Hyster F005 User manual

Hyster F005 (H3.50XL H4.00XL-5 H4.00XL-6 H4.50XL
H5.00XL) Forklift

1
PERIODIC MAINTENANCE
GENERAL
ThissectioncontainsaMAINTENANCESCHEDULE
and the instructions for maintenance and inspection.
The MAINTENANCE SCHEDULE has time intervals
for inspection, lubrication and maintenance for your lift
truck.Therecommendationforthetimeintervalsarefor
eighthoursofoperationperday.Thetimeintervalsmust
be decreased from the recommendations in the MAIN-
TENANCE SCHEDULE for 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
Donot make repairsoradjustments unless youhave
both authorization and training. Repairs and ad-
justmentsthatarenotcorrectcanmakeadangerous
operating condition.
Donotoperatealift truckthatneedsrepairs.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.
SERIAL NUMBER DATA
Theserialnumberforthelifttruckisfoundonthename-
plate and also on the right–hand side of the frame near
the counterweight.
HOW TO MOVE A DISABLED LIFT TRUCK
WARNING
Use extra caution when towing a lift truck if any of
the following conditions exist:
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 slope.
If the engine cannot run, there is no power available
for the hydraulic steering system and the service
brakes. This condition can make the lift truck diffi-
cult to steer and stop. If the lift truck uses power
fromtheenginetohelpapplythebrakes,theapplica-
tion of the brakes will be more difficult. Poor trac-
tion can cause the disabled lift truck or towing vehi-
cle 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 capac-
ity of the lift truck used to move a disabled lift truck
musthavealoadcenterequaltohalfthewidthofthe
disabledlift truck.See the nameplateof the disabled
lifttruckfortheapproximatetotalweight.Theforks
must extend the full width of the disabled lift truck.
Put the weight center of the disabled lift truck on
loadcenteroftheforks.Becarefultonotdamagethe
under side of the lift truck.
How To Tow the Lift Truck
1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3.Raisethecarriageandforksapproximately30cm(12
inches) from the surface. Install a chain to prevent the
carriage and mast channels from moving.

2
4. If another lift truck is used to tow the disabled lift
truck, that lift truck must have an equal or larger capac-
ity than the disabled lift truck. Install approximately 1/2
of a capacity load on the forks of the lift truck that is be-
ing used to tow the disabled lift truck. This 1/2capacity
load will increase the traction of the lift truck. Keep the
load as low as possible.
5.Useatowinglinkmadeofsteelthatfastenstothetow
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
blocksunder thecounterweight so thatthe lift
truck can not fall backward.
b. Before removing the counterweight, put
blocksunder the mastassemblyso that thelift
truck can not fall forward.
The surface must be solid, even, and level when the
lifttruck is putonblocks. Make sure that anyblocks
used to support the lift truck are solid, one piece
units.
NOTE: Some lift trucks have lifting eyes. These lifting
eyes can be used to raise the lift truck so that blocks can
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.
5.Ifthehydraulicsystemwill notoperate,useahydrau-
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. Make
sure the jack has a capacity of at least 1/3of 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.
11704
STEERING TIRES DRIVE TIRES
FIGURE 1. PUT A LIFT TRUCK ON BLOCKS

3
11705
FIGURE 2. MAINTENANCE POINTS FOR THE H3.50–5.00XL (H70–110XL)
1
2
5
6
7
8
910
11 12
13
14
15
16
17
19
20
21
22
23
24 25
26
27
28
29
30 31 32 33
34
37
38
39
40
41
42 11
25
22
42
14
41
11
3
4
FIGURE 3. MAINTENANCE POINTS FOR THE H6.00–7.00XL (H135–155XL)
1
235
67
8
9
10
11
12
13
14 15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31 32 35
36
37
38 40
41
15
12
11
22
42
14
22
24
17

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4
MAINTENANCE SCHEDULE
ITEM
NO. ITEM 8 hr/
Dai-
ly
150
hr/
1 Mo
350
hr/
2 Mo
1000
hr/
6 Mo
2000
hr/
1 yr
PROCEDURE
OR QUANTITY SPECIFICATION
1HYDRAULIC OIL
H3.50–5.00XL (H70–110XL)
H6.00–7.00XL (H135–155XL)
Manual Transmission
Powershift transmission
X
XC C36.0 litre (38.0 qt)
51.1 litre (54.0 qt)
49.7 litre (52.5 qt)
–18°C (0°F) and Above
SAE 10W
API CC or CC/SE/SF/SG
2ENGINE OIL
GM V–6
DIESEL
1004–4
4.2482
X
X
C
C
4.7 litre (5.0 qt)
8.0 litre (8.5 qt)
8.5 litre (9.0 qt)
–18°C (0°F) and Above
SAE 10W–30
API CC/SE/SF/SG
–18°C (0°F) and Above
SAE 10W–30
API CC/SE/SF/SG
3 POWERSHIFT
TRANSMISSION OIL
H3.50–5.00XL (H70–110XL)
H6.00–7.00XL (H135–155XL)
X C 17.0 litre (18 qt)
15.1 litre (16.0 qt)
Hydraulic and tractor
transmission oil (see the
Reference Table at the end
of this section.)
4OIL CLUTCH
SYSTEM, OIL LEVEL
H3.50–5.00XL (H70–110XL) X C 9.5 litre (10 qt) Hydraulic and tractor
transmission oil (see the
Reference Table at the end
of this section.)
5FUEL TANK
H3.50–5.00XL (H70–110XL)
H6.00–7.00XL (H135–155XL)
X60.5 litre (16 gal)
87 litre (23 gal)
85 Octane — Gasoline
Diesel No. 2
LPG — HD–5
6COOLING SYSTEM
H3.50–5.00XL (H70–110XL)
Gasoline and LPG
Diesel
H6.00–7.00XL (H135–155XL)
X C
15.1 litre (16.0 qt)
17.0 litre (18.0 qt)
19.9 litre (21.0 qt)
50% Water with
50% Ethylene Glycol
7BATTERY ELECTROLYTE X Check Level See Parts Manual
8FUEL FILTER, DIESEL X C Drain Water See Parts Manual
9RADIATOR HOSES X Check Condition
SEAT BELT, HIP RESTRAINTS
AND SEAT RAILS XCheck Condition
10 DRIVE BELTS X Check Condition
Check Tension
11 TIRES, TIRE PRESSURE X Check Condition
See Nameplate See Parts Manual
12 MAST, CARRIAGE,
LIFT CHAINS X X Check Condition and Operation
CHECK FOR LEAKS—
FUEL, OIL, WATER XCheck for Leaks
HOOD AND SEAT LATCHES X Check Condition
13 HORN, GAUGES, LIGHTS,
ALARMS XCheck Operation
STEERING X Check Operation
X=Check C=Change L=Lubricate

5
MAINTENANCE SCHEDULE
ITEM
NO. ITEM 8 hr/
Dai-
ly
150
hr/
1 Mo
350
hr/
2 Mo
1000
hr/
6 Mo
2000
hr/
1 yr
PROCEDURE
OR QUANTITY SPECIFICATION
14 SERVICE BRAKES AND
PARKING BRAKE X X X Check Operation Check Operation
15 FORKS X X Check Condition
16 LIFT CHAINS X L X Check Condition
Check
Lubrication
Engine Oil or
Hyster Part No. 171550
SAFETY LABELS X Replace as
Necessary See Parts Manual
17 DRIVE SHAFTS
H3.50–5.00XL (H70–110XL)
Transmission
H6.00–7.00XL (H135–155XL)
Transmission
Hydraulic Pump
L
L
L
2 Fittings
2 Fittings
2 Fittings
Multi–Purpose Grease1
Multi–Purpose Grease1
Multi–Purpose Grease1
18 THRUST SCREW FOR
DIFFERENTIAL
H6.00–7.00XL (H135–155XL) XCheck
Adjustment
(First 150 hours)
DOOR HINGES (WITH CAB) L 4 Fittings Multi–Purpose Grease1
19 HYDRAULIC TANK
BREATHER
H3.50–5.00XL (H70–110XL) X1
Clean or Replace
See Parts Manual
20 AIR FILTER X X Clean or
Replace2See Parts Manual
21 BRAKE FLUID X X 0.2 litre (0.4 pt) SAE J–1703
CLUTCH, BRAKE,
INCHING/BRAKE PEDALS XAdjust as Required
ENGINE SPEED
IDLE SPEED
GM V–6
Diesel
GOVERNED SPEED
All Engines
XAdjust as
Required 625 to 675 rpm
725 to 775 rpm
2400 to 2500 rpm
7 BATTERY X Clean
22 WHEEL NUTS
DRIVE AND STEER
WHEELS
XCheck Torque 610–680 N.m
(450–500 lbf ft)
23 ENGINE OIL FILTER C 1 – See NOTE 3See Parts Manual
24 STEERING AXLE
SPINDLE BEARINGS L2 Fittings Multi–Purpose Grease1
X=Check C=Change L=Lubricate
1Multi–purpose grease with 2 to 4% Molybdenum Disulfide.
2Very dirty conditions will require daily clean and check.
3Change filters on NEW lift trucks at first 100 hours on hour meter.

6
MAINTENANCE SCHEDULE
ITEM
NO. ITEM 8 hr/
Dai-
ly
150
hr/
1 Mo
350
hr/
2 Mo
1000
hr/
6 Mo
2000
hr/
1 yr
PROCEDURE
OR QUANTITY SPECIFICATION
25
26
27
28
MAST
PIVOTS
SLIDING SURFACES AND
LOAD ROLLER SURFACES
SIDE–SHIFT CARRIAGE
FORK GUIDES
L
L
L
L
2 Fittings
As Required
4 Fittings
As Required
Multi–Purpose Grease1
Multi–Purpose Grease1
Multi–Purpose Grease1
Engine Oil
PEDALS, LEVERS,
LINKAGES, CABLES.
HINGES, SEAT RAILS LAs Required Engine Oil
29 FINAL FUEL FILTER
(DIESEL) C 1 See Parts Manual
30 SPARK PLUGS C 6
Gap, 0.9 mm
(0.035 in)
See Parts Manual
31 PCV VALVE X C Replace as
Necessary See Parts Manual
32 CRANKCASE BREATHER C 1 See Parts Manual
TIMING
GM V–6
DIESEL, ALL ENGINES
XAdjust as
Required 0°BTDC @ 650 rpm
16°BTDC Static
VALVE ADJUSTMENT
GM V–6
DIESEL, ALL ENGINES
INLET (Cold)
EXHAUST (Cold)
XAdjust as
Required Not Adjustable
0.20 mm (0.008 in)
0.45 mm (0.018 in)
33 MANUAL TRANSMISSION
AND DRIVE AXLE OIL
H3.50–5.00XL (H70–110XL) X C 14.7 litre (15.5 qt) SAE 80W–90, 85W–140
34 SPEED REDUCER AND
DRIVE AXLE OIL FOR
POWERSHIFT TRANS.
H3.50–5.00XL (H70–110XL)
X C 7.6 litre (8.0 qt) SAE 80W–90, 85W–140
35 MANUAL TRANSMISSION OIL
H6.00–7.00XL (H135–155XL) X C 3.3 litre (3.5 qt) SAE 80W–90, 85W–140
36 SPEED REDUCER AND
DIFFERENTIAL
H6.00–7.00XL (H135–155XL) X C 14.3 litre (15.0 qt) SAE 80W–90, 85W–140
36 DIFFERENTIAL FOR
POWERSHIFT TRANS.
H6.00–7.00XL (H135–155XL) X C 12.1 litre (12.8 qt) SAE 80W–90, 85W–140
37 FUEL FILTER
GASOLINE
LPG C C1 1See Parts Manual See Parts Manual
X=Check C=Change L=Lubricate 1Multi–purpose grease with 2 to 4% Molybdenum Disulfide.
2Very dirty conditions will require daily clean and check.
3Change filters on NEW lift trucks at first 100 hours on hour meter.

7
MAINTENANCE SCHEDULE
ITEM
NO. ITEM 8 hr/
Dai-
ly
150
hr/
1 Mo
350
hr/
2 Mo
1000
hr/
6 Mo
2000
hr/
1 yr
PROCEDURE
OR QUANTITY SPECIFICATION
38 HYDRAULIC SYSTEM
OIL FILTER C 1 See NOTE 3See Parts Manual
39 OIL CLUTCH SYSTEM
OIL FILTER C 1 See NOTE 3See Parts Manual
40 POWERSHIFT TRANS.
OIL FILTER C1 See NOTE 3See Parts Manual
41 STEER WHEEL BEARINGS L As Required Multi–Purpose Grease1
42 DRIVE WHEEL BEARINGS L As Required Multi–Purpose Grease1
X=Check C=Change L=Lubricate
1Multi–purpose grease with 2 to 4% Molybdenum Disulfide.
2Very dirty conditions will require daily clean and check.
3Change filters on NEW lift trucks at first 100 hours on hour meter.
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY
WARNING
Donotoperatealift truckthatneedsrepairs.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.
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.
Hydraulic System Oil (See FIGURE 4.)
WARNING
At operating temperature the hydraulic oil is HOT.
Donotpermitthehotoiltotouchtheskinandcausea
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.
Checkthehydraulic oillevelwhenthe oilisatoperating
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. The oil
levelindicatedby thedipstickismost accuratewhenthe
oil temperature is 53 to 93°C (130 to 200°F).
Check the hydraulic system for leaks and damaged or
loose components.

8
1. BATTERY
2. RESERVOIR, BRAKE FLUID
3. DIPSTICK, HYDRAULIC OIL
H3.50–5.00XL (H70–110XL) H6.00–7.00XL (H135–155XL)
11725 4. BREATHER, HYDRAULIC TANK
5. BREATHER, ENGINE
6. FILL CAP, HYDRAULIC OIL
7. FILTER HEAD
1
2
34
5
6
7
3
FIGURE 4. MAINTENANCE POINTS
NOTE: BREATHER IS
ON TOP OF
HYDRAULIC TANK
AND UNDER THE
TOP OF THE FRAME.
GASOLINE/LPG
DIESEL
1. DIPSTICK FOR ENGINE OIL
2. ENGINE OIL FILL CAP
3. AIR FILTER
4. AUXILIARY COOLANT RESERVOIR
12185
12186
5. PCV VALVE (GM V–6)
6. BATTERY
7. FILL CAP, FUEL
8. COLD START AID, DIESEL
12
34
6
7
8
1
23
4
5
FIGURE 5. ENGINE MAINTENANCE POINTS
(EARLY MODELS SHOWN)

9
FIGURE 6. DRIVE BELT
12873
12
3
4
5
6
1. PULLEY, ALTERNATOR
2. PULLEY, FAN
3. PULLEY, WATER PUMP
4. PULLEY, CRANKSHAFT
5. DRIVE BELT
6. PULLEY, TENSIONER
LATE MODEL
GM V–6 SHOWN
Engine Oil (See FIGURE 5.)
After the engine has stopped, wait one minute before
checkingtheoillevel. Keeptheoilatthe correctlevelas
indicatedonthedipstick. Usethecorrectoilas shownin
the MAINTENANCE SCHEDULE.
Drive Belts
Check the drive belts for wear and damage.
Cooling System (See FIGURE 7.)
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is re-
moved, the pressure is released from the system. If
the system is hot, the steam and boiling coolant can
cause burns. DO NOT remove the cover for the ra-
diator when the engine is running.
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.Addcoolantto
the auxiliary reservoir if additional coolant is needed.
Check the radiator fins. Clean the radiator with com-
pressed air or water as needed.
11619
FIGURE 7. AUXILIARY COOLANT RESERVOIR
FULL
ADD
Air Filter (See FIGURE 5. And FIGURE 8.)
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.
Inspect the filter element. Put a bright light inside and
look for holes or other damage. If the element is dam-
aged,replaceitwithanewelement.Useaclothwithsol-
venttocleantheinsideofthecanisterwhenthefilterele-
ment is cleaned or replaced.

10
FIGURE 8. AIR FILTER
12205
2 1
34
5
6
1. CANISTER
2. O–RING
3. FILTER ELEMENT
4. BAFFLE
5. CLAMP
6. END COVER
Fuel System
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.
Check the fuel system for leaks and the condition of
parts.Whenfuelisaddedtothelifttruck,seethesection,
HowToAddFuel ToTheLiftTruckproceduresinthe
OPERATING MANUAL.
FIGURE 9. PRIMARY FUEL FILTER
Primary Fuel Filter, Diesel Engine
1. Drain the water from the primary fuel filter. See
FIGURE 9. Open the valve on the bottom of the filter
canister.Drainsomefuel(andanywater)intoacupuntil
clean fuel flows from the filter.
2. Close the valve.
Battery (See FIGURE 4.)
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 ca-
ble when doing maintenance.
Keep the battery and cable terminals clean. Check the
electrolyte level (unless maintenance–free). 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
batterytostartthe engine, followtheseprocedurescare-
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.
Tires and Wheels (See FIGURE 10.)
WARNING
Air pressure in the tires can cause tire and wheel
parts to explode. The explosion of wheel parts can
cause serious injury or death.
Completely deflate the tires before the tires are re-
moved from the lift truck.
If the air pressure is less than 80% of the correct air
pressure, the tire must be removed before air is
added. Put the tire in a safety cage when adding air
pressuretothetire.Followtheproceduresdescribed
in “Add Air To The Tires”.

11
Whenairisaddedtothetires,usearemoteairchuck.
The person adding air must stand away and to the
side and not in front of the tire.
Keepthetiresat the correctairpressure.(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 the warm tires
mustalwaysbeequaltoorgreater than thespecification
for air pressure for cold tires.
1. CHECK THE TIRE PRESSURE
2. CHECK FOR DAMAGE 9447
FIGURE 10. CHECK THE TIRES
1
2
Checkthetiresfordamage.Checkthetreadandremove
any objects that will cause damage. Check for bent or
damaged rims. Check for loose or missing parts. Re-
moveanywire,strapsorothermaterialwrappedaround
the axle.
Make sure the drive wheel nuts are tight. Tighten the
wheel nuts in a cross pattern to the correct torque value
shown in the MAINTENANCE SCHEDULE.
CAUTION
When the drive wheels have been installed check all
wheel nuts after 2 to 5 hours of operation. Tighten
thenutsinacrosspatterntothecorrecttorquevalue
shown in the MAINTENANCE SCHEDULE. When
the nuts stay tight for eight hours, the interval for
checking the torque can be extended to 350 hours.
Forks
The identification of a fork is how the fork is connected
to the carriage. The H3.50–5.00XL (H70–110XL) se-
ries of lift trucks can have either a hook fork or a pin
fork. The H6.00–7.00XL (H135–155XL) series of lift
trucks normally have a pin fork. See FIGURE 13.
Forks, Adjustment
Hook forks are connected to the carriage by hooks and
lockpins.SeeFIGURE12.Theselockpinsareinstalled
through the top fork hooks and fit into slots in the top
carriage bar. 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.
Pin forks are fastened to the carriage with large fork
pins. A lock pin for each fork fits into the top carriage
barandaslotinthefork.Theselockpinsholdthe forkin
position. See FIGURE 13. Adjust the forks as far apart
aspossibleformaximum support oftheload.Makesure
the lock pin is engaged in the carriage bar and the fork.
The fork must be locked into position after the adjust-
ment is made.
Forks, Removal And Installation
WARNING
Do not try to move a fork without a lifting device.
Eachforkfortheselifttruckscanweigh(66kgto183
kg [145 to 402 lb] for a hook fork) and (128 to 226 kg
[281 to 498 lb] for a pin fork).
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance.
HookFork(Removal).Slideahookforkto the fork re-
moval notch on the carriage. See FIGURE 12. Lower
the fork onto blocks so that the bottom hook of the fork
moves through the fork removal notch. See
FIGURE 11. Lower the carriage further so that the top
hookof the fork is disengaged from the top carriage bar.
Move the carriage away from the fork, or use a lifting
device to move the fork away from the carriage.

12
FIGURE 11. REMOVE A HOOK FORK
ÉÉÉ
ÉÉÉ
ÉÉ
ÉÉ
1
3
2
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Hook Fork (Installation). Move the fork and carriage
sothatthetophookontheforkcanengagetheuppercar-
riage bar. Raise the carriage to move the lower hook
through the fork removal notch. Slide the fork on the
carriage so that both upper and lower hooks engage the
carriage. Engage the lock pin with a notch in the upper
carriage bar.
PinFork(Removal).Lowerthecarriageandputblocks
underapinfork.Whentheweightoftheforkshavebeen
removedfromtheforkpin,removetheloadbackrestex-
tension. The load backrest extension holds the fork pin
in the carriage. Slide the fork pin from its mount in the
carriage and through the eye of the fork. See
FIGURE 13. Use a lifting device to lift the fork away
from the carriage.
Pin Fork (Installation). Install the fork pin in the car-
riage.Aligntheeyes oftheforkssothat theforkswillbe
installedontheforkpin.Whentheforkpinisinstalledin
the carriage so that it holds the forks, install the load
backrest extension. Engage the fork with the lock pin.
Inspection Of Forks, Mast, and Lift Chains
(See FIGURE 14. and FIGURE 15.)
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.
Donottrytocorrectthealignmentoftheforktips by
bending the forks or adding shims. Replace dam-
aged forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
dures. Replace damaged forks.
1. FORK REMOVAL NOTCH
2. FORK
3. HOOK
1545
2
5
1
4
3
2
3
3
3
4
4. LOCK PIN ASSEMBLY
5. CARRIAGE
FIGURE 12. HOOK FORK

13
12565
1
2
3
4
5
5
11
2
2
3
3
4
2
1. CARRIAGE
2. FORK
3. FORK PIN
4. LOCK PIN
5. LOAD BACKREST EXTENSION
FIGURE 13. PIN FORKS
3. FORK PIN DAMAGE
4. MUST BE 90% OF
DIMENSION X
5. FORK WEAR
1
5
33
2
11195
X
4
1. TIP ALIGNMENT
(MUST BE WITHIN 3%
OF FORK LENGTH)
2. CRACKS
FORK TIP ALIGNMENT
LENGTH OF FORKS 3% DIMENSION
915 mm (36 in) 27 mm (1.10 in)
1220 mm (48 in) 37 mm (1.45 in)
1830 mm (72 in) 55 mm (2.15 in)
FIGURE 14. CHECK THE FORKS
1. Inspect the welds on the mast and carriage for cracks.
Make sure that the capscrews and nuts 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 load backrest extension for cracks and
damage.
4. Inspect the forks for cracks and wear. Check that the
forktipsare alignedwithin13mm (0.5in)ofeachother.
(See FIGURE 14.) Check that the bottom of the fork is
not worn (Item 5).
5. Replace any damaged or broken parts that are used to
keep the forks locked in position.
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.Checkthat theliftchainsare correctlylubricated.Use
SAE 30 engine oil to lubricate the lift chains.
8. Inspect the lift chains for cracks or broken links and
pins. (See FIGURE 15.)

14
9. Inspect the chain anchors and pins for cracks and
damage.
10. Make sure the lift chains are adjusted so that they
haveequaltension.Adjustmentor replacementofthe
liftchainsmustbedonebyauthorizedpersonnel.See
Lift Chain Adjustments described in the GENERAL
PROCEDURES later in this section.
6705
1
2
3
4
56
7
1. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
FIGURE 15. CHECK THE LIFT CHAINS
Operator Restraint System
(See FIGURE 16.)
The seat belt, hip restraint brackets, seat and mount,
hood, latches and floor plates 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.
The seat belt must fasten correctly. Make sure the seat
belt can be pulled from the retractor and retracts
smoothly. The seat belt must not be damaged or worn.
Make sure the seat rails and latch striker are not loose.
The seat rails must lock tightly in position, but move
freely when unlocked. The seat rails must be correctly
fastenedtothemountsurface.Ifthemountsurfaceisthe
hood, the hood must be fastened to the floor plate with
the latch. The floor plate must be fastened to the lift
truck frame. Try to lift the hood to make sure it is fas-
tened correctly and will not move. See FIGURE 16.
1. LATCH STRIKER
2. HOOD LATCH
3. LATCH LEVER
4. SEAT
5. SEAT BELT LATCH
6. HIP RESTRAINT
7. SEAT RAIL
8. FLOOR PLATE
9. HOOD
10. GAS CYLINDER
11. HINGE
1
1
4
GASOLINE AND DIESEL ARRANGEMENT LPG ARRANGEMENT
2
3
65
9
4
6
5
10
77
8
11
H70–110XL SHOWN
FIGURE 16. CHECK THE HOOD AND SEAT LATCHES

15
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, use the followingproce-
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 af-
ter it touches the surface. Put the label on the sur-
face.Makesurethatallairisremovedfromunder
the label and the corners and edges are tight.
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 checks of the op-
eration. Be careful when making the checks. If the lift
truck is stationary during a check, apply the parking
brakeandputthetransmissioninNEUTRAL.Makethe
checks carefully.
Gauges, Lights, Horn, and Fuses
Start the engine. Check the gauges and lights for correct
operation as described in the OPERATING MAN-
UAL. Check the operation of the horn. If any of the
lights or gauges do not operate correctly, check the
fuses. The fuses are under the instrument panel on the
left side of the cowl. See FIGURE 17.
12200
LIGHT DSL
COLD
START HORN GAGES
XMSN
SHIFT
12
3456 1. GAUGES
2. TRANSMISSION SOLENOIDS
3. HORN
4. COLD START AID (DIESEL)
5. LIGHTS
6. OTHER OPTIONS
LH
&
GAGES
RH
7.5A
FIGURE 17. FUSES
5
25A 30A 10A
5A 5A
PLNG
Oil Level, Powershift Transmission
(See FIGURE 18.)
Apply the parking brake. Check the oil level in the
powershift transmission when the engine is running at
idle speed. If the lift truck has a direction control lever,
putthedirectioncontrolleverintheNEUTRAL(N)po-
sition. Use the correct oil shown in the MAINTE-
NANCESCHEDULE.Keeptheoillevelatthe“FULL”
mark on the dipstick. The most accurate check of the oil
level is when the transmission is at operating tempera-
ture.

16
H70–110XL
1. DIPSTICK FOR POWERSHIFT TRANSMISSION OIL OR OIL CLUTCH SYSTEM OIL
2. DIPSTICK FOR POWERSHIFT TRANSMISSION
3. FLOOR PLATE
H135–155XL
11703 11638
12
3
3
FIGURE 18. CHECK THE OIL FOR THE POWERSHIFT TRANSMISSION OR OIL CLUTCH SYSTEM
Oil Level, Oil Clutch System, H3.50–5.00XL
(H70–110XL) (See FIGURE 18.)
NOTE: The oil clutch system for the H6.00–7.00XL
(H135–155XL) lift trucks does not have a dipstick be-
cause the oil clutch uses oil from the hydraulic system.
Put the direction control lever in the NEUTRAL (N)
position.Applytheparkingbrake. Check theoillevelin
the clutch housing when the engine is running at idle
speed. The most accurate check of the oil level is when
the oil is at operating temperature. Use the correct oil as
shownin the MAINTENANCE SCHEDULE. Keep the
oil at the “FULL” mark on the dipstick.
Control Levers and Pedals
Check that the control levers for the transmission, mast
and attachment operate as described in the OPERAT-
ING MANUAL. Check that the pedals operate cor-
rectly as described in the OPERATING MANUAL.
Lift System Operation
WARNING
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.
Beforemakinganyrepairs,useblocks and chains on
themastweldmentsandcarriagesothattheycannot
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. Hydraulic oil
can be injected into the body by the 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
withoutaload.Raisethemasttoitsfullextension
height at least once. The mast components must
raiseandlowersmoothly in thecorrectsequence.
NOTE:Somepartsofthemastmoveatdifferentspeeds
during raising and lowering.
c. Theinnerweldments andthecarriagemust lower
completely.
d. Raise the mast one metre (three feet) with a ca-
pacity load. The inner weldments 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). Tilt the mast forward and backward. The
mast must tilt smoothly and both tilt cylinders
must stop evenly.
f. Check that the controls for the attachment oper-
atethefunctionsoftheattachment.(Seethesym-
bols by each of the controls.) Make sure all of the
hydraulic lines are connected correctly and do
not leak.

17
Inching/Brake Pedal
Push on the inching/brake pedal. The service brakes
must be applied before the inching/brake pedal reaches
the floor plate. Full application of the inching/brake
pedal applies the service brakes and puts the transmis-
sion in NEUTRAL.
Lift trucks with a MONOTROL pedal: when the
inching/brakepedalisfullyapplied,aswitchinthestart-
ing circuit is closed so that the engine can be started.
Service Brakes
Check the operation of the service brakes. Push on the
brake pedal. The brake pedal must stop firmly and must
not move slowly down after the brakes are applied. The
service brakes must apply equally to both drive wheels.
The service brakes must not pull the lift truck to either
sideofthedirectionoftravel whentheyare applied.The
service brakes are automatically adjusted when the
brakes are applied and the lift truck changes direction.
WARNING
Lossoffluid fromthe brake fluidreservoirindicates
a leak. Repair the brake system before using the lift
truck.Replacethebrakefluidinthesystemifthereis
dirt, water or oil in the system.
The lift truck has a brake booster that receives
power from the hydraulic system. The brake pedal
can be difficult to push when the engine is not run-
ning because the hydraulic system is not operating.
Parking Brake
Check the operation of the parking brake. The operator
must adjust the parking brake so that the lift truck does
notmoveifitisparkedonanincline.Theparkingbrake,
wheningoodconditionandcorrectlyadjusted,willhold
a lift truck with a capacity load on a 15% grade [a slope
that increases 1.5 metres in 10 metres (1.5 ft increase in
10 ft)].
Turn the adjustment knob on the end of the lever to ad-
just the parking brake. Do not tighten the adjustment so
that the brake is applied when the lever is released. The
leverfortheparking brake hasalock.Useyour fingerto
release the lock on the lever when the parking brake is
released.
Lift trucks with a MONOTROL pedal: when the
parking brake is applied, a switch in the starting circuit
is closed so that the engine can be started. The switch
also puts the transmission in NEUTRAL.
Steering System
WARNING
The lift truck has hydraulic power steering. The
steering can be difficult if the engine is not running.
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.
THRUST SCREW FOR THE
DIFFERENTIAL, H6.00–7.00XL
(H135–155XL)
(See FIGURE 19.)
Check the adjustment of the thrust screw on new lift
trucks after the first 150 hours of operation. Loosen the
lock nut and turn the thrust screw into the housing until
thescrewtouchestheringgear.Turnthethrustscrewout
of the housing 1/2turn and tighten the lock nut. Addi-
tional adjustment of the thrust screw is not normally
necessary after this time.
LIFT CHAINS, LUBRICATION
Lubricate the lift chains with SAE 30 engine oil. The
bestprocedureistoremovethechainsfromthelifttruck
and soak them in engine 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.

18
FIGURE 19. THRUST SCREW FOR THE DIFFERENTIAL
1. THRUST SCREW
2. LOCK NUT
3. RING GEAR
11651
12
12
3
FIGURE 20. DRIVE SHAFTS
3. DRIVE SHAFT FOR HYDRAULIC PUMP
4. GREASE FITTING
11638 H6.00–7.00XL (H135–155XL) ONLY
1. DRIVE SHAFT FOR TRANSMISSION
2. FILL PLUG FOR SPEED REDUCER
1
2
3
44
11638
DRIVE SHAFTS (See FIGURE 20.)
Lubricate the two grease fittings on the transmission
drive shaft with multi–purpose grease.
H6.00–7.00XL (H135–155XL) lift trucks. Lubricate
thethreegreasefittingsonthedriveshaftforthehydrau-
lic pump with multi–purpose grease. There is a grease
fitting at each universal joint and one grease fitting for
the sliding spline.
EVERY 350 HOURS OR TWO MONTHS
NOTE: Do these procedures in addition to the 150 hour checks.
ENGINE OIL AND FILTER
NOTE:Changethe oilfilterforthe engineafterthefirst
100 hours on new lift trucks.
WARNING
Long term exposure to used engine oil may cause
skin irritation or cancer. Wash with detergent and
water.
Disposal of lubricants and fluids must meet local
environmental regulations.
CAUTION
Never run the engine without oil.
Change the oil filter at the same time engine oil is
changed. Use the correct oil according to the specifica-
tions.Installa newfilter.Applycleanoil tothegasketof