CRACKS
FORK TIP ALIGNMENT
LENGTH OF FORKS 3% DIMENSION
1220 mm (48 in) 37 mm (1.45 in)
1830 mm (72 in) 55 mm (2.15 in)
2440 mm (96 in) 74 mm (2.90 in)

9
Inspection of Forks, Mast and Lift Chains
(See FIGURE 5. and FIGURE 6.)
WARNING
Never work under a raised carriage or forks. Lower
the carriage or use blocks and chains on the mast
weldments and carriage so that they can not move.
Make sure the moving parts are attached to a part
that does not move.
Do not try to correct fork tip alignment by bending
the forks or adding shims. Replace damaged forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
dures. Replace damaged forks.
1. Inspect the welds on the mast and carriage for cracks.
Make sure that the nuts and bolts are tight.
2. Inspect the channels for wear in the areas where the
rollers travel. Inspect the rollers for wear or damage.
3. Inspect the forks for cracks and wear. Check that the
fork tips are aligned (item 1, FIGURE 5.). Check that
the bottom of the fork is not worn (item 8, FIGURE 5.).
4. Replace any damaged or broken parts that are used to
keep the forks locked in position.
5.Check thatthelift chainsarecorrectlylubricated.Use
engine oil to lubricate the chains.
6. If the lift truck is equipped with a side–shift carriage
or attachment, inspect the parts for cracks and wear.
Make sure the parts that fasten the side–shift carriage or
attachment to the carriage are in good condition.
7. Inspect the lift chains for cracks or broken links and
pins. (See FIGURE 6.)
8. Inspect the chain anchors and pins for cracks and
damage.
9.Makesuretheliftchainsareadjustedsothattheyhave
equal tension. If the lift chains need repair or adjust-
ment, it must be done by authorized personnel. See the
section, THE TWO–STAGE MAST, 4000 SRM 445,
for adjustment procedures.
FIGURE 6. CHECK THE LIFT CHAINS
1. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
6705
1
2
3
4
56
7
SAFETY LABELS
WARNING
Safety labels are installed on the lift truck to give in-
formation about operation and possible hazards. It
is important that all safety labels are installed on the
lift truck and can be read.
Checkthatallsafetylabelsareinstalledinthecorrectlo-
cations on the lift truck. See the PARTS MANUAL or
the FRAME section of the SERVICE MANUAL for
the correct location of the safety labels.
Ifnew labels must be installed, usethe following proce-
dure:
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
a. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint with a cleaning solvent.
b. Remove the paper from the back of the label. Do
not touch the adhesive surface.
c. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the

10
surface. Make sure that all air is removed from
under the label and the corners and edges are
tight.
Operator Restraint System (See FIGURE 7. )
The seat belt, hip restraint brackets, seat and mounting
are all part of the operator restraint system. Each item
must be checked to make sure it is attached securely,
functions correctly and is in good condition.
Theseatbeltmustlatchsecurely.Makesuretheseatbelt
extends and retracts smoothly and is not damaged nor
torn.
Makesuretheseatrailsarenotloose.Theseatrailsmust
lock securely in position, but move freely when un-
locked. The seat rails must be securely attached to the
mounting surface.
FIGURE 7. CHECK THE SEAT
1. SEAT BELT
2. HIP RESTRAINT
3. SEAT RAIL
4. SEAT BELT RETRACTOR
12478
Steering Column Latch
Make sure the latch for the steering column operates
correctly. The latch must NOT allow the column to
move unless the latch is released.
Drive Belts
Check the drive belts for wear or damage.
Cooling System (See FIGURE 8.)
WARNING
DONOTremovetheradiatorcapwhentheengineis
hot. When the pressure cap is removed from the ra-
diator,thepressureisreleasedfromthesystem.Ifthe
systemishot,thesteamandboilingcoolantcancause
burns.
Make sure the coolant level is between the “FULL” and
the “ADD” mark on the auxiliary coolant reservoir. The
coolant will expand as it is heated and the level in the
auxiliarycoolantreservoirwillincrease. Add coolant to
the auxiliary reservoir if additional coolant is needed.
Check the radiator fins. Clean the radiator with com-
pressed air or water as needed.
FIGURE 8. AUXILIARY COOLANT
RESERVOIR
1. AUXILIARY COOLANT RESERVOIR
2. RADIATOR
12453
Check For Fuel, Oil Or Coolant Leaks
WARNING
All fuels are very flammable and can burn or cause
an explosion. Do not use an open flame to check the
fuel level or to check for leaks in the fuel system. If
there is a leak in the fuel system, extra care must be
used during the repair. Do not operate the lift truck
until a leak is repaired.
Makeavisualcheckforleaksonandunderthelifttruck.
If possible, find and repair the leak at the source. Leaks
often indicate a need for repair of damaged or worn
components. Leaks in an LPG fuel system are usually
notvisibleunless iceisvisible.There ishowever, usual-
ly a strong odor. Fuel leaks MUST be repaired NOW.

11
Check the fuel system for leaks and the condition of
parts. Also check the condition of the radiator or heater
hoses that are not leaking. Soft or cracked hoses need to
be replaced before a major leak occurs.
Hydraulic System (See FIGURE 9.)
WARNING
At operating temperature the hydraulic oil is HOT.
Do not permit the oil to touch the skin and cause a
burn.
CAUTION
Do not permit dirt to enter the hydraulic system
when the oil level is checked or the filter is changed.
Never operate the hydraulic pump without oil in the
hydraulic system. The operation of the hydraulic
pump without oil will damage the pump.
Checkthe hydraulicoillevel whentheoilisat operating
temperature, the carriage is lowered and the engine is
stopped. Add hydraulic oil only as needed. If more hy-
draulicoilisaddedthanthe“FULL”level,thehydraulic
oil will leak from the breather during operation.
Check the hydraulic system for leaks and damaged or
loose components.
1. DIPSTICK FOR HYDRAULIC OIL
2.HYDRAULIC OIL FILTER
3.BATTERY
FIGURE 9. MAINTENANCE POINTS
12454
Engine Oil (See FIGURE 10.)
After the engine has stopped, wait one minute before
checkingthe oil level.Keepthe oilatthecorrect levelas
indicatedon the dipstick.Usethe correctoilasshown in
the MAINTENANCE SCHEDULE.
FIGURE 10. ENGINE MAINTENANCE
1. ENGINE OIL DIPSTICK, DIESEL
2. ENGINE OIL FILTER, DIESEL
3. PRIMARY FUEL FILTER, DIESEL
4. FINAL FUEL FILTER, DIESEL
5. ENGINE OIL DIPSTICK, GM V8
6. FILL CAP, ENGINE OIL
(OIL FILTER ON OTHER SIDE OF ENGINE)
12454
5
6
Fuel System
WARNING
All fuels are very flammable and can burn or cause
an explosion. Do not use an open flame to check the

12
fuel level or to check for leaks in the fuel system. If
there is a leak in the fuel system, extra care must be
used during the repair. Do not operate the lift truck
until a leak is repaired.
Check the fuel system for leaks and the condition of the
parts. When fuel is added to the lift truck, see the sec-
tion, How To Add Fuel To The Lift Truck procedures
in the OPERATING MANUAL.
Primary Fuel Filter (See FIGURE 10.)
Drain the water from the primary fuel filter.
1. Open the valve on the bottom of the filter canister.
Drain some fuel (and any water) into a cup until clean
fuel flows from the filter.
2. Close the valve.
Battery (See FIGURE 9.)
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 make the
acid neutral. Acid in the eyes must be flushed with
water immediately. Wear eye protection.
Batteriesgenerateexplosivefumes.Keeptheventsin
thecapsclean.Keepsparksoropenflameawayfrom
the battery area. Do not make sparks from the bat-
tery connections. Disconnect the battery ground
cable when doing maintenance.
CAUTION
Disposal of batteries must meet local environmental
regulations.
Keep the battery and cable terminals clean. Check the
electrolyte level (unless a maintenance–free battery).
Keep the electrolyte level above the separators and
plates. Use distilled water. Do not fill the battery more
than to the bottom of the internal filler neck.
Ifthebatterybecomesdischargedandrequiresabooster
batteryto start theengine,follow theseprocedurescare-
fully when connecting the jumper cables:
a. Always connect the positive jumper cable to the
positive terminal of the discharged battery and
the negative jumper cable to the negative termi-
nal.
b. Always connect the jumper cable that is the
ground cable last.
c. Always connect the jumper cables to the dis-
charged battery before connecting them to the
booster battery.
Pre–Cleaner for Air Filter (See FIGURE 11.)
Clean the pre–cleaner for the air filter as necessary. Re-
movethecoverfor the pre–cleaner,thenremovethe dirt
from the bowl. Install the bowl and cover.
1. COVER
2. BOWL
FIGURE 11. PRE–CLEANER FOR THE AIR
FILTER
12471
Air Filter (See FIGURE 24.)
Clean or replace the air filter as necessary. Use com-
pressed air to clean the filter element. Air pressure must
be less than 210 kPa (30 psi). Apply the air from the in-
side to the outside of the element.
To inspect theelement,putabrightlightinside and look
forholesorotherdamage. Iftheelementisdamaged,re-
place it with a new element. Clean the inside of the can-
ister when changing filters.
HOW TO MAKE THE CHECKS WITH THE
ENGINE RUNNING
WARNING
FASTEN YOUR SEAT BELT! The seat belt is in-
stalledtohelptheoperatorstayonthetruckifthelift
truck tips over. IT CAN ONLY HELP IF IT IS FAS-
TENED.
Make sure that the area around the lift truck is clear be-
fore starting the engine or making any operational

13
checks. Be careful when making the checks. If the lift
truck is stationary during a check, apply the parking
brake and put the transmission in NEUTRAL. Proceed
carefully.
Gauges, Lights, Horn and Fuses,
Start the engine. Check that the gauges and lights for
correct operation as described in the OPERATING
MANUAL. Check the operation of the horn.
Thefusesareunder theinstrumentpanelontheleftside.
(See FIGURE 12.)
FIGURE 12. INSTRUMENTS AND CONTROLS
12383
NOTE: The fuse panel and diagram are behind the
access door.
1
234
56
78
910
11 12
13, 14
17
18
19
15,16
20 21
1. AIR PRESSURE GAUGE
2. LOW PRESSURE INDICATOR
3. PARKING BRAKE KNOB
4. COLD START AID
5. RANGE SELECTION LEVER
6. DIRECTION CONTROL LEVER
7. STEERING WHEEL
8. HORN
9. LIFT/LOWER CONTROL LEVER
10. TILT CONTROL LEVER
11. SIDE–SHIFT CONTROL LEVER
12. HOUR METER
13. WARNING LIGHT, ALTERNATOR
14. WARNING LIGHT, ENGINE OIL PRESSURE
15. WARNING LIGHT, TRANSMISSION OIL PRESSURE
16. WARNING LIGHT, TRANSMISSION OIL
TEMPERATURE
17. COOLANT TEMPERATURE
GAUGE
18. FUEL GAUGE (DIESEL)
19. INCHING/BRAKE PEDAL
20. BRAKE PEDAL
21. ACCELERATOR PEDAL

14
Control Levers and Pedals
Check that the control levers for the transmission, mast
and attachment and the pedals operate as described in
the OPERATING MANUAL.
Transmission Oil (See FIGURE 13.)
Apply the parking brake. Check the oil level in the
powershift transmission when the engine is running at
idlespeedand, if equipped, thedirectioncontrollever is
in the Neutral position. Use the correct oil as shown in
the Maintenance Schedule. Keep the oil level at the
“FULL” mark on the dipstick.
FIGURE 13. TRANSMISSION OIL
1. TRANSMISSION OIL DIPSTICK
2. FUEL CAP
12472
Lift System Operation
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. Do not put any part
ofyour body inor throughthe lift mechanismunless
all parts of the mast are completely lowered and the
engine is STOPPED.
WARNING
Beforemaking any repairs,useblocksandchains on
themastweldmentsandcarriagesothattheycannot
move. Make sure the moving parts are attached to a
part that does not move.
Donottrytolocatehydraulicleaksbyputtinghands
on pressurized hydraulic components. Hydraulic oil
can be injected into the body by pressure.
Do the following checks and inspections:
a. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
b. Slowly raise and lower the mast several times
without a load. Raise the mast to its full exten-
sion height at least once. The mast components
must raise and lower smoothly in the correct se-
quence.
NOTE:Somepartsofthemastmoveatdifferentspeeds
during raising and lowering.
c. The inner weldment and the carriage must lower
completely.
d. Raise the mast one metre (three feet) with a ca-
pacity load. The inner weldment and the car-
riage must raise smoothly. Lower the mast. All
moving components must lower smoothly.
e. Lower the load to approximately 0.3 metre (one
foot) from the floor. Tilt the mast forward and
backward. The mast must tilt smoothly and both
tilt cylinders must stop evenly.
f. Check that the controls operate the functions of
the attachment correctly. (See the symbols next
to each of the controls.) Make sure all of the hy-
draulic lines are connected correctly and do not
leak.
Brakes
Check that the service and parking brakes operate cor-
rectly. The service brakes must apply when the brake
pedal is depressed. The parking brake must apply when
the knob for the parking brake is pushed. The parking
brake must release when the knob is pulled. On lift
trucks with a Monotrol pedal, applying the parking
brake puts the transmission in Neutral.
NOTE: Full application of the inching/brake pedal ap-
plies the service brakes and disengages the transmis-
sion.
Steering System
WARNING
The lift truck has hydraulic power steering. The
steering can be difficult if the engine is not running.

15
Make sure the steering system operates smoothly and
gives good steering control.
EVERY 150 HOURS OR MONTHLY
NOTE: Do these procedures in addition to the 8 hour checks.
LIFT CHAINS, LUBRICATION
Lubricate the lift chains with SAE 30 engine oil. The
bestprocedureistoremovethechainsfromthe lifttruck
and soak them in oil.
WARNING
Do not repair a worn or damaged lift chain. Replace
a worn or damaged lift chain with a new chain. If a
pair of lift chains is used in the mast, both lift chains
must be replaced.
LIFT CHAIN ADJUSTMENTS
(See FIGURE 14.)
When the lift chains are correctly adjusted:
•The tension will be the same on each chain of
the chain set. Check tension by pushing on both
chains at the same time.
•The chain length will be correct.
•The chains must travel freely through the com-
plete cycle.
1. Put a load equal to 80 to 90% of the capacity load on
the forks. Lower the forks as much as possible. Tilt the
mast fully backward.
2. Check the amount that the bottom carriage roller ex-
tends below the inner channel of the mast. The carriage
roller must not extend more than 1.3 in (34 mm) below
theinnerchannel. If the adjustmentisnotcorrect, adjust
thechainanchors.Makesureeachanchorisadjustedthe
same amount.
3. Remove the load from the forks. Check the clearance
ofthecarriagewhen the mast is fully extended.Thecar-
riage must not touch the top crossmember of the inner
weldment. The chains are too tight if the carriage
touchesthecrossmember.Putthemastinaverticalposi-
tion and lower the carriage completely. If the forks do
not just touch the surface the chains are too tight. If the
chains are too tight adjust the chain anchors. Make sure
each anchor is adjusted the same amount.
1. TILT MAST FULLY BACKWARD
2. CARRIAGE ROLLER
3. FORK
4. CARRIAGE ROLLER MUST NOT
EXTEND MORE THAN 34 mm (1.3 in)
BELOW THE MAST CHANNEL
FIGURE 14. LIFT CHAIN ADJUSTMENTS
ÎÎ
ÎÎ
ÎÎ
ÎÎ
ÎÎ
1
2
4
4691
3
WARNING
Donotrepairawornliftchain.Replaceawornchain
with a new chain. If a pair of chains is used in the
mast, both chains must be replaced.
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain an-
chors are completely engaged. Make sure that all of the
adjustment is not removed from the chain anchors. The
chain anchors must be able to move in their sockets.
AIR TANKS
Operate the drain valve to check its operation and to
drainmoisturefromtheairtank.Thedrainvalvesarein-
stalled at the bottom of the air tanks.
DRIVE SHAFT
Lubricate the three fittings on the transmission drive
shaft with multi–purpose grease.

16
STEERING AXLE (See FIGURE 15.)
Lubricate the grease fittings on the tie rods and the
lower spindle bearings with multi–purpose grease.
WHEEL NUTS
Check the torque of the wheel nuts. Tighten the nuts to
640to680N.m(470to500lbfft)inthesequenceshown
in FIGURE 37.
FIGURE 15. STEERING AXLE
1. TIE ROD
2. LOWER SPINDLE BEARING 12453
SHAFTS FOR BRAKE ACTUATORS
Lubricate the grease fitting on the shafts for the brake
actuator arms.
DRIVE AXLE AND DIFFERENTIAL
The drive axle and differential use the same oil supply.
The oil level in the drive axle is correct when the oil is
even with the plug in the planetary cover. Be sure to
check both planetary covers and the differential when
checking the oil level. Make sure the “level line” on the
planetary cover is parallel to the floor.
The oil level in the differential is correct when the oil is
even with the plug in the front of the housing. Add the
correct oil as specified in the MAINTENANCE
SCHEDULE.
HYDRAULIC TANK BREATHER
(See FIGURE 2.)
Remove the hydraulic tank breather from behind the
right–hand cover and clean it in solvent. Dry the
breather with compressed air and install it.
AIR FILTER, HEATER
Remove the four screws and the air intake cover at the
right side of the cab. Remove the spring and air filter.
Clean the filter with soap and water or compressed air.
Replace the filter if it is damaged.
EVERY 350 HOURS OR TWO MONTHS
NOTE: Do these procedures in addition to the 150 hour checks.
ENGINE OIL AND FILTER (See FIGURE 9.)
NOTE:Change theoilfilter fortheengineafterthe first
100 hours on new lift trucks.
CAUTION
Never run the engine without oil.
Change the filter at the same time engine oil is changed.
Use the correct oil according to the specifications. In-
stallanewfilter. Applyclean oiltothegasketofthenew
filter. Turn the filter until the gasket touches, then
tighten
1/2to 3/4turn with your hand. Start the engine.
Check for leaks.
CAUTION
Longtermexposuretousedengineoilcancauseskin
irritationorcancer. Wash withdetergentandwater.
BRAKE ACTUATOR ARMS
Check the adjustment of the brake actuator arms as de-
scribed in the section, BRAKE SYSTEM, 1800 SRM
441.
DRIVE BELTS
(See FIGURE 16. and FIGURE 17.)
Checkthe drive belts for wear and damage. Whena pair
of drive belts are used, they must be replaced as a pair.

17
Whenapairofdrivebeltsareused,adjustthetensionfor
the tightest belt.
A gauge is available that will indicate the tension in the
drive belt. Fit the gauge at the center of the longest
length of the drive belt and measure the tension. See
FIGURE 16. The correct tension is approximately 355
N (80 lbf).
FIGURE 16. GAUGE TO CHECK DRIVE BELT
TENSION
FIGURE 17. CHECK AND ADJUST DRIVE
BELT TENSION (DIESEL)
1. PIVOT FASTENER
2. ADJUSTMENT LINK
12593
1
2
Thetensioncan also becheckedbypushing on thedrive
beltasshowninFIGURE17.Pushonthedrivebeltwith
approximately10kg(20lb)forcebetweenthealternator
and crankshaft pulleys. When the tension is correct, the
drive belt will move approximately 13 mm (0.5 in).
Loosen the capscrew on the alternator mount to adjust
the tension of the drive belts.
FIGURE 18. CHECK AND ADJUST DRIVE
BELT TENSION (GM V–8)
1. PIVOT FASTENER
2. DRIVE BELT, AIR COMPRESSOR
3. DRIVE BELT, FAN AND ALTERNATOR
121
3
MAST (See FIGURE 19.)
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. Do not put any part
ofyour body inor throughthe lift mechanismunless
all parts of the mast are completely lowered and the
engine is STOPPED.
Beforemaking any repairs,useblocksandchains on
themastweldmentsandcarriagesothattheycannot
move. Make sure the moving parts are attached to a
part that does not move.

18
1. Lubricate the sliding surfaces for the bearing blocks
along the full length of the channels as shown in
FIGURE 19. Apply lubricant only to the indicated sur-
faces.
NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
2. Lubricate the pivot pins for the mast at the grease fit-
tings on the pivot pins. Use multi–purpose grease.
FIGURE 19. LUBRICATE THE MAST
1. LOAD ROLLER
2. BEARING BLOCK
3. LUBRICATE BEARING BLOCK SURFACES
4. LUBRICATE STRIP BEARINGS
5. OUTER WELDMENT
6. INNER WELDMENT
7. CARRIAGE 12479
3. Lubricate the pivot pins for the tilt cylinders. There is
a grease fitting on each pivot pin. Use multi–purpose
grease.
4. If a side–shift carriage is installed, lubricate the fit-
tings and the sliding surfaces with multi–purpose
grease.
EMPTY CONTAINER ATTACHMENT
(See FIGURE 3.)
1. Lubricate the grease fittings for the side–shift rollers
andtheanchorpinsfortheside–shiftcylinder.Lubricate
thegreasefittingsforthelock pins.These fittingsarelo-
cated at the top of the end beams.
2. Lubricate the sliding surfaces for all of the bearing
blocks.
3. Remove the drain plugs at the bottom of both end
beams to drain moisture from the accumulators.
GENERAL LUBRICATION
Inspectallhinges,pins,linkages,cables,pedalsandlev-
ersfor wear anddamage.Lubricate thesepartsasneces-
sary with engine oil.
FORKS, CHECK FOR WEAR AND
DAMAGE (See FIGURE 5.)
WARNING
Never repair damaged forks. Do not heat, weld, or
bend the forks. Forks are made of special steel using
special methods. Replace damaged forks.
1.Checktheheelandattachmentpointsoftheforkswith
a penetrant or magnetic particle inspection.
2.Measurethethicknessoftheforksataverticalsection
wherethere isnowear.Thisis dimensionX.Now meas-
ure the thickness at the heel (5) of the fork. If the thick-
ness is not more than 90% of dimension X, replace the
fork.
LIFT CHAINS, CHECK FOR WEAR
(See FIGURE 20.)
Ifasectionofchainis3%longerthanasimilarsectionof
newchain,thechainiswornandmustbereplaced.Mea-
surethe chain forwearwhere itmovesoverthe sheaves.
If a chain scale is available, check the lift chains as
shown in FIGURE 20. If a chain scale is not available,
measure 20 links of chain. Measure from the center of a
pin to the center of another pin 20 pitches away. Com-
pare the length with the chart in FIGURE 20. Replace
the chain if the length of 20 links of the worn section is
more than the WEAR LIMIT.