Hyster J40xnt Parts and Service Periodic Maintenance 1689720 8000SRM1339 (02 2012) US EN

PERIODIC
MAINTENANCE
J30-40XNT [K160]
PART NO. 1689720 8000 SRM 1339

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Discharging the Capacitors........................................................................................................................... 2
How to Tow a Disabled Lift Truck ................................................................................................................ 2
How to Put Lift Truck on Blocks .................................................................................................................. 4
How to Raise Drive Tires .......................................................................................................................... 4
How to Raise Steer Tires .......................................................................................................................... 4
How to Clean a Lift Truck............................................................................................................................. 4
Safety Procedures When Working Near Mast.................................................................................................. 6
WHEN WORKING NEAR THE MAST ALWAYS:....................................................................................... 6
Maintenance Schedule....................................................................................................................................... 8
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 16
How to Make Checks With the Key or Keyless Switch OFF....................................................................... 16
Wheels and Tires ....................................................................................................................................... 16
Safety Labels ............................................................................................................................................. 17
Frame and Covers ..................................................................................................................................... 17
Forks, General ........................................................................................................................................... 18
Forks, Remove ........................................................................................................................................... 18
Forks, Inspect ............................................................................................................................................ 18
Fork Install ................................................................................................................................................ 19
Forks, Adjust.............................................................................................................................................. 19
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments ........................................ 19
Hydraulic Oil Level and Leaks................................................................................................................. 21
Operator Restraint System....................................................................................................................... 21
Emergency Locking Retractor (ELR) ....................................................................................................... 22
Battery Restraint System ......................................................................................................................... 22
Steering Column Adjustments ................................................................................................................. 27
Tilt Adjust Feature................................................................................................................................ 27
Tilt Memory Feature............................................................................................................................. 27
Telescopic Feature................................................................................................................................. 27
Battery Check............................................................................................................................................ 28
How to Make Checks With the Key or Keyless Switch ON......................................................................... 28
Control Levers and Pedals ........................................................................................................................ 28
Direction and Speed Controls ................................................................................................................... 28
Electrical Components .............................................................................................................................. 28
Steering System ........................................................................................................................................ 30
Hydraulic System ...................................................................................................................................... 30
Service Brakes ........................................................................................................................................... 30
Automatic Parking Brake ......................................................................................................................... 30
Operator Presence System........................................................................................................................ 31
Oil Leaks.................................................................................................................................................... 31
Maintenance Procedures After First 100 Hours or 2 Months of Service ........................................................ 31
Tire and Wheel Assemblies ........................................................................................................................... 31
Mast Sliding Surfaces.................................................................................................................................... 31
Mast Pivot Pins and Mounting Hardware ................................................................................................... 32
Fork Guides and Pins .................................................................................................................................... 32
Integral Sideshift Carriage ........................................................................................................................... 33
Check Upper and Lower Bearings............................................................................................................ 33
Header Hoses, Hose Fittings, and Clamps................................................................................................... 33
Maintenance Procedures Every 500 Hours or Three Months ......................................................................... 34
©2012 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Tire and Wheel Assemblies ........................................................................................................................... 34
Mast and Carriage......................................................................................................................................... 34
Mast Sliding Surfaces ............................................................................................................................... 34
Mast Pivot Pins, Bushings, and Mounting Hardware............................................................................. 35
Header Hoses............................................................................................................................................. 35
Fourth Function Mini Rollers Lubrication............................................................................................... 36
Lift Chain Lubrication .............................................................................................................................. 37
Lift Chain Wear Check.............................................................................................................................. 37
Check Upper and Lower Bearings............................................................................................................ 38
Fork Guides and Pins................................................................................................................................ 38
Check Lower Mounting Hook ................................................................................................................... 38
Tilt Cylinder Rod End Pins ........................................................................................................................... 39
Control Levers, Pedals, and Hinges.............................................................................................................. 40
Direction and Speed Control Pedals ............................................................................................................. 40
Hydraulic Hoses, Fittings, and Clamps........................................................................................................ 40
Hydraulic Breather Cap ................................................................................................................................ 40
Service Brakes ............................................................................................................................................... 41
Master Cylinder Oil Check ....................................................................................................................... 41
Parking Brake................................................................................................................................................ 41
Manual Override Handle .......................................................................................................................... 41
Electrical Inspection...................................................................................................................................... 42
Contactors.................................................................................................................................................. 42
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 43
Hydraulic System .......................................................................................................................................... 43
Hydraulic Oil Filter, Change .................................................................................................................... 43
Hydraulic Breather, Check ....................................................................................................................... 45
Steering Axle.................................................................................................................................................. 46
Steering Actuator and Steering Plate Torque Check .............................................................................. 46
Transaxle Oil Level Check ............................................................................................................................ 46
Transaxle Breather Check ............................................................................................................................ 47
Brake Oil Change .......................................................................................................................................... 47
Lift Chains ..................................................................................................................................................... 48
Maintenance Procedures Every 4000 Hours or Two Years.............................................................................. 48
Hydraulic Oil Change.................................................................................................................................... 48
Steering Direction Sensor Inspection ........................................................................................................... 50
Fixed Steering Column ............................................................................................................................. 50
Telescopic Steering Column...................................................................................................................... 51
Telescopic Steering Column Lubrication...................................................................................................... 52
Welding Repairs ................................................................................................................................................. 53
Lift and Tilt System Leak Check ...................................................................................................................... 54
Lift Cylinders Leak Check ............................................................................................................................ 54
Tilt Cylinder Leak Check .............................................................................................................................. 54
Battery Maintenance ......................................................................................................................................... 55
How to Charge Battery.................................................................................................................................. 55
How to Change Battery ................................................................................................................................. 56
Remove the Battery................................................................................................................................... 56
Install the Battery..................................................................................................................................... 58
Optional Side Removal of Battery ............................................................................................................ 59
Battery Size Specifications............................................................................................................................ 60
ii
Periodic Maintenance Table of Contents
TABLE OF CONTENTS (Continued)

Wheel and Tires ................................................................................................................................................. 60
General ........................................................................................................................................................... 60
Pneumatic Tires Repair ................................................................................................................................ 60
Remove Wheels From Lift Truck.............................................................................................................. 60
Remove Tire From Wheel ......................................................................................................................... 60
Remove Tire From Two-Piece Wheel ................................................................................................... 61
Remove Tire From Three- and Four-Piece Wheels ............................................................................. 62
Install Wheel in Tire ................................................................................................................................. 63
Install Two-Piece Wheel in Tire ........................................................................................................... 64
Install Three- or Four-Piece Wheel in Tire.......................................................................................... 65
Add Air to Tires ......................................................................................................................................... 66
Wheels, Install........................................................................................................................................... 66
Solid Rubber Tires on Pneumatic Wheels, Change ..................................................................................... 67
Remove Tire From Wheel ......................................................................................................................... 67
Install Tire on Wheel ................................................................................................................................ 68
Install the Wheels ..................................................................................................................................... 70
Solid Rubber (Cushioned) Tire Repair ......................................................................................................... 70
Remove Wheels From Lift Truck.............................................................................................................. 70
Remove and Install Tire on Wheel ........................................................................................................... 70
Lift Chain Adjustments ..................................................................................................................................... 71
This section is for the following models:
J30-40XNT [K160]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 1339 Introduction
Introduction
GENERAL The Maintenance Schedule has four time periods.
Perform maintenance at the DAILY, 3-MONTHS,
WARNING 1-YEAR, and 2-YEAR periods.
DO NOT make repairs or adjustments unless Your dealer for Hyster lift trucks will advise you on
you have both authorization and training. Re- the maintenance time intervals based on their survey
pairs and adjustments that are not correct can of the application.
create dangerous operating conditions.
Your dealer for Hyster lift trucks has the equipment
WARNING and trained service personnel to do a complete pro-
gram of inspection, lubrication, and maintenance. A
DO NOT operate a lift truck that needs repairs.
regular program of inspection, lubrication, and main-
Report the need for repairs to your supervisor
tenance will help your lift truck provide more effi-
immediately. If repair is necessary, attach a DO
cient performance and operate for a longer period of
NOT OPERATE tag to the steering wheel. Re-
time.
move the key from the key switch. Disconnect
the battery connector. Some users have service personnel and facilities to do
the items listed in the Maintenance Schedule. Ser-
WARNING vice manuals are available from your dealer for Hys-
DO NOT work under a raised carriage. Lower ter lift trucks to help users who do their own main-
the carriage or use a chain to prevent the car- tenance.
riage and the inner or intermediate weldments Throughout this section, forward will refer to travel
from lowering when doing maintenance. Make in the direction of the forks and left and right will be
sure that the moving parts are attached to determined by sitting in the seat facing forward. See
parts that cannot move. Figure 1.
CAUTION SERIAL NUMBER

Disposal of lubricants and fluids must meet lo-
The serial number code for the lift truck is on the
cal environmental regulations
Nameplate. The serial number code is also stamped
This section contains a Maintenance Schedule and on the left side of the front frame bulkhead, top edge
the instructions for maintenance and inspection. surface.
The Maintenance Schedule has time intervals for in-

spection, lubrication, and maintenance for your lift
truck. The service intervals are given in both oper-
ating hours recorded on the lift truck hourmeter, and
in calendar time. Use the interval that occurs first.
The recommendation for time intervals are for eight

hours of operation per day. Time intervals must be
decreased from the recommendations in the Mainte-
nance Schedule for the following conditions:
• If the lift truck is used more than eight hours per
day.
• If the lift truck must work in dirty operating con-
ditions.
• Poor ground conditions.
• Intensive usage at high performance levels or A. LEFT SIDE C. FORWARD
B. RIGHT SIDE TRAVEL
other abnormal conditions will require more fre-
quent servicing. Figure 1. Truck Orientation
1
Introduction 8000 SRM 1339
DISCHARGING THE CAPACITORS 2. Turn the key switch to the OFF position.
3. Disconnect the battery by separating the connec-

WARNING tors. Block drive wheels to prevent lift truck from
DO NOT make repairs or adjustments unless moving.
you have been properly trained and authorized
to do so. Improper repairs and adjustments 4. Make sure the Emergency Disconnect Switch
can create dangerous operating conditions. HAS NOT been activated. If the Emergency
DO NOT operate a lift truck that needs re- Disconnect Switch is activated, rotate the switch
pairs. Report the need for repairs to your to the right until it pops up
supervisor immediately. If repair is necessary,
attach a DO NOT OPERATE tag on the steering 5. Press horn button. Wait 30 seconds to be sure
wheel and disconnect the battery. capacitors are fully discharged.
Disconnect the battery and allow the capaci- HOW TO TOW A DISABLED LIFT TRUCK
tors to discharge before opening any compart-
ment covers or inspecting or repairing the elec- WARNING
trical system. DO NOT place tools on top of the
Use extra care when towing a lift truck if there
battery. If a tool causes a short circuit, the high
is a problem with any of the following:
current flow from the battery can cause per-
• Brakes DO NOT operate correctly.
sonal injury or property damage.
• Steering does not operate correctly.
Some checks and adjustments are performed • Tires are damaged.
with the battery connected. DO NOT connect • Traction conditions are bad.
the battery until the procedure instructs you • Moving the lift truck on a steep grade.
to do so. Never wear any metallic items on
If the hydraulic pump motor, which includes
your fingers, arms, or neck. Metal items can
the steering control functions, does not op-
accidentally make an electrical connection
erate, steering control of the lift truck can
and cause injury.
be slow. This can make the control of the lift
Before performing any tests or adjustments, truck difficult. If there is no electrical power,
block the lift truck to prevent unexpected steering can be difficult. DO NOT tow the lift
movement. truck if there is no power. Poor traction can
cause the disabled lift truck or towing vehicle
The capacitor in the transistor controller(s) to slide. Steep grades will require additional
can hold an electrical charge for about 10 brake force to stop the lift truck.
seconds after the battery is disconnected.
To prevent an electrical shock and personal Never carry a disabled lift truck unless the lift
injury, discharge the capacitor(s) before in- truck MUST be moved and cannot be towed.
specting or repairing any component in the The lift truck used to carry the disabled lift
drive unit compartment. Make certain that truck MUST have a rated capacity equal to
the battery has been disconnected. or greater than the weight of the disabled
lift truck. The capacity must be for a load
DO NOT short across the motor controller ter- center equal to half the width of the disabled
minals with a screwdriver or jumper wire. lift truck. See the nameplate of the disabled
lift truck for the approximate total weight.
Make certain the Emergency Disconnect The forks must extend the full width of the
Switch has not been activated. This will disabled lift truck. Center the weight of the
isolate the controller and prevent the capac- disabled lift truck on the forks and be careful
itors from discharging properly. The proper not to damage the under side of the lift truck.
way to disconnect the battery is by separating
the battery connectors. NOTE: The towed lift truck must have an operator.
Tow the lift truck slowly.
1. Ensure the capacitors are discharged by perform-
ing Step 2 through Step 5 below. 1. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Install a chain
2
to prevent the carriage and mast channels from 3. Use a towing link made of steel that attaches to
moving. the tow pins in the counterweights of both lift
trucks.
2. If another lift truck is used to tow the disabled lift
truck, it must have a weight equal to or greater 4. Remove floor mats and floor plates.
than that of the disabled lift truck. Install an ap-
proximate half-capacity load on the forks of the 5. Pull up on the manual override handle to release
lift truck that is being used to tow the disabled the parking brake. See Figure 2.
lift truck. This half-capacity load will increase
6. Tow the lift truck slowly.
the traction of the towing lift truck. Keep the
load as low as possible.
1. FRONT BULKHEAD 3. PIVOT PIN

2. MANUAL OVERRIDE HANDLE 4. TRACTION MOTORS
Figure 2. Manual Override Handle
3
Introduction 8000 SRM 1339
HOW TO PUT LIFT TRUCK ON BLOCKS • Before removing the mast and drive axle as-
sembly, put blocks under the counterweight
How to Raise Drive Tires so that the lift truck cannot tip backward.
• Before removing the battery and counter-
WARNING weight, put blocks under the mast assembly
The lift truck must be put on blocks for some so that the lift truck cannot tip forward.
types of maintenance and repair. The removal Put the lift truck on blocks only if the surface
of the following assemblies will cause large is solid, even and level. Make sure that any
changes in the center of gravity: mast and blocks used to support the lift truck are solid,
drive axle assembly, battery, and counter- one piece units.
weight. When the lift truck is put on blocks,
put additional blocks in the following posi- NOTE: Under the counterweight cover is a hole to
tions to maintain stability: insert a lifting eye. This lift point can be used to raise
• Before removing the mast and drive axle as- the steer tire so blocks can be positioned under the
sembly, put blocks under the counterweight frame.
so that the lift truck cannot tip backward.
• Before removing the battery and counter- 1. Put blocks in front and back of the drive tires to
weight, put blocks under the mast assembly prevent movement of the lift truck. See Figure 3.
so that the lift truck cannot tip forward.
2. Use a hydraulic jack to raise the steering tires.
Put the lift truck on blocks only if the surface Make sure that the jack has a capacity of at least
is solid, even and level. Make sure that any
2
/3 of the total weight of the lift truck as shown on
blocks used to support the lift truck are solid, the Nameplate.
one piece units.
3. Put the jack under the frame to raise the lift
1. Put blocks on each side (front and back) of the truck. Put blocks under the frame to support the
steer tires to prevent movement of the lift truck. lift truck.
See Figure 3.
HOW TO CLEAN A LIFT TRUCK
2. Put the mast in a vertical position. Put a block
under each outer mast channel. WARNING
3. Tilt the mast fully forward until the drive tires Compressed air can move particles so that they
are raised from the surface. cause injury to the user or to other personnel.
Make sure that the path of the compressed air
4. Put additional blocks under the frame behind the is away from all personnel. Wear protective
drive tires. goggles or a face shield to prevent injury to the
eyes.
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 CAUTION
equal to at least half the weight of the lift truck. Units may be washed with a non-heated pres-
See the Nameplate. sure washer. Steam cleaning is not recom-
mended in most instances, as condensation
How to Raise Steer Tires may form in electrical components causing
damage or erratic behavior.
WARNING NOTE: Lift trucks used in paper applications may
The lift truck must be put on blocks for some need cleaning beyond what is described here. Please
types of maintenance and repair. The removal refer to Paper Application section in the applicable
of the following assemblies will cause large Operating Manual and to available Service Gram/
changes in the center of gravity: mast and Bulletin for more detail.
drive axle assembly, battery, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
4
If it becomes necessary to clean the fork lift, follow • Floor Plates

the guidelines listed below. • Battery Compartment
• Dash/cowl assembly
1. Assure truck components are cool before starting • Armrests with electrical components
the cleaning procedure.
7. Clean the battery compartment by using a clean
2. Disconnect the battery. If an electric truck, re- cloth to wash the battery with water. Dry with
move the traction battery. compressed air. Care should be taken to keep
moisture at a minimum as some units have a
3. Remove accumulated debris using a compressed
traction or hydraulic motor directly below the
air line and nozzle.
battery compartment.
4. Lightly spray a non-corrosive cleaning agent onto
8. DO NOT pressure wash the battery. DO NOT use
the areas to be cleaned. This will help loosen
hot water. For cleaning traction batteries, refer
grime, so close contact direct spraying will not be
to the Battery section of the Service Manual.
necessary.
9. DO NOT pressure wash lift chains, sheaves or
5. Be sure to avoid directing the spray into electri-
load rollers in the mast assembly. Refer to the
cal panel compartment. Ensure over-spray does
Chains, Sheaves and Load Rollers maintenance
not come in contact with electrical components;
section in the Service Manual for proper clean-
DO NOT spray water directly at electrical compo-
ing procedures.
nents, wiring connectors or electrical enclosures.
Even sealed connectors may allow water egress 10. After cleaning, immediately run the lift truck to
under pressure or if connector is damaged. dry out components.
6. Avoid spraying in areas containing electrical
components such as:
1. DRIVE TIRES 2. STEER TIRES
Figure 3. Putting Lift Truck on Blocks
5
Safety Procedures When Working Near Mast 8000 SRM 1339
Safety Procedures When Working Near Mast

2. If parts of the mast must be in raised position,
WARNING install a safety chain to restrain the moving parts
Mast parts are heavy and can move. Distances of the mast. Connect moving parts to a part that
between parts are small. Serious injury or does not move. Follow these procedures:
death can result if part of the body is hit by
parts of the mast or the carriage. a. Put the mast in a vertical position.
• Never put any part of the body into or under
the mast or carriage unless all parts are com- b. Raise the mast to align the bottom cross-
pletely lowered or a safety chain is installed. member of the weldment that moves in the
Also make sure that the power is OFF and the outer weldment with a crossmember on the
key is removed. Put a DO NOT OPERATE tag outer weldment. On the two-stage and free-
in the operator’s compartment. lift mast, the moving part is the inner weld-
• Be careful of the forks. When the mast is ment. On the three-stage mast, it is the
raised, the forks can be at a height to cause intermediate weldment. On the four-stage
an injury. mast, it is the first intermediate weldment.
• DO NOT climb on the mast or lift truck at any See Figure 4.
time. Use a ladder or personnel lift to work
c. Use a 9.4 mm (0.370 in.) (3/8 inch) minimum
on the mast.
safety chain with a hook to fasten the cross-
• DO NOT use blocks to support the mast weld-
members together so the movable member
ments nor to restrain their movement.
cannot lower. Put the hook on the back side of
• Mast repairs require disassembly and re-
the mast. Make sure the hook is completely
moval of parts and can require removal of
engaged with a link in the chain. Make sure
the mast or carriage. Follow the repair pro-
the safety chain does not touch lift chains or
cedures in the applicable Service Manual
chain sheaves, tubes, hoses, fittings, or other
section for the mast.
parts on the mast.
The following procedures must be used when inspect-
d. Lower the mast until there is tension in the
ing or working near the mast. Additional precautions
safety chain and the free-lift cylinder (free-
and procedures can be required when repairing or re-
lift and three-stage masts only) is completely
moving the mast. See the correct Service Manual sec-
retracted. Install a DO NOT REMOVE tag
tion for the specific mast being repaired.
on the safety chain(s).
WHEN WORKING NEAR THE MAST e. Install another safety chain, 9.4 mm
ALWAYS: (0.370 in.) minimum, between the top or
bottom crossmember of the carriage and a
1. Lower the mast and carriage completely. Push crossmember on the outer weldment.
the lift/lower control lever forward and make
sure there is no movement in the mast. Make 3. Apply the parking brake, shut off the power and
sure that all parts of the mast that move are remove the key. Put a DO NOT OPERATE tag
fully lowered. in the operator’s compartment. Disconnect bat-
tery connector.
OR
Legend for Figure 4
NOTE: ILLUSTRATION FOR REFERENCE ONLY.

A. TWO-STAGE MAST C. THREE-STAGE MAST
B. FREE-LIFT MAST D. FOUR-STAGE MAST
1. OUTER WELDMENT 5. HOOK
2. INNER WELDMENT 6. FREE-LIFT CYLINDER
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. FIRST INTERMEDIATE WELDMENT 8. CROSSMEMBER
6
8000 SRM 1339 Safety Procedures When Working Near Mast
Figure 4. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
7
Maintenance Schedule 8000 SRM 1339
Maintenance Schedule
The Maintenance Schedule has time intervals for in- The Maintenance Schedule has the maximum ser-
spection, lubrication, and maintenance for your lift vice intervals for usage under normal conditions. In-
truck. The service intervals are given in both oper- spect and lubricate more frequently if the lift truck
ating hours recorded on the lift truck hourmeter, and operates in dirty, dusty, wet, or difficult conditions.
in calendar time. The recommendation is to use the
interval that comes first. The approximate locations
of the items indicated in the Maintenance Schedule
are shown in Figure 5.
Figure 5. Maintenance Points
8
8000 SRM 1339 Maintenance Schedule
Table 1. Maintenance Schedule
Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

No. Daily or or or Quantity
3 1 Year 2 Years
Months
1 Drive Tire and Wheel Assemblies
Remove foreign
Check condition.
Tire and Wheel X objects embedded
See NOTE 1.
in tire.
2 Pedals, Seat X Check
Assembly, Hood, operation/
Hinges, and Hood repair as
latch required.
L Lube as Use multipurpose
required. grease. See NOTE 2
and NOTE 3.
3 Frames, Covers, X Visually inspect
and Floor Plates for damage/
repair as
required.
X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation.
NOTE: Never use steam to clean electrical parts.
9
Table 1. Maintenance Schedule (Continued)

3 1 Year 2 Years
Months
4 Hydraulic System X Check
operation/
repair as
required.
X Check for leaks/
repair as
required.
Hydraulic Hoses, X Inspect for
Hose Fittings visible damage
and Clamps and defects.
Adjust, repair,
or replace if
necessary.
X Inspect for
kinked,
flattened, stiff
or charred
hoses/
replace if
necessary
Hydraulic Oil X Check for leaks/
repair as
required
C Change oil.
19.0 liter ISO-VG46
(5.0 gal) Total
system capacity.
Hydraulic Oil C Change oil filter. See Parts Manual.
Filter See NOTE 3.
Clean or
Breather Cap X C replace. See Parts Manual.
See NOTE 3.
5 Steering Tire and Wheel Assemblies
Tire and Wheel X Check condition. Remove foreign
See NOTE 1. objects embedded
in tire.
10

3 1 Year 2 Years
Months
6 Battery X Check level. See Use distilled water.
NOTE 5. Maintain in
Check accordance with
connection manufacturer’s
between truck service instructions.
and battery.
Battery Re- X Check
straint operation.
7 Steering System X Check Repair as required.
operation.
X Check for leaks.
Steering Position X Check sensor Replace sensor or
Sensor assembly and column gear as
column gear required
teeth.
Telescopic Steering L Lubricate. Use manual steering
Column gear grease. See
NOTE 7
Steering Actua- X Check torque. 270 N•m (200 lbf ft)
tor Bolts 3 bolts.
Steering Plate X Check torque. 305 N•m (225 lbf ft)
Bolts 4 bolts.
8 Automatic Parking CIL Check Must hold full
Brake X operation/ capacity load on a
applies and 15% grade.
releases
properly.
Manual Override L Lubricate Use multipurpose
Handle pivot pin. See grease. See NOTE 2.
NOTE 3.
11

3 1 Year 2 Years
Months
9 Service Brake X Check Use Dexron III.
operation.
X Check for leaks.
Linkage and L Lubricate. Silicone spray
Shafts lubricant,
Hyster P/N 328388.
Master Cylinder CIL X Check oil level.
Reservoir
C Change oil. Use Dexron III.
0.25 liter
(0.26 qt).
12

3 1 Year 2 Years
Months
10 Mast X Inspect for
visible damage/
check operation.
Pivot Pins L 2 fittings. Use multipurpose
Check grease. See NOTE 2.
lubrication. See
NOTE 1.
Sliding X L Lubricate as Use multipurpose
Surfaces L required. See grease. See NOTE 2.
NOTE 1 and
NOTE 4.
Mast Mounting X Tighten if 24 N•m (212 lbf in).
Capscrews required. See
NOTE 1.
Lift Chains X Check stretch SAE 30W
and lubricate. engine oil.
See NOTE 3
and NOTE 6
X Check
adjustment and
length.
See NOTE 3.
L Remove chains SAE 30W
to clean and engine oil.
lubricate.
Header Hoses, X Inspect for Adjust, repair, or
Hose Fittings visible damage replace if necessary.
and Clamps and defects. See
NOTE 1.
X Inspect for
kinked,
flattened, stiff
or charred
hoses/ replace
if necessary.
Mast L Lubricate as Use multipurpose
Fourth Function required. grease. See NOTE 2.
Mini Rollers
13

3 1 Year 2 Years
Months
11 Carriage Assembly X Inspect for
visible damage/
check operation.
Forks X Check condition/
replace if
necessary.
Fork Guides and X L Lubricate as Use multipurpose
Pins required. See grease. See NOTE 2.
NOTE 1.
Integral Sideshift L Lubricate. 2 Use multipurpose
Carriage fittings. See grease. See NOTE 2.
NOTE 1.
Integral X Check wear, 2.50 mm (0.09 in.)
Sideshift Car- 4 bearings. See Minimum thickness.
riage NOTE 1.
(Upper and
C Replace See Parts Manual.
Lower Bearings)
bearings.
Integral Sideshift X Check for wear 0.76 mm (0.03 in.)
Carriage and clearance minimum wear limit
Lower Mounting See NOTE 1
Hook and NOTE 3.
12 Transaxle
Oil Level X Check oil level. Use Dexron III.
Breather X Clean and check
operation/
replace as
necessary.
14

3 1 Year 2 Years
Months
Electrical Circuits
Battery Discon- X Check
nect Switch operation.
Horn, Lights, X Check
Alarms, and Seat operation/
Switch repair as
required.
Display Panel X Check
operation.
Contactors X Check condition/
repair as
required.
Direction and X L Check Use silicone spray
Speed Control operation/ lubricant,
Pedal lubricate as Hyster P/N 328388.
needed.
Safety Labels and Replace if
X See Parts Manual.
Operating Manual necessary.
Steering Column Check
X
Tilt Memory Lever operation.
Seat Belt and X
Check condition.
Seat Rails CIL
Check
Operator Presence
X operation/
System Check
repair if needed.
NOTE 1: Perform maintenance after the first 100 hours or 2 months of service.
NOTE 2: Multipurpose grease with 2 to 4% Molybdenum Disulfide for normal operations.
NOTE 3: Recommended service intervals are based on a normal application in a clean environment. Appli-
cations involving contaminated environments such as high levels of air borne debris (dust and waste paper);
chemical or abrasive compounds; poor ground conditions; intensive usage at high performance levels; or other
abnormal conditions will require more frequent servicing. At your request your Hyster dealer will advise you
of the appropriate service intervals based on an application survey.
NOTE 4: Maximize life of surfaces by lubricating every 250 hours for first 1000 hours.
NOTE 5: Equalization charge is required approximately each month. See manufacturer’s service instructions.
15
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1339

3 1 Year 2 Years
Months
NOTE 6: Lubricate if dry or at first sign of visible surface rust.
NOTE 7: Multipurpose lithium base grease.
Maintenance Procedures Every 8 Hours or Daily

for deep grooves or cuts in the tires. Remove ob-
WARNING jects embedded in the tire, such as wire, rocks, glass,
DO NOT operate a lift truck that needs repairs. and pieces of metal that can cause damage. See Fig-
Report the need for repairs immediately. If re- ure 6. Remove any wire, strapping, or other material
pair is necessary, put a DO NOT OPERATE tag that is wrapped around the axle to prevent damage to
in the operator’s area. Remove the key from the axle seals. Inspect wheel rims for rust or cracks
the key switch. and check for loose or missing lug nuts and broken
studs. DO NOT operate a lift truck with damage to
Inspect the lift truck every eight hours or daily be- any wheel rim, lug nuts, or studs.
fore use. Put the lift truck on a level surface. Lower
the carriage and forks and turn the key or keyless
switch to the OFF position. Remove the floor mat
and floor plate. Inspect for leaks and conditions that
are not normal. Clean any oil spills. Make sure that
lint, dust, paper and other materials are removed
from the compartments. Make the additional checks
as described in the following paragraphs of How to
Make Checks With the Key or Keyless Switch OFF
and How to Make Checks With the Key or Keyless
Switch ON.
Park the lift truck on a level surface. Lower the forks,

turn the key or keyless switch to the OFF position,
and disconnect the battery connector. Check for leaks
and conditions that are not normal. Clean up any oil
spills.
HOW TO MAKE CHECKS WITH THE KEY 1. CHECK FOR DAMAGE (REMOVE NAILS,
GLASS, AND OTHER OBJECTS FROM TREAD)
OR KEYLESS SWITCH OFF 2. MAKE SMOOTH EDGES
Wheels and Tires Figure 6. Tire Check
Inspect the drive tires and wheel assemblies and the
steer tire and wheel assemblies for damage. Look
16
8000 SRM 1339 Maintenance Procedures Every 8 Hours or Daily
Safety Labels Frame and Covers

The frame is a single weldment with mounts for the
WARNING counterweight, overhead guard, mast, steering sys-
Safety labels are installed on the lift truck to tem, hydraulic system, and transaxles. Check the
provide information about possible hazards. It condition of the frame, especially around welds, for
is important that all safety labels are installed rust, cracks, or other damage. The overhead guard
on the lift truck and can be read. must be free from defects to ensure protection to the
operator. A variety of covers and floor plates provide
Check that all safety labels are installed in the cor- protection and allow easy access to systems located
rect locations on the lift truck. See the Parts Man- inside and around the frame. See Figure 7. Make
ual or the section Frame 100 SRM 1329 of the Ser- certain that all covers and floor plates are present
vice Manual for the correct locations of the safety and secured in their proper locations.
labels.
Check that the Operating Manual is not worn or

damaged and replace it if necessary.
1. OVERHEAD GUARD 4. HOOD SIDE COVER

2. FLOOR PLATE 5. COUNTERWEIGHT COVER
3. FRAME 6. STEERING COLUMN COVER
Figure 7. Frame and Covers Check
17
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.
Forks, Remove
WARNING
DO NOT try to move a fork without a lifting
device. The forks can weigh 45 to 115 kg (99
to 254 lb).
NOTE: Forks are to be replaced only in sets and not

individually.
A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide a hook
fork to the fork removal notch on the carriage. See
Figure 8. Lower the fork onto blocks so that the lower
fork hook moves through the fork removal notch. See
Figure 9 and Figure 10. Lower the carriage further Fork Tip Alignment
so that the top fork hook is disengaged from the top Length of Forks 3% Dimension
carriage bar. Move the carriage away from the fork,
or use a lifting device to move the fork away from the 915 mm (36 in.) 27 mm (1.10 in.)
carriage. 1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
Forks, Inspect 1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
WARNING
DO NOT try to correct fork tip alignment by 1. TIP ALIGNMENT (MUST BE WITHIN 3%
bending the forks or adding shims. Replace OF FORK LENGTH)
bent forks. Never repair damaged forks by 2. CRACKS
heating or welding. Forks are made of special 3. LOCK PIN
4. HEEL OF FORK (MUST BE 90% OF DIMENSION
steel using special procedures. Replace dam- X, THICKNESS OF FORK SHANK)
aged forks. Forks are to be replaced only in 5. CARRIAGE
sets and not individually. 6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
Inspect the forks for cracks and wear. Check that the 8. FORK REMOVAL NOTCH
fork tips are aligned as shown in Figure 8. Check
that the bottom of the fork is not worn (item 4 in Figure 8. Forks Check
Figure 8).
Replace any damaged or broken parts that are used

to keep the forks locked in position. See Figure 10.
18
Forks, Adjust
NOTE: During the adjustment of the forks, the heel
of the forks should not be touching the ground.
The forks are connected to the carriage by hooks and

lock pins. See Figure 10. These lock pins are in-
stalled 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
1. CARRIAGE BARS position after the width adjustment is made.
2. HOOK FORK
3. BLOCKS Inspection of Mast, Carriage, Header
Figure 9. Hook Fork Removal Hoses, Lift Chains, and Attachments
Fork Install WARNING

Lower the lift mechanism completely. Never al-
WARNING low any person under a raised carriage. DO
DO NOT try to move a fork without a lifting NOT put any part of your body in or through
device. The forks can weigh 45 to 115 kg (99 the lift mechanism unless all parts of the mast
to 254 lbf). are completely lowered and the lift truck trac-
tion motor is OFF.
Move the fork and carriage so that the top fork hook
can engage the top carriage bar. Raise the carriage to 1. Inspect the welds on the mast, cylinders, and car-
move the lower fork hook through the fork removal riage for cracks. Make sure that the capscrews
notch. Slide the fork on the carriage so that both up- and nuts are tight.
per and lower fork hooks engage the carriage. En-
gage the lock pin with a notch in the top carriage bar. 2. Inspect the channels for wear in the areas where
See Figure 10. the rollers travel. Inspect the rollers for wear or
damage.
3. Check mast lubrication. If necessary, lubricate

the sliding surfaces and the load roller surfaces
along the full length of the channels as shown
in Figure 11. Only apply lubricant to surfaces
that are clean and dry. Only apply lubricant to
the darker areas as indicated by (1) and (2) in
Figure 11.
4. Inspect the load backrest extension for cracks

and damage.
5. If the lift truck is equipped with a sideshift car-

1. FORK 6. KNOB riage or attachment, inspect the parts for cracks
2. LOCK PIN 7. LOCK PIN and wear. Make sure the parts that fasten the
3. SPRING ASSEMBLY
4. WASHER 8. TOP FORK HOOK sideshift carriage or attachment to the carriage
5. WEDGE 9. LOWER FORK are in good condition.
HOOK
Figure 10. Fork Lock Pin Assembly
19
7. Check that lift chains are correctly lubricated.

Use SAE - 30W engine oil to lubricate lift chains.
8. Inspect the lift chains for cracks or broken links

and worn or turned pins. Lift chains must be
replaced as a set. See Figure 12.
NOTE: Chain anchor pins MUST be replaced any-

time chains are replaced.
9. Inspect the chain anchors and pins for cracks and

damage.
10. Make sure the lift chains are adjusted so that

they have equal tension. Adjustments or re-
placement of the lift chains must be done
by authorized personnel.
NOTE: MAST IS DIFFERENT, BUT LUBRICATION AR-
EAS ARE THE SAME.
A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 11. Mast Lubrication
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
WARNING
1. WORN PIN 4. HOLE WEAR
Never check for leaks by putting hands on 2. CRACKS 5. LOOSE LEAVES
hydraulic lines or components under pressure. 3. EDGE WEAR 6. DAMAGED PIN
Hydraulic oil under pressure can be injected (MAXIMUM 5% OF 7. CORROSION
into the skin. NEW)
6. Visually inspect hoses/fittings for hydraulic Figure 12. Lift Chains Check
leaks; hose covers for cuts, cracks, or exposed re-
inforcement; defective/broken clamping devices
or sheaves; and proper tracking during opera-
tion. Adjust/repair/replace hose/components as
necessary.
20
Hydraulic Oil Level and Leaks Inspect the hydraulic system for leaks and damaged
or loose components. Heavy-duty or high-tempera-
ture operations can require more frequent checks.
WARNING
At operating temperature the hydraulic oil is Operator Restraint System
HOT. DO NOT permit the oil to contact the skin
and cause a burn. There is an indicator icon on the display panel for
the seat belt. The icon is ON as described in the
WARNING Operating Manual. The indicator icon can help the
Always wear the proper protective equipment operator remember to fasten the seat belt.
including eye protection and petroleum-resis- The seat belt, hip restraint brackets, and the seat
tant gloves when handling hydraulic oil. Thor- and mounting are the parts of the operator restraint
oughly wash oil from exposed areas of skin as system. See Figure 13 and Figure 14. Each item
soon as possible. must be checked to make sure it is attached securely,
functions correctly and is in good condition.
CAUTION
The seat belt must latch securely. Make sure the seat
DO NOT permit dirt to enter the hydraulic sys-
belt extends and retracts smoothly and is not dam-
tem when the oil level is checked or the filter
aged or torn. If the seat belt cannot be pulled from
is changed.
the belt housing, the seat belt assembly must be re-
Never operate the pump without oil in the hy- placed. Keep the belt straight so that it pulls out and
draulic system. The operation of the hydraulic retracts smoothly.
pump without oil will damage the pump.
1. HOOD LATCH HANDLE

2. SEAT BELT
3. HIP RESTRAINT BRACKETS
Figure 13. Operator Restraint System
21
Make sure the seat rails are not loose. The seat rails Battery Restraint System
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached The Battery Restraint System is designed to hold the
to the mounting surface. battery within the battery compartment if a tip over
occurs. The battery restraint system contains a front
Emergency Locking Retractor (ELR) spacer plate, a battery plate, front and rear bulk-
heads, and the left and right frame plates. The lift
When the ELR style seat belt is properly buckled truck can be equipped with optional side rollers on
across the operator, the belt will permit slight op- the battery plate to help in removing the battery from
erator repositioning without activating the locking the truck. See Figure 15 and Figure 16.
mechanism. If the truck tips over, travels off a dock,
or comes to a sudden stop, the locking mechanism The hood and hood latch mechanism also help keep
will be activated and hold the operators lower torso the battery within the battery compartment if a tip
in the seat. See Figure 13 and Figure 14. over occurs. The hood can be raised for access to the
battery. A gas spring helps raise and hold the hood
A seat belt that is damaged, worn, or does not op- in the up position. See Figure 18.
erate properly will not provide protection when it is
needed. The end of the belt must fasten correctly in The battery restraint system must function so that
the latch. The seat belt must be in good condition. the operator restraint system can operate correctly.
Replace the seat belt if it is damaged or worn. Operation of the battery restraint system requires
that the maximum movement allowed for the battery
The following seat belt operation checks must be per- is 13 mm (0.5 in.) in any horizontal direction. This
formed at least three times before replacing the seat will reduce the risk of operator injury in a truck tip
belt assembly: over. An adjustable front battery spacer plate pre-
• With the hood closed and in the locked position, vents the front-to-back movement of the battery. Bat-
pull the seat belt slowly from the retractor assem- teries for this series of lift trucks must all have the
bly. Make sure the seat belt pulls out and retracts same length dimension to just fit the battery com-
smoothly. If the seat belt does not pull out of the re- partment width. For correct battery sizes, see the
tractor assembly the internal latch may be locked. Battery Maintenance section in the back of this man-
Pull firmly on the seat belt and hold for a moment ual.
to remove slack from the belt in the retractor. Re-
lease the seat belt. Seat belt will retract and the To raise the hood, perform the following:
internal latch will unlock. If the seat belt cannot
1. Use the tilt memory lever and tilt the steering
be pulled from the retractor assembly or the belt
column all the way up.
will not retract, replace the seat belt assembly.
• With the hood closed and in the locked position, 2. Slide the seat all the way back, and if necessary,
pull the seat belt with a sudden jerk. Make sure the move the armrest all the way back if lift truck is
seat belt will not pull from the retractor assembly. equipped with E-Hydraulic control levers.
If the seat belt can be pulled from the retractor
when it is pulled with a sudden jerk, replace the 3. If lift truck is equipped with manual hydraulic
seat belt assembly. levers, release the latch for the control lever as-
• With the hood in the open position, make sure the sembly (see Figure 17) and move the assembly to
seat belt will not pull from the retractor assembly. the forward position before raising the hood.
If the seat belt can be pulled from the retractor,
with the hood in the open position, replace the seat
belt assembly.
22
NOTE: STANDARD SEAT SHOWN. AN OPTIONAL SWIVEL SEAT IS AVAILABLE. SWIVEL SEAT ARRANGEMENT
IS THE SAME. HIP RESTRAINTS FOR LIFT TRUCKS WITH MANUAL HYDRAULIC SYSTEM SHOWN.
A. LEFT VIEW B. RIGHT VIEW
1. SEAT BELT 6. FORWARD/BACKWARD ADJUSTMENT LEVER
2. HIP RESTRAINT BRACKET 7. RIDE POSITION INDICATOR
3. MOUNTING HARDWARE 8. WEIGHT ADJUSTMENT KNOB
4. SEAT RAILS 9. SEAT HARNESS
5. BACKREST ANGLE ADJUSTMENT LEVER
Figure 14. Seat Components
23
1. BATTERY PLATE
2. REAR BULKHEAD
3. FRONT BULKHEAD
4. FRONT SPACER PLATE
5. RIGHT FRAME PLATE
Figure 15. Standard Battery Compartment
24
1. REAR BULKHEAD 3. SIDE ROLLER 5. FRONT SPACER PLATE

2. BATTERY PLATE 4. FRONT BULKHEAD 6. REMOVABLE SIDE PLATE
Figure 16. Optional Battery Compartment
25
Legend for Figure 17

1. RELEASE LEVER
2. EMERGENCY DISCONNECT SWITCH
From the left side of the lift truck, push the hood
release lever out towards the right side of the truck
to unlatch the hood. Place hand on the hood handle
on the left side of the hood, and raise hood to the up
position. See Figure 18.
To close hood, lower the hood to the down position

and pull the hood release lever towards right side of
the truck and release to lock. Try to lift the hood to
make sure the hood is fastened correctly.
The hood must be locked in the down position during

lift truck operation. The battery must have the front
spacer plate correctly adjusted to prevent any hori-
zontal movement of more than 13 mm (0.5 in.).
Figure 17. Release Lever, Manual Hydraulic

Control Levers
Figure 18. Hood and Hood Latch Components
26

A. CLOSED POSITION C. FRONT VIEW
B. PULL THIS DIRECTION TO OPEN D. BOTTOM VIEW
1. LATCH ASSEMBLY 4. HOOD MOUNTING BRACKET
2. HOOD 5. HOOD HINGE
3. HOOD RELEASE LEVER 6. GAS SPRING
Steering Column Adjustments

Make sure the steering column adjustment features
are functioning properly. If lift truck is equipped with
the optional telescoping steering column, make sure
the tilt memory and telescoping features are operat-
ing correctly. The tilt memory lever must NOT allow
the column to move unless the tilt memory lever is
released. See Figure 19.
Tilt Adjust Feature
The column tilt angle should be locked in position

whenever the steering column tilt position lever is
released. Use multipurpose grease as shown in the
Maintenance Schedule and lubricate the lever and
pivots as needed.
NOTE: DO NOT use multipurpose grease to lubricate

the sliding surfaces of the telescopic column.
Tilt Memory Feature
After the tilt memory lever is released, tilt the col-

umn down until the column locks into position. The
column should remain locked in place and NOT
move. Use multipurpose grease as shown in the
Maintenance Schedule and lubricate the lever and
pivots as needed.
Telescopic Feature
When the telescopic column locking handle is tight-

ened to 6 N•m (53 lbf in), the steering wheel should
remain locked in place. Use multipurpose grease as NOTE: OPTIONAL TELESCOPIC STEERING COL-
shown in the Maintenance Schedule and lubricate UMN SHOWN.
the lever and pivots as needed. 1. TILT POSITION LEVER
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 19. Steering Column Tilt Memory Lever
27
Battery Check have the correct electrolyte level. The correct level is
halfway between the top of the plates and the bottom
of the fill hole.
WARNING
Never put tools or other metal on the battery. HOW TO MAKE CHECKS WITH THE KEY
Metal on the battery can cause a short circuit
and possible damage or injury.
OR KEYLESS SWITCH ON
The acid in the electrolyte can cause injury. If WARNING

the electrolyte is spilled, use water to flush the FASTEN YOUR SEAT BELT! The seat belt is in-
area. Make the acid neutral with a solution stalled to help the operator stay on the truck if
of sodium bicarbonate (soda). Acid in the eyes the lift truck tips over. IT CAN ONLY HELP IF
must be flushed with water immediately. IT IS FASTENED.
Batteries generate explosive fumes. Keep the After completing the Checks With the Key or Key-
vents in the caps clean. Keep sparks or open less Switch OFF, perform the Checks With the
flames away from the battery area. Do not Key or Keyless Switch ON before placing the lift
make a spark from the battery connections. truck into service.
Disconnect the battery when doing mainte- Make sure the area around the lift truck is clear be-
nance. fore moving the lift truck. Be careful when making
the checks.
NOTE: There can be one of two types of batteries.
One type has removable cell caps (flooded cell). The Control Levers and Pedals
other type has sealed cells (maintenance free). The
sealed batteries require a different charger, the elec- Check that the levers for the mast and attachment
trolyte level or specific gravity cannot be checked and operate as described in the Operating Manual.
water cannot be added to the electrolyte. Make sure Check that the pedals operate correctly as described
that the voltage and the weight of the battery are cor- in the Operating Manual.
rect as shown on the Nameplate. See the Operat-
ing Manual to check for correct battery dimensions. Direction and Speed Controls
See the section Battery Maintenance for procedures
to change the battery and for a schedule on when to Check that the direction and speed control pedals op-
charge the battery. erate as described in the Operating Manual. Lu-
bricate the MONOTROL® pedal or accelerator pedal
Keep the battery case and the area for the battery joints as needed. See the Maintenance Schedule for
clean and painted. Leakage from the battery and cor- the type of lube to use.
rosion can cause a malfunction in the electric controls
of the lift truck. Use a water and sodium bicarbonate Electrical Components
(soda) solution to clean the battery and the battery
area. Keep the top of the battery clean, dry and free • Check the operation of the horn by pressing the
of corrosion. horn button on the steering wheel. The horn will
operate when the key or keyless switch is in any
Make sure the battery is charged and has the correct position. If lift truck is equipped with E-Hydraulic
voltage and ampere hour rating for the lift truck. See controls, there is a horn button located on the arm-
the Nameplate. rest. See Figure 20.
There is also a handle with a horn button on the
Inspect the battery case, connector and cables for right overhead guard leg. See Figure 21.
damage, cracks or breaks. See the battery dealer in If lift truck is equipped with lights, check the op-
the area to repair any damage. eration of the lights using the appropriate rocker
switch, located on the right side of the steering col-
On batteries with cell caps, check the level of the elec-
umn. The lights will operate when the key or key-
trolyte daily on a minimum of one cell. Add only
less switch is in any position.
distilled water, as necessary, to all cells that do not
28
• Check the strobe light by turning the key or keyless

switch to the ON position and check the operation
of the light.
• Check the backup alarm on lift trucks equipped
with a direction control switch by sitting in the seat
and turning the key or keyless switch to the ON
position. Pushing down on the direction control
switch to put it in reverse will sound the alarm.
• Check the backup alarm on lift trucks equipped
with a MONOTROL pedal by sitting on the seat,
turning the key or keyless switch to the ON
position and pressing the reverse arrow on the
MONOTROL pedal.
• Check the seat switch. Turn the key or keyless
switch to the OFF position and leave the seat. The
display panel will register a seat unoccupied er-
ror. DO NOT apply the parking brake. If the seat
switch is working correctly, an alarm will sound
when the operator leaves the seat after turning
the lift truck OFF, but does not apply the parking
brake. If lift truck is equipped with the Seat Acti-
vated parking brake option, the parking brake will
be automatically applied when the operator leaves
the seat after turning the lift truck OFF. The park-
ing brake will release when the operator returns to
the seat and the accelerator or MONOTROL pedal
is applied.
• The display panel, located in the upper right corner
of the operator’s compartment (see the Operating
Manual) is also energized when the key or keyless
1. HORN BUTTON switch is turned to the ON position. The display is
2. EMERGENCY DISCONNECT SWITCH essential to safe and productive operation of the lift
3. FORWARD/REVERSE SWITCH truck. Systems such as the battery condition and
Figure 20. Horn Button Location - E-Hydraulic fault codes are monitored by the controller and are
Controls expressed by the display. A malfunctioning display
unit may not alert an operator to a condition in
time to prevent damage to system components on
the lift truck.
• In the event of an emergency, the emergency dis-
connect switch may be used to cut off power and au-
tomatically apply the park brake. To test that this
switch is working properly turn the key or keyless
switch to the ON position. The operator can discon-
nect almost all electrical power to the lift truck by
pushing the emergency disconnect switch in until
it clicks. To reset (reconnect) the emergency dis-
connect switch and energize the electrical circuits,
the operator must turn the switch clockwise until
it pops up. See Figure 17 and Figure 20.
1. HORN BUTTON 3. RIGHT OVERHEAD
2. HANDLE GUARD LEG
Figure 21. Horn Button - Overhead Guard
29
Steering System With the load lowered, tilt the mast backward and
forward. The mast must tilt smoothly and both tilt
The steering system should operate when a properly cylinders must stop evenly.
charged battery is connected, an operator is present
in the seat, and the key or keyless switch is in the Check that the controls for the attachment operate
ON position. Move the steering tire and wheel as- the functions of the attachment. See the symbols by
sembly completely to the left by turning the steer- each of the controls. See the Operating Manual for
ing wheel. The assembly should turn smoothly to a description of what each symbol does. Make sure
its stop. The steering tire should stop approximately all of the hydraulic lines are connected correctly and
parallel to the battery. Turn the steering tire and do not leak.
wheel assembly completely to its right hand stop us-
ing the steering wheel. The steering system should Service Brakes
move smoothly and make a full range of motion from
its full left to full right position (approximately 180 WARNING
degrees). Loss of fluid from the brake fluid reservoir in-
dicates a leak. Repair the brake system before
Hydraulic System using the lift truck. Replace the brake fluid
(Dexron III) in the system if there is dirt, wa-
WARNING ter or oil in the system.
At operating temperature the hydraulic oil is
There is an indicator icon on the display panel for
HOT. DO NOT permit the oil to contact the skin
the brake fluid level. The icon is illuminated as de-
and cause a burn.
scribed in the Operating Manual. If the icon is illu-
minated during operation, the fluid in the reservoir
WARNING for the brake master cylinder is too low. Add brake
Always wear the proper protective equipment fluid (Dexron III) and check for leaks. The reservoir
including eye protection and petroleum-resis- is under the brake pedal and floor plate. See Fig-
tant gloves when handling hydraulic oil. Thor- ure 5. Clean the area around the fill cap so that no
oughly wash oil from exposed areas of skin as dirt enters the reservoir.
soon as possible.
Check the operation of the service brakes. Push on
the brake pedal. The brakes must be applied before
CAUTION the pedal reaches the floor plate. The brake pedal
DO NOT permit dirt to enter the hydraulic sys- must stop firmly and must not move slowly down af-
tem when the oil level is checked or the filter the brakes are applied. The brakes must apply
ter is changed. Never operate the pump with- equally to both drive wheels with no noticeable pull
out oil in the hydraulic system. The operation to either side.
of the hydraulic pump without oil will damage
the pump. Automatic Parking Brake
NOTE: Some parts of the mast move at different There is an indicator icon on the display panel for the
speeds during raising and lowering. Automatic Parking Brake (APB). The icon is illumi-
nated as described in the Operating Manual. The
Slowly raise and lower the mast several times with-
parking brake is automatically applied when the lift
out a load. The mast components must raise and
tuck is not in motion, or direction with acceleration
lower smoothly in the correct sequence. The carriage
has not been selected.
raises first, then the inner weldment and intermedi-
ate weldment (three-stage masts only). Make sure the service brakes operate correctly be-
fore checking the operation of the Automatic Parking
The inner and intermediate weldments and the car-
Brake. Check the operation of the Automatic Park-
riage must lower completely.
ing Brake. The Automatic Parking Brake, when in
Raise the forks 1 m (3 ft) with a capacity load. The good condition and correctly adjusted, will hold a lift
inner weldment and carriage must raise smoothly. truck with a capacity load on a 15% grade [a slope
Lower the forks. All moving components must lower that increases 1.5 m in 10 m (1.5 ft. increase in 10 ft)].
smoothly.
30
8000 SRM 1339 Maintenance Procedures After First 100 Hours or 2 Months of Service
If Automatic Parking Brake requires adjustment, no- travel forward or backward, or the hydraulic func-
tify service personnel. tions operate, when the operator is not on the seat,
the OPS system is not working properly. See the sec-
Operator Presence System tion Electrical System 2200 SRM 1337 to repair or
replace the seat switch that makes up the OPS sys-
Check the operation of the Operator Presence Sys- tem. See the Operating Manual for more informa-
tem (OPS). Turn the lift truck power ON while sit- tion on how the OPS works.
ting in the seat. Once lift truck power is ON, get
up off the seat. If the OPS is working correctly, a Oil Leaks
switch in the operator’s seat will automatically dis-
able all hydraulic and electrical functions so that the Visually check the hydraulic system, steering sys-
lift truck cannot travel forward or backward when tem, brake system, and transaxles for leaks.
the operator is not on the seat. If the lift truck can
Maintenance Procedures After First 100 Hours or

2 Months of Service
TIRE AND WHEEL ASSEMBLIES NOTE: The load rollers and sheaves have sealed bear-
ings that do not need additional lubrication.
Inspect the wheel rims for rust and cracks. DO NOT
weld a cracked wheel rim or straighten a bent rim. Lubricate the sliding surfaces and the load roller sur-
Welding, heating, or bending a wheel rim can weaken faces along the full length of the channels of the mast
its capacity. Always replace damaged tires or wheel and carriage as shown in Figure 22 and Figure 23.
rims immediately. DO NOT operate a truck with a Apply lubricant only to the indicated surfaces.
broken stud or missing lug nuts.
MAST SLIDING SURFACES
WARNING
Use special safety precautions when working
on or near the mast or carriage. See Safety Pro-
cedures When Working Near Mast.
DO NOT work under a raised carriage. Lower

the carriage or install a safety chain to prevent
the carriage from lowering when performing
maintenance on the mast and lift chains.
Cleaning solvents can be flammable and toxic

and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer. A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
CAUTION 1. LUBRICATE STRIP BEARINGS SURFACES

2. LUBRICATE SURFACES WHERE LOAD
DO NOT use steam or high-pressure water to ROLLERS TRAVEL
clean the load rollers or the lift chains. Steam 3. LOAD ROLLER
and high-pressure water can remove the lu-
brication from the bearings in the load rollers. Figure 22. Mast Lubrication
Water in the bearings of the sheaves and the
link pins of chains can also shorten the service
life of these parts.
31
Maintenance Procedures After First 100 Hours or 2 Months of Service 8000 SRM 1339
1. LUBE FITTING 3. OUTER MAST

2. PIVOT PIN
Figure 24. Mast Mounting Lubrication
FORK GUIDES AND PINS

Lubricate the fork pins and guides with multipur-
1. OUTER WELDMENT pose grease as shown in the Maintenance Schedule.
2. INNER WELDMENT If lift truck is used in dirty, dusty, or difficult condi-
3. FREE-LIFT CHAIN
4. FREE-LIFT CYLINDER tions, lubrication of the fork pins and guides may be
5. MAIN LIFT CYLINDER required more frequently. Inspect the forks for wear.
6. LOWERING CONTROL VALVE (EXTERNAL) See Maintenance Procedures Every 8 Hours or Daily
for the procedures to inspect the forks. See Figure 25.
Figure 23. Two-Stage Mast With Full Free Lift
MAST PIVOT PINS AND MOUNTING

HARDWARE
Lubricate the mast pivot pins at the grease fittings
on the pivot pins. Use multipurpose grease shown
in the Maintenance Schedule. See Figure 24. Check
the mast mounting capscrews on the retainer caps.
Tighten capscrews to the torque value shown in the
Maintenance Schedule.
1. FORK 5. WEDGE
2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN
4. WASHER ASSEMBLY
Figure 25. Fork Lock Pin Assembly
32
8000 SRM 1339 Maintenance Procedures After First 100 Hours or 2 Months of Service
INTEGRAL SIDESHIFT CARRIAGE and proper tracking during operation. Adjust/re-

pair/replace hoses/components as necessary.
Check Upper and Lower Bearings
1. Lower the carriage completely and remove the
forks.
2. Remove the backrest and the lower mounting

hooks from the sideshift carriage.
3. Use a crane with a capacity of at least 450 kg

(1000 lb) to lift the outer frame away from the
inner carriage.
4. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
a. If either of the upper bearings is worn to less

than 2.50 mm (0.09 in.) thickness, replace
both of the upper bearings by driving the up-
per bearings out of the carriage bar. See Fig-
ure 26.
b. If either of the lower bearings is worn to NOTE: TWO- AND THREE-STAGE FULL FREE-LIFT
less than 2.50 mm (0.09 in.) thickness, re- CARRIAGE SHOWN.
place both of the lower bearings by prying the
1. UPPER BEARING
lower bearings from the lower carriage bar. 2. LOWER HOOK
3. LOAD ROLLER
5. Lubricate the bearings at the lube fittings with 4. SNAP RING
multipurpose grease as shown in the Mainte- 5. SIDESHIFT CYLINDER
nance Schedule. See Figure 26. 6. LOWER BEARING
7. SHIMS
8. INNER CARRIAGE
HEADER HOSES, HOSE FITTINGS, AND 9. LUBE FITTING
CLAMPS 10. OUTER FRAME
Visually inspect hoses/fittings for hydraulic leaks; Figure 26. Integral Sideshift Carriage
hose covers for cuts, cracks, or exposed reinforce-
ment; defective/broken clamping devices or sheaves;
33
Maintenance Procedures Every 500 Hours or Three Months 8000 SRM 1339
Maintenance Procedures Every 500 Hours or Three Months

NOTE: Perform the checks in the Maintenance Pro- Water in the bearings of the sheaves and the
cedures Every 8 Hours or Daily section prior to per- link pins of chains can also shorten the service
forming the procedures in this section. life of these parts.
TIRE AND WHEEL ASSEMBLIES NOTE: The load rollers and sheaves have sealed bear-
ings that do not need additional lubrication.
Inspect the wheel rims for rust and cracks. DO NOT
weld a cracked wheel rim or straighten a bent rim. Lubricate the sliding surfaces and the load roller sur-
Welding, heating, or bending a wheel rim can weaken faces along the full length of the channels of the mast
its capacity. Always replace damaged tires or wheel and carriage as shown in Figure 27 and Figure 28.
rims immediately. DO NOT operate a truck with a Apply lubricant only to the indicated surfaces.
broken stud or missing lug nuts.
MAST AND CARRIAGE

Mast Sliding Surfaces
WARNING
Use special safety precautions when working
on or near the mast or carriage. See Safety Pro-
cedures When Working Near Mast.
DO NOT work under a raised carriage. Lower

the carriage or install a safety chain to prevent
the carriage from lowering when performing
maintenance on the mast and lift chains.
Cleaning solvents can be flammable and toxic A. UPPER LOAD ROLLERS

and can cause skin irritation. When using B. LOWER LOAD ROLLERS
mendations of the manufacturer. 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE SURFACES WHERE LOAD
ROLLERS TRAVEL
CAUTION 3. LOAD ROLLER
DO NOT use steam or high-pressure water to
Figure 27. Mast Lubrication
clean the load rollers or the lift chains. Steam
and high-pressure water can remove the lu-
brication from the bearings in the load rollers.
34
8000 SRM 1339 Maintenance Procedures Every 500 Hours or Three Months
Mast Pivot Pins, Bushings, and Mounting

Hardware
Lubricate the mast pivot pins with multipurpose
grease at the grease fittings on the pivot pins. Use
multipurpose grease shown in the Maintenance
Schedule. See Figure 29. Check the mast mounting
capscrews on the retainer caps. If needed, tighten
capscrews to the torque value shown in the Mainte-
nance Schedule.
Header Hoses
Visually inspect hoses/fittings for hydraulic leaks;
hose covers for cuts, cracks, or exposed reinforce-
ment; defective/broken clamping devices or sheaves;
and proper tracking during operation. Adjust/re-
pair/replace hoses/components as necessary.
1. GREASE FITTING 3. OUTER MAST

2. PIVOT PIN
Figure 29. Mast Mounting Lubrication
NOTE: TYPICAL MAST SHOWN.

1. OUTER WELDMENT
2. INNER WELDMENT
3. FREE-LIFT CHAIN
4. FREE-LIFT CYLINDER
5. MAIN LIFT CYLINDER
6. LOWERING CONTROL VALVE (EXTERNAL)
Figure 28. Two-Stage Mast With Full Free Lift
35
Fourth Function Mini Rollers Lubrication 2. Remove four nuts, spacers, and capscrews from
hose bracket. See Figure 30.
WARNING 3. Remove hose bracket and mini rollers from free-
When working on or near the mast, see Safety lift cylinder.
Procedures When Working Near Mast in this
SRM 4. Clean hose brackets and lubricate mini rollers
with multipurpose grease shown in the Mainte-
If the lift truck is equipped with a four function mast, nance Schedule.
the mini rollers for the fourth function hoses need
to be lubricated at the 500 hours/3 months service 5. Install hose brackets and mini rollers to free-lift
interval. The fourth function mini rollers are located cylinder using four nuts, spacers, and capscrews.
on top of the free-lift cylinder. See Figure 30.
6. Remove blocks from carriage and lower carriage
1. To lubricate the mini rollers, raise the carriage to increase tension of hoses on hose sheaves.
to remove tension and loosen the fourth function
hoses. Place blocks under carriage to keep fourth
function hoses loose.
NOTE: SEVERAL MAST COMPONENTS OMITTED FOR CLARITY.

1. CAPSCREW 5. NUT
2. LEFT HOSE BRACKET 6. FREE-LIFT CYLINDER
3. MINI ROLLERS 7. FREE-LIFT CHAIN
4. SPACER 8. RIGHT HOSE BRACKET
Figure 30. Fourth Function Mini Rollers Lubrication
36
Lift Chain Lubrication
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
SRM
DO NOT repair worn or damaged lift chains. If

a lift chain is worn or damaged, both lift chains
must be replaced.
NOTE: Perform this maintenance only if not perform-

ing the 2000 hours maintenance procedures. Other-
wise, go to the Maintenance Procedures Every 2000
Hours or Yearly for lift chain lubrication procedures.
Lubricate lift chains with SAE 30W engine oil. The

best procedure is to remove the chains from the lift
truck and soak them in engine oil. Be sure to clean
any dirt or grease from chains before lubricating. DO
NO USE STEAM TO CLEAN THE LIFT CHAINS. Pitch Wear Limit
Total length of
The maximum
Lift Chain Wear Check 20 links (pitch)
length of 20
of new chain
links.
WARNING
When working on or near the mast or carriage, 12.7 mm 254.0 mm 261.6 mm
refer to Safety Procedures When Working Near (0.5 in.) (10.0 in.) (10.3 in.)
Mast in this section. 15.90 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
DO NOT work under a raised carriage. Lower 19.10 mm 381.0 mm 392.4 mm
the carriage or use a safety chain to prevent (0.75 in.) (15.0 in.) (15.4 in.)
the carriage from lowering when doing main- 25.4 mm 508.0 mm 523.3 mm
tenance on the mast and lift chains. (1.0 in.) (20.0 in.) (20.6 in.)
31.80 mm 635.0 mm 654.10 mm
1. If a section of chain is 3% longer than a similar (1.25 in.) (25.0 in.) (25.75 in.)
section of new chain, the chain is worn and must 44.50 mm 889.0 mm 915.70 mm
be replaced. If a chain scale is available (Hyster (1.75 in.) (35.0 in.) (36.05 in.)
Part No. 599737), check the lift chains as shown 50.8 mm 1016.0 mm 1046.5 mm
in Figure 31. If a chain scale is not available, (2.0 in.) (40.0 in.) (41.2 in.)
measure 20 links of chain. Measure from the cen-
ter of a pin to the center of another pin 20 pitches
NOTE: THE INSTRUCTIONS FOR MEASURING
away. Compare the length with the chart in Fig-
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
ure 31. Replace the chain if the length of 20 links
SCALE.
of the worn section is more than the maximum
wear limit. 1. CHAIN WEAR SCALE
Figure 31. Lift Chains Check
37
INTEGRAL SIDESHIFT CARRIAGE b. If either of the lower bearings is worn to

less than 2.50 mm (0.09 in.) thickness, re-
Check Upper and Lower Bearings place both of the lower bearings by prying the
lower bearings from the lower carriage bar.
1. Lower the carriage completely and remove the
forks. 5. Lubricate the bearings at the lube fittings with
multipurpose grease as shown in the Mainte-
2. Remove the backrest and the lower mounting nance Schedule. See Figure 32.
hooks from the sideshift carriage.
Fork Guides and Pins
3. Use a crane with a capacity of at least 450 kg
(1000 lb) to lift the outer frame away from the Lubricate the fork pins and guides with multipur-
inner carriage. pose grease as shown in the Maintenance Schedule.
If lift truck is used in dirty, dusty or difficult condi-
4. Clean the bearing areas. Inspect the sideshift
tions, lubrication of the fork pins and guides may be
bearings for wear as follows:
required more frequently. Inspect the forks for wear.
a. If either of the upper bearings is worn to less See Maintenance Procedures Every 8 Hours or Daily
than 2.50 mm (0.09 in.) thickness, replace for the procedures to inspect the forks. See Figure 33.
both of the upper bearings by driving the up-
per bearings out of the carriage bar. See Fig- Check Lower Mounting Hook
ure 32.
Inspect the lower mounting hooks for wear. Replace
the hooks if they are worn beyond the wear limit.
The wear limit clearance range is 0.76 mm (0.03 in.)
minimum and 1.52 mm (0.06 in.) maximum. See A
in Figure 34.
1. FORK 5. WEDGE
2. LOCK PIN 6. KNOB
NOTE: TWO- AND THREE-STAGE FULL FREE-LIFT 3. SPRING 7. LOCK PIN
CARRIAGE SHOWN. 4. WASHER ASSEMBLY
1. UPPER BEARING 6. LOWER BEARING Figure 33. Fork Lock Pin Assembly
2. LOWER HOOK 7. SHIMS
3. LOAD ROLLER 8. INNER CARRIAGE
4. SNAP RING 9. LUBE FITTING
5. SIDESHIFT 10. OUTER FRAME
CYLINDER
Figure 32. Integral Sideshift Carriage, Check

Bearings
38

A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
TILT CYLINDER ROD END PINS

Lubricate the tilt cylinder rod end pins with multi-
purpose grease shown in the Maintenance Schedule.
See Figure 35.
Figure 34. Lower Mounting Hooks Wear Limit

and Clearance Adjustment
A. FRAME ATTACHMENT B. MAST ATTACHMENT

1. PIN
2. ROD END PIN
3. LUBRICATION FITTING
Figure 35. Tilt Cylinder Rod End Pins, Lube
39
CONTROL LEVERS, PEDALS, AND HYDRAULIC BREATHER CAP

HINGES
The hydraulic breather cap allows air to enter the
Lubricate linkages, pedal shafts, control cables hydraulic tank when the hydraulic oil is pumped
(throttle and parking brake) hood hinges, and seat out to the cylinders. When the hydraulic oil returns
rails. Use a silicone spray lubricant, Hyster Part to the tank, air is expelled through the hydraulic
Number 328388. breather cap. A filter in the cap protects the hy-
draulic system from particles of dirt and other
DIRECTION AND SPEED CONTROL contaminants. If the filter becomes excessively
PEDALS dirty, air flow can be restricted, causing pressures
and vacuums to build inside the tank. If air flow
Lubricate the MONOTROL pedal or the accelerator becomes restricted through the hydraulic breather
pedal joints as needed. See the Maintenance Sched- cap, replace the assembly. Keep the hydraulic tank
ule for lubricant type to use. area clean and DO NOT overfill the hydraulic tank.
See Figure 36.
HYDRAULIC HOSES, FITTINGS, AND
CLAMPS
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
WARNING
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin
Completely lower forks to relieve hydraulic

pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
1. HYDRAULIC TANK
Inspect all hydraulic hoses for kinks, Verify that 2. HYDRAULIC FILTER
there are no crushed, flattened, or twisted hoses. 3. HYDRAULIC BREATHER CAP/DIPSTICK
Check for hard, stiff, or charred hoses. Adjust or
replace any hoses as necessary. Check all fittings Figure 36. Hydraulic Breather Cap Check
and clamps and replace if necessary.
40
SERVICE BRAKES the minimum safe level, the system may need to be
bled before returning to service. See Brake System
Master Cylinder Oil Check 1800 SRM 1332 for procedures on bleeding the brake
system.
WARNING
PARKING BRAKE
Loss of fluid from the master cylinder indicates
a leak. This condition can cause brake failure, Manual Override Handle
resulting in material damage or personal in-
jury. Repair the brake system before return- Lubricate the pivot pin on the manual override han-
ing to service if a leak is suspected. Drain and dle with multipurpose grease as shown in the Main-
flush the service brake system when contami- tenance Schedule. See Figure 38.
nated by dirt, water, or other unapproved flu-
ids.
NOTE: When adding fluid to the reservoir, use only

Dexron® III.
The service brake system is a self-contained system

filled with hydraulic oil and does not require frequent
service. However, normal operation does use a small
amount of hydraulic oil so the master cylinder reser-
voir must be checked and refilled at the 500-hr/3-
month interval.
A float switch inside the reservoir activates an indi-

cator light on the display panel if the hydraulic oil
drops below the minimum safe level between checks,
as in the case of a leak. The reservoir, mounted on
top of the master cylinder (see Figure 37), stores a
small amount of hydraulic to compensate for normal
loss.
Remove the floor plates. Locate the master cylinder

1. MASTER 3. MASTER
assembly near the brake pedal. Remove the reser- CYLINDER CAP CYLINDER
voir cap and fill the reservoir to the full mark with 2. BRAKE PEDAL RESERVOIR
hydraulic oil according to the Maintenance Schedule.
Reinstall the reservoir cap and check for leaks. If Figure 37. Master Cylinder Oil Check
there is a leak or if the fluid level has dropped below
41
1. FRONT BULKHEAD 3. PIVOT PIN

2. MANUAL OVERRIDE HANDLE 4. TRACTION MOTORS
Figure 38. Manual Override Handle
ELECTRICAL INSPECTION
Contactors
WARNING
Disconnect the battery connector to prevent
injury from electric shock before you make
any inspections or repairs to the contactors
Discharge the capacitors when you make any

electrical inspections or repairs inside of the
electrical compartment.
1. Disconnect the battery and discharge the capaci-

tors. See Discharging the Capacitors in the Intro-
duction section in the front of this service man-
ual. Place a DO NOT CONNECT BATTERY tag
on battery connector and remove key. If truck
is equipped with a keyless start switch, place a 1. CONTACTOR ASSEMBLY
cover over keyless switch. 2. TRACTION MOTOR CONTROLLER
2. Remove the floor mat and floor plate for access to Figure 39. Contactor Inspection
the contactors. See Figure 39.
42
8000 SRM 1339 Maintenance Procedures Every 2000 Hours or Yearly
3. Disconnect the power cable connector from con- 5. Connect the power cable connector to contactor
tactor assembly. assembly.
4. Inspect the contactors. The contacts are made 6. Install the floor plate and floor mat.
of a special silver alloy. The contacts will look
black and rough from normal operation. This 7. Remove the DO NOT CONNECT BATTERY tag
condition does not cause problems with the oper- from truck battery connector and reconnect the
ation of the lift truck. Cleaning is not necessary. battery. If lift truck is equipped with a keyless
DO NOT USE A FILE ON THE CONTACTS. DO start switch, remove cover from switch.
NOT LUBRICATE THE CONTACTS. If the con-
tactors need to be replaced, see service manual
Electrical System 2200 SRM 1337 for proce-
dures.
Maintenance Procedures Every 2000 Hours or Yearly

Perform the Maintenance Procedures Every 8 Hours counterweight for access to the hydraulic filter.
or Daily and Maintenance Procedures Every 500 Unscrew and remove filter lid, O-ring, and spring
Hours or Three Months prior to performing the from filter head. See Figure 40.
procedures in this section.
NOTE: Have a container large enough to hold the fil-
HYDRAULIC SYSTEM ter assembly and allow for final hydraulic oil drain-
ing. See the Maintenance Schedule for oil quantity.
Hydraulic Oil Filter, Change
2. Remove the hydraulic filter element from the fil-
ter housing and place into the container. Cover
WARNING the filter head to prevent any foreign materials
At operating temperature, the hydraulic oil is from getting into the hydraulic tank.
HOT. DO NOT permit the hot oil to touch the
skin and cause a burn.
CAUTION
Filter element must be installed with the debris
CAUTION cup on the bottom and the check valve on the
DO NOT permit dirt to enter the hydraulic sys- top. Installing the filter element upside down
tem when the oil level is checked or the filter could result in severe damage to the hydraulic
is changed. Dirt can cause damage to the com- system, including blown hoses.
ponents of the hydraulic system.
3. Install the new hydraulic filter element into filter
Never operate the hydraulic pump without oil housing.
in the hydraulic system. The operation of the
hydraulic pump without oil will damage the 4. Lubricate new O-ring with clean hydraulic oil
pump. and install it on filter head. Inspect spring and
filter lid. If worn or damaged, replace with new
parts. See Parts Manual.
CAUTION
Disposal of lubricants and fluids must meet lo- 5. Install spring and filter lid onto filter head.
cal environmental regulations. Tighten filter lid to 13.6 N•m (120 lbf in). See
Figure 40.
1. Put lift truck on a level surface and lower the
mast. Remove the tow pin and remove cover from
43
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1339
NOTE: COUNTERWEIGHT COVER NOT SHOWN FOR CLARITY.

1. HYDRAULIC TANK 7. SPRING
2. HYDRAULIC FILTER 8. LID
3. FILTER HOUSING 9. BREATHER CAP/DIPSTICK
4. FILTER HEAD 10. PAN HEAD SCREW
5. FILTER ELEMENT 11. TANK LEVEL SENSOR PLUG
6. O-RING
Figure 40. Hydraulic Filter Assembly
44
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
6. Turn lift truck power ON; operate hydraulic con-

trols for 30 seconds. Check for leaks. Turn lift
truck power OFF and check hydraulic oil level.
Add oil if necessary. If using filtered oil: re-
move tank level sensor or tank level sensor plug
and add oil. If using non-filtered oil: remove
filter lid and pour hydraulic oil through filter el-
ement; install filter lid, tighten lid to 13.6 N•m
(120 lbf in). Use hydraulic oil shown in the Main-
tenance Schedule. See Figure 40.
7. Install the cover on the counterweight and install

the tow pin.
Hydraulic Breather, Check

1. HYDRAULIC BREATHER
WARNING 2. CAPSCREW
At operating temperature, the hydraulic oil is Figure 41. Hydraulic Breather
skin and cause a burn.
WARNING
CAUTION Cleaning solvents can be flammable and toxic
and may cause skin irritation. When using
DO NOT permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
mendations of the manufacturer.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. Compressed air can move particles so that they
cause injury to the user or to other personnel.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
is away from all personnel. Wear protective
hydraulic pump without oil will damage the
goggles or a face shield to prevent injury to the
pump.
eyes.
CAUTION 3. Wash breather in solvent and use compressed air

to dry.
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 4. Inspect breather for damage. Replace if dam-
aged. See the Parts Manual if replacement is
1. Put lift truck on a level surface and lower the
required.
mast. Remove the tow pin and counterweight
cover from counterweight for access to the hy- 5. Install the breather and three capscrews into the
draulic breather. See Figure 41. hydraulic tank.
2. Remove three capscrews and breather from hy- 6. Install cover to counterweight and install the tow
draulic tank. pin.
45
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1339
STEERING AXLE
Steering Actuator and Steering Plate
Torque Check
The steering actuator and steering plate are
mounted to the rear of the frame below the coun-
terweight. The steering tire and wheel assemblies,
steering actuator and steering plate support much of
the weight of the battery, frame, and counterweight.
The action of steering pushes and pulls on the actu-
ator in various directions.
The mounting bolts and nuts that attach the actua-

tor to the frame should be checked to ensure proper
torques every 2000 hours or yearly. The bolts and
nuts that attach the steering plate to the frame
should also be checked. For access to the mounting
bolts and nuts for the actuator and steering plate,
perform the following: NOTE: BOTTOM VIEW SHOWN.
1. Put lift truck on blocks for access to the steering 1. STEERING PLATE BOLTS AND NUTS
actuator and steering plate bolts and nuts. See 2. STEERING ACTUATOR BOLTS AND NUTS
the Introduction section at the beginning of this 3. STEERING ACTUATOR
SRM for the procedures on putting the lift truck 4. STEERING PLATE
on blocks. Turn the key or keyless switch to the
Figure 42. Steering Actuator and Steering
OFF position.
Plate Torque Check
2. Remove the steering wheel and tire from steering
6. After all bolts and nuts on both the steering ac-
axle. See the Wheel and Tires section for proce-
tuator and steering plate, have been checked, in-
dures on removing the steering wheels and tires.
stall the steering wheels and tires to the steering
3. Check the three bolts and nuts that attach the axle. See the Wheel and Tires section for proce-
steering actuator to the steering plate. If they dures on installing the steering wheels and tires.
are loose, tighten nuts and bolts to 270 N•m
(200 lbf ft). See Figure 42. TRANSAXLE OIL LEVEL CHECK
4. Check the four bolts and nuts that secure the Place the lift truck on blocks as described in How to
steering plate to the counterweight. See Fig- Put Lift Truck on Blocks located in the front of this
ure 42. If there is play between the steering plate manual and remove the drive wheel assembly.
and the bolts, remove the bolts, nuts, and wash- Each transaxle has its own separate oil supply and
ers from the steering actuator one at a time. each transaxle must be checked separately. Remove
5. Apply Loctite® 271 to the threads of each bolt the oil fill plug to check the level of the oil. See Fig-
and reinstall the mounting bolts, washers and ure 43. The oil should be level with the bottom of
nuts. The torque value for each mounting bolt the hole. If it is necessary to add oil, add oil through
is 305 N•m (225 lbf ft). the fill plug hole until the oil is level with the bottom
of the hole. Install the oil fill plug and torque it to
22 N•m (195 lbf in).
46
resulting in material damage or personal in-

jury. Repair the brake system before return-
ing to service if a leak is suspected. Drain and
flush the service brake system when contami-
nated by dirt, water, or other unapproved flu-
ids.
CAUTION
The brake system uses Dexron® III. Use of au-
tomotive or other unapproved fluids can dam-
age the brake system.
NOTE: Bleeding air from the brake system requires

two technicians. One technician must sit in the
seat and operate the brake pedal while the other
opens and closes the brake bleed valve located on
the transaxle housing.
To change oil in the brake system:
1. Place the lift truck on blocks as described in How

to Put Lift Truck on Blocks located in the front of
this manual. Remove the drive wheel assembly.
2. Remove the floor plates and ensure that the mas-

ter cylinder reservoir is filled with transmission
fluid (Dexron® III).
3. Put one end of a rubber hose on the bleed valve

on transaxle housing. Put the other end of the
hose into an empty container.
NOTE: RIGHT SIDE SHOWN LEFT SIDE IS SIMILAR. 4. Loosen bleed valve one turn counterclockwise to
drain brake oil from brake system. Slowly push
1. OIL FILL PLUG 3. OIL DRAIN PLUG the brake pedal, and hold it at the end stroke.
2. OIL CHECK PLUG
Close the bleed valve and release the brake
Figure 43. Transaxle Oil Level Check pedal. Check level of fluid in master cylinder
reservoir, fill as necessary.
Install the drive wheel assembly, and tighten the
wheel nuts to 170 N•m (125 lbf ft) in a diametric NOTE: The new brake oil will be easily recognizable,
pattern. Remove the lift truck from the blocks. as it is much more clear than the darker used trans-
mission fluid.
TRANSAXLE BREATHER CHECK
5. Repeat Step 1 through Step 3 until there is new
1. Inspect transaxle breather for visible damage. If brake oil exiting the bleed valve.
damaged, replace breather. See service manual
Transaxle 1300 SRM 1330 for procedure. 6. Repeat the procedure for the other side of the
transaxle.
BRAKE OIL CHANGE 7. Install the drive wheel assembly and tighten to
170 N•m (125 lbf ft) in a diametric pattern. Re-
WARNING move the lift truck from the blocks.
Loss of fluid from the master cylinder indicates
a leak. This condition can cause brake failure,
47
Maintenance Procedures Every 4000 Hours or Two Years 8000 SRM 1339
INTEGRAL SIDESHIFT CARRIAGE is away from all personnel. Wear protective

goggles or a face shield to prevent injury to
Replace all four bearings regardless of wear. The pro- the eyes.
cedures for replacing the bearings are in the Mainte-
nance Procedures Every 500 Hours or Three Months NOTE: Cleaning and lubrication of lift chains will be
section under Integral Sideshift Carriage. needed more frequently in very dirty, dusty, or con-
taminated applications.
LIFT CHAINS
Remove the lift chains. Clean the lift chains by soak-
ing them in a solvent that has a petroleum base for at
WARNING
least 30 minutes. Use compressed air to completely
Cleaning solvents can be flammable and toxic dry the chains when they are clean.
and can cause skin irritation. When using
cleaning solvents, always follow the recom- Lubricate the lift chains by soaking them in SAE
mendations of the manufacturer. 30W engine oil for at least 30 minutes. Remove the
chains from the oil. Hang the chains for one hour so
Compressed air can move particles so they excess oil will drain from the chains.
cause injury to the user or to other personnel.
Maintenance Procedures Every 4000 Hours or Two Years

Perform the Maintenance Procedures Every 8 Hours
or Daily, Maintenance Procedures Every 500 Hours
CAUTION
or Three Months, and Maintenance Procedures Ev- Disposal of lubricants and fluids must meet lo-
ery 2000 Hours or Yearly prior to performing the pro- cal environmental regulations.
cedures in this section.
1. Put lift truck on blocks for access to the hydraulic
oil drain hose underneath the lift truck. See
HYDRAULIC OIL CHANGE
the Introduction section at the beginning of this
SRM for the procedures on putting the lift truck
WARNING on blocks. Turn the key or keyless switch to the
At operating temperature, the hydraulic oil is OFF position.
skin and cause a burn. 2. Remove tow pin and counterweight cover from
counterweight to allow access to breather cap/
dipstick
CAUTION
DO NOT permit dirt to enter the hydraulic sys- 3. Remove the breather cap/dipstick to allow for
tem when the oil level is checked or the filter faster draining.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. 4. Locate the hydraulic tank drain hose. See Fig-
ure 44. Cut the two strap clamps retaining the
Never operate the hydraulic pump without oil drain hose and route drain hose under the side
in the hydraulic system. The operation of the of the frame to the outside of the lift truck. Posi-
hydraulic pump without oil will damage the tion the drain hose to drain into a container suit-
pump. able for storing used hydraulic oil. See the Main-
tenance Schedule for hydraulic oil quantity and
container size needed.
48
8000 SRM 1339 Maintenance Procedures Every 4000 Hours or Two Years
1. BUTTON HEAD RIVET 6. HYDRAULIC MOTOR

2. SCREW CLAMP 7. DRAIN HOSE
3. HYDRAULIC TANK 8. STRAP CLAMPS
4. HYDRAULIC OIL FILTER 9. TANK LEVEL SENSOR PLUG
5. HYDRAULIC BREATHER CAP/DIPSTICK
Figure 44. Hydraulic Oil Change
5. Remove the screw clamp and remove the button oil; install sensor or plug. If using non-filtered
head rivet and allow oil to drain into container. oil: remove filter lid and pour hydraulic oil into
tank through filter element; install filter lid. See
6. When the oil has drained, reinstall the button Figure 44. DO NOT overfill the hydraulic tank.
head rivet into the drain hose and secure with
screw clamp. 9. Operate the lift pump for one to two minutes to
purge air from the hydraulic system. Remove
7. Coil hose and secure hose into position with two breather cap/dipstick and check the oil level on
new strap clamps. the dipstick. If more oil is needed, add oil shown
in the Maintenance Schedule.
8. Fill the hydraulic tank to the proper level with
new hydraulic oil as shown in the Maintenance 10. Remove lift truck from blocks.
Schedule. If using filtered oil: remove tank
level sensor or tank level sensor plug and add
49
STEERING DIRECTION SENSOR

INSPECTION
Fixed Steering Column
NOTE: Tag all electrical connectors during removal
to aid in installation.
1. Disconnect battery connector. Discharge the ca-

pacitors. See Discharging the Capacitors in the
Introduction section in the front of this service
manual.
2. Remove horn button, nut, and rod from steering

wheel. See Figure 45.
3. Remove hex nut and steering wheel from steer-

ing column. If necessary, use puller tool to re-
move steering wheel. See Figure 45.
4. Remove steering column upper cover by pressing

from both sides near the bottom and pulling up.
Clips should remain attached to cover. See Fig-
ure 46.
5. Disconnect spring from sensor assembly. See 1. STEERING COLUMN UPPER COVER
Figure 46. 2. FIXED STEERING COLUMN
3. SPRING
4. SENSOR ASSEMBLY
Figure 46. Fixed Steering Column Covers
NOTE: TELESCOPIC STEERING COLUMN SHOWN.

1. STEERING 4. ROD
COLUMN 5. HEX NUT
2. HORN BUTTON 6. STEERING WHEEL
3. NUT
1. SENSOR ASSEMBLY
Figure 45. Steering Wheel 2. MAGNET GEAR TEETH
3. COLUMN GEAR TEETH
Figure 47. Steering Gears
50
8000 SRM 1339 Maintenance Procedures Every 4000 Hours or Two Years
6. Swing open sensor assembly. It will only swing

30° with the lower cover installed. See Figure 47.
7. Inspect magnet gear teeth. See Figure 47.

Replace sensor assembly if magnet teeth are
cracked or missing. See Electrical System
2200 SRM 1337 for sensor replacement proce-
dures.
8. Connect battery connector, turn lift truck ON,

and rotate steering column to fully inspect col-
umn gear teeth. See Figure 47. Replace column
gear if teeth are cracked or missing. See Steer-
ing System 1600 SRM 1331 for column gear re-
placement procedure. Disconnect battery con-
nector.
9. Swing sensor assembly back to original position.
10. Connect spring to sensor assembly.
11. Install steering column upper cover by pressing

from both sides and pushing against lower cover
until snapped in place. See Figure 46.
12. Install steering wheel and hex nut onto steering

column. See Figure 45. Tighten hex nut to 40 to
54 N•m (30 to 40 lbf ft).
13. Install rod, nut, and horn button onto steering 1. TELESCOPIC STEERING COLUMN
2. STEERING COLUMN TOP COVER
wheel. See Figure 45. 3. STEERING COLUMN TELESCOPING COVER
4. STEERING COLUMN UPPER COVER
14. Connect battery connector. 5. CAPSCREW
6. WASHER
Telescopic Steering Column 7. SPRING
8. SENSOR ASSEMBLY
to aid in installation. Figure 48. Telescopic Steering Column Covers
1. Disconnect battery connector. Discharge the ca- 6. Remove steering column telescoping cover from
pacitors. See Discharging the Capacitors in the telescopic steering column. See Figure 48.
manual. 7. Remove capscrew, washer, and steering column
upper cover from telescopic steering column. See
2. Remove horn button, nut, and rod from steering Figure 48.
8. Disconnect spring from sensor assembly. See
3. Remove hex nut and steering wheel from steer- Figure 48.
ing column. If necessary, use puller tool to re-
move steering wheel. See Figure 45. 9. Swing open sensor assembly. It will only swing
30° with the lower cover installed. See Figure 47.
4. Telescope steering column to fully UP position.
10. Inspect magnet gear teeth. See Figure 47.
5. Remove steering column top cover, by pressing Replace sensor assembly if magnet teeth are
both sides near the bottom and pulling up. Clips cracked or missing. See Electrical System
should remain attached to cover. See Figure 48. 2200 SRM 1337 for sensor replacement proce-
dures.
51
11. Reconnect battery connector, turn lift truck ON, 4. Telescope column to fully UP position.
and rotate steering column to fully inspect col-
umn gear teeth. See Figure 47. Replace column 5. Remove steering column top cover from tele-
gear if teeth are cracked or missing. See Steer- scopic steering column by pressing both sides
ing System 1600 SRM 1331 for column gear re- near the bottom and pulling up. Clips should
placement procedure. Disconnect battery con- remain attached to cover. See Figure 48.
nector.
6. Remove steering column telescoping cover from
12. Swing sensor assembly back to original position. telescopic steering column. See Figure 48.
13. Connect spring to sensor assembly. 7. Remove capscrew, washer, and steering column
upper cover from telescopic steering column. See
14. Install steering column upper cover, washer, and Figure 48.
capscrew onto telescopic steering column. See
Figure 48. 8. Lubricate telescopic steering column with man-
ual steering gear grease. See Figure 49. See
15. Install steering column telescoping cover onto Maintenance Schedule.
telescopic steering column. See Figure 48.
16. Install steering column top cover, by pressing

down onto telescopic steering column. See Fig-
ure 48.
17. Lower telescopic steering column to fully DOWN

position.
18. Install steering wheel and hex nut onto steering

column. See Figure 45. Tighten hex nut to 40 to
54 N•m (30 to 40 lbf ft).
19. Install rod, nut, and horn button onto steering

20. Connect battery connector.
TELESCOPIC STEERING COLUMN

LUBRICATION
to aid in installation.
1. Disconnect battery connector. Discharge the ca- NOTE: BOLD ARROW INDICATES GREASE APPLI-
pacitors. See Discharging the Capacitors in the CATION LOCATION.
Figure 49. Telescopic Steering Column
manual.
Lubrication
2. Remove horn button, nut, and rod from steering
3. Remove hex nut and steering wheel from tele-

scopic steering column. If necessary, use puller
tool to remove steering wheel. See Figure 45.
52
8000 SRM 1339 Welding Repairs
9. Install steering column upper cover, washer, and 13. Install steering wheel and hex nut onto telescopic
capscrew onto telescopic steering column. See steering column. See Figure 45. Tighten hex nut
Figure 48. to 40 to 54 N•m (30 to 40 lbf ft).
10. Install steering column telescoping cover onto 14. Install rod, nut, and horn button onto steering
telescopic steering column. See Figure 48. wheel. See Figure 45.
11. Install steering column top cover, by pressing 15. Connect battery connector.
down onto telescoping cover. See Figure 48.
12. Lower telescopic steering column to fully DOWN

position.
Welding Repairs
removal of all paint (prime and finish coats) to
WARNING the metal around the area to be welded, local
Welding can cause a fire or an explosion. Al- ventilation, and/or supplied-air respiratory
ways follow the instructions in the Frame sec- protection.
tion of the service manual if a hydraulic tank
must be welded. Make sure there is no fuel, oil,
or grease near the weld area. Make sure there CAUTION
is good ventilation in the area where the weld- When an arc welder is used, always disconnect
ing must be done. the battery connector on the lift truck. This
action will prevent damage to the motor con-
DO NOT heat, weld, or bend forks. Forks are trollers.
made of special steel using special methods.
Get information from your dealer for Hyster Connect the ground clamp for the arc welder as
lift trucks before welding on a mast. close as possible to the weld area. This action
will prevent damage to a bearing from the large
current from the welder.
WARNING
Forklift frames and components may be NOTE: Remove all electronic controllers prior to arc
painted with a catalyzed paint, such as welding on these lift trucks. The removal procedures
polyurethane or a two-part primer. Weld- for the electronic controllers are outlined in Electri-
ing, burning, or other heat sufficient to cause cal System 2200 SRM 1337.
thermal decomposition of the paint may re-
lease isocyanates. These chemicals are allergic All welding repairs require special welding instruc-
sensitizers to the skin and respiratory tract tions. Talk to your dealer for Hyster lift trucks be-
and overexposure may occur without odor fore welding on the lift truck. If an acetylene or arc
warning. Should work be performed, utilize welder is used, perform the procedures in the previ-
good industrial hygiene practices including ous WARNING and CAUTION.
53
Lift and Tilt System Leak Check 8000 SRM 1339
Lift and Tilt System Leak Check

LIFT CYLINDERS LEAK CHECK in the NEUTRAL position, there are leaks inside
the hydraulic system. The maximum speed that
WARNING the carriage is allowed to lower is 50 mm (2 in.)
per 10 minutes when the hydraulic oil is 30°C
Never allow any person under a raised car-
(86°F). If the oil temperature is 70°C (160°F), the
riage. Do not put any part of your body in or
maximum speed that the carriage can lower is
through the lift mechanism unless all parts of
150 mm (6 in.) per 10 minutes.
the mast are completely lowered, the key is in
the OFF position, and the key is removed. 3. If the leak rate is greater than the above specifi-
cations, check the lift cylinders for internal leaks.
Before making any repairs, use chains on the
Remove the load from the forks. Install a gate
mast weldments and carriage so that they can-
valve in the supply line between the main con-
not move. Make sure the moving parts are at-
trol valve and the mast. Put a capacity load on
tached to the parts that cannot move.
the forks again. Raise the carriage and load so
DO NOT try to find hydraulic leaks by putting that the rods of the main lift cylinders extend at
your hand on hydraulic components under least 0.60 m (2 ft). Close the gate valve. If the car-
pressure. Hydraulic oil can be injected into riage or mast weldments lower slowly, the seals
the body by pressure. in the lift cylinders are worn.
During test procedures for the hydraulic sys- 4. If the carriage and mast weldments do not move,
tem, fasten the load to the carriage with chains open the gate valve and check for movement
to prevent it from falling. Keep all personnel again. If the carriage lowers when the gate valve
away from the lift truck during the tests. is open, check for leaks in the hydraulic lines or
fittings. If no leaks are found, the main control
1. Operate the hydraulic system. Put a capacity valve may have a defect. Remove the load from
load on the forks and raise and lower the load the forks.
several times. Lower the load and tilt the mast
forward and backward several times. Check for TILT CYLINDER LEAK CHECK
leaks.
To check the tilt system for hydraulic leaks, see the
2. Raise the carriage and load so that the rods of the service manual section Cylinder Repair 2100 SRM
main lift cylinders extend at least 60 cm (2 ft). If 1382 for the procedures.
the carriage lowers slowly with the control valve
54
8000 SRM 1339 Battery Maintenance
Battery Maintenance
HOW TO CHARGE BATTERY NOTE: This series of trucks can have one of two types
of batteries. One type has removable cell caps. A
WARNING green key for battery voltage shows in the window of
the battery connector for batteries with cell caps. The
The acid in the electrolyte can cause injury.
other type has sealed cells and the electrolyte cannot
If electrolyte is spilled, use water to flush the
be checked. A gray key for battery voltage shows in
area. Make the acid neutral with a solution of
the window of the battery connector for sealed bat-
sodium bicarbonate (soda) and water. Acid in
teries. These sealed batteries also require a different
the eyes must be immediately flushed with wa-
charger.
ter.
NOTE: Many installations have battery chargers
Batteries generate explosive fumes when they
that can follow a program to automatically charge a
are being charged. Keep fire, sparks, and burn-
battery according to recommendations of the battery
ing material away from the battery charger
manufacturer. Use the recommendations of the
area. Prevent sparks from the battery connec-
battery manufacturer for charging the battery.
tors.
Correct use of the hydrometer and proper operation
Charge batteries only in the special area for
of the battery charger is important. See Figure 50.
charging batteries. When charging the bat-
Follow the instructions of the charger manufacturer.
teries, keep the vent caps clean. The battery
Never let the battery discharge below the minimum
charger area must have ventilation so that
value given by the battery manufacturer. A fully
explosive fumes are removed. Open the hood
charged battery will have a specific gravity of 1.265
over the battery or remove the cover if the
to 1.310 at 25°C (77°F). Never charge a battery at a
battery has a cover.
rate that will raise the electrolyte temperature above
Disconnect the battery when doing cleaning 49°C (120°F). Never let a battery stay discharged for
and maintenance. long periods.
NORMAL CHARGE: This is the charge that is nor-

CAUTION mally given to a battery that is discharged from nor-
Never connect the battery charger plug to mal service. Many users give this charge at a regular
the plug of the lift truck; you can damage the interval based on usage. This practice will keep the
electronic controller. Make sure the battery battery fully charged if the battery is not discharged
charger voltage is the correct voltage for the below the limit. Always use a hydrometer to check
battery. the battery if the interval charge cycle is used. Fre-
quent charging of a battery that has a 2/3 or more
Use only battery chargers approved by the bat- charge can decrease battery life.
tery manufacturer or dealer.
CAUTION
Always make sure the color in the window of
the charger connector is the same as the color
in the window of the battery connector.
55
Battery Maintenance 8000 SRM 1339
an equalizing charge, there may be a defective cell.

Consult your battery dealer.
See the section Industrial Battery 2240 SRM 1 for

additional information on the charging and mainte-
nance of a battery.
NOTE: Many users have battery chargers that can

follow a program to automatically charge a battery
according to recommendations of the battery man-
ufacturer. Use the recommendations of the battery
manufacturer for charging the battery.
HOW TO CHANGE BATTERY

Remove the Battery
WARNING
Specific Electrolyte Correction Correct Batteries are heavy and can cause an injury.
Gravity Temp. Points Value Use care to avoid injury. DO NOT put hands,
Reading arms, feet, or legs between the battery and a
1.210 31°C (88°F) +0.003 1.213 solid object.
1.210 27°C (81°F) +0.001 1.211 Make sure the capacity of the crane and
1.210 25°C (77°F) 0.000 1.210 spreader bar is greater than the weight of the
battery. The weight of the battery is normally
1.210 18°C (64°F) 0.004 1.206 shown on the battery case. The maximum
+0.001 or 0.001 for each 2°C (35.6°F) from the battery weight is shown on the lift truck
25°C (77°F) base value. Nameplate. The spreader bar must NOT be
made of metal or it must have insulated straps.
Figure 50. Battery Check The replacement battery must fit the battery
area correctly. Adjust the front spacer plate to
NOTE: Some batteries are maintenance free and do
prevent battery movement in the battery com-
not require checking the electrolyte. DO NOT at-
partment. Make sure that the battery voltage
tempt to check electrolyte in batteries with sealed
and weight of the replacement battery is cor-
cells.
rect as shown on the Nameplate.
EQUALIZING CHARGE: This charge is at a low rate
Before connecting the battery, make sure the
and balances the charge in all of the cells. The equal-
key or keyless switch is in the OFF position and
izing charge is normally given approximately once a
the parking brake is set.
month. It is a charge at a slow rate for 3 to 6 hours
in addition to the regular charging cycle.
CAUTION
DO NOT give an equalizing charge more than once Batteries must be discarded according to local
a week. The most accurate specific gravity mea- environmental regulations.
surements for a charged battery will be after an
equalizing charge. If the specific gravity difference 1. Using the tilt memory lever, tilt the steering col-
is more than 0.020 between cells of the battery after umn fully upright. See Figure 51.
56
NOTE: OPTIONAL TELESCOPIC STEERING COL-

UMN SHOWN.
1. TILT POSITION LEVER
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 51. Steering Column Tilt Memory Lever

A. MANUAL CONTROL LEVERS
2. If lift truck is equipped with manual hydraulic B. E-HYDRAULIC ARMREST MINI-LEVERS
control levers, pull the release latch for the con- 1. MANUAL CONTROL LEVERS RELEASE LATCH
trol lever assembly and move the assembly to the 2. E-HYDRAULIC ARMREST ADJUSTMENT
forward position. On lift trucks equipped with HANDLES
E-Hydraulic control mini-levers, move the arm-
rest all the way back if necessary to raise the Figure 52. Hydraulic Control Lever Release
hood. See Figure 52.
4. Disconnect the battery connector and move it to
3. Slide the seat all the way back. Push the latch a position so that it will not be damaged during
handle to the right to raise the hood and seat to battery removal. Lift the side panels to remove
the fully raised position. them.
5. Use a spreader bar and crane to lift the battery

from the lift truck. See Figure 53.
57
Battery Maintenance 8000 SRM 1339
Install the Battery
WARNING
Correct operation of the battery restraint sys-
tem requires that the battery does not move
more than 13 mm (0.50 in.). Make sure the bat-
tery spacer plate is correctly adjusted. Serious
injury to personnel can occur if battery spacer
plate is not adjusted correctly.
1. When a replacement battery is installed, make

sure the battery fits the battery compartment
width with a maximum of 13 mm (0.50 in.) clear-
ance. Use a spreader bar and crane and install
battery into lift truck. See Figure 53.
Figure 53. Changing Battery 2. The lift trucks are equipped with adjustable
spacers in the battery compartment. Add or
remove shims from under the front spacer bar
to control the movement of the battery. the bat-
tery is not to move more than a total of 13 mm
(0.50 in.) forward or backward. See Figure 54.
A. 13 mm (0.50 in.)
1. SPACER PLATE 3. FRONT BULKHEAD
2. ADJUSTMENT CAPSCREW 4. BATTERY
Figure 54. Battery Spacer Adjustment
58
3. Connect the battery connector. Install the side The lift trucks can be equipped for the optional side
panels. battery removal. See Figure 55. This option consists
of a battery removal door on the right side of the lift
4. Close the hood and pull latch handle to lock hood. truck and a roller or slider tray beneath the battery.
Slide seat to desired position. To remove the battery, operate the retention mecha-
nism, and remove the door from the lift truck. Posi-
5. If lift truck is equipped with E-Hydraulic
tion a suitable battery stand or roller tray next to the
mini-levers, adjust the armrest if it was moved
battery compartment. Be sure that the height of the
prior to raising the hood. If lift truck is equipped
battery stand is the same as the height of the bottom
with manual hydraulic control levers, pull
of the battery in the lift truck. Remove the battery
release lever out and move the control lever as-
from the lift truck onto the battery stand.
sembly into position over the hood. Release the
release lever to lock the control lever assembly To install the battery, position the battery and bat-
into place. tery stand next to the lift truck. Slide the battery
from the battery stand into the battery compartment
Optional Side Removal of Battery using the roller tray. Make sure the battery fits the
battery compartment width with a maximum of
WARNING 13 mm (0.50 in.) clearance. Secure the battery
Batteries are heavy and can cause an injury. retention mechanism and install the door.
Always use a battery roller stand or tray when
trucks are equipped with optional battery
rollers or slide.
1. BATTERY REMOVAL DOOR 2. RETENTION MECHANISM 3. ROLLER TRAY
Figure 55. Optional Side Battery Removal
59
Wheel and Tires 8000 SRM 1339
BATTERY SIZE SPECIFICATIONS replacing a battery to verify the truck rating to en-
sure that the battery (and spacer if so equipped) is
Batteries function as part of the lift truck’s counter- of the proper size. See the Operating Manual for
weight system. Installing a battery that is too small exact battery specifications for your lift truck.
can leave the lift truck lacking sufficient weight to
counter the rated load. Refer to the Nameplate when
Wheel and Tires

GENERAL Type of tire and tire pressure (pneumatic tires)
are shown on the Nameplate. Make sure Name-
WARNING plate is correct for type of tires on lift truck.
The type of tire and the tire pressure (pneu-
matic tires) are shown on the Nameplate. Make WARNING
sure the Nameplate is correct for the type of Wheels must be changed and tires repaired by
tires on the lift truck. trained personnel only.
Wheels must be changed and tires repaired by Deflate tire completely before removing wheel
trained personnel only. from lift truck. Air pressure in tires can cause
tire and rim parts to explode, causing serious
Always wear safety glasses. injury or death.
The lift trucks covered in this Operating Manual can Always wear safety glasses.
be equipped with either solid rubber tires that look
like pneumatic tires or solid rubber tires (often called Never loosen nuts that hold inner and outer
cushion tires). See Figure 56 and Figure 58. These wheel halves together when there is air pres-
variations in the tires can cause a variation in the sure in tire.
types of wheels and in the disassembly and assembly
procedures. 1. Put lift truck on blocks as described in How to Put
Lift Truck on Blocks at beginning of this section.
PNEUMATIC TIRES REPAIR
2. Remove air from tire. Remove valve core to make
Remove Wheels From Lift Truck sure that all air is out of inner tube. Push a wire
through valve stem to make sure that valve stem
does not have a restriction.
WARNING
A solid rubber tire that is the same shape as 3. Remove wheel nuts and remove wheel and tire
a pneumatic tire can be installed on a three- from lift truck. Lift truck tires and wheels are
piece or four-piece wheel for a pneumatic tire. heavy.
DO NOT make changes in parts of rim if this
type of solid rubber tire is installed instead of Remove Tire From Wheel
a pneumatic tire. Changes to parts of rim can
cause a failure of wheel and can cause an acci- NOTE: When disassembling wheels, see Figure 56.
dent. There are several types of wheels used on this series
of lift trucks.
60
8000 SRM 1339 Wheel and Tires
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 56. Types of Pneumatic Wheels
Remove Tire From Two-Piece Wheel
WARNING
Make sure all air pressure is removed from tire before wheel is disassembled. Air pressure in tires
can cause tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move with enough force to
cause an injury.
STEP 1.
Remove nuts that fasten wheel rims together.
61
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all air pressure is removed from tire before wheel is disassembled. Air pressure in tires
can cause tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move with enough force to
cause an injury.
STEP 1.
Loosen tire bead from side flange.
62
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen bead from outer side of wheel rim. Remove
valve stem from wheel. If there is a washer, keep it
for installation during assembly.
STEP 4.
Remove wheel from tire.
Install Wheel in Tire Do not use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
WARNING parts together. Make sure that side ring is in
correct position. Ends of side ring must not
Damage to the tire and wheel assembly and in-
touch. Clearance at ends of lock ring will be
jury or death can occur if you do not do the fol-
approximately 13 to 25 mm (0.5 to 1.0 in.) after
lowing procedures:
it is installed. If clearance is wrong, the wrong
• Clean and inspect all parts of wheel before
part has been used.
installing tire.
• DO NOT use any damaged or repaired wheel NOTE: There are two types of wheels used on this
parts. series of lift trucks. See Figure 56. Make sure you
• Make sure that all parts of wheel are correct use the correct procedure.
parts for that wheel assembly.
• DO NOT mix parts between different types or 1. Clean and inspect all parts of wheel. Paint any
manufacturers of wheels. parts that have rust or corrosion.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different manufactur- 2. Install a new inner tube in tire. Used tubes and
ers on any one lift truck. flaps can cause tire failure.
63
WARNING WARNING
Do not lubricate tire bead with antifreeze or Do not lubricate tire bead with antifreeze or
petroleum-based liquid. Vapors from these liq- petroleum-based liquid. Vapors from these liq-
uids can cause an explosion during inflation or uids can cause an explosion during inflation or
use. use.
3. Apply rubber lubricant or soap solution to tire 5. Make sure rim is correct size for tire. Lubricate
bead and tube. part of wheel that contacts bead and flap.
4. Install new tire flap. 6. Install two-piece wheel in tire as shown in In-
stall Two-Piece Wheel in Tire. Install three-piece
or four-piece wheel in tire as shown in Install
Three- or Four-Piece Wheel in Tire.
Install Two-Piece Wheel in Tire
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of wheel before installing tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of wheel are correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or types of wheel assemblies of different manufac-
turers on any one lift truck.
Do not use a steel hammer on wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure that side ring is in correct position. Ends of side ring must not touch. Clear-
ance at ends of lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If
clearance is wrong, the wrong part has been used.
CAUTION
Do not use pneumatic-shaped solid tires on two-piece bolt together drive wheels. Spinning may
occur.
STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
64
STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (129 lbf ft). Add air pressure to tire. (See
Nameplate.)
Install Three- or Four-Piece Wheel in Tire
WARNING
procedures:
STEP 1.
Install inner tube and rubber flap in tire.
STEP 2.
Install wheel rim in tire. Install the washer on the
stem (if removed during disassembly). Make sure
stem of inner tube is aligned with slot in rim.
65
STEP 3.
Turn over rim and tire. Put blocks under rim so rim
is 8 to 10 cm (3 to 4 in.) above floor. Install flange
seat (if used) and lock ring.
STEP 4.
Put lock ring in correct position on rim.
Add Air to Tires to make sure all of the air pressure has been re-
moved and then make adjustments. The clear-
WARNING ance at the ends of the lock ring will be 13 to
25 mm (0.5 to 1.0 in.) when the tire has the cor-
Add air pressure to the tires only in a safety
rect air pressure.
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire.
Do not sit or stand by the safety cage. Do not

use a hammer to try and correct the position of
the side flange or lock ring when the tire has
air pressure greater than 20 kPa (3 psi).
1. Put the tire in a safety cage. See Figure 57.
2. Add 20 kPa (3 psi) of air pressure to the tire.
3. Check that all wheel parts are correctly installed.

Tap the lock ring with a soft hammer to make
sure that the lock ring is in the seat. Figure 57. Add Air to Tires
4. If installation is correct, add air pressure to the
Wheels, Install
tire to the specified pressure.
Install wheel on hub. Tighten the steering wheel
5. Check that all wheel parts are correctly installed.
nuts in a cross pattern to a torque value of 225 to
If installation is not correct, remove all of the air
280 N•m (166 to 207 lbf ft). Tighten the drive wheel
pressure from the tire. Remove the valve core
nuts in a cross pattern to a torque value of 339 to
380 N•m (250 to 280 lbf ft). If wheels are two-piece
66
rims, make sure nuts that fasten rim halves together Always wear safety glasses.
are toward brake drum when they are installed.
1. Put lift truck on blocks as described in How to Put
SOLID RUBBER TIRES ON PNEUMATIC Lift Truck on Blocks at beginning of this section.
WHEELS, CHANGE 2. Remove wheel nuts and remove wheel and tire
from lift truck. Lift truck tires and wheels are
WARNING heavy.
Wheels must be changed and tires repaired by
trained personnel only.
Remove Tire From Wheel
WARNING
Keep tire tools in firm contact with wheel. If tool slips, it can move with enough force to cause
serious injury.
When disassembling wheels, see Figure 56. There are several types of wheels used on these series of lift trucks.
WARNING
Wheels must be changed and tires repaired by trained personnel only.
Always wear safety glasses.
STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.
67
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
Install Tire on Wheel
WARNING
procedures:
When assembling wheels, see Figure 56. There are several types of wheels used on these series of lift trucks.
Do not use a two-piece pneumatic wheel for solid rubber tires.
68
CAUTION
Too much lubricant can cause tire to slide and move around wheel rim.
STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side ring,
and lock ring in position on wheel rim. Install cage
on tire. Use press to push tire onto wheel rim so side
flange and lock ring can be installed.
69
STEP 4.
While cage is holding tire on wheel rim, install lock
ring. Use tire tool to make sure lock ring is in correct
position.
Install the Wheels wheel are as shown in Figure 58. Also check the
Nameplate of the lift truck for the correct tire size
Install the wheel on the hub. Tighten steer wheel and tread width.
nuts to 225 to 280 N•m (166 to 207 lbf ft) and the
drive wheel nuts to 339 to 380 N•m (250 to 280 lbf ft). 1. The correct tools, equipment and a press ring
must be used for each size of wheel. Use a press
SOLID RUBBER (CUSHIONED) TIRE to push the wheel from the rim and tire. The ca-
REPAIR pacity of the press must be approximately 355 to
1779 kN (80,000 to 400,000 lb). For the tire sizes,
Remove Wheels From Lift Truck see the Nameplate.
2. When the drive wheels are installed on the lift

WARNING truck, tighten the wheel nuts to 340 to 380 N•m
The type of tire is shown on the Nameplate. (251 to 280 lbf ft).
Make sure the Nameplate is correct for the type
of tires on the lift truck. 3. The steering wheels are fastened to the spindle of
the steering axle with a large castle nut. Make
Wheels must be changed and tires repaired by sure the inner and outer bearings are correctly
trained personnel only. lubricated with grease. Install the inner bearing
assembly and wheel on the spindle. Install the
Always wear safety glasses.
outer bearing cone and castle nut.
NOTE: Solid rubber tires made from softer or harder
4. Tighten the castle nuts of the steer wheel spin-
material can be installed as optional equipment. The
dles to 68 N•m (50 lbf ft) while rotating the
tread on solid rubber tires can be either smooth or it
wheel in each direction at EACH installation.
can have lugs. DO NOT mix types of tires or tread
Loosen castle nuts 1/4 turn. Pull and push at
on lift truck.
top of wheel to check for movement (end play). If
1. Raise the lift truck as described in How to Put there is movement, tighten castle nut to 3 N•m
Lift Truck on Blocks in this manual. (27 lbf in).
2. Remove the wheel nuts and remove the wheel 5. Install cotter pins at the nearest alignment po-
from the lift truck. Lift truck wheels are heavy. sitions. If cotter pin cannot be installed, tighten
the castle nut to the first position where the cot-
Remove and Install Tire on Wheel ter pin can be installed. Install caps for bearings.
Additional torque checks are not required.
NOTE: Make sure the tires are installed on the
wheels so that the outside edges of the tire and
70
8000 SRM 1339 Lift Chain Adjustments
A. STEERING TIRES AND WHEELS C. WIDE TREAD

B. DRIVE TIRES AND WHEELS
1. OUTSIDE OF SOLID RUBBER TIRE
2. WHEEL
3. OVERHANG
Figure 58. Wheel and Tires
Lift Chain Adjustments

NOTE: When the lift chain adjustments are com-
WARNING plete, make sure the threads on the nuts of the
When working on or near the mast, see Safety chain anchors are completely engaged. Inspect the
Procedures When Working Near Mast in this torque of the prevailing torque nut (locknut) used
section. to adjust the chain anchor with every lift chain
adjustment. After carriage and or mast section(s)
Never allow anyone under a raised carriage.
are adjusted for proper ground clearance, prevent
DO NOT put any part of your body in or
the carriage and or mast section(s) from fully low-
through the lift mechanism unless all parts
ering (see Safety Procedures When Working Near
of the mast are completely lowered and the
Mast). With slack chain(s), check locknut torque. If
power is OFF.
2.5 N•m (22.1 lbf in) for 1/2-20, 4.5 N•m (39.8 lbf in)
DO NOT try to find hydraulic leaks by putting for 5/8-18 nuts, 6.0 N•m (53.1 lbf in) for 3/4-16 of
your hand on hydraulic components under torque cannot be reached; replace locknut. The chain
pressure. Hydraulic oil can be injected into anchors, after adjustment, must be able to move on
the body by the pressure. their mountings.
During test procedures for the hydraulic sys- 1. When adjusting lift chains on forklift trucks
tem, fasten the load to the carriage with chains equipped with either pin- or hook-type forks in-
to prevent it from falling. Keep all personnel stalled, go to Step 2. If forklift truck is normally
away from the lift truck during the tests. equipped with a hook-type carriage and has an
attachment without forks, go to Step 3.
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of the NOTE: Prior to performing adjustment procedures,
chain set. Check tension by pushing on both chains make sure the forklift truck is parked on a level sur-
at the same time. face and the mast is in the vertical position.
• The chain length will be correct.
2. Adjust chain anchors which support the carriage
• The chains must travel freely through the complete
until the bottom of the fork heel is 6 ±3 mm (0.24
cycle.
±0.12 in.) above floor level. See Figure 59.
71
Lift Chain Adjustments 8000 SRM 1339
Table 2. Hook-Type Carriage Chain Adjustment
Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)

Class IV 133.5 ±3 mm (5.26 ±0.12 in.)
1. MAST
2. CARRIAGE
3. FORK
4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE FLOOR LEVEL.
Figure 59. Lift Chain Adjustment, Hook- or

Pin-Type Forks 1. MAST
2. CARRIAGE
3. Adjust chain anchors which support the carriage 3. DISTANCE FROM FLOOR TO LOWER
until the bottom of the lower carriage bar is above CARRIAGE BAR
the floor level as shown in Table 2. See Figure 60.
Figure 60. Lift Chain Adjustment, Hook-Type
Carriage
72
TECHNICAL PUBLICATIONS
8000 SRM 1339 2/12 (11/11)(8/11)(11/10)(6/10)(2/10)(4/09) Printed in U.S.A.

Hyster J40xnt Parts and Service Periodic Maintenance 1689720 8000SRM1339 (02 2012) US EN

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Hyster J40xnt Parts and Service Periodic Maintenance 1689720 8000SRM1339 (02 2012) US EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hyster J40xnt Parts and Service Periodic Maintenance 1689720 8000SRM1339 (02 2012) US EN

Uploaded by

Copyright:

Available Formats

PERIODIC

PART NO. 1689720 8000 SRM 1339

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2012 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

CAUTION SERIAL NUMBER

The Maintenance Schedule has time intervals for in-

The recommendation for time intervals are for eight

3. Disconnect the battery by separating the connec-

1. FRONT BULKHEAD 3. PIVOT PIN

Figure 2. Manual Override Handle

If it becomes necessary to clean the fork lift, follow • Floor Plates

1. DRIVE TIRES 2. STEER TIRES

Figure 3. Putting Lift Truck on Blocks

Safety Procedures When Working Near Mast

Legend for Figure 4

NOTE: ILLUSTRATION FOR REFERENCE ONLY.

Figure 4. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

Figure 5. Maintenance Points

Table 1. Maintenance Schedule

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr 2000 hr 4000 hr Procedure or Specification

NOTE: Never use steam to clean electrical parts.

Maintenance Procedures Every 8 Hours or Daily

Park the lift truck on a level surface. Lower the forks,

Safety Labels Frame and Covers

Check that the Operating Manual is not worn or

1. OVERHEAD GUARD 4. HOOD SIDE COVER

Figure 7. Frame and Covers Check

The identification of a fork describes how the fork is

NOTE: Forks are to be replaced only in sets and not