Manutencao Hyster H40 70FT, Maintenance Hyster H40 70FT

PERIODIC
MAINTENANCE
S40-70FT, S55FTS [F187];
H40-70FT [L177]
PART NO. 1580525
8000 SRM 1150
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.
Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
Keep the unit clean and the working area clean and orderly.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or 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 background. The CAUTION symbol and word are on yellow background.
Periodic Maintenance
Table of Contents
TABLE OF CONTENTS
General .................................................................................................................................................................
Serial Number Data ........................................................................................................................................
How to Move Disabled Lift Truck...................................................................................................................
How to Tow Lift Truck ................................................................................................................................
How to Put Lift Truck on Blocks ....................................................................................................................
How to Raise Drive Tires ............................................................................................................................
How to Raise Steering Tires .......................................................................................................................
How to Clean a Lift Truck...............................................................................................................................
Maintenance Schedule.........................................................................................................................................
Maintenance Procedures Every 8 Hours or Daily............................................................................................
How to Make Checks With Engine Stopped.................................................................................................
Tires and Wheels .......................................................................................................................................
Safety Labels .............................................................................................................................................
Mast, Carriage, Lift Chains, Header Hoses, Attachment .......................................................................
Operator Restraint System.......................................................................................................................
Automatic Locking Retractor (ALR) ....................................................................................................
Emergency Locking Retractor (ELR) ...................................................................................................
Adjust Seat - Full Suspension ..............................................................................................................
Adjust Seat - Internal Suspension .......................................................................................................
Hood and Seat Latches .............................................................................................................................
Engine Compartment................................................................................................................................
Paper Application ......................................................................................................................................
Fuel, Oil, and Coolant Leaks, Check ........................................................................................................
Hydraulic Hoses ........................................................................................................................................
Coolant Hoses ............................................................................................................................................
Steering Column Gas Cylinder.................................................................................................................
Transmission .............................................................................................................................................
Hydraulic System Oil ................................................................................................................................
Engine Oil ..................................................................................................................................................
Air Filter ....................................................................................................................................................
Forks ..........................................................................................................................................................
Remove ..................................................................................................................................................
Inspect ...................................................................................................................................................
Install.....................................................................................................................................................
Adjust.....................................................................................................................................................
How to Make Checks With Engine Running................................................................................................
Indicator Lights, Horn, Fuses, and Relays ..............................................................................................
Service Brakes ...........................................................................................................................................
Brake Fluid Level .................................................................................................................................
Operation, Check ..................................................................................................................................
Parking Brake ...........................................................................................................................................
Engine Oil Pressure ..................................................................................................................................
Cooling System ..........................................................................................................................................
Steering System ........................................................................................................................................
Control Levers and Pedals ........................................................................................................................
Lift System, Operate .................................................................................................................................
First Service After First 100 Hours of Operation ............................................................................................
Mazda and GM Engine Oil and Oil Filter....................................................................................................
Yanmar Engine Oil and Oil Filter ................................................................................................................
Maintenance Procedures Every 250 Hours or 6 Months .................................................................................
Mazda and GM Engine Oil and Oil Filter....................................................................................................
2013 HYSTER COMPANY
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Table of Contents
TABLE OF CONTENTS (Continued)

Drive Belt .......................................................................................................................................................
Mazda 2.0L and 2.2L Engines ..................................................................................................................
Fan and Alternator Drive Belt .............................................................................................................
GM 2.4L Engine ........................................................................................................................................
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) ..............................
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only)..................................
Maintenance Procedures Every 500 Hours or 6 Months .................................................................................
Hydraulic System Oil ....................................................................................................................................
Hydraulic Tank Breather ..............................................................................................................................
Inspect........................................................................................................................................................
Battery ...........................................................................................................................................................
Yanmar Engine Oil and Oil Filter ................................................................................................................
Drive Belt .......................................................................................................................................................
Yanmar Diesel Engine...............................................................................................................................
PCV Valve ......................................................................................................................................................
Clean Debris From Radiator Core ................................................................................................................
Transmission Oil Level .................................................................................................................................
Wet Brake Planetary Housing Oil Level Check...........................................................................................
Forks...............................................................................................................................................................
Mast Lubrication ...........................................................................................................................................
Header Hose Checks......................................................................................................................................
Lift Chain Lubrication ..................................................................................................................................
Tilt Cylinder Lubrication ..............................................................................................................................
Master Brake Cylinder Rod End Pin Lubrication .......................................................................................
Manual Hydraulic Levers Lubrication .........................................................................................................
Brake Fluid ....................................................................................................................................................
Tie Rod Lubrication (H40-70FT)...................................................................................................................
Differential and Drive Axle Oil (Dry Brake) ................................................................................................
Maintenance Procedures Every 1000 Hours or 6 Months ...............................................................................
Valve Clearance, Check and Adjust..............................................................................................................
Ignition System..............................................................................................................................................
GM 2.4L Engine ........................................................................................................................................
Mazda 2.0L and 2.2L Engines ..................................................................................................................
LPG Fuel Filter Element Replace, GM 2.4L Engine ...................................................................................
Remove.......................................................................................................................................................
Install .........................................................................................................................................................
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant
Engines) .........................................................................................................................................................
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only ...............................................
Remove.......................................................................................................................................................
Clean/Inspect .............................................................................................................................................
Install .........................................................................................................................................................
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only ...............................
Remove and Replace .................................................................................................................................
Fuel Filter Replacement, Yanmar Engine....................................................................................................
Priming the Fuel System (Yanmar)..............................................................................................................
Lift Chains Wear Check ................................................................................................................................
Lift Chain Lubrication ..................................................................................................................................
Integral Sideshift Carriage, Check Bearings ...............................................................................................
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Table of Contents

Integral Sideshift Carriage, Check Lower Mounting Hooks .......................................................................
Steering Axle..................................................................................................................................................
Control Levers and Pedals ............................................................................................................................
Maintenance Procedures Every 2000 Hours or Annually ...............................................................................
Hydraulic System ..........................................................................................................................................
Hydraulic Filter, Replace ..........................................................................................................................
Hydraulic Tank Breather, Replace ...........................................................................................................
Air Filter ........................................................................................................................................................
PCV Valve ......................................................................................................................................................
Oxygen Sensor ..............................................................................................................................................
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) ...........
Remove and Replace .................................................................................................................................
LPG Regulator Fuel Filter, GM Engines......................................................................................................
Remove.......................................................................................................................................................
Install .........................................................................................................................................................
Gasoline Fuel Filter.......................................................................................................................................
Remove and Replace for Lift Trucks Equipped with GFI .......................................................................
Timing Belt ....................................................................................................................................................
Mazda Engines ..........................................................................................................................................
GM 2.4L Engine ........................................................................................................................................
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) .........................
Gasoline Fuel Injector, Mazda Engines........................................................................................................
LPG Fuel Injector, GM Engines....................................................................................................................
Gasoline Fuel Injector, GM Engines .............................................................................................................
Fuel Injector, Yanmar Engines .....................................................................................................................
Forks...............................................................................................................................................................
Integral Sideshift Carriage ...........................................................................................................................
Bearings, Replace ......................................................................................................................................
Transmission Oil and Filter (Dry Brake), Replace ......................................................................................
Iron Transmission Housing ......................................................................................................................
Aluminum Transmission Housing ...........................................................................................................
Remove ..................................................................................................................................................
Clean and Inspect .................................................................................................................................
Install.....................................................................................................................................................
Transmission Oil Change, Wet Brake Drive Axle .......................................................................................
Iron Transmission Housing ......................................................................................................................
Aluminum Transmission Housing ...........................................................................................................
Wet Brake Axle Center Section and Planetary Housing, Oil Change ........................................................
Brake Fluid (Master Cylinder), Change.....................................................................................................
Brake Fluid (Dry Brake), Remove ..............................................................................................................
Service Brakes (Dry Brake) ........................................................................................................................
Differential (Dry Brake) ..............................................................................................................................
Maintenance Procedures Every 4000 Hours or 2 Years.................................................................................
Hydraulic Oil, Replace ................................................................................................................................
Cooling System ............................................................................................................................................
Safety Procedures When Working Near Mast................................................................................................
Hood Latch Check ............................................................................................................................................
Lift Chain Adjustments ...................................................................................................................................
Jump-Starting the Lift Truck..........................................................................................................................
Jump-Starting Using a Battery Charger ...................................................................................................
Jump-Starting a Lift Truck Using Another Lift Truck .............................................................................
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Table of Contents

Welding Repairs ...............................................................................................................................................
Overhead Guard Changes ...............................................................................................................................
Wheel and Tire Replacement ..........................................................................................................................
General .........................................................................................................................................................
Solid Rubber Tire, Change (S Series) .........................................................................................................
Remove and Install Tire on Wheel .........................................................................................................
Pneumatic Tire With Tube, Repair.............................................................................................................
Remove Wheels From Lift Truck............................................................................................................
Remove Tire From Wheel .......................................................................................................................
Remove Tire From Two-Piece Wheel .................................................................................................
Remove Tire From Three- and Four-Piece Wheels ...........................................................................
Install Wheel in Tire ...............................................................................................................................
Install Three-Piece or Four-Piece Wheel in Tire ...............................................................................
Install Tire on Two-Piece Wheel ........................................................................................................
Install Two-Piece Wheel in Tire .........................................................................................................
Add Air to Pneumatic Tires With Tube......................................................................................................
Install the Wheels ...................................................................................................................................
Dual Drive Wheels, Install .....................................................................................................................
Pneumatic Tubeless Tire, Repair................................................................................................................
Remove Wheels From Lift Truck............................................................................................................
Install Tire on Wheel ..............................................................................................................................
Add Air to Pneumatic Tubeless Tire ......................................................................................................
Wheels, Install.........................................................................................................................................
Solid Rubber Tires on Pneumatic Wheels, Change ...................................................................................
Install Tire on Wheel ..............................................................................................................................
Adhesives and Sealants ...................................................................................................................................
This section is for the following models:
S40-70FT, S55FTS [F187];
H40-70FT [L177]
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8000 SRM 1150
General
General
WARNING
DO NOT make repairs or adjustments unless
you have both authorization and training. Repairs and adjustments that are not correct can
make a dangerous operating condition.
WARNING
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag
in the operators area. Remove the key from
the key switch.
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance of your lift
truck. The service intervals are provided in both operating hours recorded on the lift truck hourmeter
and in calendar time. The recommendation is to use
the interval that comes first.
The recommendations for the time intervals provided
is for eight hours of operation per day. The time intervals must be decreased from the recommendations
in the Maintenance Schedule for the following conditions:

The lift truck is used more than eight hours per
day.
The lift truck must work in dirty operating conditions.
Poor ground conditions.
Intensive usage at high performance levels or
other abnormal conditions will require more frequent servicing.
Your dealer for Hyster lift trucks has the equipment
and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A
regular program of inspection, lubrication, and maintenance will help your lift truck provide more efficient performance and operate for a longer period of
time.
Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service manuals are available from your dealer for Hyster lift
trucks to help users who do their own maintenance.
SERIAL NUMBER DATA

The serial number for the lift truck is on the Nameplate. It is also on the right side of the frame, under
the floor plate.
General
HOW TO MOVE DISABLED LIFT TRUCK

How to Tow Lift Truck
WARNING
Use extra caution when towing a lift truck if
any of the following conditions exist:
Brakes do not operate correctly.
Steering does not operate correctly.
Tires are damaged.
Traction conditions are bad.
The lift truck must be towed on a slope.
If the engine cannot run, there is no power
available for the hydraulic steering system
and the service brakes. This condition can
make the lift truck difficult to steer and stop.
If the lift truck uses power from the engine to
help apply the brakes, the application of the
brakes will be more difficult. Poor traction can
cause the disabled lift truck or towing vehicle
to slide. A slope will also make the lift truck
more difficult to stop.
8000 SRM 1150

from surface. Install chain around a mast crossmember and carriage to prevent carriage and
mast channels from moving.
4. If another lift truck is used to tow the disabled lift
truck, that lift truck must have an equal or larger
capacity than the disabled lift truck. Install approximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck.
This 1/2 capacity load will increase traction of lift
truck. Keep load as low as possible.
5. Use a towing link made of steel that fastens to
tow pins in counterweights of both lift trucks.
Slowly and carefully remove the slack out of the
towing link. See Figure 1.
Never lift and move a disabled lift truck unless

the disabled lift truck MUST be moved and
cannot be towed. A lift truck used to move
a disabled lift truck MUST have a capacity
rating equal to or greater than the weight of
the disabled lift truck. The capacity of the lift
truck used to move a disabled lift truck must
have a load center equal to half the width of
the disabled lift truck. See the Nameplate of
the disabled lift truck for the approximate
total weight. The forks must extend the full
width of the disabled lift truck. Put the weight
center of the disabled lift truck on load center
of the forks. Be careful to not damage the
underside of the lift truck.
1. The towed lift truck must have an operator.
2. Tow truck slowly.
3. Using a lift truck or a lifting device that could
be attached to the mast (I.E. come-a-long), raise
carriage and forks approximately 30 cm (12 in.)
1. STEEL TOW LINK
2. TOW PIN
Figure 1. Towing the Lift Truck
8000 SRM 1150
HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine, transmission, and counterweight.
When the lift truck is put on blocks, put additional blocks in the following positions to
maintain stability:
Before removing the mast and drive axle, put
blocks under the counterweight so the lift
truck cannot fall backward.
Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure any
blocks used to support the lift truck are solid,
one-piece units.
CAUTION
These lift trucks are equipped with cowl lifting
eyes. The cowl lifting eyes are to be used to
lift the front of the lift truck only. Lifting more
than the front of the lift truck with the cowl
lifting eyes will damage the cowl section.
General
2. Put mast in vertical position. Put a block under
each outer mast channel.
3. Tilt mast fully forward until drive tires are raised
from surface.
4. Put additional blocks under frame behind drive
tires.
5. If hydraulic system will not operate, use a hydraulic jack under the side of the frame near the
front. Make sure jack has a capacity equal to at
least half the weight of the lift truck. See Nameplate.
How to Raise Steering Tires

NOTE: Some lift trucks are equipped with lifting eyes
for the purpose of lifting the entire lift truck. If lift
truck is equipped with these type of lifting eyes, the
lift truck can be lifted and blocks installed.
1. Apply parking brake. Put blocks on both sides
(front and back) of drive tires to prevent movement of lift truck. See Figure 2.
2. Use hydraulic jack to raise steering tires. Make
sure jack has a capacity of at least 2/3 of total
weight of lift truck as shown on the Nameplate.
3. Put jack under steering axle or frame to raise
lift truck. Put blocks under frame to support lift
truck.
1. Put blocks on each side (front and back) of steering tires to prevent movement of lift truck. See
Figure 2.
General
8000 SRM 1150
1. DRIVE TIRES
2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
HOW TO CLEAN A LIFT TRUCK

WARNING
Engine, exhaust system components and other
components are hot to the touch. Be sure lift
truck components are cool before starting inspection and cleaning, or personal injury may
occur.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
CAUTION
Units may be washed with a non-heated pressure washer. Steam cleaning is not recommended in most instances, as condensation
may form in electrical components causing
damage or erratic behavior.
NOTE: Lift trucks used in paper applications may
need cleaning beyond what is described here. Please
refer to Paper Application section in the applicable

Operating Manual and to available Service Gram/
Bulletin for more detail.
If it becomes necessary to clean the fork lift, follow
the guidelines listed below.
1. Assure truck components are cool before starting
the cleaning procedure.
2. Disconnect the battery. If an electric truck, remove the traction battery.
3. Remove accumulated debris using a compressed
air line and nozzle.
4. Lightly spray a non-corrosive cleaning agent onto
the areas to be cleaned. This will help loosen
grime, so close contact direct spraying will not be
necessary.
5. Be sure to avoid directing the spray into electrical panel compartment. Ensure overspray does
not come in contact with electrical components;
do not spray water directly at electrical components, wiring connectors or electrical enclosures.
Even sealed connectors may allow water egress
under pressure or if connector is damaged.
8000 SRM 1150
Maintenance Schedule
6. Avoid spraying in areas containing electrical

components such as:
Floor Plates
Battery Compartment
Dash/cowl assembly
Armrests with electrical components
7. Clean the battery compartment by using a clean
cloth to wash the battery with water. Dry with
compressed air. Care should be taken to keep
moisture at a minimum as some units have a
traction or hydraulic motor directly below the
battery compartment.
8. DO NOT pressure wash the battery. Do not use

hot water. For cleaning traction batteries, refer
to the Battery section of the Service Manual.
9. DO NOT pressure wash lift chains, sheaves or
load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
section in the Service Manual for proper cleaning procedures.
10. After cleaning, immediately start and run the lift
truck to dry out components.
NOTE: The lift trucks shown in Figure 3 through
Figure 10 and Figure 12 through Figure 16 represent S40-70FT, S55FTS (F187) lift trucks, H40-70FT
(L177) are similar.
The lift truck shown in Figure 11 represents H4070FT (L177) lift trucks only.
8000 SRM 1150
Figure 3. GM 2.4L Gas Trucks (Prior to Jan. 2011)
8000 SRM 1150
Figure 4. GM 2.4L LPG Trucks (Prior to Jan. 2011)
8000 SRM 1150
Figure 5. Mazda 2.0L and 2.2L Gas Trucks (Except 2007 Emission Compliant Engines)
8000 SRM 1150
Figure 6. Mazda 2.0L and 2.2L LPG Trucks (Except 2007 Emission Compliant Engines)
8000 SRM 1150
Figure 7. Mazda 2.0L and 2.2L Gas Trucks (2007 Emission Compliant Engines Only)
10
8000 SRM 1150
Figure 8. Mazda 2.0L and 2.2L LPG Trucks (2007 Emission Compliant Engines Only)
11
8000 SRM 1150
Figure 9. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
12
8000 SRM 1150
Figure 10. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (Prior to Jan. 2011)
13
Figure 11. Yanmar 2.6L and 3.3L Diesel Trucks (Prior to Jan. 2011)
14
8000 SRM 1150
8000 SRM 1150
Figure 12. GM 2.4L Gas Trucks with Aluminum Case Transmission (After January, 2011)
15
8000 SRM 1150
Figure 13. GM 2.4L LPG Trucks with Aluminum Case Transmission (After January, 2011)
16
8000 SRM 1150
Figure 14. Mazda 2.0L and 2.2L Gas Trucks with Aluminum Case Transmission (After January,
2011)
17
8000 SRM 1150
Figure 15. Mazda 2.0L and 2.2L LPG Trucks with Aluminum Case Transmission (After January,
2011)
18
8000 SRM 1150
Figure 16. Yanmar 2.6L and 3.3L Diesel Trucks (After January, 2011)
19
8000 SRM 1150

Table 1. Maintenance Schedule
Item
No.
27
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo
1000 2000 hr/ 4000 hr/ Procedure or

hr/
1 yr
2 yr
Quantity
6 mo
Specification
Tires
Check Condition
See Nameplate
Safety Labels
Replace as
Necessary
See Parts Manual
Check Condition
and Lubrication
See Parts Manual
Seat Belt, Hip

Restraints, and Seat
Rails
Check Condition
and Operation
Hood and Seat Latches
Check Condition
and Operation
Engine Compartment
Remove
Combustible
Materials
See NOTE 5
Paper Application:
Engine Compartment,
Truck Components,
Exhaust Wraps,
Radiator, Radiator
Screen if equipped,
Belly Pan if equipped
Check Condition
Clean as
Required
Replace as
Required
See NOTE 10
Check for Leaks - Fuel,

Oil, Water
Check for Leaks

See NOTE 1
Hydraulic Hoses
Check Condition
See Parts Manual
13
Coolant Hoses
Check Condition
See Parts Manual
18
Fuel Tank (Gas)

S40-70FT, S55FTS
(F187)
CIL
40.5 liter
(10.7 gal)
85 Octane Gasoline
Minimum
18
Fuel Tank (Gas)

H40-70FT (L177)
CIL
52 liter (13.7 gal) 85 Octane Gasoline

Minimum
18
Fuel Tank (LPG)
CIL
29.9 liter
(7.9 gal)
15.2 kg (33.5 lb)
LPG - HD 5, HD 10
18
Fuel Tank (Diesel)

H40-70FT (L177)
CIL
52 liter (13.7 gal)
Diesel No. 2
Horn, Lights, Alarms
Check Operation
Service Brakes
Check Operation
25
Parking Brake
Check Operation
Steering Controls and

Steering Column Gas
Cylinder
Check Condition
and Operation
30, Mast, Carriage, Header

31 Hoses, Lift Chains,
Attachment
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
20
8000 SRM 1150
Table 1. Maintenance Schedule (Continued)

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
Specification
24
Transmission
Check for Leaks
24
Transmission
Check Operation
Hydraulic Oil
S40-70FT, S55FTS
(F187)
30.1 liter (32 qt)

See NOTE 2,
NOTE 3 and
NOTE 16.
ISO VG 46
Hydraulic Oil
15C (5F) and
Above
Hydraulic Oil
H40-70FT (L177)
39.8 liter (42 qt)

See NOTE 2,
NOTE 3 and
NOTE 16.
ISO VG 46
Hydraulic Oil
15C (5F) and
Above
Hydraulic Oil Filter
10
Hydraulic Tank
Breather
Battery and Cable

Terminals
Engine Oil
Mazda
2.0L Engine
(Gas/LPG)
X
CIL
3.9 liter (4.1 qt)

See NOTE 4 and
NOTE 5.
7C (20F)
and Below
SAE 5W-20
16C (60F)
and Below
SAE 5W-30
18C (0F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Engine Oil
Mazda 2.2L
Engine
(Gas/LPG)
X
CIL
4.2 liter (4.4 qt)

See NOTE 4 and
NOTE 5.
7C (20F)
and Below
SAE 5W-20
16C (60F)
and Below
SAE 5W-30
18C (0F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
1 Filter
See NOTE 16.
See Parts Manual
Inspect and
Replace as
Required
See Parts Manual
Clean
21
8000 SRM 1150

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
Engine Oil
GM 2.4L Engine
(Gas/LPG)
X
CIL
21
Engine Oil Filter

Mazda 2.0L
and 2.2L and GM
2.4L Engines
(Gasoline)
Engine Oil
Yanmar 2.6L
and 3.3L
Engine
(Diesel)
21
Engine Oil Filter

Yanmar 2.6L
and 3.3L
(Diesel)
20
Air Filter
CIL
20
Air Filter
X
CIL
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
5.0 liter (5.3 qt)

See NOTE 4 and
NOTE 5.
7C (20F)
and Below
SAE 5W-20
16C (60F)
and Below
SAE 5W-30
18C (0F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
1 Filter
See NOTE 4
and NOTE 5.
See Parts Manual
10.2 liter
(10.8 qt)
See NOTE 4
and NOTE 5.
20C (68F)
and Over
SAE 40
10 to 30C (50 to 86F)
SAE 30
0 to 20C (32 to 68F)
SAE 20
16 to 40C
(3 to 103F)
SAE 15W-40
20 to 30C
( 4 to 86F)
SAE 10W-30
10 to 10C
(14 to 50F)
SAE 20W
20 to 10C
( 4 to 50F)
SAE 10W
1 Filter
See NOTE 4
and NOTE 5.
See Parts Manual
1 Filter
See NOTE 5,
NOTE 6, and
NOTE 13.
See Parts Manual
1 Filter
See NOTE 5,
NOTE 6, and
NOTE 13.
See Parts Manual
22
Specification
8000 SRM 1150

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
16
Drive Belt
Mazda 2.0L
and 2.2L
(Gas/LPG)
Check for Wear

and Damage.
Adjust as
Needed.
16
Drive Belt
GM 2.4L Engines
(Gas/LPG)
Check for Wear

and Damage.
No adjustment
needed.
16
Drive Belt
Yanmar 2.6L
3.3L Engines
(Diesel)
17
Specification
Check for Wear

and Damage.
Adjust as
Needed.
and
LPG Regulator
Mazda 2.0L
and 2.2L Engines
Drain Tar See

NOTE 5.
Engine Idle Speed

Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
See NOTE 5.
800 25 rpm
Engine Governed Speed

Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
See NOTE 5.
2700 25 rpm
LPG Regulator GM
2.4L Engine
Drain Tar See

NOTE 5.
Engine Idle Speed

GM 2.4L
(Gas/LPG)
See NOTE 5.
800 25 rpm

GM 2.4L
(Gas/LPG)
See NOTE 5.
2700 25 rpm
Engine Idle Speed

Yanmar 2.6L
and 3.3L
(Diesel)
See NOTE 5.
825 25 rpm

Yanmar 2.6L
(Diesel)
See NOTE 5.
2700 25 rpm

Yanmar 3.3L
(Diesel)
See NOTE 5.
2600 25 rpm
PCV Valve
Replace as
Necessary
See NOTE 14.
See Parts Manual
23
8000 SRM 1150

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
X
Oxygen Sensor
Specification
Check Indicator Light
Valve Adjustment
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
Adjust as
Required
Intake
0.15 mm (0.006 in.)
Cold
Exhaust
0.35 mm (0.014 in.)
Cold
Valve Adjustment
Yanmar 2.6L
and 3.3L
Diesel Engines
Adjust as
Required
Intake
0.20 mm (0.008 in.)
Cold
Exhaust
0.20 mm (0.008 in.)
Cold
Timing
Mazda 2.0L
and 2.2L Engines
(Gas)
Adjust as
Required
61 BTDC
(Orange Mark)
Timing
Mazda 2.0L
and 2.2L Engines
(LPG)
Adjust as
Required
61 BTDC
(Orange Mark)
LPG Fuel Filter

Mazda 2.0L
and 2.2L Engines
(2007
Emission
Compliant Engines
Only)
1 Filter
See Parts Manual
1 Filter
See Parts Manual
19
LPG Fuel Regulator

Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emission Compliant Engines)
19
LPG Fuel Injector

Vapor Filter
Mazda 2.0L
and 2.2L Engines
(Except 2007 Emission Compliant Engines)
1 Filter
See Parts Manual
19
Fuel Filter, LPG

GM 2.4L Engines
1 Filter
See Parts Manual
24
8000 SRM 1150

Item
No.
Item
19
Fuel Filter
Mazda 2.0L
and 2.2L (Except
2007 Emission Compliant Engines) and
GM 2.4L Engines
(Gasoline)
19
Fuel Filter
Mazda 2.0L
and 2.2L Engines
(2007
Emission
Compliant Engines
Only )
(Gasoline)
19
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
C
Specification
1 Filter
See Parts Manual
1 Filter
See Parts Manual
Fuel Water Separator

Yanmar 2.6L
and 3.3L Engines
(Diesel)
1 Filter
See Parts Manual
19
In-line Fuel Filter

Yanmar 2.6L and
3.3L
Engines
(Diesel)
1 Filter
See Parts Manual
15
Timing Belt
Replace
See NOTE 7.
See Parts Manual
22
Fuel Injector
Mazda 2.0L
and 2.2L Engines
(LPG, Except 2007
Emission Compliant
Engines)
1 Injector
See NOTE 8.
Check and Clean

If Required
22
Fuel Injectors
4 Injectors
See NOTE 8.
Check and Replace

If Required
Check
Plug Wires
4 Plugs
See Parts Manual

0.8 0.1 mm (0.031
0.004 in.)
4 Injectors
Check and Replace

If Required
Check
Plug Wires
4 Plugs
See Parts Manual

0.8 to 0.9 mm
(0.032 to 0.035 in.)
Mazda 2.0L
and 2.2L Engines
(Gas)
5
Spark Plugs
Mazda 2.0L
and 2.2L Engines
(Gas/LPG)
22
Fuel Injectors
GM 2.4L Engines
Gas/LPG
Spark Plugs
GM 2.4L Engines
(Gas/LPG)
25
8000 SRM 1150

Item
No.
22
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
X
Fuel Injectors
Yanmar 2.6L
and 3.3L Engine
(Diesel)
Specification
4 Injectors
Check and Replace

If Required
12, Cooling System

14
Mazda 2.0L
and 2.2L Engines
(Serpentine
and Square
Wave)
X
CIL
11.0 liter
(11.6 qt)
See NOTE 15
12, Cooling System

14
Mazda 2.0L
and 2.2L Engines
(Square Wave
w/Air Oil
Cooler)
X
CIL
10.6 liter
(11.2 qt)
See NOTE 15
12, Cooling System

14
GM 2.4L Engine
X
CIL
10.6 liter
(11.2 qt)
See NOTE 15
12, Cooling System

14
Yanmar 2.6L
and 3.3L Engines
X
CIL
11.5 liter
(12.1 qt)
See NOTE 15
Clean Debris From

Radiator Core
7
Transmission Oil
Dry BrakesCase
See NOTE 5
20 liter (21 qt)
John Deere
JDM J20C
13 liter (14 qt)
John Deere
JDM J20C
1 Filter
See NOTE 4.
See Parts Manual
Check Condition
Iron
Transmission Oil
Dry Brakes- Aluminum Case
23
Transmission Oil Filter
28
Forks
29
Mast
Sliding Surfaces
and Load Roller Surfaces
Lubricate
As Required
See NOTE 11.
29
Header Hoses
Check Condition
30
Lift Chains
30
Lift Chains
X, L
26
Multipurpose Grease
See NOTE 9.
Lube as
Required. Check
for Wear
SAE 30W
Engine Oil
Check
Lubrication
See NOTE 12.
SAE 30W
Engine Oil
8000 SRM 1150

Item
No.
Item
Mast
Sideshift
Carriage
8 hr/ 250
1
hr/
day 6 mo
X
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
Specification
Lube as
Required
2 Fittings
Multipurpose Grease
See NOTE 9.
Integral Sideshift
Carriage
Fork
Positioner
Lube as
Required
2 Fittings
See NOTE 5.
Multipurpose Grease
See NOTE 9.
Mast
Pivots
2 Fittings
Multipurpose Grease
See NOTE 9.
Mast
Integral
Sideshift
Carriage
(Upper/Lower
Bearings)
Lube as
Required
2 Fittings
4 Bearings
Multipurpose Grease
See NOTE 9.
2.5 mm (3/32 in.) is
minimum thickness
Check for Wear

and Clearance.
See NOTE 2 and
NOTE 5
0.76 mm (0.03 in.)

Minimum Wear
Limit.
4 Fittings
Multipurpose Grease
See NOTE 9.
Mast
Integral
Sideshift
Carriage
(Lower Mounting
Hooks)
Tilt Cylinder Ends
Brake Master Cylinder

Rod End Pin
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Manual Hydraulic
Hand Levers
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
26
Brake Fluid
Master Cylinder
Dry Brakes
CIL
0.25 liter
(0.53 pt)
SAE J-1703
DOT-3
26
Brake Oil
Master Cylinder
Wet Brakes
CIL
0.35 liter
(0.74 pt)
Dexron III from

Sealed Container
11
Steering Axle
Tie Rod Ends H4070FT (L177)
4 Fittings
Multipurpose Grease
See NOTE 9.
11
Steering Axle
King Pin
H40-70FT (L177)
2 Fittings
Multipurpose Grease
See NOTE 9.
27
8000 SRM 1150

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
Specification
11
Steering Axle
Spindle
Bearings S40-70FT,
S55FTS (F187)
4 Fittings
Multipurpose Grease
See NOTE 9.
Pedals, Levers, Seat

Rails, Cables, Hinges,
Linkages, Hood Latch
Lubricate as
Necessary
Hyster Part No.

328388
Service Brakes
Dry Brakes
Check Lining
Thickness
1.0 mm (0.040 in.)

Minimum
32
Differential and Drive

Axle Oil
Dry Brakes
S40-70FT, S55FTS
(F187)
5.0 liter (5.3 qt)
SAE 80W-90 or
85W-140
32
Differential and Drive

Axle Oil
Dry Brakes
H40-70FT (L177)
6.5 liter (6.9 qt)
SAE 80W-90 or
85W-140
Transmission Oil
Wet Brakes- Iron
Case
H40-70FT (L177)
20 liter (21 qt)
John Deere
JDM J20C
Transmission Oil
Wet Brakes- Aluminum Case
H40-70FT (L177)
13 liter (14 qt)
John Deere
JDM J20C
32
Wet Brake Axle

Planetary Housing
Oil, Left Side
0.5 liter (0.5 qt)
SAE 80W/90
32
Wet Brake Axle

Planetary Housing
Oil, Right Side
2.0 liter (2.1 qt)
SAE 80W/90
32
Wet Brake Axle, Center

Section Oil
1.0 liter (1.1 qt)
John Deere JDM

J20C
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours
of operation.
28
8000 SRM 1150

Item
No.
Item
8 hr/ 250
1
hr/
day 6 mo
500
hr/
6 mo

hr/
1 yr
2 yr
Quantity
6 mo
Specification
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive
compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require
more frequent servicing. At your request your Hyster dealer will advise you of the appropriate service intervals based on
an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Replace timing belt on Mazda engines every 3500 hours. Use only hour interval.
NOTE 8: Check fuel injectors at 5000 hours or 7 years.
NOTE 9: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 10: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should
be done at least once every 8 hours or more frequently, depending upon operating environment. Use compressed air and
steam clean as necessary.
NOTE 11: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 12: Lubricate at first sign of visible surface rust.
NOTE 13: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every
2000 Hours or Annually to change air filter element.
NOTE 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled water or deionized water.
NOTE 16: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures
1900 SRM 1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or
highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less
frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
29
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 1150

HOW TO MAKE CHECKS WITH ENGINE
STOPPED
WARNING
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE
tag in the operators area. If the lift truck is
equipped with a key switch, remove the key
from the key switch.
Put lift truck on a level surface. Lower carriage
and forks, stop the engine, and apply parking brake.
Open hood and check for leaks and conditions that
are not normal. Clean any oil or fuel spills. Ensure
all surfaces are free of oils, lubricants, fuel, and organic dust or fibers (paper, wood, cotton, agricultural
grass/grain, etc.).
damaged rims. Check for loose or missing hardware.

Remove any wire, strapping, or other material that
is wrapped around the axle. See Figure 17.
Safety Labels
WARNING
Safety labels are installed on the lift truck to
provide information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be
read.
Check that all safety labels are installed in the correct location on lift truck. See the Parts Manual,
Model Description section in the Operating Manual or section Frame 100 SRM 1120 for correct location of safety labels. See Parts Manual for part
numbers of the safety labels.
Tires and Wheels

Check tires for damage. Check tread and remove any
objects that will cause damage. Check for bent or
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 17. Tire Check
30
8000 SRM 1150
Mast, Carriage, Lift Chains, Header Hoses,

Attachment
WARNING
Lower the lift mechanism completely. Never
allow any person under a raised carriage. DO
NOT put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED. DO NOT try to correct the alignment of the fork tips by bending the forks or
adding shims. Never repair damaged forks by
heating or welding. Forks are made of special
steel using special procedures. If either fork is
damaged, replace the forks as a set.

6. Check that lift chains are correctly lubricated.
Use SAE 30W engine oil as necessary to lubricate
lift chains.
7. Inspect lift chains for cracks or broken links, and
worn or turned pins. See Figure 18.
8. Inspect chain anchors and pins for cracks and
damage.
9. Make sure lift chains are adjusted so that they
have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.
1. Inspect welds on mast and carriage for cracks.

Make sure that capscrews and nuts are tight.
2. Inspect channels for wear in areas where the
rollers travel. Inspect rollers for wear or damage.
3. Inspect load backrest extension for cracks and
damage.
4. If lift truck is equipped with an integral sideshift
carriage or attachment, inspect the parts for
cracks and wear. Make sure the parts that fasten the integral sideshift carriage or attachment
to carriage are in good condition.
5. Visually inspect hoses/fittings for hydraulic
leaks; hose cover for cuts, cracks or exposed reinforcement; defective/broken clamping devices
or sheaves; proper tracking during operation.
Adjust/repair/replace hose/components as necessary. See Mast Repairs, 2-, 3-, and 4-Stage
Masts 4000 SRM 1148 for quick disconnect procedures.
1.
2.
3.
4.
WORN PIN
CRACKS
EDGE WEAR
HOLE WEAR
5. LOOSE LEAVES
6. TURNED PIN
7. CORROSION
Figure 18. Lift Chain Check
31
Operator Restraint System

NOTE: The seat belt can be either black or red.
The seat belt, hip restraint, seat, hood, and hood
latch are all part of the operator restraint system.
Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good
condition. See Figure 19.
Automatic Locking Retractor (ALR)

NOTE: S40-70FT, S55FTS (F187) lift trucks produced
before November 2005 are equipped with the ALR
type seat belts.
The seat belt must fasten securely. Make sure the
seat belt extends and retracts smoothly and is not
frayed or torn. If the seat belt is damaged or does not
operate properly, it must be replaced. See Figure 19.
Emergency Locking Retractor (ELR)

NOTE: Lift trucks produced after November 2005
are equipped with the Emergency Locking Retractor
(ELR) style seat belt.
When the ELR style seat belt is properly buckled
across the operator, the belt will permit slight operator repositioning without activating the locking
mechanism. If truck tips, travels off a dock, or comes
to a sudden stop, the locking mechanism will be activated and hold the operators lower torso in the seat.
A seat belt that is damaged, worn, or does not operate properly will not provide protection when it is
needed. The end of the belt must fasten correctly in
the latch. The seat belt must be in good condition.
Replace the seat belt if damage or wear is seen. See
Figure 19.
NOTE: The following seat belt operation checks must
be performed three times before replacing the seat
belt assembly.
With the hood closed and in the locked position,
pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts
smoothly. If the seat belt cannot be pulled from the
retractor assembly or the belt will not retract, replace the seat belt assembly.
With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
32
8000 SRM 1150

seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
when it is pulled with a sudden jerk, replace the
seat belt assembly.
With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
with the hood in the open position, replace the seat
belt assembly.
Adjust Seat - Full Suspension

Seat Position Adjustment (Standard Seat)
Fore and aft adjustment - It is recommended that
the seat be adjusted so that the thigh is horizontal to the ground in order to achieve the best ergonomic position. See Figure 19.
Seat Position Adjustment (Swivel Seat)
The seat swivels 12 degrees to the right to allow the
operator a more ergonomic position when driving
in reverse.
The seat swivels 5 degrees to the left to allow an
easier exit of the truck.
The neutral position is shown in Figure 19.
Seat Adjustment for Operator Weight
CAUTION
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
NOTE: It is important to adjust the weight setting for
each operator.
NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
The target is for the "ride indicator" to fall between
the arrows when the operator sits upright in the
seat with the feet positioned on the pedals. This
ensures that the operator is set at the midpoint of
the 80 mm (3.15 in.) suspension.
The handle can be turned as shown to increase or
decrease the weight resistance. Pull handle out before turning. As the handle is turned the "stiffness"
of the suspension can be felt to increase or decrease
on which way the handle is turned.
8000 SRM 1150
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

A. AUTOMATIC LOCKING RETRACTOR
B. EMERGENCY LOCKING RETRACTOR AND

SWIVEL SEAT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
LATCH STRIKER
HOOD LATCH
FORWARD/BACKWARD ADJUSTMENT
HOOD
OPERATOR WEIGHT ADJUSTMENT
SEAT RAIL
ARM REST
SEAT BELT
SEAT
HIP RESTRAINT
HOOD HINGE
SWIVEL ADJUSTMENT
BACKREST ANGLE ADJUSTMENT
Figure 19. Hood, Standard Seat, and Swivel Seat Check
33
Adjust Seat - Internal Suspension

Seat Position Adjustment (Swivel Seat)
The seat swivels 10.5 degrees to the right to allow
the operator a more ergonomic position when driving in reverse.
The seat swivels 5 degrees to the left to allow an
easier exit of the truck.
The neutral position is shown in Figure 20.
Seat Adjustment for Operator Weight
CAUTION
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
8000 SRM 1150

NOTE: The seat is designed for maximum weight of
135 kg (298 lb).
The target is for the "ride indicator" to fall between
the arrows when the operator sits upright in the
seat with the feet positioned on the pedals. This
ensures that the operator is set at the midpoint of
the 40 mm (1.57 in.) suspension.
The weight adjustment knob can be turned left or
right to increase or decrease the weight resistance.
As the weight adjustment knob is turned the "stiffness" of the suspension can be felt to increase or decrease on which way the weight adjustment knob
is turned.
NOTE: It is important to adjust the weight setting for

each operator.
NOTE: OPTIONAL SWIVEL SEAT SHOWN.

A. STANDARD, NON SUSPENSION SEAT
B. FULL SUSPENSION SEAT
1.
2.
3.
4.
5. BACKREST ANGLE ADJUSTMENT LEVER

6. ARMREST
7. SWIVEL LATCH RELEASE LEVER
SEAT BELT
WEIGHT ADJUSTMENT KNOB
RIDE POSITION INDICATOR
FORWARD/BACKWARD ADJUSTMENT LEVER
Figure 20. Seat Adjustment
34
8000 SRM 1150
Hood and Seat Latches

Make sure seat rails and latch striker are not loose.
Seat rails must lock tightly in position, but move
freely when unlocked. See Figure 19. Seat rails must
be correctly fastened to the hood and the hood fastened to hinges on frame. Try to lift the hood to make
sure it is fastened correctly and will not move. If adjustment is required, go to Hood Latch Check.
Engine Compartment
Check for the presence of any combustible material
such as paper, leaves, etc. Remove any combustible
materials.
Paper Application
Vehicles used in paper applications require regular
inspection and cleaning to minimize the risk of fire.
This should be done at least once every eight hours
or more frequently depending upon operating environment. The paper application option will help
limit the contact of paper or tissue scraps to hot
surfaces under the hood, but frequent maintenance
is required.
WARNING
Engine and exhaust system components are
hot to touch. Be sure lift truck components are
cool before starting inspection and cleaning or
personal injury may occur.
Ensure truck engine cools properly by allowing it to
idle for several minutes. Shutting truck down while
hot will not allow engine to cool quickly due to the
loss of coolant circulation. The heat trapped under
the hood may actually increase engine temperature
because of no heat transfer through the radiator.
With engine off and lift truck components cooled,
check and clean the radiator and if equipped, radiator screen. Check engine manifold, exhaust pipes,
muffler and catalytic converter for paper scraps.
Clean as required. Check and clean engine compartment components, transmission, fan shroud, belly
pan if equipped, and inside frame ledges to avoid
paper, dust and oil accumulation. Check axle and
cowl openings for paper buildup and bailing wire.
Remove any debris.
WARNING
eyes.
CAUTION
Air pressure, nozzle or extension tube may
cause damage to exhaust wraps and radiator
fins. Assure that air pressure, nozzle or extension tube does not damage exhaust wraps or
radiator fins.
Paper removal can generally be accomplished using a
compressed air line and nozzle. An extension may be
helpful to access hard to reach places. Remove floor
plates and side covers for better access to engine compartment. Open or removed belly pan, if equipped.
Clean components with compressed air. Take care
to maintain the integrity of the exhaust wraps when
cleaning with compressed air and use caution to not
force debris into openings. Check the condition of exhaust wraps for wear, proper fit, contamination with
oil or antifreeze, gaps in coverage, failed fasteners
and replace as necessary. Do not reuse wraps if they
have been removed for some other service operation.
WARNING
Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose
your skin to steam.
If compressed air did not adequately remove debris,
steam clean to remove any persistent accumulation
of material or oil. Protect electrical components from
moisture when steam cleaning. Do not spray exhaust
wraps directly with high pressure steam. Allow lift
truck to air dry before returning to work in a contaminated environment. Paper dust and scraps will
adhere to wet surfaces.
Check the condition of exhaust wraps for wear,
proper fit, contamination with oil or antifreeze, gaps
in coverage, failed fasteners and replace as necessary. Do not reuse wraps if they have been removed
for some other service operation.
35
8000 SRM 1150
Fuel, Oil, and Coolant Leaks, Check

WARNING
All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame
to check the fuel level or to check for leaks in
the fuel system. If there is a leak in the fuel system, extra care must be used during the repair.
DO NOT operate the lift truck until a leak is repaired.
Make a visual check for leaks on and under the lift
truck. If possible, find and report leaks to maintenance for repair. Leaks often indicate a need for repair of damaged or worn components. Leaks in the
LPG fuel system are usually not visible unless ice
is present. There is however, usually a strong odor.
Fuel leaks MUST be repaired IMMEDIATELY.
1. TILT LEVER
2. GAS CYLINDER
Figure 21. Steering Column Gas Cylinder and

Tilt Lever
Check fuel system for leaks and the condition of

parts. When fuel is added to lift truck, see section
HOW TO ADD FUEL TO THE LIFT TRUCK in the
Operating Manual.
Hydraulic System Oil
Also check the condition of radiator or heater hoses

that are not leaking. Soft or cracked hoses need to be
replaced before a major leak occurs.
At operating temperature, the hydraulic oil is

HOT. DO NOT permit the hot oil to touch the
skin and cause a burn.
Hydraulic Hoses
Check condition of hydraulic hoses for serviceability by inspecting for cracks or other obvious damage. Check to ensure that the hydraulic hoses are
not leaking. If any hose is leaking, report it to maintenance for repair.
Coolant Hoses
Check condition of coolant hoses for serviceability by
inspecting for cracks or other obvious damage. Check
to ensure that the coolant hoses are not leaking. If
any hose is leaking, report it to maintenance for repair.
Steering Column Gas Cylinder

Make sure the gas cylinder for steering column operates correctly. The cylinder must NOT allow column
to move unless tilt lever is released. See Figure 21.
Transmission
Check transmission for leaks and damaged or loose
components. Heavy-duty or high temperature operations can require more frequent checks.
36
WARNING
CAUTION
DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter
is changed.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.
After engine has stopped, wait one minute before
checking the oil level. Keep hydraulic oil at the correct level as indicated on dipstick. Use correct oil as
shown in the Maintenance Schedule.
Check hydraulic system for leaks and damaged or
loose components. Heavy-duty or high-temperature
operations can require more frequent checks.
8000 SRM 1150
Engine Oil
After engine has stopped, wait one minute before
checking oil level. Keep oil at correct level as indicated on the dipstick. Use the correct oil as shown in
the Maintenance Schedule.
See Figure 22 for lift trucks equipped with a Yanmar
2.6L and 3.3L diesel engine.
See Figure 23 for lift trucks equipped with GM engine.
See Figure 24 for lift trucks equipped with a Mazda
engine (except 2007 emission compliant engines).
engine (2007 emission compliant engines).
There is an indicator light for the engine oil pressure
on the Display Switch Cluster. During normal operation, the red indicator light will illuminate when the
key switch is turned to ON, if the truck is equipped
with a key switch, or when the Power ON/OFF button is pressed, if the truck is equipped with a Power
ON/OFF option, and will stay illuminated until correct oil pressure is obtained, at which time the light
will go OFF.
If the light continues to stay on when engine is running, the engine oil pressure is low. Stop the engine
and check the oil level. Do not restart the engine until the low pressure condition has been corrected.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
BATTERY
AUXILIARY COOLANT RESERVOIR
RADIATOR CAP
DRIVE BELT
AIR FILTER
ENGINE OIL FILTER
DIPSTICK ENGINE OIL
FUEL FILTER
FUEL INJECTOR
ENGINE OIL FILL
Figure 22. Yanmar 2.6L and 3.3L Diesel Engine

Maintenance Points
37
Figure 23. GM Engine Maintenance Points
38
8000 SRM 1150
8000 SRM 1150

Legend for Figure 23
A. GAS ENGINE
B. LPG ENGINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DIPSTICK ENGINE OIL

BATTERY
RADIATOR CAP
ENGINE OIL FILL
DRIVE BELT
AIR FILTER
FUEL FILTER
ENGINE OIL FILTER
PCV VALVE
SPARK PLUGS
FUEL INJECTOR
39
8000 SRM 1150
Figure 24. Mazda Engine Maintenance Points (Except 2007 Emission Compliant Engines)
40
8000 SRM 1150

A. GAS ENGINE
B. LPG ENGINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DIPSTICK ENGINE OIL

BATTERY
RADIATOR CAP
ENGINE OIL FILL
DRIVE BELT
AIR FILTER
FUEL FILTER
ENGINE OIL FILTER
PCV VALVE
SPARK PLUGS
FUEL INJECTOR
41
8000 SRM 1150
Figure 25. Mazda Engine Maintenance Points (2007 Emission Compliant Engines Only)
42
8000 SRM 1150

A. LPG ENGINE
B. GAS ENGINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DIPSTICK ENGINE OIL

BATTERY
RADIATOR CAP
ENGINE OIL FILL
DRIVE BELT
Air Filter
The air filter canister should not be opened until an
air filter element replacement is required. An air
filter element replacement is required when one of
the following occurs:
The optional air flow restriction indicator light on
the dash illuminates.
If equipped, the manual air flow indicator is red.
The specified number of hours has passed since the
last filter element replacement.
DO NOT operate lift truck until the air filter element
has been replaced.
AIR FILTER
FUEL FILTER
ENGINE OIL FILTER
PCV VALVE
SPARK PLUGS
FUEL INJECTORS (GAS ONLY)
NOTE: If lift truck is equipped with a fork positioner

attachment, perform Step 1 and Step 2. If lift truck
is not equipped with a fork positioner attachment, go
to Step 4.
NOTE: Depending on the size and configuration of
the forks installed on the lift trucks equipped with
a fork positioner, there may be a spacer bar between
the inner and outer fork carriers. See Figure 26.
1. Lower the carriage and remove four capscrews
from inner fork carriers. Remove inner fork carriers from integral sideshift carriage. See Figure 27.
Forks
NOTE: Forks must be removed or installed by trained
personnel only.
The identification of a fork describes how the fork is
connected to the carriage. These lift trucks have hook
forks.
Remove
WARNING
DO NOT try to move a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 253 lb).
CAUTION
Remove fork latch pins if adding a fork positioner attachment. Damage to forks and other
carriage components can occur if fork latch
pins are not removed prior to using attachment.
1.
2.
3.
4.
OUTER FORK CARRIER

CAPSCREW
SPACER BAR*
INNER FORK CARRIER
*SPACER BAR USED ON 977 mm (38.5 in.) AND

1067 mm (42 in.) CLASS II CARRIAGES.
Figure 26. Fork Carrier Spacer Bar
NOTE: Forks are to be replaced only in sets and not

individually.
43
1.
2.
3.
4.
OUTER FORK CARRIER

FORKS
INNER FORK CARRIER
SIDESHIFT CARRIAGE ASSEMBLY
8000 SRM 1150
5. FORK POSITIONER
6. CAPSCREWS
7. FORK REMOVAL NOTCH
Figure 27. Fork Removal, Lift Trucks Equipped With Fork Positioner Attachment
2. Slide fork to fork removal notch in bottom bar of
carriage. See Figure 27.
3. Lower fork onto blocks so bottom hook of fork
moves through the fork removal notch. Lower
carriage further so top hook of the fork is disengaged from top carriage bar. Move carriage away
from fork or use a lifting device to move fork away
from carriage. See Figure 28.
4. A fork can be removed from the carriage for replacement of the fork or other maintenance. Lift
lock pin and slide a hook fork to the fork removal
notch on carriage. See Figure 28 and Figure 29.
Lower fork onto blocks so that the bottom hook of
the fork moves through fork removal notch. See
Figure 29. Lower carriage further so that the top
hook of fork is disengaged from the top carriage
bar. Move carriage away from the fork, or use
a lifting device to move fork away from the carriage.
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 28. Hook Fork Removal
44
8000 SRM 1150
Inspect
Install
1. Inspect forks for cracks and wear. Check that the

fork tips are aligned as shown in Figure 29.
2. Check that the bottom of fork is not worn. See
Figure 29, item 4.
3. Replace any damaged or broken parts that are
used to keep the forks locked in position.
WARNING
DO NOT try to move a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 253 lb).
CAUTION
Remove fork latch pins if adding a fork positioner attachment. Damage to forks and other
carriage components can occur if fork latch
pins are not removed prior to using attachment.
NOTE: Forks are to be replaced only in sets and not
individually.
NOTE: If lift truck is not equipped with fork positioner, go to Step 1. If lift truck is equipped with fork
positioner, go to Step 2.
1. Move the fork and carriage so that the top
hook on the fork can engage the upper carriage
bar. Raise the carriage to move the lower hook
through the fork removal notch. Slide the fork on
the carriage so that both upper and lower hooks
engage the carriage. Engage the lock pin with a
notch in the upper carriage bar. See Figure 30.
2. If lift truck is equipped with a fork positioner
attachment, install inner fork carriers using
four capscrews. Tighten capscrews to 35 Nm
(25 lbf ft). See Figure 27.
Fork Tip Alignment

Length of Forks
915 mm (36 in.)
1067 mm (42 in.)
1220 mm (48 in.)
1372 mm (54 in.)
1524 mm (60 in.)
1830 mm (72 in.)
Adjust
3% Dimension
27
32
37
41
46
55
mm
mm
mm
mm
mm
mm
(1.10
(1.26
(1.46
(1.61
(1.81
(2.17
in.)
in.)
in.)
in.)
in.)
in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93
8. FORK REMOVAL NOTCH
NOTE: During the adjustment of the forks, the heel

of the forks should not be touching the ground.
NOTE: The information below applies to lift trucks
NOT equipped with fork positioner attachment.
The forks are connected to the carriage by hooks and
lock pins. See Figure 28 and Figure 30. Lock pins are
installed through the top fork hooks and fit into slots
in the top carriage bar. If pin does not remain engaged in carriage slot, replace with new pin. Adjust
forks as far apart as possible for maximum support
of the load. Hook forks will slide along 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 lock pin is engaged in the carriage bar to lock
fork in position after the width adjustment is made.
Figure 29. Forks Check
45
8000 SRM 1150

the lift truck tips over. IT CAN ONLY HELP IF
IT IS FASTENED.
Make sure that the area around the lift truck is clear
before starting the engine or making any checks of
the operation. Be careful when making the checks.
If the lift truck is stationary during a check, apply
the parking brake and put the transmission in NEUTRAL. Make the checks carefully.
Indicator Lights, Horn, Fuses, and Relays

1.
2.
3.
4.
FORK
LOCK PIN
SPRING
WASHER
5. WEDGE
6. KNOB
7. LOCK PIN
ASSEMBLY
Figure 30. Fork Lock Pin Assembly
HOW TO MAKE CHECKS WITH ENGINE

RUNNING
WARNING
Report the need for repair immediately. If repair is necessary, put a DO NOT OPERATE tag
in the operators area. If lift truck is equipped
with a key switch, remove the key.
WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if
46
If lift truck is equipped with a key switch, turn

key to ON position. If lift truck is equipped with a
Power ON/OFF button, press button to turn system
power ON. All warning lights and indicator lights
will light up for two seconds (start check) when
system power is turned ON. See Figure 31. Check
all indicator lights for correct operation as described
in the Operating Manual. Check the operation of
the horn. Start the engine by turning the key switch
to the Start position, if truck is equipped with a key
switch, or press the engine start button, if lift truck
is equipped with this button. If any indicator lights
do not operate correctly, stop the engine and check
the fuses. The fuses are located in the Power Distribution Module (PDM) which is under the hood and
next to the battery on the right side. See Figure 32.
8000 SRM 1150
Item
Warning and Indicator Light
Warning Light, Engine Malfunction Light
Warning Light, System Malfunction Light
Indicator Light, Air Filter Restriction
Indicators Light, Direction and Transmission
Warning Light, Brake Oil Level Malfunction Indicator
Warning Light, Fasten Seat Belt Malfunction Indicator
Warning Light, Parking Brake Malfunction Indicator
Warning Light, Alternator Malfunction Indicator
Warning Light, Transmission Oil Temperature Malfunction Indicator
10
Warning Light, Engine Oil Pressure Malfunction Indicator
11
Warning Light, Engine Coolant Temperature Malfunction Indicator
12
Warning Light, Coolant Level in Radiator Malfunction Indicator
13
Warning Light, Fuel Level Indicator
14
Indicator Light, 1st Gear Locking (Duramatch Plus 2 Transmissions)
15
Indicator Light, Water Separator (Diesel Only)
16
Indicator Light, Cold Start (Diesel Only)

Figure 31. Warning and Indicator Lights
47
8000 SRM 1150
NOTE: HOOD REMOVED FOR CLARITY.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
BATTERY
PDM
RESISTOR (68 OHM)
START RELAY
STARTER (30-AMP FUSE)
IGNITION 3 RELAY
BACKUP RELAY
BACKUP (20-AMP FUSE)
IGNITION (30-AMP FUSE)
SPARE FUEL PUMP (20-AMP FUSE)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
SPARE FUEL PUMP RELAY

BATTERY (25-AMP FUSE)
FRONT WORK LIGHT (20-AMP FUSE)
FRONT/REAR WORK LIGHT RELAYS
REAR WORK LIGHT (20-AMP FUSE)
IGNITION 1 (20-AMP FUSE)
IGNITION RELAY
SEMICONDUCTOR TRANSZORB
Figure 32. PDM Showing Fuses and Relays
Service Brakes
Brake Fluid Level
WARNING
Small amounts of water in the brake system
can cause reduced braking performance if the
water reaches the wheel cylinder areas. DO
NOT allow water entry. Ensure that the sealed
reservoir lid is properly replaced.
On lift trucks with wet brake drive axles, only
use Dexron III oil from sealed container in the
master cylinder.
48
On lift trucks with dry brake drive axles, only

use SAE J-1703 (DOT 3) brake fluid in the master cylinder.
WARNING
If the brake system has a power assist (or
boosted master cylinder), braking will be more
difficult if the engine is not running.
Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before
using the lift truck. Replace the brake fluid in
the system if there is dirt or water in the system.
8000 SRM 1150

There is an indicator light on the Display Switch
Cluster for the brake fluid. The red light is ON
when the key switch is in the START position or
the Power ON/OFF button is pressed, and must go
OFF when the engine is running. If the light is on
when the engine is running, the brake fluid level in
the reservoir is too low.

2. For burnished brakes, test the operation of the
parking brake. The lift truck with a capacity load
must not move when parking brake is applied on
a 15 percent grade [a slope that increases 1.5 m
in 10 m (1.5 ft in 10 ft)].
Operation, Check
Check the operation of the service brakes. Push on
the inching/brake pedal. The service brakes must be
applied before the inching/brake pedal reaches the
floor plate. The pedal must stop firmly and must
not move slowly down after the brakes are applied.
The service brakes must apply equally to both drive
wheels. The service brakes must not pull the lift
truck to either side of the direction of travel when
they are applied. The service brakes are automatically adjusted when the transmission is in reverse
and the lift truck is moving and the brakes are firmly
applied. Full application of the inching/brake pedal
applies the service brakes and puts the transmission
in NEUTRAL.
Lift trucks with a MONOTROL pedal. When
the inching/brake pedal is fully applied, a switch in
the starting circuit is closed so that the engine can be
started.
Parking Brake
Make sure service brakes are adjusted and the operation of the automatic adjuster mechanism is correct
before parking brake is adjusted.
Lift trucks with a MONOTROL pedal. The
switch energizes the seat warning circuit when hand
lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction
solenoid. There is also a switch on the left side of
bracket. This switch prevents engine from starting
unless parking brake is applied.
NOTE: Make sure parking brake is released before
making adjustment.
1. Turn adjustment knob to raise the equalized link
and tighten parking brake cables shown in Figure 33. DO NOT tighten the adjustment so that
brake is applied when the lever is released. The
lever for the parking brake has a lock. Use your
thumb or finger to release lock on lever when
parking brake is released.
1.
2.
3.
4.
LOCK BUTTON RELEASE

OFF POSITION
ON POSITION
ADJUSTMENT KNOB
Figure 33. Parking Brake
Engine Oil Pressure

NOTE: The engine will enter shutdown mode after a
warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
lift trucks equipped with a Mazda engine and powertrain protection system. Lift trucks equipped with a
Yanmar diesel engine will enter the shutdown mode
when the engine oil pressure is less than 49 kPa
(7 psi) on lift trucks with powertrain protection
system. See the Engine Shutdown procedures in
the Operating Manual.
There is an indicator light for the engine oil pressure
on the Display Switch Cluster. During normal operation, the red indicator light will illuminate when the
key switch is turned to ON, if the truck is equipped
49
8000 SRM 1150
with a key switch, or when the power ON/OFF button is pressed, if the truck is equipped with this option, and will stay illuminated until correct oil pressure is obtained, at which time the light will go off.
and the level in the auxiliary coolant reservoir will

increase.
If the light continues to stay on when engine is running, the engine oil pressure is low. Stop the engine
and check the oil level. Do not restart the engine until the low pressure condition has been corrected.
Additives may damage the cooling system. Before using additives, contact your local Hyster
dealer.
See Figure 22 for lift trucks equipped with a Yanmar

2.6L and 3.3L diesel engine.
See Figure 23 for lift trucks equipped with GM engine.
Cooling System
WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
CAUTION
If coolant is added, see Maintenance Schedule for correct solution.
WARNING
eyes.
Check the radiator fins. Turn engine OFF and clean
the radiator with compressed air or water as needed.
Check for and remove any debris on the radiator core.
If the indicator light turns on again after restarting,
shut down the lift truck and do not operate the lift
truck until the problem is corrected.
NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown,
if coolant temperature reaches 121C (250F) or
above on lift trucks with powertrain protection system and a Mazda engine. Lift trucks equipped with
a Yanmar diesel engine will enter shutdown mode
when coolant temperature reaches 110C (230F)
or above on lift trucks with powertrain protection
system. See ENGINE SHUTDOWN procedures in
the Operating Manual.
There is an indicator light on the Display Switch
Cluster for the coolant temperature. The red light
is on when key switch is in the START position or
the Power ON/OFF button is pressed, and must go
off when the engine is running. If light is on when
engine is running, the coolant and engine are too hot.
Stop engine and check coolant level in the coolant
recovery reservoir.
Make sure coolant level is between the ADD and
FULL marks on the auxiliary coolant reservoir. See
Figure 34. The coolant will expand as it is heated
50
1.
2.
3.
4.
5.
FILL CAP
FULL MARK
ADD MARK
RADIATOR CAP
Figure 34. Auxiliary Coolant Reservoir
8000 SRM 1150
Steering System
WARNING
The lift truck has hydraulic power steering.
The steering can be difficult if the engine is
not running.
Make sure steering system operates smoothly and
provides good steering control. Make sure steering
column can be adjusted and the gas cylinder function
is correct.
Control Levers and Pedals

Check that control levers for the transmission, mast,
and attachment operate as described in Operating
Manual. Check that pedals operate correctly as described in Operating Manual.
Lift System, Operate

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast at the
end of this section.
Lower the lift mechanism completely. Never
allow any person under a raised carriage. DO
NOT put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
If the mast cannot be lowered, use chains on
the mast weldments and carriage so that they
cannot move. Make sure the moving parts are
attached to a part that does not move.
First Service After First 100 Hours of Operation

DO NOT try to find hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
the pressure.
Perform the following checks and inspections:
1. Turn engine OFF and check for leaks in the
hydraulic system. Check condition of hydraulic
hoses and tubes.
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
2. Slowly raise and lower mast several times without a load. Raise mast to its full height at least
once. The mast components must raise and lower
smoothly in the correct sequence. Hose must
track properly during operation.
3. The inner weldments and the carriage must
lower completely.
4. Raise the mast 1 m (3 ft) with a capacity load.
The inner weldments and the carriage must raise
smoothly. Lower the mast. All moving components must lower smoothly.
5. Lower the load to approximately 0.3 m (1 ft). Tilt
mast forward and backward. The mast must
tilt smoothly and both tilt cylinders must stop
evenly.
6. Check that the controls for the attachment operate the functions of the attachment. See the
symbols by each of the controls. Make sure all of
the hydraulic lines are connected correctly and
do not leak.

MAZDA AND GM ENGINE OIL AND OIL
FILTER
NOTE: The engine oil and oil filter must also be
changed after the first 100 hours of operation for a
newly installed engine.
your hand. Fill engine with oil as specified in Maintenance Schedule, until full mark reached on the dipstick. Start engine. Check area around oil filter for
leaks, shut engine off and check oil dipstick, if low
add oil. See Figure 35.
Change engine oil and oil filter. Apply clean oil to

gasket of new filter. Install new filter. Turn filter until gasket touches, then tighten 1/2 to 3/4 turn with
51
8000 SRM 1150
NOTE: BOTTOM VIEW OF ENGINE SHOWN.

A. MAZDA
B. GM
1. OIL FILTER
2. DRAIN PLUG
Figure 35. Engine Oil Change
YANMAR ENGINE OIL AND OIL FILTER

Change engine oil and oil filter. Apply clean oil to
gasket of new filter. Install new filter. Turn filter until gasket touches, then tighten 1/2 to 3/4 turn with
your hand. Fill engine with oil as specified in Maintenance Schedule, until full mark reached on the dipstick. Start engine. Check area around oil filter for
leaks, shut engine off and check oil dipstick, if low
add oil. See Figure 36.

1. OIL FILTER
2. DRAIN PLUG
Figure 36. Engine Oil Change Yanmar Diesel
52
8000 SRM 1150
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform 8-hour checks prior to performing
procedures in this section.
MAZDA AND GM ENGINE OIL AND OIL

FILTER
Change engine oil and engine oil filter. Use correct oil
according to Maintenance Schedule. Apply clean oil
to gasket of new filter. Install new filter. Turn filter
until gasket touches, then tighten 1/2 to 3/4 turn with
your hand. Start engine. Check area around oil filter
for leaks. See Figure 37.
NOTE: Change oil and oil filter for engine at first 100
hours of operation on new lift trucks.

A. MAZDA
B. GM
1. OIL FILTER
2. DRAIN PLUG
Figure 37. Engine Oil Change
53
8000 SRM 1150
DRIVE BELT
GM 2.4L Engine
Mazda 2.0L and 2.2L Engines
Fan and Alternator Drive Belt
Check drive belt for fan and alternator for wear and
damage. See Figure 39. The belt tensioner on GM
2.4L engine is a nonadjustable, self-tensioning device
with two positions: tension applied and tension relieved. Adjustments are not needed.
Check drive belt for fan and alternator for wear and
damage.
Check tension by pushing on drive belt to check deflection. When pressure is 98 N (22 lbf), correct deflection is approximately 7 to 8 mm (0.3 in.). Loosen
alternator support bracket to adjust tension of belt.
See Figure 38.
1. BELT
2. DRIVE TOOL SLOT
3. SELF-ADJUSTING TENSIONER
1. CHECK TENSION HERE
2. ALTERNATOR SUPPORT BRACKET
Figure 38. Drive Belts Check and Adjustment,
Mazda Engines
54
Figure 39. GM 2.4L Engine Drive Belt
8000 SRM 1150
DRAIN TAR FROM LPG REGULATOR

(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES)
NOTE: For 2007 Mazda Emission Compliant Engines
go to Drain Tar From LPG Regulator (2007 Mazda
Emission Compliant Engines Only).
1. Warm engine to operating temperature.
2. Shut fuel valve off and run engine until engine
runs out of fuel and stops.
3. Raise hood.
4. Remove tar drain screw from regulator. Allow tar
to drain from regulator. When tar has completely
drained, install tar drain screw in regulator. See
Figure 40 and Figure 41.
1. TAR DRAIN SCREW
Figure 41. GM LPG Regulator
1. TAR DRAIN SCREW

Figure 40. Mazda LPG Regulator
55
DRAIN TAR FROM LPG REGULATOR (2007

MAZDA EMISSION COMPLIANT ENGINES
ONLY)
8000 SRM 1150

10. Install EPR assembly, see LPG Fuel System,
Mazda 2.0L and 2.2L Emission Compliant
Engines 900 SRM 1326.
NOTE: The following procedures are for 2007 Mazda

Emission Compliant Engines Only.
NOTE: Draining the LPG regulator when engine is
warm will help the oils to flow freely from the regulator.
1. Warm engine to operating temperature.
2. Close fuel valve on tank and run engine until it
runs out of fuel and stops. Try to restart engine
2-3 times until it no longer starts.
3. Turn the key to the OFF position.
4. Raise hood and disconnect negative battery cable.
5. Remove the EPR assembly, see LPG Fuel System, Mazda 2.0L and 2.2L Emission Compliant Engines 900 SRM 1326.
6. Remove the retaining pin in the fuel temperature
sensor and remove from the electronic pressure
regulator (EPR). See Figure 42.
7. Using a suitable container, rotate the EPR 90 so
that the outlet fitting is pointing down and drain
the EPR.
1. FUEL TEMPERATURE SENSOR

2. RETAINING PIN
3. ELECTRONIC PRESSURE REGULATOR (EPR)
8. Inspect and remove any tar or debris from the

secondary chamber.
Figure 42. 2007 Mazda Emission Compliant

EPR Assembly
9. Install fuel temperature sensor and retaining

pin. See Figure 42.
56
8000 SRM 1150

NOTE: Perform the 8-hour and 250-hour checks prior
to performing the procedures in this section.
HYDRAULIC SYSTEM OIL

WARNING
CAUTION
is changed.
pump.
CAUTION
WARNING
eyes.
CAUTION
Direct air pressure on the filter element can
cause damage. Direct air pressure away from
filter element.
1. Using compressed air, remove any dirt and debris in the frame cavity around the breather. See
Figure 43.
2. Replace the breather if oil has accumulated in
the cavity or on the breather, or if dirt has accumulated at the breather passages at the bottom
of the breather.
Additives may damage the hydraulic system.

Before using additives, contact your local Hyster dealer.
Check the hydraulic oil level when the oil is at operating temperature with the mast in a vertical position,
the carriage lowered, and the engine stopped.
See Figure 47 for lift trucks equipped with iron transmission housing.
See Figure 48 for lift trucks equipped with aluminum
transmission housing.
Add hydraulic oil only as needed. If hydraulic oil
is above the FULL level, the hydraulic oil will leak
from the breather during operation. The oil level indicated by the dipstick is most accurate when the oil
temperature is 53 to 93C (130 to 200F).
HYDRAULIC TANK BREATHER

Inspect
NOTE: When inspecting the breather, do not remove
it. The breather element is a non serviceable part. If
it is damaged, replace with a new breather element.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 43. Hydraulic Tank Breather
57
8000 SRM 1150
BATTERY
WARNING
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the
eyes must be flushed with water immediately.
Wear eye protection.
WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flame away from the battery area. DO NOT
make sparks from the battery connections.
Disconnect the battery ground cable when
doing maintenance.
Disconnect the negative and positive terminals of the
battery. Using a damp cloth clean the case of the battery. If the terminals are corroded, clean the terminals with a wire brush. Connect the negative and
positive cables to their respective terminals.
YANMAR ENGINE OIL AND OIL FILTER

NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks.
Change engine oil and engine oil filter. See Maintenance Schedule for correct oil type and amount. Apply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten 1/2 to
3/4 turn with your hand. Start engine. Check area
around oil filter for leaks. Figure 44.

1. OIL FILTER
2. DRAIN PLUG
Figure 44. Engine Oil Change Yanmar Diesel
DRIVE BELT
Yanmar Diesel Engine
NOTE: The drive belt tension may be checked at any
of the three positions A, B, or C shown in Figure 45
which ever is most easily accessible.
Check the drive belt for the fan and alternator for
wear and damage. Check tension by pushing on drive
belt with a force of 98 N (22 lbf) to check deflection
at any one of three possible positions. See Figure 45.
Check Table 2 for the correct deflection of the V-belt.
Loosen alternator support bracket bolt to adjust tension of belt. See Figure 46. When the tension of
the V-belt is correct, tighten the alternator support
bracket bolt, and check the belt tension again.
Table 2. V-Belt Deflection Table

Used V-Belt Tension
58
New V-Belt Tension
10-13 mm
(0.375-0.5 in.)
7-10 mm
(0.250-0.375 in.)
8-13 mm
(0.3125-0.5 in.)
8-11 mm (0.31250.4375 in.)
5-8 mm (0.18750.3125 in.)
7-11 mm
(0.250-0.4375 in.)
8000 SRM 1150
PCV VALVE
Remove the PCV Valve (positive crankcase ventilation valve) from the valve cover. Check the operation
of the PCV Valve by shaking the PCV Valve and listen for the check ball rattling inside. If the check ball
does not rattle, replace the PCV Valve.
See Figure 23 for lift trucks equipped with a GM engine.
CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and remove
material causing radiator core to be plugged or restricted.
WARNING
Figure 45. Yanmar Diesel Engine Drive Belt

eyes.
Clean with compressed air, adjusted to a maximum
output of 103 kPa (15 psi), and blow debris from core
and fan shroud.
TRANSMISSION OIL LEVEL

WARNING
At operating temperature, the transmission oil
is HOT. DO NOT permit the hot oil to touch the
CAUTION
DO NOT permit dirt to enter the transmission
when the oil level is checked or the filter is
changed.
1. SUPPORT
BRACKET BOLT
2. ALTERNATOR
3. PRY BAR
Figure 46. Yanmar Diesel Engine Drive Belt

Adjustment
NOTE: Transmission oil temperature should be at

least 50C (120F) when checking oil level.
If engine has been running, the engine must be shut
down for one minute or longer prior to checking the
oil level.
59

See Figure 47 for lift trucks equipped with iron transmission housing.
See Figure 48 for lift trucks equipped with aluminum
transmission housing.
8000 SRM 1150

If the transmission oil is low, add oil to transmission
at the dipstick tube at the correct level as indicated
on the dipstick. Use the correct oil as shown in the
Maintenance Schedule.
NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK
2. TRANSMISSION OIL DIPSTICK
Figure 47. Transmission and Hydraulic Oil Check
Figure 48. Transmission and Hydraulic Oil Check
60
8000 SRM 1150

NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK
2. TRANSMISSION OIL DIPSTICK
WET BRAKE PLANETARY HOUSING OIL

LEVEL CHECK
1. Remove the planetary housing fill/level plugs

and O-rings. See Figure 49.
WARNING
At operating temperature, the transmission
and wet brake planetary carrier housing oil is
CAUTION
DO NOT permit dirt to enter the center body
when the oil level is checked. Dirt will contaminate the oil and cause damage to the center
body of the axle.
1. RIGHT PLANETARY HOUSING

2. LEFT PLANETARY HOUSING
3. O-RING
2. Visually check oil level. If necessary, add oil at

the right fill/level port for the right planetary
housing and at the left fill/level port for the
left planetary housing until the oil/level port
has overflowed. The correct oil is shown in the
Maintenance Schedule or Figure 50.
3. Install the planetary housing fill/level plug and
O-rings and tighten to 40 Nm (29.5 lbf ft).
4. FILL/LEVEL PLUG
5. CENTER SECTION
Figure 49. Planetary Housings Fill/Level Plugs
61
8000 SRM 1150
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY SECTION - USE SAE 80W/90
C. CENTER HOUSING (BRAKE COOLING CHAMBER) - USE JDM J20C
1. OIL FILL/LEVEL PLUG
2. OIL BREATHER
3. COOLING OIL INLET PORT

Figure 50. Oil Application Diagram
62
8000 SRM 1150
FORKS
WARNING
Never repair damaged forks. DO NOT heat,
weld, or bend the forks. Forks are made of special steel using special methods. Replace damaged forks as a complete set.
Measure thickness of forks with a fork arm caliper
(Hyster Part No. 3020387) at a vertical section where
there is no wear. This thickness is dimension X. Now
measure thickness at heel of fork (see Figure 29). If
the thickness of the heel is not greater than 90% of
dimension X, replace fork.

NOTE: When lubricating the mast mounting/pivot
pins, the load must be removed from the normal
contact surface to allow grease to properly lubricate
the normal contact surfaces of the mast bushings.
2. Raise carriage about 61 cm (2 ft), and tilt the
mast fully back. Place blocks under the outer
mast channels to within 13 mm (0.5 in.) of the
channels. See Figure 52.
3. Tilt the mast fully forward. See Figure 52.
MAST LUBRICATION
WARNING
Procedures When Working Near Mast in this
section.
NOTE: The load rollers and sheaves have sealed bearings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller surfaces along full length of channels as shown in
Figure 51.
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
A. MAST TILTED FULLY BACK

B. MAST TILTED FORWARD
1. BLOCK
2. MAST
Figure 52. Blocking the Mast
Figure 51. Mast Lubrication
63
8000 SRM 1150
4. Tilt mast fully back. Remove the blocks from under the channels.
shown in the Maintenance Schedule. See Figure 53 and Figure 54.
5. If a integral sideshift carriage is installed, lubricate sliding surfaces at grease fittings with
multipurpose grease shown in the Maintenance
Schedule. See Figure 55
6. If a fork positioner is installed, lubricate sliding surfaces at lube fittings with multipurpose
grease shown in the Maintenance Schedule. See
Figure 56.
Lubricate the mast pivot bushings at grease fittings on outer mast. Use multipurpose grease
1.
2.
3.
4.
5.
6.
MAST HANGER BUSHINGS

LUBE FITTINGS
MAST BUSHING PLUGS
TILT PIN
ROD END
ANCHOR PIN
7.
8.
9.
10.
11.
12.
CAPSCREW
NUT
WASHER
ROD END BUSHING
TILT CYLINDER ASSEMBLY
MAST MOUNTING CAP
Figure 53. Mast Mounting Hanger Lubrication
64
8000 SRM 1150
1. OUTER MAST
2. MAST PIVOT BUSHING
3. LUBRICATION FITTING
Figure 54. Pivot Pin Lubrication
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
UPPER BEARINGS
LOWER HOOKS
LOAD ROLLER
SNAP RING
SIDESHIFT CYLINDER
LOWER BEARINGS
SHIMS
INNER CARRIAGE
LUBE FITTINGS
OUTER FRAME
Figure 55. Integral Sideshift Carriage
65
1. LUBE FITTING, SIDESHIFT CARRIAGE

2. LUBE FITTING, FORK POSITIONER
3. FORK CARRIER
8000 SRM 1150
4. UPPER FORK POSITIONER CYLINDER

5. LOWER FORK POSITIONER CYLINDER
6. SIDESHIFT CYLINDER
Figure 56. Fork Positioner Lubrication
HEADER HOSE CHECKS

Daily inspection plus; kinked, crushed, flattened or
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/replace hose/components as necessary. See Mast Repairs, 2-, 3-, and 4-Stage Masts 4000 SRM 1148
for quick disconnect procedures.
LIFT CHAIN LUBRICATION

WARNING
Procedures When Working Near Mast in this
section.
66
DO NOT repair worn or damaged lift chains. If

a lift chain is worn or damaged, both lift chains
must be replaced.
NOTE: The 500 Hour/6 Months Lift Chain Lubrication should not be performed in combination with the
1000 Hour/6 Months Lift Chain Lubrication.
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
NOT USE STEAM TO CLEAN THE LIFT CHAINS.
8000 SRM 1150
TILT CYLINDER LUBRICATION

NOTE: The floor plate must be removed in order to
lubricate the rear tilt cylinder lubrication fittings.
Lubricate the tilt cylinder ends. Use multipurpose

grease shown in the Maintenance Schedule. There
are four lubrication fittings. See Figure 57.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW
2. RETAINER
3. ANCHOR PIN
5. TILT SPACER
Figure 57. Tilt Cylinder Lubrication
67
8000 SRM 1150
MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION
Lubricate the master brake cylinder rod end pin. Use
engine oil as shown in the Maintenance Schedule.
See Figure 58 and Figure 59.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 59. Master Brake Cylinder Rod End Pin
Lubrication (Wet Brake)
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 58. Master Brake Cylinder Rod End Pin
Lubrication (Dry Brake)
68
8000 SRM 1150
MANUAL HYDRAULIC LEVERS

LUBRICATION
Lubricate the bushings for the manual hydraulic
levers. Use spray lubricant as listed in the Maintenance Schedule. See Figure 60.

master cylinder.
Replace the brake oil in the system if there is
dirt or water in the system.
Remove the dash board from the cowl. The brake
fluid reservoir is located on the cowl, at the master cylinder. Add brake fluid, as necessary. Use the
brake fluid shown in the Maintenance Schedule. See
Figure 61 and Figure 62.
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1.
2.
3.
4.
BUSHINGS
ROD END PIN
HYDRAULIC LEVERS
LOCKING RING (COTTER PIN)
Figure 60. Manual Hydraulic Levers
Lubrication
BRAKE FLUID
WARNING
1. BRAKE FLUID RESERVOIR

2. MOUNTING BRACKET
3. COWL
Figure 61. Brake Fluid Reservoir (Dry Brakes)
69
8000 SRM 1150
TIE ROD LUBRICATION (H40-70FT)

Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There are two
lubrication fittings on each tie rod. See Figure 63.
1. AXLE
Figure 63. Tie Rod Lubrication
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
RESERVOIR CAP
BRAKE OIL RESERVOIR
RESERVOIR MOUNTING BRACKET
COWL
UPPER BRAKE OIL SUPPLY HOSE
CYLINDRICAL BLOCK OUTLET FITTING
LOWER BRAKE OIL SUPPLY HOSE
NIPPLE
MASTER CYLINDER
CYLINDRICAL BLOCK DRAIN PLUG
CYLINDRICAL BLOCK
CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 62. Brake Oil Change (Wet Brakes)
70
8000 SRM 1150
DIFFERENTIAL AND DRIVE AXLE OIL

(DRY BRAKE)
The differential and drive axle use the same oil supply. The oil level must be between 0 to 10 mm (0 to
0.40 in.) below the bottom edge of fill hole. The fill
hole for checking the oil level is on the front of the
differential housing. Remove fill plug and check fluid
level by sticking a finger into the fill hole to feel if the
fluid level is at the bottom edge of the fill hole. See
Figure 64. If oil is low, add oil shown in the Maintenance Schedule until the oil level is between 0 to
10 mm (0 to 0.40 in.) below the bottom edge of fill
hole. Install fill plug and check for leaks.
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
Figure 64. Drive Axle Fluid Fill
71
8000 SRM 1150

NOTE: Perform the 8-hour, 250-hour, and 500-hour
checks prior to performing the procedures in this section.
VALVE CLEARANCE, CHECK AND

ADJUST
The GM 2.4L engine has hydraulic valve lifters and
does not require valve clearance adjustments during normal service. Check the valve clearance on
Mazda and Yanmar engines and make adjustments
as needed. See the Maintenance Schedule for valve
clearances.
Additional engine information is available in the following sections:
GM Engine Repair, GM 2.4 Liter Engine 600
SRM 1121
Mazda Engine, 2.0L and 2.2L 600 SRM 1122
IGNITION SYSTEM
GM 2.4L Engine
The GM 2.4L gasoline and LPG engines have an electronic control unit (ECU) that controls the ignition
timing. There are no adjustments. Change the spark
plugs every 1000 hours. The correct spark plug gap
is 0.8 to 0.9 mm (0.032 to 0.035 in.).
Mazda 2.0L and 2.2L Engines

The Mazda 2.0L and 2.2L engines have an electronic
ignition system. Change the spark plugs and check
the timing every 1000 hours. The correct spark plug
gap is 0.8 0.1 mm (0.031 0.004 in.).
The correct timing for the Mazda 2.0L and 2.2L engines is as follows:
Gasoline = 6 1 BTDC at 800 25 rpm (Orange
mark)
LPG = 6 1 BTDC at 800 25 rpm (Orange mark)
For all Mazda engines except 2007 emission compliant engines, see Electrical System, Mazda 2.0L
and 2.2L 2200 SRM 1143. For 2007 Mazda emission
compliant engines, see Electrical System, Mazda
2.0L and 2.2L Emission Compliant Engines 2200
SRM 1327.
72
LPG FUEL FILTER ELEMENT REPLACE,

GM 2.4L ENGINE
Remove
WARNING
LPG can cause an explosion. DO NOT permit
any sparks or open flames in the work area.
1. Close fuel valve on tank. Run engine until it
stops.
2. Disconnect negative battery cable.
WARNING
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.
3. Remove the bolt and seal washer retaining the
top section of the fuel filter housing. Discard seal
washer. See Figure 65.
4. Remove top section of fuel filter housing.
5. Remove and discard housing O-ring.
6. Remove fuel filter and fuel filter O-ring.
Install
1. Clean and inspect the fuel filter housing for contamination or damage.
2. Install the new fuel filter and fuel filter O-ring.
See Figure 65.
3. Install new housing O-ring.
4. Install top section of fuel filter housing.
5. Install bolt and new seal washer. Tighten bolt to
13 Nm (115 lbf in).
8000 SRM 1150

8. Check for leaks at connections by using soapy
solution or electronic leak detector. If leaks are
detected, make proper repairs.
LPG VAPOR FUEL FILTER REPLACE,

MAZDA ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
WARNING
Remove and install a new LPG vapor fuel filter element as follows:
1. Close fuel valve on tank. Run engine until all fuel
is gone and engine stops.
3. Slowly loosen all hose fittings to filter. Let any
fuel drain from fittings before disassembling filter unit.
4. Remove capscrews and filter cover.
1.
2.
3.
4.
5.
6.
7.
BOLT
SEAL WASHER
FUEL FILTER HOUSING TOP SECTION
FUEL FILTER
FUEL FILTER O-RING
HOUSING O-RING
FUEL FILTER HOUSING BOTTOM SECTION
Figure 65. Fuel Filter Removal and Installation

NOTE: Opening the fuel valve too quickly can cause
the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve,
wait a few seconds, and then slowly open the fuel
valve again. This will reset the excess fuel valve.
6. Slowly open the fuel valve on tank.
5. Remove O-ring, filter element, and spring. Discard spring, filter element, and O-ring. See Figure 66.
6. Install new spring, new filter element, and new
O-ring.
7. Install filter cover to filter body with capscrews.
Tighten hose fittings.
NOTE: Leaks are normally indicated by a buildup of
frost around a loose fitting. A leak may also be discovered by using soapy water.
8. Open fuel valve on LPG tank and check for leaks.
If leaks are found, tighten fittings.
7. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.
73
1. FILTER BODY
2. SPRING
3. O-RING
4. FILTER ELEMENT
5. FILTER COVER
6. CAPSCREW
Figure 66. Mazda LPG Vapor Fuel Filter
LPG FUEL FILTER REPLACE, MAZDA 2007

EMISSION COMPLIANT ENGINES ONLY
Remove
WARNING
1. Close fuel valve on tank and run engine until it
runs out of fuel and stops. Try to restart engine
2-3 times until it no longer starts.
8000 SRM 1150
1.
2.
3.
4.
5.
6.
7.
8.
BOLT*
SEAL WASHER
FUEL FILTER HOUSING TOP SECTION*
FUEL FILTER
FUEL FILTER O-RING
HOUSING O-RING
FUEL FILTER HOUSING BOTTOM SECTION*
LOW PRESSURE SWITCH
*NOT SERVICED SEPARATELY

Figure 67. Mazda 2007 Emission Compliant
Fuel Filter Removal/Installation
5. Remove and discard housing O-ring.
6. Remove and discard fuel filter and fuel filter
O-ring.
Clean/Inspect
1. Clean and inspect the fuel filter housing top section for contamination or damage. If damaged,
replace the housing.
WARNING
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.
2. Clean and inspect the fuel filter housing bottom

section for contamination or damage. If damaged, replace the housing.
Install
1. Install the new fuel filter and fuel filter O-ring.
See Figure 67.
2. Install new housing O-ring.
3. Remove the bolt and seal washer from the fuel

filter housing top section. Discard seal washer.
See Figure 67.
3. Install fuel filter housing top section onto fuel

filter housing bottom section.
4. Remove fuel filter housing top section from fuel

filter housing bottom section.
4. Install bolt and new seal washer. Tighten bolt to

13 Nm (115 lbf in).
74
8000 SRM 1150
NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.
5. Slowly open the fuel valve on tank.
6. Connect the negative battery cable.
7. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.
8. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.
GASOLINE FUEL FILTER REPLACEMENT,

MAZDA 2007 EMISSION COMPLIANT
ENGINES ONLY
Remove and Replace
1. Raise the hood and disconnect the negative terminal of the battery.
2. Remove and discard the fuel filter. See Figure 68.
3. Install the new fuel filter and tighten the clamp
screws to 2.45 to 2.77 Nm (22 to 25 lbf in).
1. SCHRADER VALVE
2. FUEL FILTER
3. FUEL PUMP/SENDER UNIT
Figure 68. Fuel Filter Replacement, Mazda
2007 Emission Compliant Engines Only
4. Connect the negative terminal of the battery and

close the hood.
75
8000 SRM 1150
FUEL FILTER REPLACEMENT, YANMAR

ENGINE
CAUTION
Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the
diesel fuel flow.
NOTE: See Figure 69 for all steps in the following
procedure.
1. Stop the engine and allow it to cool.
2. Close all fuel cocks in the line.
NOTE: Tag connectors prior to disconnecting to aid
in reconnecting.
3. Disconnect fuel filter sensor connector.
4. Place an approved container under the fuel filter.
5. Open the drain plug to drain fuel from the fuel
filter.
6. Remove the fuel filter from the fuel filter head.
Wipe up any spilled fuel immediately.
7. Remove the drain plug from the fuel filter. Discard the O-ring.
8. Remove the fuel filter sensor from the fuel filter
element and discard the O-ring.
9. Remove the inline fuel filter from the inlet nipple that goes to the fuel injection pump. See Figure 70.
10. Dispose of the fuel, fuel filters, and O-ring in accordance with local directives.
11. Install the new inline fuel filter into the inlet nipple.
12. Install the fuel filter sensor assembly in the new
fuel filter using the new O-ring supplied with the
fuel filter.
76
1.
2.
3.
4.
5.
6.
7.
8.
9.
FUEL FILTER ASSEMBLY

FUEL FILTER ELEMENT
FUEL FILTER SENSOR CONNECTOR
FUEL FILTER HEAD
O-RING
DRAIN PLUG
FUEL FILTER SENSOR
INLINE FUEL FILTER
INLET NIPPLE
Figure 69. Yanmar Fuel Filter Replacement
8000 SRM 1150
PRIMING THE FUEL SYSTEM (YANMAR)

1. Place an approved container under the air bleed
port. See Figure 71.
2. Loosen the air bleed port 2 or 3 turns.
CAUTION
NEVER use the starter motor to crank the engine in order to prime the fuel system. This
may cause the starter to overheat and damage
the coils and/or the ring gear.
3. Operate the fuel priming pump until the fuel
coming out of the air bleed port is free of bubbles.
See Figure 71.
4. Tighten the air bleed port.
1.
2.
3.
4.
INLINE FUEL FILTER

FUEL LINE
WATER SEPARATOR/FUEL FILTER
FUEL SUPPLY VALVE
5. Wipe up any fuel that may have spilled, and dispose of the fuel and rags in accordance with local
directives.
Figure 70. In-Line Fuel Filter Replacement

13. Install the new O-ring on the drain plug, and install the drain plug on the new fuel filter element.
Hand tighten only.
14. Clean the fuel filter head mounting surface and
apply a small amount of diesel fuel to the gasket
on the new fuel filter element.
15. Install the new fuel filter element until it contacts the fuel filter head mounting surface.
Tighten one additional turn.
16. Open all the fuel cocks in the fuel line.
17. Reconnect the fuel filter sensor connector.
18. Prime the fuel system. See Priming the Fuel System (Yanmar).
19. Check for fuel leaks.
1. AIR BLEED PORT

2. FUEL PRIMING PUMP
Figure 71. Priming the Fuel System
77
8000 SRM 1150
LIFT CHAINS WEAR CHECK

If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. Measure chain for wear where it moves over
sheaves. Using a chain scale, (Hyster P/N 871796)
check lift chains as shown in Figure 72.
LIFT CHAIN LUBRICATION

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
Compressed air can move particles so they
goggles or a face shield to prevent injury to
the eyes.
Remove the lift chains. Clean the lift chains by soaking them in a solvent that has a petroleum base for
at least 30 minutes. Use compressed air, adjusted to
a maximum output of 103 kPa (15 psi), to completely
dry the chains when they are clean.
Lubricate the lift chains by soaking them in 30W engine oil for at least 30 minutes. Remove the chains
from the oil. Hang the chains for one hour so excess
oil will drain from the chains.
Pitch
12.7 mm
(0.50 in.)
15.9 mm
(0.63 in.)
19.1 mm
(0.75 in.)
25.4 mm
(1.00 in.)
Total Length
of 20 Links
(Pitch) of New
Chain
254.0
(10.0
317.5
(12.5
381.0
(15.0
508.0
(20.0
mm
in.)
mm
in.)
mm
in.)
mm
in.)
Wear Limit
(The
Maximum
Length of 20
Links)
261.6
(10.3
327.0
(12.9
392.4
(15.4
523.3
(20.6
1. CHAIN WEAR SCALE

Figure 72. Lift Chains Check
78
mm
in.)
mm
in.)
mm
in.)
mm
in.)
8000 SRM 1150
INTEGRAL SIDESHIFT CARRIAGE, CHECK

BEARINGS

3. Use a lifting device with a capacity of at least

450 kg (1000 lb) to lift outer frame away from
inner carriage.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
4. Clean bearing areas. Inspect sideshift bearings

for wear as follows:
INTEGRAL SIDESHIFT CARRIAGE, CHECK

LOWER MOUNTING HOOKS
a. If either upper bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both upper bearings by driving upper bearings out of
carriage bar.
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 74.
1. Lower carriage completely and remove forks.

2. Remove backrest and the lower mounting hooks
from sideshift carriage. See Figure 73.
b. If either lower bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both
lower bearings by prying lower bearings from
lower carriage bar.
UPPER BEARING
LOWER HOOK
LOAD ROLLER
SNAP RING
SIDESHIFT CYLINDER
LOWER BEARING
SHIMS
INNER CARRIAGE
LUBE FITTING
OUTER FRAME
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.
Figure 73. Integral Sideshift Carriage
Figure 74. Lower Mounting Hooks Wear Limit
and Clearance Adjustment
79
8000 SRM 1150
STEERING AXLE
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side of
the steering axle. See Figure 75. Use multipurpose
grease as shown in the Maintenance Schedule.
CONTROL LEVERS AND PEDALS

Lubricate linkages, pedal shafts, control cables
(throttle, hood, parking brake), and seat rails. Use a
silicone spray lubricant, Hyster Part No. 328388.
A. S40-70FT, S55FTS (F187)

B. H40-70FT (L177)
1. STEERING AXLE
Figure 75. Lubricate Spindle Bearings
80
8000 SRM 1150
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and
1000-hour checks prior to performing the procedures
in this section.
HYDRAULIC SYSTEM
Hydraulic Filter, Replace
WARNING
CAUTION
is changed. Dirt can cause damage to the components of the hydraulic system.
pump.
CAUTION
1. Put lift truck on a level surface and lower carriage.
2. Unscrew and remove lid and spring from head.
Remove and discard O-ring from lid. See Figure 76.
NOTE: Have container large enough to hold the filter
element and allow for final hydraulic oil draining.
NOTE: Note placement of filter element and handle
prior to removal to aid in installation.
3. Remove filter element and O-ring from bowl and
place in container. Cover head to prevent any
foreign material from getting into the hydraulic
tank. See Figure 76.
5. Remove and discard O-ring from top of bowl. See

Figure 76.
6. Remove and discard quad ring from head. See
Figure 76.
7. Clean housing and cover plate as necessary.
8. Inspect filter housing, especially sealing surfaces, for damage. Replace if damaged.
9. Inspect dipstick plug. Replace O-ring and plug
as necessary.
10. Lubricate sealing surfaces on filter housing and
cover plate with clean hydraulic oil.
11. Lubricate new quad ring with clean hydraulic oil
and install onto head. See Figure 76.
12. Lubricate new O-ring with clean hydraulic oil
and install onto top of bowl. See Figure 76.
and install on bottom of new filter element. See
Figure 76.
14. Install new filter element into bowl as noted during removal. See Figure 76.
and install on lid. See Figure 76.
16. Install spring and lid onto head. See Figure 76.
Hand tighten lid.
CAUTION
17. Start the truck, and allow it to run for 30 seconds.
Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
the hydraulic oil, see Hydraulic Oil, Replace.
4. After filter element has drained, discard filter element and O-ring.
81
8000 SRM 1150
Hydraulic Tank Breather, Replace

1. Raise the hood and remove the right rear side
panel. See Figure 77.
2. Unscrew and remove old hydraulic tank
breather, and replace with new hydraulic tank
breather.
3. Install right rear side panel and close hood. See
Figure 77.
1. HOOD/SEAT ASSEMBLY
2. RIGHT REAR SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 77. Hydraulic Tank Breather
1.
2.
3.
4.
5.
O-RING
SPRING
LID
HEAD
QUAD RING
6.
7.
8.
9.
10.
FILTER ELEMENT
BOWL
DIPSTICK PLUG
FILTER HOUSING
COVER PLATE
Figure 76. Hydraulic Filter
82
8000 SRM 1150
AIR FILTER
The air filter canister should not be opened until an
air filter element replacement is required. An air
filter element replacement is required when one of
the following occurs:
The optional air flow restriction indicator light on
the dash illuminates.
The optional manual air flow indicator button pops
up.
The specified number of hours has passed since the
last filter element replacement.
CAUTION
3. Gently pull the filter element from the canister.

Avoid dislodging contaminants from the element
or knocking it against the canister.
4. With a clean, soft rag, clean the inside surface
of the canister. Remove liner assembly to make
cleaning easier. Clean well around the locking
tabs that retain the element. Clean tabs make
new filter element installation easier. Be careful
not to knock any contaminants into the outlet
tube to the engine.
5. Inspect liner and O-ring assembly for damage. If
damaged, replace liner and O-ring assembly.
DO NOT to allow dirt to enter the engine air

intake when replacing the air filter element. A
small amount of dirt could cause engine damage.
6. Install liner assembly into canister by pushing

in. Make sure liner assembly is properly seated
in the canister. It will fit snugly into and be centered in the canister.
1. Shut off engine. Never open air filter canister or

remove filter element with engine running.
If your air filter assembly is equipped with a secondary element in place of the liner assembly, replace the secondary element with every 2 to 3 primary element replacements.
2. Unlatch and remove cover. To remove filter element, press and rotate filter element counterclockwise about 1/8 turn until the filter element
is free. To assist removal, gently move the end
back and forth to help break the seal. See Figure 78.
1. CANISTER
2. DUST EVACUATION VALVE
3. LINER ASSEMBLY
7. Inspect the new filter element for voids, cuts,

tears or indentations in the urethane-sealing
surfaces. Do not use if damage is detected.
4. FILTER ELEMENT
5. COVER
Figure 78. Air Filter
83
CAUTION
The element must be properly installed to ensure adequate engine protection. An improperly installed element may allow dirt and dust
to enter and damage the engine.
NOTE: Proper element installation is required to allow the cover to be installed correctly. Never reinstall
a used element. Never install a damaged element.
Always use a Hyster-approved filter element.
8. Install the new filter element into the canister.
Press and rotate the filter element 1/8 turn clockwise until fully engaged in the canister. See Figure 79.
8000 SRM 1150

NOTE: If the filter element is properly installed, the
cover will fit easily into the canister with no gap between the cover and the canister. If cover does not
fit easily, the filter element is not installed properly.
Do not use a cover that is bent, damaged, or missing
latches.
9. Install cover into the canister and ensure the INLET arrow is in line with the canister inlet.
NOTE: Do not use latches to pull cover down against
the canister. If cover does not fit completely against
the canister with no gaps, the element is not installed
correctly.
10. Fasten the latches to secure the cover to the canister. Make sure the latches penetrate the slots
in both the canister and the cover.
11. Inspect the entire air intake system for leaks.
Inspect all clamps for tightness and tighten if
necessary. Inspect all hoses for damage. Replace damaged hoses. Inspect the dust evacuation valve for damage. If damaged, replace the
dust evacuation valve.
PCV VALVE
Install a new PCV valve.
1. PUSH IN
2. TWIST TO LOCK
Figure 79. Air Filter Label
CAUTION
During cover installation, DO NOT force the
cover on the canister. To do so will result in
damage to the filter element, cover, and possibly the canister.
84
See Figure 23 for lift trucks equipped with a GM engine.

8000 SRM 1150
OXYGEN SENSOR
NOTE: The 2007 Mazda emission compliant engines
are equipped with Pre and Post Catalytic Converter
Oxygen Sensors.
Check that the oxygen sensor electrical connector is
seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair.
See Figure 80 for lift trucks equipped with a GM or
Mazda engine.
engine (2007 Mazda emission compliant engines).
A. MAZDA EXHAUST SYSTEM

B. GM EXHAUST SYSTEM
1. OXYGEN SENSOR
2. EXHAUST PIPE
3. MANIFOLD
Figure 80. Oxygen Sensor
85
1. MUFFLER
2. POST-CATALYTIC CONVERTER OXYGEN
SENSOR
3. PRE-CATALYTIC CONVERTER OXYGEN
SENSOR
8000 SRM 1150
4. EXHAUST PIPE (EXHAUST MANIFOLD TO

CATALYTIC CONVERTER)
5. EXHAUST PIPE (CATALYTIC CONVERTER TO
MUFFLER)
6. CATALYTIC CONVERTER
Figure 81. Oxygen Sensors for 2007 Mazda Emission Compliant Engines
LPG REGULATOR FUEL FILTER, MAZDA

ENGINES (EXCEPT 2007 MAZDA
EMISSION COMPLIANT ENGINES)
Remove and Replace
1. Close shutoff valve on tank. Run engine until it
stops.
2. Remove six capscrews, fuel filter cover, and two
filter elements. Discard filter elements. See Figure 82.
3. Install two new filter elements and six capscrews
on fuel filter cover. Tighten six capscrews to 6.4
to 7.9 Nm (57 to 70 lbf in).
1. FILTER ELEMENTS
2. CAPSCREWS
3. FUEL FILTER
COVER
Figure 82. Mazda LPG Regulator Fuel Filter
86
8000 SRM 1150
LPG REGULATOR FUEL FILTER, GM

ENGINES

5. Open shutoff valve on LPG tank and check for
leaks.
Remove
1. Close shutoff valve on tank. Run engine until it
stops.
2. Disconnect the hose from the inlet fitting.
3. Remove the inlet fitting from the LPG regulator.
Discard the O-ring. See Figure 83.
4. Remove and discard the plastic cap, foam filter,
paper filter, and rubber washer from the LPG
regulator.
5. Disconnect the hose from the outlet fitting. Remove three screws and the outlet fitting from the
LPG regulator. Discard the O-ring.
6. Remove and discard the screen from the LPG regulator.
Install
1. Install a new screen in the LPG regulator.
2. Install a new O-ring on the outlet fitting. Using
three screws, install the outlet fitting on the LPG
regulator.
3. Install new rubber washer, paper filter, foam filter, and plastic cap in the LPG regulator.
1.
2.
3.
4.
5.
LPG REGULATOR
INLET FITTING
O-RING
PLASTIC CAP
FOAM FILTER
6.
7.
8.
9.
10.
PAPER FILTER
RUBBER WASHER
SCREWS
OUTLET FITTING
SCREEN
Figure 83. GM LPG Regulator
4. Install new O-ring on the inlet fitting. Install

inlet fitting into the LPG regulator and connect
hose to the inlet fitting.
87
8000 SRM 1150
GASOLINE FUEL FILTER

Remove and Replace for Lift Trucks
Equipped with GFI
1. Raise the hood and disconnect the negative terminal of the battery.
2. Remove and discard the fuel filter. See Figure 84.
3. Install the new fuel filter and tighten the clamp
screws to 2.45 to 2.77 Nm (22 to 25 lbf in).
4. Connect the negative terminal of the battery and
close the hood.
A. MAZDA (EXCEPT 2007 EMISSION COMPLIANT

ENGINES)
B. GM 2.4L
1. FUEL FILTER
2. FUEL TANK
3. FUEL PUMP/SENDER UNIT
Figure 84. Fuel Filter Replacement
88
8000 SRM 1150
TIMING BELT
Mazda Engines
Change timing belt after 3500 hours of operation.
The cover for the timing belt must be removed for
checks and adjustments. See the section Mazda Engine, 2.0L and 2.2L 600 SRM 1122 for more information.
GM 2.4L Engine
The cover for the timing belt must be removed for
checks and adjustments. See the section GM Engine
Repair, GM 2.4 Liter Engine 600 SRM 1121 for
more information.
LPG FUEL INJECTOR, MAZDA ENGINES

(EXCEPT 2007 MAZDA EMISSION
COMPLIANT ENGINES)
For removal and cleaning instructions, see the section LPG Fuel System, Mazda 2.0L and 2.2L Engines 900 SRM 1125.
GASOLINE FUEL INJECTOR, MAZDA

ENGINES
For removal and cleaning instructions, see the section Gasoline Fuel System, Mazda 2.0L and 2.2L
900 SRM 1127 for all Mazda engines except 2007
emission compliant engines. For 2007 emission compliant engines, see the section Gasoline Fuel System, Mazda 2.0L and 2.2L Emission Compliant
Engines 900 SRM 1325.
FORKS
WARNING
Never repair damaged forks. DO NOT heat,
weld, cut, drill, or bend the forks. Forks are
made of special steel using special methods.
Replace damaged forks as a set.
Check heel and attachment points of forks with a
penetrant or by magnetic particle inspection.
INTEGRAL SIDESHIFT CARRIAGE

Bearings, Replace
Replace all four bearings regardless of wear. See section, Maintenance Procedures Every 1000 Hours or
6 Months for the procedure.
TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACE
Iron Transmission Housing
WARNING
CAUTION
changed. Dirt can cause damage to the transmission components.
LPG FUEL INJECTOR, GM ENGINES

For removal and cleaning instructions, see the section LPG Fuel System, GM 2.4L Engine 900 SRM
1124.
CAUTION
FUEL INJECTOR, YANMAR ENGINES
NOTE: Change the transmission oil filter at the first

500 hours of operation on new lift trucks. Before removing the oil filter, make a hole at the top of the
filter and allow five minutes for the oil to drain down
into the transmission. This will reduce the oil that
will run out of the filter and onto the transmission
when the filter is removed.
For removal and cleaning instructions, see the section Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L
600 SRM 1205.
NOTE: The drain plug for the transmission is on the

lower right side of the cover of the transmission, toward the rear of the lift truck.
GASOLINE FUEL INJECTOR, GM ENGINES

For removal and cleaning instructions, see the section Gasoline Fuel System, GM 2.4L Engine 900
SRM 1126.
89

1. Remove drain plug, spring, and screen. Drain oil
into a container.
8000 SRM 1150

3. When oil has drained, first install screen, then
spring, and transmission drain plug.
4. Remove and discard transmission breather.
Install new transmission breather and hand
tighten.
5. Remove and discard old transmission oil filter.
Apply clean oil to gasket of new transmission oil
filter. Install new filter and hand tighten.
6. Add oil to transmission at the dipstick tube. The
correct oil is shown in the Maintenance Schedule.
7. Start and run the engine for approximately five
minutes after fill to allow oil to lubricate parts
within the transmission.
8. Turn the key to the OFF position, check for leaks,
and check oil level. Top off oil, if necessary.
NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR THE SAKE OF
CLARITY.
1.
2.
3.
4.
5.
6.
7.
TRANSMISSION
TRANSMISSION DRAIN PLUG
SPRING
SCREEN
TRANSMISSION OIL FILTER
TRANSMISSION DIPSTICK
TRANSMISSION BREATHER
Figure 85. Transmission Oil Change
WARNING
cleaning solvents, always follow the solvent
manufacturers recommended safety procedures.
Make sure the path of the compressed air is
away from all personnel. Wear protective goggles or a face shield to prevent injury to the
eyes.
2. Clean screen with cleaning solvent, and dry with
compressed air, adjusted to the maximum output
of 103 kPa (15 psi).
90
Aluminum Transmission Housing

Remove
WARNING
CAUTION
CAUTION
500 hours of operation on new lift trucks.
1. Remove drain plug. When oil is completely
drained, install drain plug.
See Figure 86 for lift trucks equipped with an
aluminum gear drive manufactured before January, 2011.
8000 SRM 1150

aluminum gear drive manufactured after January, 2011.


aluminum gear drive manufactured after July,
2013.


2013.

2013.
2. Remove capscrews washers, charge pump, and

charge pump gasket. Discard gasket.

2013.

2013.
2013.
3. Remove suction screen spring and suction screen.
2013.
2013.
4. Remove flange head capscrews and hydraulic
gear pump.
5. Remove and discard transmission oil filter.

2013.
2013.
2013.
2013.
91
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
SUCTION SCREEN
SUCTION SCREEN SPRING
CHARGE PUMP GASKET
CHARGE PUMP
WASHER
CAPSCREW
FLANGE HEAD CAPSCREW
HYDRAULIC GEAR PUMP
Figure 86. Transmission Oil Filter Change Aluminum Gear Drive (Prior to January, 2011)
92
8000 SRM 1150
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
SUCTION SCREEN
CHARGE PUMP GASKET
CHARGE PUMP
WASHER
CAPSCREW
HYDRAULIC GEAR PUMP
Figure 87. Transmission Oil Filter Change Aluminum Chain Drive (After January, 2011)
8000 SRM 1150
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
SUCTION SCREEN
CHARGE PUMP GASKET
CHARGE PUMP
WASHER
CAPSCREW
HYDRAULIC GEAR PUMP
Figure 88. Transmission Oil Filter Change Aluminum Gear Drive (After July, 2013)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
SUCTION SCREEN
CHARGE PUMP GASKET
CHARGE PUMP
WASHER
CAPSCREW
HYDRAULIC GEAR PUMP
Figure 89. Transmission Oil Filter Change Aluminum Chain Drive (After July, 2013)
93
Clean and Inspect
WARNING
eyes.
1. Clean suction screen spring and suction screen
with cleaning solvent and dry with compressed
air. Inspect spring and screen for damage. Replace if damaged.
2. Wipe exterior surfaces of transmission housing,
hydraulic gear pump and charge pump with solvent soaked clot and dry with a lint-free cloth.
Inspect housing and pumps for damage. Replace
if damaged.
3. Clean metal threaded components with solvent
and dry with compressed air. Clean plastic
threaded components with warm soapy water
and dry with a lint-free cloth. Inspect components for damage. Replace if damaged.
Install
1. Install new transmission breather.
2013.
2013.
2. Install suction screen and suction screen spring.
94
8000 SRM 1150

2013.
2013.
3. Using seven washers and seven capscrews install new charge pump gasket and charge pump.
Tighten capscrews to 19 Nm (168 lbf in).
2013.
2013.
4. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of
sealant to either hydraulic gear pump or transmission housing face. Hold pump in the correct
position on the transmission. Install flange head
capscrews into pump and transmission housing.
Tighten capscrews to 38 Nm (28 lbf ft).
2013.
8000 SRM 1150

2013.
5. Apply clean oil to gasket of new transmission oil
filter and install filter onto transmission.
2013.
2013.
CAUTION
500 hours of operation on new lift trucks. Before removing the oil filter, make a hole at the top of the
filter and allow five minutes for the oil to drain down
into the transmission. This will reduce the oil that
will run out of the filter and onto the transmission
when the filter is removed.
NOTE: The drain plug for the transmission is on the
lower right side of the cover of the transmission, toward the rear of the lift truck.
1. Remove drain plug, spring, and screen. Drain oil
into a container. See Figure 90.
6. Add oil to transmission at dipstick tube. The correct oil is shown in the Maintenance Schedule.
7. Start and run engine for approximately five minutes after fill to allow oil to lubricate parts within
transmission.
8. Turn key to OFF position, check for leaks, and
check oil level. Top off oil, if necessary.
TRANSMISSION OIL CHANGE, WET

BRAKE DRIVE AXLE
Iron Transmission Housing
WARNING
CAUTION
NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR THE SAKE OF
CLARITY.
1.
2.
3.
4.
5.
6.
7.
TRANSMISSION
SPRING
SCREEN
Figure 90. Transmission Oil Change
95
WARNING
eyes.
compressed air, adjusted to the maximum output
3. When oil has drained, first install screen, then
spring, and transmission drain plug. See Figure 90.
Install new transmission breather and hand
tighten. See Figure 90.
5. Remove and discard old transmission oil filter.
Apply clean oil to gasket of new transmission oil
filter. Install new filter and hand tighten. See
Figure 90.
6. Add oil to transmission at the dipstick tube. The
within the transmission.
8. Turn the key to the OFF position, check for leaks,
and check oil level. Top off oil, if necessary.
Aluminum Transmission Housing

WARNING
The oil used for the transmission should not be
contaminated. If the transmission oil becomes
96
8000 SRM 1150

contaminated, the oil must be drained and replaced with new oil.
WARNING
CAUTION
changed. Dirt will contaminate the oil and
cause damage to the transmission and wet
brake planetary carrier housing components.
CAUTION
500 hours of operation on new lift trucks.
1. Place a container under transmission. Remove
transmission temperature sensor to drain oil.
See Figure 91. When oil is completely drained,
install transmission temperature sensor.
2. Using clamp pliers, slide two clamps toward middle of brake cooling hose. See Figure 92.
3. Remove brake cooling hose from wet brake drive
axle and transmission assembly. See Figure 92.
4. Remove capscrews, washers, charge pump, and
charge pump gasket. Discard gasket. See Figure 91.
5. Remove suction screen spring and suction screen.
See Figure 91.
6. Remove flange head capscrews and hydraulic
gear pump. See Figure 91.
7. Remove and discard transmission oil filter. See
Figure 91.
8. Remove and discard transmission breather. See
Figure 91.
8000 SRM 1150
1.
2.
3.
4.
5.
6.
7.
TRANSMISSION
SUCTION SCREEN
CHARGE PUMP GASKET
8.
9.
10.
11.
12.
13.
CHARGE PUMP
WASHER
CAPSCREW
HYDRAULIC GEAR PUMP
TRANSMISSION TEMPERATURE SENSOR
Figure 91. Transmission Oil Change - Aluminum Housing
97
1. WET BRAKE DRIVE AXLE

2. CLAMP
8000 SRM 1150
3. BRAKE COOLING HOSE

4. TRANSMISSION ASSEMBLY
Figure 92. Brake Cooling Line Remove/Install

9. Drain oil from left planetary housing as described below:
a. Place container under left planetary housing.
b. Remove drain plug from housing. See Figure 94. Remove and discard O-ring from
drain plug.
c. Remove fill/level plug from housing. Removing fill/level plug allows oil to drain at a
faster rate. See Figure 93.
d. Drain oil into container. When oil has completely drained, install new O-ring on drain
plug then install drain plug in housing.
Tighten drain plug to 40 Nm (29.5 lbf ft).
WARNING
98
eyes.
compressed air, adjusted to a maximum output
11. Install new transmission breather.
ure 91.
See Fig-
12. Install suction screen and suction screen spring.

See Figure 91.
13. Using seven washers and seven capscrews install new charge pump gasket and charge pump.
See Figure 91. Tighten capscrews to 19 Nm
(168 lbf in).
14. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of
sealant to either hydraulic gear pump or transmission housing face. Hold pump in the correct
position on the transmission. Install flange head
capscrews into pump and transmission housing.
See Figure 91. Tighten capscrews to 38 Nm
(28 lbf ft).
8000 SRM 1150

15. Apply clean oil to gasket of new transmission oil
filter. Install oil filter and hand tighten. See
Figure 91.

fill/level plug will allow the oil to drain at a
faster rate. See Figure 93.
16. Install brake cooling hose to wet brake drive axle

and transmission assembly. See Figure 92.
2. Place an empty container under the center section drain plug and under the right and left planetary housing drain plugs.
17. Using clamp pliers, slide hose clamps into position on each end of brake cooling hose to secure
cooling hose in proper position. See Figure 92.
3. Remove drain plugs and wait until oil has

drained completely. Remove and discard O-rings
from drain plugs. See Figure 94.
18. Add transmission oil to transmission at the dipstick tube. The correct oil and volume is shown
in the Maintenance Schedule.
4. Install new O-rings on drain plugs. Install

drain plugs. Tighten the drain plugs to 40 Nm
(29.5 lbf ft).

within the transmission. Add transmission oil to
transmission at the dipstick tube as needed.
20. Turn the key to the OFF position and check for
leaks and check oil level.
WET BRAKE AXLE CENTER SECTION

AND PLANETARY HOUSING, OIL CHANGE
1. Remove the planetary housing fill/level plugs
and O-rings. Discard O-rings. Removing the
CAUTION
Before adding oil, ensure the truck is parked
and on level ground.
5. Add oil at the fill/level port for the right and left
planetary housing until the oil/fill level port has
overflowed. The correct oil is shown in the Maintenance Schedule or Figure 95.
6. Install new O-ring on planetary fill/level plugs.
Install fill/level plugs.
7. The center section (cooling chamber) will fill with
fluid automatically as it circulates through and
back to the transmission.
99

3. O-RING
8000 SRM 1150
4. FILL/LEVEL PLUG
5. CENTER SECTION (COOLING CHAMBER)
Figure 93. Planetary Housings Fill/Level Plugs
100
8000 SRM 1150

2. O-RING
3. DRAIN PLUG
4. CENTER SECTION (COOLING CHAMBER)

Figure 94. Center Section and Planetary Housings Drain Plugs
101
8000 SRM 1150
A. LEFT PLANETARY HOUSING - USE SAE 80W/90

B. RIGHT PLANETARY HOUSING - USE SAE 80W/90
C. CENTER SECTION (COOLING HOUSING) - USE JDM J20C
1. OIL FILL/LEVEL PLUG
2. OIL BREATHER
3. COOLING OIL INLET PORT

Figure 95. Oil Application Diagram
102
8000 SRM 1150
BRAKE FLUID (MASTER CYLINDER),

CHANGE
WARNING
master cylinder.
1. Remove dashboard from cowl.
CAUTION
2. Remove brake fluid reservoir from bracket on
cowl. See Figure 96 and Figure 97.
3. Remove the brake oil reservoir cover and cylindrical block drain plug. Pour the fluid into a suitable container with a 0.25 liter (0.53 pt) minimum capacity. Install the cylindrical block drain
plug. Refill reservoir with clean oil from a sealed
container and install cover on the reservoir. The
4. Install reservoir into bracket located on cowl.
1. BRAKE FLUID RESERVOIR
2. MOUNTING BRACKET
3. COWL
Figure 96. Brake Fluid Change (Dry Brake)
103
8000 SRM 1150

3. Loosen special fitting at wheel cylinder one turn
so that used brake fluid can be removed from
brake system. Slowly push brake pedal and hold
it at the end of its stroke. Close special fitting.
Release brake pedal.
NOTE: New brake fluid will be easily recognized, as
the color will be more clear than the used fluid, which
will be darker.
4. Repeat Step 1 through Step 3 until there is new
brake fluid in the container.
5. Check level of brake fluid in reservoir for master
cylinder during the procedure. Make sure to keep
brake fluid at the correct level.
6. Repeat the procedure for the other wheel cylinder.
SERVICE BRAKES (DRY BRAKE)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
RESERVOIR CAP
BRAKE OIL RESERVOIR
RESERVOIR MOUNTING BRACKET
COWL
UPPER BRAKE OIL SUPPLY HOSE
CYLINDRICAL BLOCK OUTLET FITTING
LOWER BRAKE OIL SUPPLY HOSE
NIPPLE
MASTER CYLINDER
CYLINDRICAL BLOCK DRAIN PLUG
CYLINDRICAL BLOCK
CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 97. Brake Oil Change (Wet Brakes)
BRAKE FLUID (DRY BRAKE), REMOVE

Perform the following procedure to remove used
brake fluid from the remainder of the brake system.
1. Ensure that the master cylinder reservoir is
filled with brake fluid.
2. Put one end of a rubber hose on the special fitting
of the wheel cylinder. Put the other end of the
hose into a empty container.
104
Check brake lining and parts of the brake assembly

for wear or damage. The minimum acceptable brake
lining thickness is 1.0 mm (0.040 in.). If brake linings
are worn thinner than the specification, replace the
brake linings. See section Brake System 1800 SRM
1135 for the removal and installation procedures of
the drive wheels and brake drums. If the brake linings or brake shoes are worn or damaged, they must
be replaced. Brake shoes must be replaced in complete sets. Inspect brake drums for cracks or damage. Replace any damaged parts.
WARNING
Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings
is a cancer or lung disease hazard. DO NOT
create dust! DO NOT clean brake parts with
compressed air or by brushing. Follow the
cleaning procedure in this section. When the
brake drums are removed, DO NOT create
dust.
DO NOT sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used.
8000 SRM 1150

Brake cleaning procedures are as follows:
CAUTION
DO NOT use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
of brake parts. DO NOT permit oil or grease in
the brake fluid or on the brake linings.

3. The fill hole is on the front of the differential
housing. Add oil shown in the Maintenance
Schedule until oil level is at the lower edge of
the fill hole. Install fill plug and rotate the drive
wheels in order to get oil pumped into the axle.
Remove the fill plug and check the oil level. Add
oil, as necessary. Install fill plug and check for
leaks. See Figure 98.
1. DO NOT release brake lining dust from brake

linings into the air when brake drum is removed.
2. Use a solvent approved for cleaning of brake
parts to wet lining dust. Follow the instructions
and cautions of the manufacturer for the use of
the solvent. If a solvent spray is used, do not
create brake lining dust with the spray.
3. When the brake lining dust is wet, clean parts.
Put any cloth or towels in a plastic bag or an
airtight container while they are still wet. Put
a DANGEROUS FIBERS warning label on the
plastic bag or airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential can
be found in the section Drive Axle and Differential
Assembly Repair 1400 SRM 1132 or Drive Axle
and Differential Assembly Repair, (Dry Brake)
1400 SRM 1214.
1. Place lift truck on blocks. See How to Raise Drive
Tires in this manual.
2. The differential and drive axle use the same oil
supply. Place a container with a minimum capacity of 5 liter (5.3 qt) under the differential. Remove drain plug located in the bottom of the differential and drain oil from the differential completely. Install drain plug.
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
Figure 98. Drive Axle Fluid Fill
105
Maintenance Procedures Every 4000 Hours or 2 Years
8000 SRM 1150

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000hour, and 2000-hour checks prior to performing the
procedures in this section.
HYDRAULIC OIL, REPLACE

WARNING
At operating temperature the hydraulic oil is
CAUTION
is changed. Dirt can cause damage to the components of the hydraulic system.
pump.
CAUTION
NOTE: Heavy-duty or contaminated applications will
require hydraulic oil change at 2000 hours.
NOTE: Replace the hydraulic oil filter at the same
time the oil is changed.
1. Replace hydraulic oil as described below:
a. Place a container with a minimum capacity
of 30.1 liter (32 qt) under the drain plug at
the bottom of the hydraulic tank. To drain
the oil, remove drain plug from the bottom of
the hydraulic tank. See Figure 99.
b. When tank is empty, inspect the inside of the
tank for any foreign matter or possible fungus. If necessary, clean the inside of the tank
in accordance with the instructions found in
section Frame 100 SRM 1120.
c. When either the inspection or the cleaning
of the tank is completed, install drain plug
in the bottom of the hydraulic tank. Tighten
drain plug to 38 Nm (28 lbf ft).
106
CAUTION
2. Fill hydraulic tank with oil specified in the Maintenance Schedule.
3. When oil level is correct, operate system and
check for leaks.
COOLING SYSTEM
1. Put lift truck on a level surface. Stop engine.
Place a container with a minimum capacity of
30.1 liter (32 qt) under the radiator drain valve
which could be located on either the lower left or
right side of the radiator on the engine side of the
radiator.
WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the engine is running.
CAUTION
2. Open drain valve and remove radiator cap. Drain
coolant into the container. Flush cooling system. Check hoses for damage. Replace with new
hoses, as needed.
3. Disconnect the hose leading from the auxiliary
reservoir to fitting at the top of the radiator under the radiator cap, and drain the reservoir into
the same container used for the radiator coolant.
Check the reservoir for contaminants and flush,
as necessary. Connect the hose back on the fitting at the top of the radiator.
8000 SRM 1150

the auxiliary reservoir to a level between the
ADD and FULL marks on the reservoir.
CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster
dealer.
4. Close drain valve. Fill cooling system, use Ethylene Glycol Boron-free Antifreeze. Purchase a
pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. Fill
1. HYDRAULIC TANK
5. Install radiator cap. Start engine. Check for

leaks. Add coolant to auxiliary coolant reservoir
as needed. Coolant level should be between the
ADD and FULL marks on the reservoir.
2. DRAIN PLUG
Figure 99. Hydraulic Oil Change
107
Safety Procedures When Working Near Mast
8000 SRM 1150

The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
Never put any part of the body into or under
the mast or carriage unless all parts of the
mast are completely lowered or a safety chain
is installed. Also make sure that the power is
off and the key is removed. Put a DO NOT OPERATE tag in the operators compartment.
Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
DO NOT use blocks to support the mast weldments nor to restrain their movement.
Mast repairs require disassembly and removal of parts and can require removal of
the mast or carriage. Follow the repair procedures in the correct Service Manual for
the mast.
NOTE: If there is no power to lower the mast on lift
trucks equipped with Electronic Hydraulic System,
there is an emergency load lowering valve located
on the hoist/lower valve section of the main control
valve. See the Operating Manual for the procedures to lower a load using the emergency load lowering valve.
1. Lower mast and carriage completely. Push lift/
lower control lever forward and make sure there
is no movement in the mast. Make sure all parts
of the mast that move are fully lowered.
108
OR
2. If parts of the mast must be in a raised position,
install a safety chain to restrain the moving parts
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Put mast in vertical position.
b. Raise mast to align bottom crossmember
of weldment that moves in outer weldment
with a crossmember on outer weldment.
On the two-stage and free-lift mast, the
moving part is the inner weldment. On
the three-stage mast, it is the intermediate
weldment. See Figure 100.
c. Use a 3/8-in. minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
hook on the back side of the mast. Make sure
the hook is completely engaged with a link in
the chain. Make sure the safety chain does
not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (freelift, three-stage, and four-stage masts only)
is completely retracted. If running, stop engine. Apply parking brake. Install a DO
NOT REMOVE tag on the safety chain(s).
e. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the carriage and a crossmember on the
outer weldment.
3. Apply parking brake. After lowering or restraining the mast, shut off power and remove key. Put
a DO NOT OPERATE tag in the operators compartment.
8000 SRM 1150
A. TWO-STAGE LFL MAST

B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST

D. FOUR-STAGE FFL MAST
1.
2.
3.
4.
5.
6.
7.
8.
OUTER MAST
INNER MAST
INTERMEDIATE MAST
HOOK
FREE-LIFT CYLINDER
CARRIAGE BAR
CROSSMEMBER
FIRST INTERMEDIATE MAST
Figure 100. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
109

Manutencao Hyster H40 70FT, Maintenance Hyster H40 70FT

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PERIODIC

PART NO. 1580525

8000 SRM 1150

2013 HYSTER COMPANY

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

8000 SRM 1150

in the Maintenance Schedule for the following conditions:

SERIAL NUMBER DATA

HOW TO MOVE DISABLED LIFT TRUCK

8000 SRM 1150

Never lift and move a disabled lift truck unless

1. STEEL TOW LINK

Figure 1. Towing the Lift Truck

8000 SRM 1150

HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Steering Tires

8000 SRM 1150

HOW TO CLEAN A LIFT TRUCK

refer to Paper Application section in the applicable

8000 SRM 1150

6. Avoid spraying in areas containing electrical

8. DO NOT pressure wash the battery. Do not use

8000 SRM 1150

Figure 3. GM 2.4L Gas Trucks (Prior to Jan. 2011)

8000 SRM 1150

Figure 4. GM 2.4L LPG Trucks (Prior to Jan. 2011)

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

8000 SRM 1150

1000 2000 hr/ 4000 hr/ Procedure or

See Parts Manual

See Parts Manual

Seat Belt, Hip

Hood and Seat Latches

Check for Leaks - Fuel,

Check for Leaks

See Parts Manual

See Parts Manual

Fuel Tank (Gas)

Fuel Tank (Gas)

52 liter (13.7 gal) 85 Octane Gasoline

Fuel Tank (LPG)

Fuel Tank (Diesel)

52 liter (13.7 gal)

Horn, Lights, Alarms

Steering Controls and

30, Mast, Carriage, Header

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

8000 SRM 1150

Table 1. Maintenance Schedule (Continued)

1000 2000 hr/ 4000 hr/ Procedure or

Check for Leaks