(05-2008) - Uk-En - Period Maint

PERIODIC
MAINTENANCE
S4.0, 4.5, 5.50FT; S5.5FTS [G004];
H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT [N005, P005]
PART NO. 1624760 8000 SRM 1248

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number Data ...................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 1
How to Tow Lift Truck............................................................................................................................... 1
How to Put Lift Truck on Blocks................................................................................................................... 3
How to Raise Drive Tires .......................................................................................................................... 3
How to Raise Steering Tires ..................................................................................................................... 3
Maintenance Schedule....................................................................................................................................... 4
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 16
How to Make Checks With Engine Stopped................................................................................................. 16
Tires and Wheels ....................................................................................................................................... 16
Safety Labels ............................................................................................................................................. 17
Mast, Carriage, Lift Chains, Header Hoses, Attachment ....................................................................... 17
Operator Restraint System....................................................................................................................... 17
Emergency Locking Retractor (ELR) ................................................................................................... 18
Hood and Seat Latches ............................................................................................................................. 18
Engine Compartment................................................................................................................................ 19
Paper Application...................................................................................................................................... 19
Fuel, Oil, and Coolant Leaks, Check........................................................................................................ 19
Hydraulic Hoses ........................................................................................................................................ 20
Coolant Hoses ............................................................................................................................................ 20
Steering Column Gas Cylinder................................................................................................................. 20
Transmission ............................................................................................................................................. 20
Hydraulic System Oil ................................................................................................................................ 20
Engine Oil .................................................................................................................................................. 20
Air Filter .................................................................................................................................................... 23
Forks .......................................................................................................................................................... 23
Remove .................................................................................................................................................. 23
Inspect ................................................................................................................................................... 23
Install..................................................................................................................................................... 24
Adjust..................................................................................................................................................... 24
Integral Sideshift Carriage....................................................................................................................... 25
How to Make Checks With Engine Running................................................................................................ 25
Indicator Lights, Horn, Fuses, and Relays .............................................................................................. 25
Service Brakes ........................................................................................................................................... 27
Brake Oil Level ..................................................................................................................................... 27
Operation, Check .................................................................................................................................. 28
Parking Brake ........................................................................................................................................... 28
Engine Oil Pressure .................................................................................................................................. 28
Cooling System .......................................................................................................................................... 29
Steering System ........................................................................................................................................ 30
Control Levers and Pedals........................................................................................................................ 30
Lift System, Operate ................................................................................................................................. 30
First Service After First 100 Hours of Operation ............................................................................................ 31
GM 4.3L Engine Oil Filter ............................................................................................................................ 31
Cummins 4.5L and QSB 3.3L Engine Oil Filter .......................................................................................... 31
Hydraulic System .......................................................................................................................................... 32
Hydraulic Filter, Replace .......................................................................................................................... 32
Transmission Oil Filter, Replace................................................................................................................... 33
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 33
Hydraulic System Oil .................................................................................................................................... 33
©2008 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Hydraulic Tank Breather .............................................................................................................................. 34
Inspect........................................................................................................................................................ 34
Battery ........................................................................................................................................................... 34
Cummins 4.5L and QSB 3.3L Engine Oil and Filter................................................................................... 35
GM 4.3L and QSB 3.3L Engine Oil and Filter............................................................................................. 35
Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ................................... 36
Remove....................................................................................................................................................... 36
Install ......................................................................................................................................................... 36
Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) .................................................................... 38
Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ............................................................. 39
Controlled Venting .................................................................................................................................... 39
Manual Bleeding ....................................................................................................................................... 39
Drain Tar From LPG Regulator.................................................................................................................... 39
Drive Belt ....................................................................................................................................................... 40
GM 4.3L Engine ........................................................................................................................................ 40
Fan and Alternator Drive Belt ............................................................................................................. 40
Drive Belt ....................................................................................................................................................... 40
Cummins 4.5L and QSB 3.3L Diesel Engine........................................................................................... 40
Fan and Alternator Drive Belt ............................................................................................................. 40
Clean Debris From Radiator Core ................................................................................................................ 41
Transmission Oil Level.................................................................................................................................. 41
Wet Brake Center Body Oil Level Check ..................................................................................................... 42
Forks............................................................................................................................................................... 44
Mast Lubrication ........................................................................................................................................... 44
Header Hose Checks...................................................................................................................................... 46
Lift Chain Lubrication .................................................................................................................................. 47
Tilt Cylinder Lubrication .............................................................................................................................. 47
Master Brake Cylinder Rod End Pin Lubrication ....................................................................................... 48
Manual Hydraulic Levers Lubrication ......................................................................................................... 48
Brake Oil ........................................................................................................................................................ 49
Tie Rod Lubrication for Lift Truck Models S4.0, 4.5, 5.50FT; S5.5FTS (G004) ......................................... 49
Tie Rod Lubrication for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(N005, P005) .................................................................................................................................................. 50
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes........................................................ 50
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 51
Valve Clearance, Check and Adjust.............................................................................................................. 51
Ignition System.............................................................................................................................................. 51
GM 4.3L Engine ........................................................................................................................................ 51
LPG Fuel Filter Element Replace, GM 4.3L Engine ................................................................................... 51
Remove....................................................................................................................................................... 51
Install ......................................................................................................................................................... 51
In-Line Filter Replacement, Cummins 4.5L Engine ................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Lift Chains Wear Check ................................................................................................................................ 54
Lift Chain Lubrication .................................................................................................................................. 54
Integral Sideshift Carriage, Check Sliding Surfaces................................................................................... 54
Steering Axle (Spindle Bearings) for Lift Truck Models S4.0, 4.5, 5.50FT; S5.5FTS (G004) .................... 55
Steering Axle (Spindle Bearings) for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (N005, P005) .............................................................................................................................. 55
Control Levers and Pedals ............................................................................................................................ 55
ii
Periodic Maintenance Table of Contents

Inspect Engine Electrical System, Connectors ............................................................................................ 55
Maintenance Procedures Every 2000 Hours or Annually ............................................................................... 56
Hydraulic System .......................................................................................................................................... 56
Hydraulic Filter, Replace .......................................................................................................................... 56
Hydraulic Tank Breather, Replace ........................................................................................................... 56
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires................................................................ 57
Cooling System, GM 4.3L and Cummins 4.5L and QSB 3.3L Engines ...................................................... 58
Air Filter ........................................................................................................................................................ 58
Oxygen Sensor ............................................................................................................................................... 60
LPG Regulator Fuel Filter, GM Engine ....................................................................................................... 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
LPG Fuel Injector, GM Engines.................................................................................................................... 61
Fuel Injector, Cummins 4.5L and QSB 3.3L Engine ................................................................................... 61
Forks............................................................................................................................................................... 61
Transmission Oil and Filter (Dry Brake), Replace ...................................................................................... 61
Transmission and Wet Brake Planetary Carrier Housing Oil Change ...................................................... 62
Wet Brake Center Section Oil Change ......................................................................................................... 64
Remove....................................................................................................................................................... 64
Install ......................................................................................................................................................... 64
Brake Oil (Master Cylinder), Change........................................................................................................... 65
Brake Oil (Dry Brake), Remove .................................................................................................................... 66
Service Brakes (Dry Brake) .......................................................................................................................... 66
Differential (Dry Brake) ................................................................................................................................ 67
Test LPG/GAS Regulator Pressure............................................................................................................... 67
Check Throttle Shaft for Sticking................................................................................................................. 67
Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... 67
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine.............................................. 68
Maintenance Procedures Every 4000 Hours or 2 Years................................................................................... 69
Hydraulic Oil, Replace .................................................................................................................................. 69
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ...................................................... 70
Safety Procedures When Working Near Mast.................................................................................................. 72
Fuel Filter Water Removal ................................................................................................................................ 75
Hood Latch Check .............................................................................................................................................. 76
Lift Chain Adjustments ..................................................................................................................................... 77
Jump-Starting the Lift Truck............................................................................................................................ 78
Jump-Starting Using a Battery Charger ..................................................................................................... 78
Jump-Starting a Lift Truck Using Another Lift Truck ............................................................................... 78
Welding Repairs ................................................................................................................................................. 79
Overhead Guard Changes ................................................................................................................................. 79
Wheel and Tire Replacement ............................................................................................................................ 80
General ........................................................................................................................................................... 80
Solid Rubber Tire, Change (S Series) ........................................................................................................... 80
Remove and Install Tire on Wheel ........................................................................................................... 80
Pneumatic Tire With Tube, Repair ............................................................................................................... 81
Remove Wheels From Lift Truck.............................................................................................................. 81
Remove Tire From Wheel ......................................................................................................................... 81
Remove Tire From Two-Piece Wheel ................................................................................................... 82
Remove Tire From Three- and Four-Piece Wheels ............................................................................. 83
Install Wheel in Tire ................................................................................................................................. 84
Install Three-Piece or Four-Piece Wheel in Tire ................................................................................. 84
iii
Table of Contents Periodic Maintenance

Install Tire on Two-Piece Wheel........................................................................................................... 85
Install Two-Piece Wheel in Tire ........................................................................................................... 86
Add Air to Pneumatic Tires With Tube ........................................................................................................ 86
Install the Wheels ..................................................................................................................................... 87
Dual Drive Wheels, Install ....................................................................................................................... 87
Pneumatic Tubeless Tire, Repair.................................................................................................................. 88
Remove Wheels From Lift Truck.............................................................................................................. 88
Remove Tire From Wheel ......................................................................................................................... 88
Install Tire on Wheel................................................................................................................................. 90
Add Air to Pneumatic Tubeless Tire ........................................................................................................ 92
Wheels, Install........................................................................................................................................... 93
Solid Rubber Tires on Pneumatic Wheels, Change ..................................................................................... 93
Remove Wheel From Tire ......................................................................................................................... 93
Install Tire on Wheel................................................................................................................................. 95
Snap-On-Tire, Change................................................................................................................................... 96
Remove Snap-On-Tire, Solid Tire From Wheel ....................................................................................... 97
Install Snap-On-Tire, Solid Tire on Wheel .............................................................................................. 98
Adhesives and Sealants ..................................................................................................................................... 99
This section is for the following models:
S4.0, 4.5, 5.50FT; S5.5FTS [G004];

H4.0FT5/FT6, H4.5FTS5,H4.5FT6, H5.0-5.5FT [N005, P005]
iv
8000 SRM 1248 General
General
shown in the Maintenance Schedule. Service Man-
WARNING uals are available from your dealer for Hyster lift
Do not make repairs or adjustments unless you trucks to help users who do their own maintenance.
have both authorization and training. Repairs
and adjustments that are not correct can make SERIAL NUMBER DATA
a dangerous operating condition.
The serial number for the lift truck is on the name-
plate. It is also on the right side of the frame, under
WARNING the floor plate.
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If re- HOW TO MOVE DISABLED LIFT TRUCK
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from How to Tow Lift Truck
the key switch.
WARNING
CAUTION Use extra caution when towing a lift truck if
Disposal of lubricants and fluids must meet lo- any of the following conditions exist:
cal environmental regulations. • Brakes do not operate correctly.
• Steering does not operate correctly.
This section contains a Maintenance Schedule and • Tires are damaged.
the instructions for maintenance and inspection. • Traction conditions are bad.
• The lift truck must be towed on a slope.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift If the engine cannot run, there is no power
truck. The service intervals are given in both oper- available for the hydraulic steering system
ating hours recorded on the lift truck hourmeter and and the service brakes. This condition can
in calendar time. The recommendation is to use the make the lift truck difficult to steer and stop.
interval that comes first. If the lift truck uses power from the engine to
help apply the brakes, the application of the
The recommendations for the time intervals given for
brakes will be more difficult. Poor traction can
eight hours of operation per day. The time intervals
cause the disabled lift truck or towing vehicle
must be decreased from the recommendations in the
to slide. A slope will also make the lift truck
Maintenance Schedule for the following conditions:
more difficult to stop.
• The lift truck is used more than eight hours per
day. Never lift and move a disabled lift truck unless
• The lift truck must work in dirty operating condi- the disabled lift truck MUST be moved and
tions. cannot be towed. A lift truck used to move
• Poor ground conditions. a disabled lift truck MUST have a capacity
• Intensive usage at high performance levels or rating equal to or greater than the weight of
other abnormal conditions will require more fre- the disabled lift truck. The capacity of the lift
quent servicing. truck used to move a disabled lift truck must
have a load center equal to half the width of
Your dealer for Hyster lift trucks has the equipment
the disabled lift truck. See the nameplate of
and trained service personnel to do a complete pro-
the disabled lift truck for the approximate
gram of inspection, lubrication, and maintenance. A
total weight. The forks must extend the full
regular program of inspection, lubrication, and main-
width of the disabled lift truck. Put the weight
tenance will help your lift truck provide more effi-
center of the disabled lift truck on load center
cient performance and operate for a longer period of
of the forks. Be careful to not damage the
time.
underside of the lift truck.
Some users have service personnel and equipment
1. The towed lift truck must have an operator.
to do the inspection, lubrication, and maintenance
2. Tow truck slowly.
1
General 8000 SRM 1248
3. Using a lift truck or a lifting device that could towing link made of steel that fastens to the tow
be attached to the mast (I.E. come-a-long), raise pins in the counterweights of both lift trucks. See
carriage and forks approximately 30 cm (12 in.) Figure 1. Slowly and carefully remove the slack
from surface. Install chain around a mast cross- out of the towing link.
member and the carriage to prevent carriage and
mast channels from moving. 6. If lift trucks are equipped with a leaded counter-
weight without a tow pin (see Figure 1), use a
4. If another lift truck is used to tow the disabled lift towing link made of steel that fastens to the two
truck, that lift truck must have an equal or larger center grill bars of both lift trucks. Slowly and
capacity than the disabled lift truck. Install ap- carefully remove the slack out of the towing link.
proximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck. Lift truck models that are equipped with a leaded
This 1/2 capacity load will increase traction of lift counterweight, that are covered in this SRM are
truck. Keep load as low as possible. S5.5FTS (G004).
5. If lift trucks are equipped with a tow pin in the

counterweight (standard counterweight), use a
A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)

B. COUNTERWEIGHT WITH TOW PIN (STANDARD COUNTERWEIGHT)
1. TOWING LINK 2. CENTER GRILL BARS 3. TOW PIN
Figure 1. Counterweight Types
2
8000 SRM 1248 General
HOW TO PUT LIFT TRUCK ON BLOCKS 2. Put mast in vertical position. Put a block under
each outer mast channel.
How to Raise Drive Tires
3. Tilt mast fully forward until drive tires are raised
from surface.
WARNING
The lift truck must be put on blocks for some 4. Put additional blocks under frame behind drive
types of maintenance and repair. The removal tires.
of the following assemblies will cause large
changes in the center of gravity: mast, drive 5. If hydraulic system will not operate, use a hy-
axle, engine, transmission, and counterweight. draulic jack under the side of the frame near the
When the lift truck is put on blocks, put ad- front. Make sure jack has a capacity equal to at
ditional blocks in the following positions to least half the weight of the lift truck. See Name-
maintain stability: plate.
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift How to Raise Steering Tires
truck cannot fall backward.
NOTE: Some lift trucks are equipped with lifting eyes
• Before removing the counterweight, put
for the purpose of lifting the entire lift truck. If the
blocks under the mast assembly so the lift
lift truck is equipped with this type of lifting eyes,
truck cannot fall forward.
the lift truck can be lifted and blocks installed.
The surface must be solid, even, and level when
1. Apply parking brake. Put blocks on both sides
the lift truck is put on blocks. Make sure any
(front and back) of drive tires to prevent move-
blocks used to support the lift truck are solid,
ment of lift truck. See Figure 2.
one-piece units.
2. Use hydraulic jack to raise steering tires. Make
CAUTION sure jack has a capacity of at least 2/3 of total
These lift trucks are equipped with cowl lifting weight of lift truck as shown on the nameplate.
eyes. The cowl lifting eyes are to be used to 3. Put jack under steering axle or frame to raise
lift the front of the lift truck only. Lifting more lift truck. Put blocks under frame to support lift
than the front of the lift truck with the cowl truck.
lifting eyes will damage the cowl section.
1. Put blocks on each side (front and back) of steer-

ing tires to prevent movement of lift truck. See
Figure 2.
3
Maintenance Schedule 8000 SRM 1248
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
Maintenance Schedule
NOTE: The lift truck shown in Figure 3 represents NOTE: The 500-hour, 1000-hour/6-month mainte-
S4.0, 4.5, 5.5FT; S5.5FTS (G004) lift trucks. nance services are performed either at the specified
hours or at 6 months whichever occurs first.
NOTE: The lift trucks shown in Figure 3, Figure 4,
and Figure 5 represent H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (N005, P005) lift trucks.
4
8000 SRM 1248 Maintenance Schedule
Figure 3. GM 4.3L LPG Trucks;S4.0, 4.5, 5.50FT; S5.5FTS (G004) Shown
5
Figure 4. Cummins 4.5L Diesel for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(N005)
6
Figure 5. Cummins QSB 3.3L Diesel for Lift Truck Models H80, 90, 100, 110, 120FT (P005)
7
Table 1. Maintenance Schedule
Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 1 yr 2 yr Quantity
25 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
28, 29 Mast, Carriage, X Check Condition See Parts Manual
Header Hoses, Lift and Lubrication
Chains, Attachment
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat X Check Condition
Latches and Operation
Engine X Remove
Compartment Combustible
Materials
See NOTE 5.
Paper Application: X Check Condition.
Engine Clean as
Compartment, Required.
Truck Components, Replace as
Exhaust Wraps, Required.
Radiator, Radiator
Screen if equipped, See NOTE 8.
Belly Pan if equipped
Check for Leaks - X Check for Leaks.
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition See Parts Manual
13 Coolant Hoses X Check Condition See Parts Manual
16 Fuel Tank (LPG) CIL 15.1 to 20.4 kg LPG - HD 5, HD 10
(33.5 to 45.0 lb)
Full
16 Fuel Tank (Short CIL 79 liter (20.8 gal) Diesel No. 2
Wheel Base)
Cummins 4.5L
and QSB 3.3L
(Diesel)
H4.0FT5; H4.5FTS5;
H5.0-5.5FT (N005,
P005)
16 Fuel Tank (Long CIL 100.3 liter Diesel No. 2
Wheel Base) (26.5 gal)
Cummins 4.5L
and QSB 3.3L
Diesel Engine
H4.0FT6; H4.5FT6;
H5.0-5.5FT (N005,
P005)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
8
Table 1. Maintenance Schedule (Continued)
Horn, Lights, X Check Operation
Alarms,
Fuses, and Relays
1 Service Brakes X Check Operation
23 Parking Brake X Check Operation
Steering Controls X Check Condition
and Steering Column and Operation
Gas Cylinder
22 Transmission X Check for Leaks John Deere
JDM J20C
22 Transmission X Check Operation
3 Hydraulic Oil X X C 39.4 liter (41.6 qt) ISO VG 46
GM 4.3L See NOTE 2 and Hydraulic Oil
S4.0, 4.5, 5.50FT; NOTE 3. 15 C (5 F) and Above
S5.5FTS (G004)
(Short Wheel Base) See NOTE 2 and Hydraulic Oil
H4.0FT6; H4.5FT6; NOTE 3. 15 C (5 F) and Above
H5.0-5.5FT
(N005, P005)
(Long Wheel Base) See NOTE 2 and Hydraulic Oil
H4.0FT6; H4.5FT6; NOTE 3. 15 C (5 F) and Above
H5.0-5.5FT (N005,
P005)
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
See NOTE 4.
10 Hydraulic Tank X C Inspect and Clean See Parts Manual
Breather as Required
See NOTE 5.
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 4.7 liter (5.0 qt) 7 C (20 F) and Below
GM 4.3L CIL See NOTE 5. SAE 5W-20
Engine (LPG) 16 C (60 F) and Below
SAE 5W-30
18 C (0 F) and Above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L Engine See NOTE 4 and
NOTE 5.
9
9 Engine Oil X C 13.0 liter (13.7 qt) 0 C (32 F) and Below
Cummins 4.5L CIL See NOTE 5. SAE 0W-30
Diesel Engine 25 to 20 C
( 13 to 68 F)
SAE 5W-30
20 to 20 C ( 4 to 68 F)
SAE 10-30
SAE 5W-40 or 15W-40
API CH-4 or CI-4
9 Engine Oil X C 7.5 liter (8 qt) 0 C (32 F) and Below
Cummins QSB CIL See NOTE 5. SAE 0W-30
3.3L Diesel 25 to 20 C
Engine ( 13 to 68 F)
SAE 5W-30
20 to 20 C ( 4 to 68 F)
SAE 10-30
SAE 5W-40 or 15W-40
API CH-4 or CI-4
19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins 4.5L and See NOTE 4 and
QSB 3.3L Diesel NOTE 5.
Engine
18 Air Filter CIL C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
Engine Oil Pressure CIL Check Oil GM Engine
Pressure 207 to 380 kPa
(30 to 55 psi)
Cummins 4.5L
Diesel Engine
at High Idle
207 kPa (30 psi)
at Low Idle
69 kPa (10 psi)
Cummins QSB 3.3L
Diesel Engine 49 kPa
(7 psi) Minimum
15 Drive Belt X Check for Wear
GM Engine and Damage.
No Adjustment
Needed.
See NOTE 5.
10
15 Drive Belt X Check for Wear
Cummins 4.5L and Damage.
and QSB 3.3L No Adjustment
Diesel Engine) Needed.
See NOTE 5.
LPG Regulator X Drain Tar
GM 4.3L Engine See NOTE 5.
Engine Idle Speed X 750 ±25 rpm
GM 4.3L (LPG) See NOTE 5.
Engine Governed X 2400 ±25 rpm
Speed See NOTE 5.
GM 4.3L (LPG)
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature Less
Cummins 4.5L than 77 C (170 F)
Diesel
Hot Engine Temperature
Cummins 4.5L Greater than 77 C
Diesel (170 F)
Speed (No Load)
Cummins 4.5L
Diesel
Cold Engine Temperature Less
Cummins QSB Than 30 C (86 F)
3.3L Diesel
Hot Engine Temperature
Cummins QSB Greater Than
3.3L Diesel 30 C (86 F)
Speed (No Load)
Cummins QSB
3.3L Diesel
Oxygen Sensor X Replace as
GM 4.3L Engine CIL Necessary
4 Valve Adjustment Not Adjustable
GM 4.3L Engine
4 Valve Adjustment X Adjust as 0.254 mm (0.010 in.)
Cummins 4.5L Required Cold
Diesel Engine Exhaust
0.508 mm (0.020 in.)
Cold
11
4 Valve Adjustment X Adjust as 0.35 mm (0.014 in.)
Cummins QSB Required Cold Exhaust 0.50 mm
3.3L Diesel See NOTE 13 (0.02 in.) Cold
Engine
17 Fuel Filter, LPG C 1 Filter See Parts Manual
GM
17 Fuel Water Separator CIL C 1 Filter See Parts Manual
Filter Drain Water from
Cummins 4.5L Filter as Required
and QSB 3.3L
Diesel Engine
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins 4.5L
Diesel Engine
17 Final Fuel Filter C 1 Filter See Parts Manual
Cummins QSB
3.3L Diesel
Engine
20 Fuel Injectors X Check and Replace
GM 4.3L LPG If Required
Engine 6 Injectors
5 Spark Plugs C Check Plug Wires See NOTE 9.
GM 4.3L Engine 6 Plugs
12, 14 Cooling System X C 15.1 liter (15.9 qt) 50% Water and 50%
GM 4.3L Engine CIL Ethylene Glycol
Boron-Free Antifreeze
12, 14 Cooling System X C 13.5 liter (14.2 qt) 50% Water and 50%
Cummins 4.5L CIL Ethylene Glycol
Engine Boron-Free Antifreeze
12, 14 Cooling System X C 10.4 liter (11 qt) 50% Water and 50%
Cummins QSB CIL Ethylene Glycol
3.3L Diesel Boron-Free Antifreeze
Engine
Clean Debris From X See NOTE 5.
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brake JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check Condition
26 Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
Lift System, Operate X Check Operation
12
27 Mast L Lubricate Multipurpose Grease
Sliding Surfaces as Required See NOTE 7.
and Load Roller See NOTE 10.
Surfaces
27 Header Hoses X Check Condition
28 Lift Chains X Check Lubrication SAE 30W
See NOTE 11. Engine Oil
28 Lift Chains L L, X Check for Wear SAE 30W
Lube as Required Engine Oil
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast X L X Lube as Required Multipurpose Grease
Integral 8 Fittings See NOTE 7.
Sideshift 4 Bearing Strips
Carriage
Sliding Surfaces
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

See NOTE 7.
Brake Master L SAE 10W-30
Cylinder Rod End API SL
Pin ILSAC GF3
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SL
ILSAC GF3
SAE J2362
24 Brake Oil CIL X C 0.35 liter (0.74 pt) Dexron® III from sealed
Master Cylinder container
11 Steering Axle L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 7.
Tie Rods See NOTE 7.
S4.0, 4.5, 5.50FT;
S5.5FTS (G004)
Tie Rods See NOTE 7.
H4.0FT5/FT6;
H4.5FTS5,
H4.5FT6;
H5.0-5.5FT
(N005, P005)
13
2 Pedals, Levers, L Lubricate as Use Silicone Spray
Seat Rails, Cables, Necessary Hyster Part No. 328388
Hinges, Linkages,
Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
(Dry Brake) Thickness Minimum
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Hyster Part Number
328388)
30 Differential and X C 6.0 liter (6.3 qt) SAE 80W-90 or
Drive Axle Oil 85W-140
(Dry Brake)
7/30 Transmission and X C 28.8 liter (30.4 qt) John Deere
Wet Brake Planetary JDM J20C
Carrier Housing Oil
S4.0FT (G004)
Carrier Housing Oil
S4.5FT, 5.50FT;
S5.5FTS (G004)
Carrier Housing Oil
H4.0FT5/FT6;
H4.5FTS5, H4.5FT6;
H5.0-5.5FT (N005,
P005)
30 Wet Brake Center X C 2.0 liter (2.1 qt) John Deere
Section Oil JDM J20C
S4.0, 4.5, 5.50FT;
S5.5FTS (G004)
30 Wet Brake Center X C 2.0 liter (2.1 qt) John Deere
Section Oil JDM J20C
H4.0FT5/FT6;
H4.5FTS5, H4.5FT6;
H5.0-5.5FT (N005,
P005)
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel Lines,
and Fittings
14
Inspect Lock-Off for X
Leaks, and Ensure
Lock-Off Closing
Test LPG Regulator X
Pressure
Check Air Induction X
System for Leaks
Check Manifold for X
Vacuum Leaks
Check Throttle Shaft X
for Sticking
Check Injectors and X
Rails for leaks
32 Inspect Exhaust X
Manifolds and Piping
for Leaks
Inspect Catalyst X
Inlet and Outlet
31 Ignition System C Replace
Distributor, Rotor,
and Spark Plug
Wires
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, and all other fluid filters after first 100 hours of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving
contaminated environment, poor ground conditions, intensive usage at high performance levels or other abnormal condi-
tions 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: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: 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. Used compressed air and
steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000 SRM 1249 for plug gap and type of plug to use.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate at first sign of visible rust.
15
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1248
NOTE 12: 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 13: Initial valve lash adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at
2000-hour/2-year intervals, whichever comes first.
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE parking brake. Open the hood and check for leaks
STOPPED 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,
WARNING
wood, cotton, agricultural grass/grain, etc.).
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If Tires and Wheels
repair is necessary, put a DO NOT OPERATE
tag in the operator’s area. If the lift truck is Check the tires for damage (see Figure 6). Check the
equipped with a key switch, remove the key tread and remove any objects that will cause damage.
from the key switch. Check for bent or damaged rims. Check for loose or
missing hardware. Remove any wire, strapping, or
Put the lift truck on a level surface. Lower the other material that is wrapped around the axle.
carriage and forks, stop the engine, and apply the
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 6. Tire Check
16
8000 SRM 1248 Maintenance Procedures Every 8 Hours or Daily
Safety Labels or sheaves; proper tracking during operation.

Adjust/repair/replace hose/components as neces-
sary.
WARNING
Safety labels are installed on the lift truck to 6. Check that the lift chains are correctly lubri-
give information about operation and possible cated. Use SAE 30 engine oil as necessary to
hazards. It is important that all safety labels lubricate the lift chains.
are installed on the lift truck and can be read.
7. Inspect the lift chains for cracks or broken links,
Check that all safety labels are installed in the cor- and worn or turned pins. See Figure 7.
rect location on the lift truck. See the Parts Man-
ual, Model Description section in the Operating 8. Inspect the chain anchors and pins for cracks and
Manual or the section Frame 100 SRM 1243 for the damage.
correct location of the safety labels. See the Parts
Manual for the part numbers of the safety labels. 9. Make sure the lift chains are adjusted so that
they have equal tension. Adjustments or re-
Mast, Carriage, Lift Chains, Header Hoses, placement of the lift chains must be done
by authorized personnel.
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 align-
ment 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.
1. Inspect the welds on the mast and carriage for

cracks. Make sure that the capscrews and nuts
are tight.
2. Inspect the channels for wear in the areas where

the rollers travel. Inspect the rollers for wear or 1. WORN PIN 5. LOOSE LEAVES
2. CRACKS 6. TURNED PIN
damage. 3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
3. Inspect the load backrest extension for cracks
and damage. Figure 7. Lift Chain Check
4. If the lift truck is equipped with an integral Operator Restraint System
sideshift carriage or attachment, inspect the
parts for cracks and wear. Make sure the parts The seat belt, hip restraint, seat, hood, and hood
that fasten the integral sideshift carriage or latch are all part of the operator restraint system.
attachment to the carriage are in good condition. See Figure 8. Each item must be checked to make
sure it is fastened correctly, functions correctly, and
5. Visually inspect hoses/fittings for hydraulic is in good condition.
leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
17
Emergency Locking Retractor (ELR) Legend for Figure 8
When the ELR style seat belt is properly buckled 1. LATCH STRIKER
across the operator, the belt will permit slight op- 2. HOOD LATCH
3. FORWARD/BACKWARD ADJUSTMENT
erator repositioning without activating the locking 4. HOOD
mechanism. If the truck tips, travels off a dock, or 5. OPERATOR WEIGHT ADJUSTMENT
comes to a sudden stop, the locking mechanism will 6. SEAT RAIL
be activated and hold the operator’s lower torso in 7. ARM REST
the seat. 8. SEAT BELT
9. SEAT
A seat belt that is damaged worn or does not operate 10. HIP RESTRAINT
11. HOOD HINGE
properly will not give 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 8.
The following seat belt operation checks must be per-

formed:
• With the hood closed and in the locked position,
pull the seat belt slowly from the retractor assem-
bly. 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, re-
place the seat belt assembly.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
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
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE
belt assembly.
1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
5. SEAT BELT
Figure 9. Swivel Seat Controls
Hood and Seat Latches

Make sure the seat rails and latch striker are not
loose. The seat rails must lock tightly in position,
but move freely when unlocked (see Figure 8 and Fig-
ure 9). The seat rails must be correctly fastened to
the hood and the hood fastened to the hinges on the
frame. Try to lift the hood to make sure it is fas-
tened correctly and will not move. If adjustment is
required, go to Hood Latch Check.
Figure 8. Hood and Seat Check
18
Engine Compartment fins. Assure that air pressure, nozzle or exten-

sion tube does not damage exhaust wraps or
Check for the presence of any combustible material radiator fins.
such as paper, leaves, etc. Remove any combustible
materials. Paper removal can generally be accomplished using a
compressed air line and nozzle. An extension may be
Paper Application helpful to access hard to reach places. Remove floor
plates and side covers for better access to engine com-
Vehicles used in paper applications require regular partment. Open or removed belly pan, if equipped.
inspection and cleaning to minimize the risk of fire. Clean components with compressed air. Take care
This should be done at least once every 8 hours to maintain the integrity of the exhaust wraps when
or more frequently depending upon operating en- cleaning with compressed air and use caution to not
vironment. The paper application option will help force debris into openings. Check the condition of ex-
limit the contact of paper or tissue scraps to hot haust wraps for wear, proper fit, contamination with
surfaces under the hood, but frequent maintenance oil or antifreeze, gaps in coverage, failed fasteners
is required. and replace as necessary. Do not reuse wraps if they
have been removed for some other service operation.
WARNING
Engine and exhaust system components are WARNING
hot to touch. Be sure lift truck components are Be careful when cleaning with steam. Steam
cool before starting inspection and cleaning or can cause serious burns. Wear protective cloth-
personal injury may occur. ing, gloves, and eye protection. Never expose
your skin to steam.
Ensure the truck engine cools properly by allowing
it to idle for several minutes. Shutting the truck If compressed air did not adequately remove debris,
down while hot will not allow the engine to cool steam clean to remove any persistent accumulation
quickly due to the loss of coolant circulation. The of material or oil. Protect electrical components from
heat trapped under the hood may actually increase moisture when steam cleaning. Do not spray exhaust
the engine temperature because of no heat transfer wraps directly with high pressure steam. Allow lift
through the radiator. With engine off and lift truck truck to air dry before returning to work in a con-
components cooled, check and clean the radiator and taminated environment. Paper dust and scraps will
if equipped, radiator screen. Check engine manifold, adhere to wet surfaces.
exhaust pipes, muffler and catalytic converter for
paper scraps. Clean as required. Check and clean Check the condition of exhaust wraps for wear,
the engine compartment components, transmission, proper fit, contamination with oil or antifreeze, gaps
fan shroud, belly pan if equipped, and inside frame in coverage, failed fasteners and replace as neces-
ledges to avoid paper, dust and oil accumulation. sary. Do not reuse wraps if they have been removed
Check axle and cowl openings for paper buildup and for some other service operation.
bailing wire. Remove any debris.
Fuel, Oil, and Coolant Leaks, Check
WARNING
Compressed air can move particles so that they WARNING
cause injury to the user or to other personnel. All fuels are very flammable and can burn or
Make sure that the path of the compressed air cause an explosion. Do not use an open flame
is away from all personnel. Wear protective to check the fuel level or to check for leaks in
goggles or a face shield to prevent injury to the the fuel system. If there is a leak in the fuel sys-
eyes. tem, extra care must be used during the repair.
Do not operate the lift truck until a leak is re-
paired.
CAUTION
Air pressure, nozzle or extension tube may Make a visual check for leaks on and under the lift
cause damage to exhaust wraps and radiator truck. If possible, find and report the leak to main-
tenance for repair. Leaks often indicate a need for
repair of damaged or worn components. Leaks in the
19
LPG fuel system are usually not visible unless ice Transmission
is present. There is however, usually a strong odor.
Fuel leaks MUST be repaired IMMEDIATELY. Check the transmission for leaks and damaged or
loose components. Heavy-duty or high temperature
Check the fuel system for leaks and the condition of operations can require more frequent checks.
parts. When fuel is added to the lift truck, see the
section HOW TO ADD FUEL TO THE LIFT TRUCK Hydraulic System Oil
in the Operating Manual.
Also check the condition of the radiator or heater WARNING

hoses that are not leaking. Soft or cracked hoses need At operating temperature, the hydraulic oil is
to be replaced before a major leak occurs. HOT. Do not permit the hot oil to touch the skin
and cause a burn.
Hydraulic Hoses
CAUTION
Check the condition of the hydraulic hoses for ser-
viceability by inspecting for cracks or other obvious Do not permit dirt to enter the hydraulic sys-
damage. Check to insure that the hydraulic hoses tem when the oil level is checked or the filter
are not leaking. If any hose is leaking, report it to is changed.
maintenance for repair. Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
Coolant Hoses hydraulic pump without oil will damage the
Check the condition of the coolant hoses for service- pump.
ability by inspecting for cracks or other obvious dam-
After the engine has stopped, wait one minute before
age. Check to insure that the coolant hoses are not
checking the oil level. Keep the hydraulic oil at the
leaking. If any hose is leaking, report it to mainte-
correct level as indicated on the dipstick. Use the
nance for repair.
correct oil as shown in the Maintenance Schedule.
Steering Column Gas Cylinder Check the hydraulic system for leaks and damaged or
loose components. Heavy-duty or high-temperature
Make sure the gas cylinder for the steering column
operations can require more frequent checks.
operates correctly. The cylinder must NOT allow the
column to move unless the tilt lever is released. See
Engine Oil
Figure 10.
WARNING
At operating temperature, the engine oil is
HOT. Do not permit the hot oil to touch the
skin and cause a burn.
CAUTION
Do not permit dirt to enter the engine when the
oil level is checked or the filter is changed.
Never operate the engine without oil. The op-

eration of the engine without oil will damage
the engine.
After the engine has stopped, wait one minute before

checking the oil level. See Figure 11, Figure 12, and
Figure 13. Keep the oil at the correct level as indi-
1. TILT LEVER 2. GAS CYLINDER
cated on the dipstick. Use the correct oil as shown in
Figure 10. Steering Column Gas Cylinder and the Maintenance Schedule.
Tilt Lever
20
Legend for Figure 11

A. TOP VIEW
B. RIGHT HAND SIDE SHOWN
1. BATTERY
2. AUXILIARY COOLANT RESERVOIR
3. RADIATOR CAP
4. WATER SEPARATOR
5. AIR FILTER
6. LIFT PUMP
7. FUEL INJECTION PUMP
8. ENGINE OIL FILL CAP
9. INLINE FUEL FILTER
10. DIPSTICK ENGINE OIL
11. FUEL INJECTOR
12. DRIVE BELT
Figure 11. Cummins 4.5L Diesel Engine

Maintenance Points for Lift Truck Models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(N005)
21
A. RIGHT SIDE FRONT VIEW B. LEFT SIDE FRONT VIEW

1. DIPSTICK 15. ALTERNATOR
2. TURBOCHARGER 16. ALTERNATOR BELT ADJUSTMENT
3. OIL FILL CAP 17. TEMPERATURE SENDING UNIT
4. AIR INLET HOUSING 18. WATER INLET/THERMOSTAT HOUSING
5. FUEL PRIMER PUMP 19. TURBOCHARGER AIR INLET
6. FUEL/WATER SEPARATOR 20. TURBOCHARGER WASTEGATE
7. ECM 21. TURBOCHARGER EXHAUST
8. FUEL FILTER 22. TURBOCHARGER EXHAUST MANIFOLD
9. STARTER 23. OIL FILTER
10. FUEL RAIL 24. TURBOCHARGER OIL DRAIN LINE
11. ELECTRONIC FUEL PUMP 25. TURBOCHARGER OIL FEEL LINE
12. WATER PUMP 26. OIL PAN
13. CRANK POSITIONING SENSOR 27. OIL PAN DRAIN PLUG
14. CAM POSITIONING SENSOR 28. DRIVE BELT
Figure 12. Cummins QSB 3.3L Diesel Engine Maintenance Points for Lift Truck Models
22
Forks
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 de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 253 lb).
NOTE: Forks are to be replaced only in sets and not

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

ment of the fork or other maintenance. Lift the lock
pin and slide a hook fork to the fork removal notch
on the carriage. See Figure 14 and Figure 15. Lower
the fork onto blocks so that the bottom hook of the
fork moves through the fork removal notch. See Fig-
ure 15. Lower the carriage further so that the top
1. DIPSTICK ENGINE OIL
2. BATTERY hook of the fork is disengaged from the top carriage
3. AUXILIARY COOLANT RESERVOIR bar. Move the carriage away from the fork, or use
4. RADIATOR CAP a lifting device to move the fork away from the car-
5. ENGINE OIL FILL riage.
6. DRIVE BELT
7. AIR FILTER Inspect
8. FUEL FILTER
9. ENGINE OIL FILTER 1. Inspect the forks for cracks and wear. Check that
10. SPARK PLUGS
11. FUEL INJECTOR the fork tips are aligned as shown in Figure 15.
Check that the bottom of the fork is not worn (4,
Figure 13. GM Engine Maintenance Points Figure 15).
2. Replace any damaged or broken parts that are

Air Filter used to keep the forks locked in position.
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
Do not operate the lift truck until the air filter ele-
ment has been replaced.
1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
Figure 14. Hook Fork Removal
23
Install
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. En-
gage the lock pin with a notch in the upper carriage
bar.
Adjust
NOTE: During the adjustment of the forks, the heel

of the forks should not be touching the ground.
The forks are connected to the carriage by hooks and

lock pins. See Figure 14 and Figure 16. The lock
pins are installed through the top fork hooks and fit
into slots in the top carriage bar. If pin does not re-
main engaged in carriage slot, replace with new pin.
Adjust the forks as far apart as possible for maxi-
mum support of the load. Hook forks will slide along
the carriage bars to adjust for the load to be lifted.
Raise the lock pin in each fork to slide the fork on
Fork Tip Alignment the carriage bar. Make sure the lock pin is engaged
in the carriage bar to lock the fork in position after
Length of Forks 3% Dimension the width adjustment is made.
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
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 1. FORK 5. WEDGE
7. MAXIMUM ANGLE 93 2. LOCK PIN 6. KNOB
8. FORK REMOVAL NOTCH 3. SPRING 7. LOCK PIN
4. WASHER ASSEMBLY
Figure 15. Forks Check
Figure 16. Fork Lock Pin Assembly
24
Integral Sideshift Carriage HOW TO MAKE CHECKS WITH ENGINE

RUNNING
Check for cracks, wear and damage. If damaged,
see Mast Repairs, 2 and 3-Stage Masts 4000 SRM
1250 for repair procedures. If necessary, lubricate WARNING
sliding surfaces at grease fittings with multipurpose DO NOT operate a lift truck that needs repairs.
grease shown in the Maintenance Schedule. See Fig- Report the need for repair immediately. If re-
ure 17. pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. If lift truck is equipped
with a key switch, remove the key.
WARNING
FASTEN YOUR SEAT BELT! The seat belt is in-
stalled to help the operator stay on the truck if
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 NEU-
TRAL. Make the checks carefully.
1. CAPSCREWS
2. LOWER HOOK Indicator Lights, Horn, Fuses, and Relays
3. APRON
4. LOWER BEARING STRIPS If lift truck is equipped with a key switch, turn
5. UPPER BEARING STRIPS key to ON position. If lift truck is equipped with a
6. GREASE FITTINGS Power ON/OFF button, press button to turn system
7. CYLINDER ROD power on. All warning light and indicator lights
8. SNAP RING
9. ROD SCRAPER will light up for two seconds (start check) when
10. ROD BUSHINGS system power is turned ON. See Figure 18. Check
11. SEAL all indicator lights for correct operation as described
12. FIXED FRAME in the Operating Manual. Check the operation of
the horn. Start the engine by turning the key switch
Figure 17. Integral Sideshift Carriage 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, check the fuses. The fuses
are located in the Power Distribution Module (PDM)
which is under the hood next to the battery on the
right side. See Figure 19.
25
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 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 Malfunction 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 18. Warning and Indicator Lights
26
NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE)
Figure 19. PDM Showing Fuses and Relays
Service Brakes using the lift truck. Replace the brake oil in
the system if there is dirt or water in the sys-
Brake Oil Level tem.
WARNING Do NOT use "DOT" fluid, only use Dexron III oil
from sealed container to prevent possible dam-
Small amounts of water in the brake system
age to the brake system. Failure to observe the
can cause reduced braking performance if the
above Warning could result in death or serious
water reaches the wheel cylinder areas. Do
injury.
not allow water entry. Ensure that the sealed
reservoir lid is properly replaced. There is an indicator light on the Display Switch
Cluster for the brake oil. The red light is ON when
The brake system has a boosted master cylin-
the key switch is in the START position or the Power
der, braking will be more difficult if the engine
ON/OFF button is pressed, and must go OFF when
is not running.
the engine is running. If the light is on when the en-
Loss of oil from the brake oil reservoir indi- gine is running, the brake fluid oil in the reservoir is
cates a leak. Repair the brake system before too low.
27
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 automat-
ically 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 the service brakes are adjusted and the
operation of the automatic adjuster mechanism is 1. LOCK BUTTON RELEASE
correct before the parking brake is adjusted. 2. OFF POSITION
3. ON POSITION
Lift trucks with a MONOTROL® pedal. The 4. ADJUSTMENT KNOB
switch energizes the seat warning circuit when hand Figure 20. Parking Brake
lever is released. This switch puts the transmission
in NEUTRAL by de-energizing the direction sole- Engine Oil Pressure
noid. There is also a switch on the left-hand side of
bracket. This switch prevents engine from starting NOTE: The engine will enter shutdown mode after a
unless parking brake is applied. warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
NOTE: Make sure parking brake is released before lift trucks with powertrain protection system. Lift
making adjustment. trucks equipped with a Cummins diesel engine will
1. Turn the adjustment knob to raise the equalized enter the shutdown mode when the engine oil pres-
link and tighten the parking brake cables shown sure is less than 49 kPa (7 psi) on lift trucks with pow-
in Figure 20. Do not tighten the adjustment so ertrain protection system. See the Engine Shut-
that the brake is applied when the lever is re- down procedures in the Operating Manual.
leased. The lever for the parking brake has a There is an indicator light for the engine oil pressure
lock. Use your thumb or finger to release the lock on the Display Switch Cluster. During normal opera-
on the lever when the parking brake is released. tion, the red indicator light will illuminate when the
2. For burnished brakes, test the operation of the key switch is turned to ON, if the truck is equipped
parking brake. The lift truck with a capacity load with a key switch, or when the power ON/OFF but-
must not move when parking brake is applied on ton is pressed, if the truck is equipped with a key-
a 15 percent grade [a slope that increases 1.5 m less option, and will stay illuminated until correct oil
in 10 m (1.5 ft in 10 ft). pressure is obtained, at which time the light will go
off.
28
If the light continues to stay on when engine is run- If coolant is added, use the correct mixture of wa-
ning, the engine oil pressure is low. Stop the engine ter and ethylene glycol shown in the Maintenance
and check the oil level. See Figure 13 for lift truck Schedule.
models S4.0, 4.5, 5.50FT; S5.5FTS (G004) and Fig-
ure 11 and Figure 13 for lift truck models H4.0FT5/ WARNING
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (N005, P005).
Compressed air can move particles so that they
Do not restart the engine until the low pressure con-
cause injury to the user or to other personnel.
dition has been corrected.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
Cooling System goggles or a face shield to prevent injury to the
eyes.
WARNING
DO NOT remove the radiator cap from the radi- Check the radiator fins. Clean the radiator with com-
ator when the engine is hot. When the radiator pressed air or water as needed. Check for and re-
cap is removed, the pressure is released from move any debris on the radiator core. If the indicator
the system. If the system is hot, the steam and light turns on again after restarting, shut down the
boiling coolant can cause burns. 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 118 C (245 F) or above
for GM 4.3L lift trucks with powertrain protection
system. Lift trucks equipped with a Cummins 4.5L
or QSB 3.3L diesel engine will enter the shutdown
mode when the coolant temperature reaches 114 C
(238 F) or above on lift trucks with powertrain pro-
tection system. See the Engine Shutdown proce-
dures in the Operating Manual.
There is an indicator light on the Display Switch

Cluster for the coolant temperature. 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 coolant and engine
are too hot. Stop the engine and check the coolant
level in the coolant recovery reservoir.
Make sure the coolant level is between the ADD and

FULL marks on the auxiliary coolant reservoir (see
Figure 21). The coolant will expand as it is heated 1. FILL CAP
2. FULL HOT MARK
and the level in the auxiliary coolant reservoir will 3. FULL COLD MARK
increase. 4. ADD COLD MARK
CAUTION Figure 21. Auxiliary Coolant Reservoir

Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
29
Steering System Do not try to find hydraulic leaks by putting

hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
WARNING
the pressure.
The lift truck has hydraulic power steering.
The steering can be difficult if the engine is Perform the following checks and inspections:
not running.
1. Check for leaks in the hydraulic system. Check
Make sure the steering system operates smoothly the condition of the hydraulic hoses and tubes.
and provides good steering control. Make sure the
steering column can be adjusted and the gas cylinder NOTE: Some parts of the mast move at different
function is correct. speeds during raising and lowering.
Control Levers and Pedals 2. Slowly raise and lower the mast several times
without a load. Raise the mast to its full height
Check that the control levers for the transmission, at least once. The mast components must raise
mast, and attachment operate as described in Oper- and lower smoothly in the correct sequence. Hose
ating Manual. Check that the pedals operate cor- must track properly during operation.
rectly as described in Operating Manual.
3. The inner weldments and the carriage must
Lift System, Operate lower completely.
4. Raise the mast 1 m (3 ft) with a capacity load.

WARNING The inner weldments and the carriage must raise
When working on or near the mast, see Safety smoothly. Lower the mast. All moving compo-
Procedures When Working Near Mast at the nents must lower smoothly.
end of this section.
5. Lower the load to approximately 0.3 m (1 ft). Tilt
Lower the lift mechanism completely. Never the mast forward and backward. The mast must
allow any person under a raised carriage. Do tilt smoothly and both tilt cylinders must stop
not put any part of your body in or through evenly.
the lift mechanism unless all parts of the mast
6. Check that the controls for the attachment op-
are completely lowered and the engine is
erate the functions of the attachment. See the
STOPPED.
symbols by each of the controls. Make sure all of
If the mast cannot be lowered, use chains on the hydraulic lines are connected correctly and
the mast weldments and carriage so that they do not leak.
cannot move. Make sure the moving parts are
attached to a part that does not move.
30
8000 SRM 1248 First Service After First 100 Hours of Operation
First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL FILTER CUMMINS 4.5L AND QSB 3.3L ENGINE
OIL FILTER
NOTE: The engine oil filter must also be changed af-
ter the first 100 hours of operation for a newly in- Change engine oil filter. See Figure 23. Apply clean
stalled engine. oil to gasket of new filter. Install new filter. Turn fil-
ter until gasket touches, then tighten 1/2 to 3/4 turn
Change engine oil filter. See Figure 22. Apply clean
with your hand. Start engine. Check area around oil
oil to gasket of new filter. Install new filter. Turn fil-
filter for leaks.
ter until gasket touches, then tighten 1/2 to 3/4 turn
with your hand. Start engine. Check area around oil
filter for leaks.
NOTE: LEFT SIDE OF ENGINE SHOWN

1. OIL FILTER NOTE: BOTTOM LEFT-HAND SIDE SHOWN
2. DRAIN PLUG
3. ENGINE OIL DIPSTICK 1. OIL FILTER 2. DRAIN PLUG
4. ENGINE OIL FILL
Figure 23. Engine Oil Filter Change, Cummins
Figure 22. GM 4.3L Engine Filter Oil Change
4.5L Diesel (Shown)
31
First Service After First 100 Hours of Operation 8000 SRM 1248
HYDRAULIC SYSTEM 5. Start the truck, and allow it to run for 30 seconds.
Check for leaks. Stop engine and check hydraulic
Hydraulic Filter, Replace oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
WARNING the hydraulic oil, see Hydraulic Oil, Replace.
At operating temperature, the hydraulic oil is
HOT. Do not permit the hot oil to touch the skin
and cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic sys-
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system.
Never operate the hydraulic pump without oil

hydraulic pump without oil will damage the
pump.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. Put lift truck on a level surface and lower the car-

riage. Unscrew and remove filter lid and spring
from head. See Figure 24. Lift the hydraulic fil-
ter element enough to allow the hydraulic oil to
drain.
NOTE: Have container large enough to hold the filter

element and allow for final hydraulic oil draining.
2. Remove the hydraulic filter element and O-ring

from the bowl and place into the container. Cover
the head to prevent any foreign materials from
getting into the hydraulic tank.
3. Lubricate new O-ring with hydraulic oil and in-

stall it on the bottom of the new filter element.
Install the new filter element into the bowl.
4. Install spring and filter lid onto head. 1. LID 6. FITTING

2. SPRING 7. QUAD RING
3. O-RING 8. FILTER ELEMENT
CAUTION 4. CAPSCREW 9. BOWL
Additives may damage the hydraulic system. 5. HEAD
Before using additives, contact your local Hys-
ter dealer. Figure 24. Hydraulic Filter
32
8000 SRM 1248 Maintenance Procedures Every 500 Hours or 6 Months
TRANSMISSION OIL FILTER, REPLACE 2. Check oil level at the dipstick tube. If necessary,
add additional oil shown in the Maintenance
Schedule. Check for leaks during operation.
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. Dirt can cause damage to the trans-
mission components.
CAUTION
NOTE: The transmission oil filter must also be

changed after the first 100 hours of operation for a
newly installed transmission.
NOTE: 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. See Figure 25. NOTE: ALL MAJOR COMPONENTS AND FRAME
This will reduce the oil that will run out of the filter COMPONENTS REMOVED FOR THE SAKE OF
and onto the transmission when the filter is removed. CLARITY.
1. TRANSMISSION
1. Remove and discard transmission oil filter. Ap- 2. TRANSMISSION DRAIN PLUG
ply clean oil to gasket of new transmission oil fil- 3. SPRING
ter. Install new transmission oil filter and hand 4. SCREEN
tighten. See Figure 25. 5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
7. TRANSMISSION BREATHER
Figure 25. Transmission Oil Filter Change
Maintenance Procedures Every 500 Hours or 6 Months

NOTE: Perform the 8-hour checks prior to performing Never operate the hydraulic pump without oil
the procedures in this section. in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
HYDRAULIC SYSTEM OIL pump.
WARNING CAUTION
At operating temperature, the hydraulic oil is Additives may damage the hydraulic system.
HOT. Do not permit the hot oil to touch the skin Before using additives, contact your local Hys-
and cause a burn. ter dealer.
CAUTION Check the hydraulic oil level when the oil is at operat-
ing temperature with the mast in a vertical position,
the carriage lowered, and the engine stopped. See
tem when the oil level is checked or the filter
Figure 37. Add hydraulic oil only as needed. If hy-
is changed.
draulic oil is above the FULL level, the hydraulic oil
33
Maintenance Procedures Every 500 Hours or 6 Months 8000 SRM 1248
will leak from the breather during operation. The oil the area. Use a solution of sodium bicarbon-
level indicated by the dipstick is most accurate when ate (soda) to make the acid neutral. Acid in the
the oil temperature is 53 to 93 C (130 to 200 F). eyes must be flushed with water immediately.
Wear eye protection.
HYDRAULIC TANK BREATHER
Inspect WARNING
Batteries generate explosive fumes. Keep the
NOTE: When inspecting the breather, do not remove vents in the caps clean. Keep sparks or open
it. The breather element is a non serviceable part. If flame away from the battery area. Do not
it is damaged, replace with a new breather element. make sparks from the battery connections.
Disconnect the battery ground cable when
1. Raise the hood and remove the right rear side doing maintenance.
panel See Figure 26.
Disconnect the negative and positive terminals of the
battery. Using a damp cloth clean the case of the bat-
WARNING
tery. If the terminals are corroded, clean the termi-
Compressed air can move particles so that they nals with a wire brush. Connect the negative and
cause injury to the user or to other personnel. positive cables to their respective terminals.
goggles or a face shield to prevent injury to the
eyes.
CAUTION
Direct air pressure on the filter element can
cause damage. Direct air pressure away from
filter element.
2. Using compressed air, remove any dirt and de-

bris in the frame cavity around the breather. See
Figure 26.
3. If necessary, unscrew and 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
4. Install right rear side panel and close hood. See

Figure 26.
1. HOOD/SEAT ASSEMBLY
BATTERY 2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
WARNING
Figure 26. Hydraulic Tank Breather
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
34
CUMMINS 4.5L AND QSB 3.3L ENGINE GM 4.3L AND QSB 3.3L ENGINE OIL AND
OIL AND FILTER FILTER
NOTE: Change the oil filter for the engine at the first NOTE: Change the oil filter for the engine at the first
100 hours of operation on new lift trucks. 100 hours of operation on new lift trucks.
Change engine oil and engine oil filter. See Fig- Change engine oil and engine oil filter. See Fig-
ure 27. Use the correct oil according to the Main- ure 28. Use the correct oil according to the Main-
tenance Schedule. Apply clean oil to gasket of new tenance Schedule. Apply clean oil to gasket of new
filter. Install new filter. Turn filter until gasket filter. Install new filter. Turn filter until gasket
touches, then tighten 1/2 to 3/4 turn with your hand. touches, then tighten 1/2 to 3/4 turn with your hand.
Start engine. Check area around oil filter for leaks. Start engine. Check area around oil filter for leaks.
NOTE: LEFT SIDE OF ENGINE SHOWN

1. OIL FILTER 2. DRAIN PLUG
Figure 28. GM 4.3L Engine Oil Change (Shown)
NOTE: BOTTOM LEFT HAND SIDE.

1. OIL FILTER 2. DRAIN PLUG
Figure 27. Engine Oil Change Cummins 4.5L

Diesel (Shown)
35
FUEL/WATER SEPARATOR FILTER Install

REPLACEMENT, CUMMINS 4.5L AND QSB
1. Clean the fuel filter head mounting surface and
3.3L ENGINE apply a small amount of diesel fuel to the gasket
on the new fuel filter element. See Figure 29 and
CAUTION Figure 30.
2. Before installing the filter element, fill the filter
element with diesel fuel. This method will aid in
Replace the fuel filter at specified intervals to pre- bleeding the fuel system.
vent contaminants from adversely affecting the
diesel fuel flow. CAUTION
Do not overtighten the filter element. Over-
Remove
tightening the filter element may distort the
1. Stop engine and allow it to cool. threads.
2. Disconnect air inlet elbow to access the fuel filter 3. Install the new fuel filter element until it con-
element. See Figure 29. tacts the fuel filter head mounting surface.
Tighten one additional turn.
3. Disconnect fuel filter sensor connector from the
fuel filter element. 4. Connect the fuel sensor connector to fuel filter
element
CAUTION 5. Connect air inlet elbow hose.
Drain the water/fuel into a container and dis-
pose in accordance with local environmental 6. Open the fuel supply valve.
regulations.
7. Prime the fuel system. See Priming the Fuel Sys-
4. Open the drain valve by turning the valve coun- tem (Cummins 4.5L and QSB 3.3L Engine).
terclockwise approximately 3 1/2 turns until
8. Check for fuel leaks.
draining occurs. Drain until fuel filter element
is empty.
5. Remove and discard fuel filter element.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. IN-LINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
36
Figure 29. Cummins 4.5L Engine Fuel System
37

A. RIGHT VIEW
B. TOP VIEW
1. TURBO
2. HEAD
3. BELL HOUSING
4. FLYWHEEL
5. OIL PAN
6. ENGINE BLOCK
7. ELECTRONIC FUEL PUMP
8. FUEL FILTER
9. WATER OUTLET HOUSING
10. WATER PUMP BELT
11. WATER INLET HOUSING
12. OIL FILL CAP
13. WATERGATE
14. TURBO
15. AIR INLET HOUSING
16. OIL DIPSTICK
17. EXHAUST MANIFOLD
18. EXHAUST OUTLET
19. ENGINE ECM
20. STARTER
21. FUEL/WATER SEPARATOR
22. PRIMER PUMP
23. INTAKE MANIFOLD
24. FUEL FILTER
25. AIR INLET
26. INJECTOR LINE
FINAL FUEL FILTER REPLACEMENT

(CUMMINS QSB 3.3L ENGINE)
CAUTION
Replace the fuel filter at specified intervals to pre-

diesel fuel flow.
1. Close any OEM fuel valves (if applicable) to pre-

vent fuel from draining.
2. Clean the area around the fuel filter head.
CAUTION
Drain the fuel into a container and dispose in
accordance with local environmental regula-
Figure 30. Cummins QSB 3.3L Engine Fuel tions.
System
3. Remove the fuel filter.
4. Clean the gasket surface.
5. Fill the new fuel filter with clean fuel, and lubri-
cate the gasket with clean engine oil.
38
6. Install fuel filter.

WARNING
7. Start engine and check for leaks around the fuel The pressure spray released by the fuel injec-
filter. tors can penetrate the skin and cause serious
personal injury. Wear clothes and protective
PRIMING THE FUEL SYSTEM (CUMMINS clothing.
4.5L AND QSB 3.3L ENGINE)
5. Crank the engine until fuel is expelled from the
Controlled Venting loosen fittings. Tighten the injector line fittings
while cranking. The engine should fire.
CAUTION
When using the starting motor to vent the sys-
CAUTION
tem, do not engage it for more than 30 seconds, Disposal of lubricants and fluids must meet lo-
or starter motor damage will occur. Wait 2 min- cal environmental regulations.
utes before engaging the starter again.
6. Wipe up any fuel that may have spilled and dis-
Controlled venting is provided at the injection pump pose of the fuel and rags in accordance with local
through the fuel drain manifold. Small amounts of directives.
air introduced by changing the filters or injection
pump supply line will be vented automatically if the DRAIN TAR FROM LPG REGULATOR
fuel filter element is changed and filled prior to in- 1. Warm engine to operating temperature.
stallation.
2. Shut fuel valve off and run engine until the en-
Manual Bleeding gine runs out of fuel and stops.
Manual Bleeding will be required if one of the follow- 3. Raise the hood.
ing conditions exist.
• The fuel filter is not filled prior to installation. 4. Remove tar drain screw from regulator. Allow tar
• The fuel injection pump is replaced. to drain from regulator. When tar has completely
• The high pressure fuel line connections are loos- drained, install tar drain screw in regulator. See
ened, or lines are replaced. Figure 31.
• It is an initial engine start up after an extended
period of no engine operation.
If equipped with electronic fuel pump (Cummins

QSB 3.3L), with the accelerator pedal or lever in the
idle position, turn the key to the ON position. Wait
for the "Wait to Start" light to go out. Start the truck.
If the engine does not start after 3 attempts, check

fuel supply system. The lack of blue or white smoke
indicates the lack of fuel being supplied to the engine.
1. Crack open the fuel line to the injector pump. See

Figure 29.
2. Operate the hand lever until fuel is expelled from

the loosened fitting.
3. Tighten the fuel line to the injector pump to

9 N•m (80 lbf in). See Figure 29.
4. Crack open one of more of the injector lines lo- 1. TAR DRAIN SCREW
cated on the cylinder head.
Figure 31. GM LPG Regulator
39
DRIVE BELT Legend for Figure 33
GM 4.3L Engine NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING

TENSIONERS.
Fan and Alternator Drive Belt
1. FAN PULLEY
Check drive belt for wear and damage. See Figure 32. 2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY
A few small cracks that run across belt are accept- 4. SERPENTINE BELT
able. A belt with cracks that run length of belt or a 5. TENSIONER CENTERING PULLEY
belt with missing pieces is not acceptable. See Fig- 6. ALTERNATOR PULLEY
ure 33 for the drive belt arrangement.
DRIVE BELT
Cummins 4.5L and QSB 3.3L Diesel
Engine
Fan and Alternator Drive Belt
Check drive belt for wear and damage. See Figure 34.
A few small cracks that run across belt are accept-
able. A belt with cracks that run length of belt or a
belt with missing pieces is not acceptable. See Fig-
ure 35 and Figure 36 for the drive belt arrangement.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 32. Drive Belt Inspection
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 34. Drive Belt Inspection
Figure 33. GM 4.3L Drive Belt Arrangement
40

1. ALTERNATOR BELT ADJUSTMENT BRACKET
2. DRIVE BELT
3. CAMSHAFT PULLEY
5. ALTERNATOR PULLEY
CLEAN DEBRIS FROM RADIATOR CORE

Check the radiator core for restrictions and remove
material causing radiator core to be plugged or re-
stricted.
WARNING
Compressed air can move particles so that they
goggles or a face shield to prevent injury to the
eyes.
NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD- Clean with compressed air, adjusted to a maximum
JUSTING TENSIONERS. output of 103 kPa (15 psi), and blow debris from core
and fan shroud.
1. ALTERNATOR PULLEY
2. CAMSHAFT PULLEY TRANSMISSION OIL LEVEL
3. WATER PUMP PULLEY
5. TENSIONER CENTERING PULLEY WARNING
At operating temperature, the transmission oil
Figure 35. Cummins 4.5L Diesel Engine Drive is HOT. Do not permit the hot oil to touch the
Belt Arrangement skin and cause a burn.
CAUTION
Do not permit dirt to enter the transmission
when the oil level is checked or the filter is
changed.
If engine has been running, the engine must be shut

down for one minute or longer prior to checking the
oil level (see Figure 37). 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.
Figure 36. Cummins QSB 3.3L Diesel Engine

Drive Belt Arrangement
41
1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 37. Transmission and Hydraulic Oil Check
WET BRAKE CENTER BODY OIL LEVEL 1. Remove the center body fill/level plug. See Fig-
CHECK ure 38 for lift truck models S4.0, 4.5, 5.50FT;
S5.5FTS (G004) and Figure 39 for lift truck
models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
WARNING
H5.0-5.5FT (N005, P005).
At operating temperature, the center section
oil is HOT. Do not permit the hot oil to touch 2. Visually check oil level. If necessary, add oil at
the skin and cause a burn. the fill/level port until the oil/fill level port has
overflowed. The Correct oil is shown in the Main-
CAUTION tenance Schedule.
Do not permit dirt to enter the center body 3. Install center body oil/level fill level plug and
when the oil level is checked. Dirt will contam- tighten to 30 to 50 N•m (22 to 37 lbf ft).
inate the oil and cause damage to the center
body of the axle.
42
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER SECTION DRAIN PLUG
4. CENTER SECTION FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER SECTION B. FRONT VIEW SHOWN
Figure 38. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
S4.0, 4.5, 5.50FT; S5.5FTS (G004) PLUGS
3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
Figure 39. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
(N005, P005)
43
FORKS NOTE: When lubricating the mast mounting/pivot

pins, the load must be removed from the normal
WARNING contact surface to allow grease to properly lubricate
the normal contact surfaces of the mast bushings
Never repair damaged forks. Do not heat, weld,
or bend the forks. Forks are made of special 2. Raise the carriage about 61 cm (2 ft), and tilt the
steel using special methods. Replace damaged mast fully back. Place blocks under the outer
forks as a complete set. mast channels to within 13 mm (0.5 in.) of the
channels See Figure 41.
Measure thickness of forks with a fork arm caliper
(Hyster Part No. 3020387) at a vertical section where 3. Tilt the mast fully forward. See Figure 41.
there is no wear. This thickness is dimension X. Now
measure thickness at heel of fork (see Figure 15). If
the thickness of the heel is not greater than 90% of
dimension X, replace fork.
MAST LUBRICATION
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: The load rollers and sheaves have sealed bear-

ings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller sur-

faces along full length of channels as shown in
Figure 40.
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS A. MAST TILTED FULLY BACK
B. MAST TILTED FORWARD
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES 1. BLOCK 2. MAST
3. LOAD ROLLER
Figure 41. Blocking the Mast
Figure 40. Mast Lubrication
44
4. Lubricate the mast pivot bushings at grease fit- 6. If a sideshift carriage is installed, lubricate slid-
tings on outer mast. See Figure 42 and Figure 43. ing surfaces at grease fittings with multipurpose
Use multipurpose grease shown in the Mainte- grease shown in the Maintenance Schedule. See
nance Schedule. Figure 44.
5. Tilt mast fully back. Remove the blocks from un-

der the channels
1. MAST HANGER BUSHINGS 7. CAPSCREW

2. LUBE FITTINGS 8. NUT
3. MAST BUSHING PLUGS 9. WASHER
4. TILT PIN 10. ROD END BUSHING
5. ROD END 11. TILT CYLINDER ASSEMBLY
6. ANCHOR PIN 12. MAST MOUNTING CAP
Figure 42. Mast Mounting Hanger Lubrication
45
1. OUTER MAST 2. MAST PIVOT BUSHING 3. LUBRICATION FITTING
Figure 43. Pivot Pin Lubrication

1. CAPSCREWS 6. GREASE FITTINGS
2. LOWER HOOK 7. CYLINDER ROD
3. APRON 8. SNAP RING
4. LOWER BEARING 9. ROD SCRAPER
STRIPS 10. ROD BUSHING
5. UPPER BEARING 11. SEAL
STRIPS 12. FIXED FRAME
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/re-
place hose/components as necessary.
Figure 44. Integral Sideshift Carriage
46
LIFT CHAIN LUBRICATION Lubricate lift chains with SAE 30 engine oil. The best
procedure is to remove the chains from the lift truck
WARNING 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.
section.
TILT CYLINDER LUBRICATION
Do not repair worn or damaged lift chains. If a
NOTE: The floor plate must be removed in order to
lift chain is worn or damaged, both lift chains
lubricate the rear tilt cylinder lubrication fittings.
must be replaced.
Lubricate the tilt cylinder ends. Use multipurpose
NOTE: The 500 Hour/6 Months Lift Chain Lubrica-
grease shown in the Maintenance Schedule. There
tion should not be performed in combination with the
are four lubrication fittings. See Figure 45.
1000 Hour/6 Months Lift Chain Lubrication.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 3. ANCHOR PIN 5. TILT SPACER
2. RETAINER 4. LUBRICATION FITTING
Figure 45. Tilt Cylinder Lubrication
47
MASTER BRAKE CYLINDER ROD END MANUAL HYDRAULIC LEVERS

PIN LUBRICATION LUBRICATION
Lubricate the master brake cylinder rod end pin. Use Lubricate the bushings for the manual hydraulic
engine oil shown in the Maintenance Schedule. See levers. Use spray lubricant as listed in the Mainte-
Figure 46. nance Schedule. See Figure 47.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 46. Master Brake Cylinder Rod End Pin

Lubrication
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 47. Manual Hydraulic Levers

Lubrication
48
BRAKE OIL Legend for Figure 48

1. RESERVOIR CAP
WARNING 2. BRAKE OIL RESERVOIR
Small amounts of water in the brake system 3. RESERVOIR MOUNTING BRACKET
can cause reduced braking performance if the 4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
water reaches the wheel cylinder areas. Do 6. CYLINDRICAL BLOCK OUTLET FITTING
not allow water entry. Ensure that the sealed 7. LOWER BRAKE OIL SUPPLY HOSE
reservoir lid is properly replaced. 8. NIPPLE
9. MASTER CYLINDER
Replace the brake oil in the system if there is 10. CYLINDRICAL BLOCK DRAIN PLUG
dirt or water in the system. 11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
CAUTION
Do NOT use "DOT" fluid, only use Dexron III TIE ROD LUBRICATION FOR LIFT TRUCK
oil from sealed container to prevent possible MODELS S4.0, 4.5, 5.50FT; S5.5FTS (G004)
damage to the brake system.
Lubricate the tie rods. Use multipurpose grease
Remove the dash board from the cowl. The brake oil shown in the Maintenance Schedule. There is one
reservoir is located on the cowl, at the master cylin- lubrication fittings on each tie rod. See Figure 49.
der. See Figure 48. Add brake oil, as necessary. Use
the brake fluid shown in the Maintenance Schedule.
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE)
Figure 49. Tie Rod Lubrication for Lift Truck

Models S4.0, 4.5, 5.50FT; S5.5FTS (G004)
Figure 48. Brake Oil Reservoir
49
TIE ROD LUBRICATION FOR LIFT

TRUCK MODELS H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (N005, P005)
Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There is one
lubrication fittings on each tie rod. See Figure 50.
1. DRIVE AXLE
2. CHECK/FILL PLUG
3. DRAIN PLUG
Figure 51. Drive Axle (Dry Brake) Fluid Fill

for Lift Truck Models S4.0, 4.5, 5.50FT; S5.5FTS
(G004)

2. LUBRICATION FITTING (SPINDLE)
3. STEERING AXLE
Figure 50. Tie Rod Lubrication for Lift Truck

Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (N005, P005)
DIFFERENTIAL AND DRIVE AXLE OIL,

LIFT TRUCK MODELS WITH DRY BRAKES
The differential and drive axle use the same oil sup-
ply. 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 1. CHECK/FILL PLUG
level by sticking a finger into the fill hole to feel if the 2. DRAIN PLUG
fluid level is at the bottom edge of the fill hole. See 3. DRIVE AXLE
Figure 51 and Figure 52. If oil is low, add oil shown Figure 52. Drive Axle (Dry Brake) Fluid Fill
in the Maintenance Schedule until the oil level is be- for Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
tween 0 to 10 mm (0 to 0.40 in.) below the bottom H4.5FT6; H5.0-5.5FT (N005, P005)
edge of fill hole. Install fill plug and check for leaks.
50
Maintenance Procedures Every 1000 Hours or 6 Months

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

ADJUST
The GM 4.3L engine has hydraulic valve lifters and
does not require valve clearance adjustments during
normal service.
See the Maintenance Schedule for valve clearances.
Additional engine information is available in the fol-

lowing sections:
• GM Engines, 4.3 Liter V-6 600 SRM 1251
•
IGNITION SYSTEM
GM 4.3L Engine
The GM 4.3L gasoline and LPG engines have an elec-
tronic 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 0.9 mm (0.035 in.).
1. BOLT
2. SEAL WASHER
LPG FUEL FILTER ELEMENT REPLACE, 3. FUEL FILTER HOUSING TOP SECTION
GM 4.3L ENGINE 4. FUEL FILTER
5. FUEL FILTER O-RING
Remove 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
WARNING Figure 53. Fuel Filter Removal and Installation

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area. 4. Remove top section of fuel filter housing.
1. Close fuel valve on tank. Run engine until it 5. Remove and discard housing O-ring.
stops. 6. Remove fuel filter and fuel filter O-ring.
2. Disconnect negative battery cable.
Install
WARNING 1. Clean and inspect the fuel filter housing for con-
A small amount of fuel may still be present in tamination or damage.
the fuel line. Use gloves to prevent burns and
2. Install the new fuel filter and fuel filter O-ring.
wear eye protection. If liquid fuel continues
See Figure 53.
to flow from the connections when loosened,
check to make sure the manual valve is fully 3. Install new housing O-ring.
closed.
4. Install top section of fuel filter housing.
3. Remove the bolt and seal washer retaining the
top section of the fuel filter housing. Discard seal 5. Install bolt and new seal washer. Tighten bolt to
washer. See Figure 53. 13 N•m (115 lbf in).
51
NOTE: Opening the fuel valve too quickly can cause Remove
the internal excessive flow valve to close, restricting
the flow of fuel. If this happens, close the fuel valve, 1. Stop Engine and allow it to cool.
wait a few seconds, and then slowly open the fuel
2. Close fuel supply valve located on the fuel send-
valve again. This will reset the excess fuel valve.
ing unit. See Figure 54.
6. Slowly open the fuel valve on tank.
7. Turn the key to the ON position and back to

CAUTION
the OFF position to pressurize the fuel system. Drain the fuel into a container and dispose in
Check for leaks. accordance with local environmental regula-
tions.
8. Check for leaks at connections by using soapy
solution or electronic leak detector. If leaks are 3. Loosen clamps and disconnect two fuel lines from
detected, make proper repairs. the in-line fuel filter. Remove and discard the
in-line fuel filter
IN-LINE FILTER REPLACEMENT,
Install
CUMMINS 4.5L ENGINE
1. Install in-line fuel filter by connecting the two
CAUTION fuel lines and tighten clamps. See Figure 54.
2. Open the fuel supply valve.
3. Check for fuel leaks.
Replace the fuel filter at specified intervals to pre-
diesel fuel flow.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. IN-LINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
52
Figure 54. Cummins 4.5L Engine Fuel System
53
LIFT CHAINS WEAR CHECK cleaning solvents, always follow the recom-
mendations of the manufacturer.
If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re- Compressed air can move particles so they
placed. Measure chain for wear where it moves over cause injury to the user or to other personnel.
sheaves. Using a chain scale, Hyster P/N 871796 Make sure that the path of the compressed air
check lift chains as shown in Figure 55. is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
the eyes.
Remove the lift chains. Clean the lift chains by soak-

ing 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 en-

gine 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.
INTEGRAL SIDESHIFT CARRIAGE, CHECK

SLIDING SURFACES
1. Check the sideshift carriage sliding surfaces,
and if necessary lubricate sliding surface at the
grease fittings with multipurpose grease shown
in the Maintenance Schedule. See Figure 56.
Pitch Wear Limit
Total Length
(The
of 20 Links
Maximum
(Pitch) of New
Length of 20
Chain
Links)
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
1. CHAIN WEAR SCALE

1. CAPSCREWS 6. GREASE FITTINGS
Figure 55. Lift Chains Check 2. LOWER HOOK 7. CYLINDER ROD
3. APRON 8. SNAP RING
LIFT CHAIN LUBRICATION 4. LOWER BEARING 9. ROD SCRAPER
STRIPS 10. ROD BUSHING
5. UPPER BEARING 11. SEAL
WARNING STRIPS 12. FIXED FRAME
Cleaning solvents can be flammable and toxic Figure 56. Integral Sideshift Carriage
and can cause skin irritation. When using
54
STEERING AXLE (SPINDLE BEARINGS)

FOR LIFT TRUCK MODELS S4.0, 4.5,
5.50FT; S5.5FTS (G004)
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side of
the steering axle. See Figure 57. Use multipurpose
grease as shown in the Maintenance Schedule.

2. LUBRICATION FITTING (SPINDLE BEARINGS)
3. STEERING AXLE
Figure 58. Lubricate Spindle Bearings for

Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
1. STEERING AXLE H4.5FT6; H5.0-5.5FT (N005, P005)
3. LUBRICATION FITTING (SPINDLE BEARINGS) INSPECT ENGINE ELECTRICAL SYSTEM,
CONNECTORS
Figure 57. Lubricate Spindle Bearings for Lift
Truck Models S4.0, 4.5, 5.50FT; S5.5FTS (G004) When inspecting the electrical system, check the fol-
lowing:
STEERING AXLE (SPINDLE BEARINGS)
FOR LIFT TRUCK MODELS H4.0FT5/FT6; • Check and clean battery connection. Ensure that
H4.5FTS5, H4.5FT6; H5.0-5.5FT (N005, connections are tight.
• Check battery for damage or cracks to the case.
P005) Replace if necessary.
Lubricate the spindle bearings on the steering axle. • Check positive and negative cables for corrosion,
There are four lubrication fittings, two on each side of rubbing, and chaffing. Tighten connections at both
the steering axle. See Figure 58. Use multipurpose ends.
grease as shown in the Maintenance Schedule. • Check engine wire harness for rubbing, chaffing,
pinching, and cracks or breaks in the wiring.
CONTROL LEVERS AND PEDALS • Check engine harness connectors. Check to ensure
connectors are fitted and locked by pushing the
Lubricate linkages, pedal shafts, control cables connectors together. Pull on the connector halves
(throttle, hood, parking brake), and seat rails. Use a to make sure they are locked.
silicone spray lubricant, Hyster Part No. 328388. • Check ignition coil wire and spark plug wires for
hardening, cracking, arching, chaffing, separation,
split boot covers, and proper fit. Replace spark
55
Maintenance Procedures Every 2000 Hours or Annually 8000 SRM 1248
plugs at the recommended interval as shown in the • Check the MIL, charging, and oil pressure lights
Maintenance Schedule. for operation by starting the engine and checking
• Check that all electrical components are securely that the light illuminates before turning out.
mounted and retained to the engine or chassis.
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 500-hour, and 1000-hour 2. Remove the hydraulic filter element and O-ring
checks prior to performing the procedures in this sec- from the bowl and place into the container. Cover
tion. the head to prevent any foreign materials from
getting into the hydraulic tank.
HYDRAULIC SYSTEM
3. Lubricate new O-ring with hydraulic oil and in-
Hydraulic Filter, Replace stall it on the bottom of the new filter element.
Install the new filter element into the bowl.
WARNING 4. Install spring and filter lid onto head.
At operating temperature, the hydraulic oil is
HOT. Do not permit the hot oil to touch the skin
CAUTION
and cause a burn.
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
CAUTION ter dealer.
tem when the oil level is checked or the filter 5. Start the truck, and allow it to run for 30 seconds.
is changed. Dirt can cause damage to the com- Check for leaks. Stop engine and check hydraulic
ponents of the hydraulic system. oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
Never operate the hydraulic pump without oil the hydraulic oil, see Hydraulic Oil, Replace.
hydraulic pump without oil will damage the Hydraulic Tank Breather, Replace
pump.
1. Raise the hood and remove the right rear side
panel. See Figure 60.
CAUTION
Disposal of lubricants and fluids must meet lo- 2. Unscrew and remove old hydraulic tank
cal environmental regulations. breather, and replace with new hydraulic tank
breather.
1. Put lift truck on a level surface and lower the car-
riage. Unscrew and remove filter lid and spring 3. Install right rear side panel and close hood. See
from head. See Figure 59. Lift the hydraulic fil- Figure 60.
ter element enough to allow the hydraulic oil to
drain.
NOTE: Have container large enough to hold the filter

element and allow for final hydraulic oil draining.
56
8000 SRM 1248 Maintenance Procedures Every 2000 Hours or Annually
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK BREATHER
Figure 60. Hydraulic Tank Breather
IGNITION SYSTEM; DISTRIBUTOR CAP,

ROTOR, AND SPARK PLUG WIRES
NOTE: Make sure the key is in the OFF position and
the negative battery cable has been removed from the
battery before removing the ignition system.
Remove and discard spark plug wire assembly, coil

wire, spark plugs, distributor cap, and rotor. For
procedures see High Voltage Switch (HVS) Igni-
tion, GM 4.3L EPA Compliant Engines 2200 SRM
1097 for Spark Plug Wire Remove/Install, Distribu-
1. LID 6. FITTING
2. SPRING 7. QUAD RING tor Cap Removal/Installation, and Rotor Disassem-
3. O-RING 8. FILTER ELEMENT ble, Ignition Coil Wire Removal, and Spark Plug Re-
4. CAPSCREW 9. BOWL placement.
5. HEAD
Figure 59. Hydraulic Filter
57
COOLING SYSTEM, GM 4.3L AND as needed. Coolant level should be between the
CUMMINS 4.5L AND QSB 3.3L ENGINES ADD and FULL marks on the reservoir.
1. Put lift truck on a level surface. Stop engine. AIR FILTER

Place a container with a minimum capacity of
15.1 liter (15.9 qt) under the radiator drain valve The air filter canister should not be opened until an
which could be located on either the lower left or air filter element replacement is required. An air
right side of the radiator on the engine side of the filter element replacement is required when one of
radiator. the following occurs:
• The optional air flow restriction indicator light on
the dash illuminates
WARNING • The optional manual air flow indicator button pops
DO NOT remove the radiator cap from the ra- up
diator when the engine is hot. When the radi- • The specified number of hours has passed since the
ator cap is removed, the pressure is released last filter element replacement
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 en- CAUTION
gine is running. Do not to allow dirt to enter the engine air in-
take when replacing the air filter element. A
small amount of dirt could cause engine dam-
CAUTION age.
cal environmental regulations. 1. Shut off the engine. Never open the air filter can-
ister or remove the filter element with the engine
2. Open drain valve and remove radiator cap. Drain running.
coolant into the container. Flush cooling sys-
tem. Check hoses for damage. Replace with new 2. Unlatch and remove the cover. To remove filter
hoses, as needed. element, press and rotate filter element counter-
clockwise about 1/8 turn until the filter element
3. Disconnect the hose leading from the auxiliary is free. To assist removal, gently move the end
reservoir to fitting at the top of the radiator un- back and forth to help break the seal. See Fig-
der the radiator cap, and drain the reservoir into ure 61.
the same container used for the radiator coolant.
Check the reservoir for contaminants and flush, 3. Gently pull the filter element from the canister.
as necessary. Connect the hose back on the fit- Avoid dislodging contaminants from the element
ting at the top of the radiator. or knocking it against the canister.
4. With a clean, soft rag, clean the inside surface of

CAUTION the canister. Remove the liner assembly to make
Additives may damage the cooling system. Be- cleaning easier. Clean well around the locking
fore using additives, contact your local Hyster tabs that retain the element. Clean tabs make
dealer. new filter element installation easier. Be careful
not to knock any contaminants into the outlet
4. Close drain valve. Fill cooling system with the tube to the engine.
correct coolant mixture of 50% water and 50%
ethylene glycol boron-free antifreeze. Fill the 5. Inspect the liner and O-ring assembly for dam-
auxiliary reservoir to a level between the ADD age. If damaged, replace the liner and O-ring as-
and FULL marks on the reservoir. sembly.
5. Install radiator cap. Start engine. Check for
leaks. Add coolant to auxiliary coolant reservoir
58
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 61. Air Filter
6. Install the liner assembly into the canister by

pushing in. Make sure the liner assembly is
properly seated in the canister. It will fit snugly
into and be centered in the canister.
If your air filter assembly is equipped with a sec-

ondary element in place of the liner assembly, re-
place the secondary element with every 2 to 3 pri-
mary element replacements.
7. Inspect the new filter element for voids, cuts,

tears or indentations in the urethane-sealing
surfaces. Do not use if damage is detected.
1. PUSH IN 2. TWIST TO LOCK
CAUTION Figure 62. Air Filter Label
The element must be properly installed to en-
sure adequate engine protection. An improp-
erly installed element may allow dirt and dust CAUTION
to enter and damage the engine. During cover installation, do not force the
cover on the canister. To do so will result in
NOTE: Proper element installation is required to al- damage to the filter element, cover, and possi-
low the cover to be installed correctly. Never reinstall bly the canister.
a used element. Never install a damaged element.
Always use a Hyster-approved filter element. NOTE: If the filter element is properly installed, the
cover will fit easily into the canister with no gap be-
8. Install the new filter element into the canister. tween the cover and the canister. If the cover does
Press and rotate the filter element 1/8 turn clock- not fit easily, the filter element is not installed prop-
wise until fully engaged in the canister. See Fig- erly. Do not use a cover that is bent, damaged, or
ure 62. missing latches.
9. Install the cover into the canister and ensure the

INLET arrow is in line with the canister inlet.
59
NOTE: Do not use the latches to pull the cover down 3. Remove the inlet fitting from the LPG regulator.
against the canister. If the cover does not fit com- Discard the O-ring. See Figure 64.
pletely against the canister with no gaps, the element
is not installed correctly.
10. Fasten the latches to secure the cover to the can-

ister. 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. Re-
place damaged hoses. Inspect the dust evacua-
tion valve for damage. If damaged, replace the
dust evacuation valve.
OXYGEN SENSOR
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 63.
1. LPG REGULATOR 6. PAPER FILTER

2. INLET FITTING 7. RUBBER WASHER
3. O-RING 8. SCREWS
4. PLASTIC CAP 9. OUTLET FITTING
5. FOAM FILTER 10. SCREEN
Figure 64. GM LPG Regulator
4. Remove and discard the plastic cap, foam filter,

paper filter, and rubber washer from the LPG
regulator.
1. OXYGEN SENSOR
2. ELECTRICAL CONNECTOR 5. Disconnect the hose from the outlet fitting. Re-
3. EXHAUST PIPES TO EXHAUST MANIFOLD move three screws and the outlet fitting from the
LPG regulator. Discard the O-ring.
Figure 63. Oxygen Sensor Location for
Lift Truck Models H4.0FT5/FT6; H4.5FTS5, 6. Remove and discard the screen from the LPG reg-
H4.5FT6; H5.0-5.5FT (N005, P005) and S4.0, 4.5, ulator.
5.50FT; S5.5FTS (G004)
Install
LPG REGULATOR FUEL FILTER, GM
1. Install a new screen in the LPG regulator.
ENGINE
2. Install a new O-ring on the outlet fitting. Using
Remove three screws, install the outlet fitting on the LPG
regulator.
1. Close shutoff valve on tank. Run engine until it
stops. 3. Install new rubber washer, paper filter, foam fil-
ter, and plastic cap in the LPG regulator.
2. Disconnect the hose from the inlet fitting.
60
4. Install new O-ring on the inlet fitting. Install NOTE: Change the transmission oil filter at the first
inlet fitting into the LPG regulator and connect 100 hours of operation on new lift trucks. See Fig-
hose to the inlet fitting. ure 65. Before removing the oil filter, make a hole
at the top of the filter and allow five minutes for the
5. Open shutoff valve on LPG tank and check for oil to drain down into the transmission. This will re-
leaks. duce the oil that will run out of the filter and onto the
transmission when the filter is removed.
LPG FUEL INJECTOR, GM ENGINES
1. The drain plug for the transmission is on the
For removal and cleaning instructions, see the sec- lower right side of the cover of the transmission,
tion LPG Fuel System, GM 4.3L Engine 900 SRM toward the rear of the lift truck. Remove drain
1242. plug, spring, and screen. See Figure 65. Drain oil
into a container. when oil is completely drained,
FUEL INJECTOR, CUMMINS 4.5L AND install drain plug.
QSB 3.3L ENGINE
For removal and cleaning instructions for lift WARNING
truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Cleaning solvents can be flammable and toxic
H5.0-5.5FT (N005, P005) equipped with the Cum- and can cause skin irritation. When using
mins 4.5L or QSB 3.3L diesel engine, contact your cleaning solvents, always follow the solvent
local Hyster dealer or see Hyster Hypass Online. manufacturer’s recommended safety proce-
dures.
FORKS
Compressed air can move particles so they
WARNING
Make sure the path of the compressed air is
Never repair damaged forks. Do not heat, weld, away from all personnel. Wear protective gog-
cut, drill, or bend the forks. Forks are made gles or a face shield to prevent injury to the
of special steel using special methods. Replace eyes.
damaged forks as a set.
2. Clean screen with cleaning solvent, and dry with
Check heel and attachment points of forks with a compressed air, adjusted to a maximum output
penetrant or by magnetic particle inspection. of 103 kPa (15 psi).
TRANSMISSION OIL AND FILTER (DRY 3. When oil has drained, first install screen, then
BRAKE), REPLACE spring, and drain plug.
4. Remove and discard transmission breather.

WARNING Install new transmission breather and hand
At operating temperature, the transmission oil tighten.
skin and cause a burn. 5. Remove and discard old oil filter. Apply clean oil
to gasket of new filter. Install new filter and hand
tighten.
CAUTION
Do not permit dirt to enter the transmission 6. Add oil to transmission at the dipstick tube. The
when the oil level is checked or the filter is correct oil is shown in the Maintenance Schedule.
changed. Dirt can cause damage to the trans-
mission components.
CAUTION
61
TRANSMISSION AND WET BRAKE

PLANETARY CARRIER HOUSING OIL
CHANGE
WARNING
The oil used for the wet brake drive axle or
transmission should not be contaminated. If ei-
ther the wet brake planetary carrier housings
and/or transmission oil becomes contaminated,
the oil must be drained and replaced with new
oil.
WARNING
At operating temperature, the transmission
and wet brake planetary carrier housing oil
CAUTION
NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF Do not permit dirt to enter the transmission or
CLARITY. wet brake planetary carrier housing when the
oil level is checked or the filter is changed. Dirt
1. TRANSMISSION will contaminate the oil and cause damage to
2. TRANSMISSION DRAIN PLUG the transmission and wet brake planetary car-
3. SPRING
4. SCREEN rier housing components.
5. TRANSMISSION OIL FILTER
7. TRANSMISSION BREATHER CAUTION
Figure 65. Transmission Oil Change cal environmental regulations.
7. Start and run the engine for approximately 5 NOTE: Change the transmission oil filter at the first
minutes after fill to allow oil to lubricate parts 100 hours of operation on new lift trucks. See Fig-
within the transmission and wet brake portion ure 66. Before removing the oil filter, make a hole
of the drive axle center section. With the truck at the top of the filter and allow five minutes for the
in the ON position, See Maintenance Schedule oil to drain down into the transmission. This will re-
to add additional oil at the transmission dipstick duce the oil that will run out of the filter and onto the
tube that will need to be added to properly fill the transmission when the filter is removed.
wet brake portion of the drive axle center section
and transmission. 1. The drain plug for the transmission is on the
lower right side of the cover of the transmission,
8. Turn the key to the OFF position and check for toward the rear of the lift truck. Remove drain
leaks and check oil level. plug, spring, and screen. See Figure 66. Drain oil
into a container, once oil is completely drained,
9. Turn the key to the OFF position and check oil reinstall drain plug.
level. If necessary, top off oil.
62
Make sure the path of the compressed air is

away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
3. Clean screen with cleaning solvent, and dry with

compressed air, adjusted to a maximum output
of 103 kPa (15 psi).
4. When oil has drained, first install screen, then

spring, and drain plug.
NOTE: ALL MAJOR COMPONENTS AND FRAME

COMPONENTS REMOVED FOR CLARITY.
1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG
3. SPRING
4. SCREEN
5. TRANSMISSION OIL FILTER
7. TRANSMISSION BREATHER
Figure 66. Transmission Oil Change
2. Remove planetary carrier housing drain plug

and fill/level plug. Drain oil into a suitable
container. When oil is completely drained, re- A. REAR VIEW SHOWN
install drain plug and fill/level plug. Tighten B. FRONT VIEW SHOWN
to 30 to 50 N•m (22 to 37 lbf ft). For lift truck
models S4.0, 4.5, 5.50FT; S5.5FTS (G004) see 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Figure 67. For lift truck models H4.0FT5/FT6; 2. PLANETARY CARRIER HOUSING DRAIN
H4.5FTS5, H4.5FT6; H5.0-5.5FT (N005, P005) PLUGS
see Figure 68. 3. CENTER BODY DRAIN PLUG
4. CENTER BODY FILL/LEVEL PLUG
WARNING 6. PLANETARY CARRIER HOUSING (LH)
Cleaning solvents can be flammable and toxic 7. CENTER BODY
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
S4.0, 4.5, 5.50FT; S5.5FTS (G004)
dures.
Compressed air can move particles so they

63
7. Add oil to transmission at the dipstick tube. The

correct oil is shown in the Maintenance Schedule.
8. Start and run the engine for approximately 5

minutes after fill to allow oil to lubricate parts
within the transmission and wet brake plan-
etary carrier housings. With the truck in the
ON position, See Maintenance Schedule to add
additional oil at the transmission dipstick tube
that will need to be added to properly fill the
planetary carrier housings and transmission.
For lift truck models S4.0, 4.5, 5.50FT; S5.5FTS
(G004) see Figure 67. For lift truck models
(N005, P005) see Figure 68.
9. Turn the key to the OFF position and check for

leaks and check oil level.
WET BRAKE CENTER SECTION OIL

CHANGE
Remove
1. Remove the center body fill/level plug. Remov-
ing the fill/level plug will allow the oil to drain
at a faster rate. For lift truck models S4.0,
4.5, 5.50FT; S5.5FTS (G004) see Figure 67.
For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (N005, P005) see Fig-
ure 68.
A. REAR VIEW SHOWN
B. FRONT VIEW SHOWN 2. Place and empty container under the center body
drain plug.
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS 3. Remove the center body drain plug, and wait un-
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS til oil has drained completely.
3. CENTER BODY FILL/LEVEL PLUG
4. CENTER BODY DRAIN PLUG Install
6. PLANETARY CARRIER HOUSING (LH) 1. Install drain plug for the center body. Tighten
7. CENTER BODY to 30 to 50 N•m (22 to 37 lbf ft). For lift truck
models S4.0, 4.5, 5.50FT; S5.5FTS (G004), see
Figure 67. For lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (N005, P005),
see Figure 68.
(N005, P005)
5. Remove and discard transmission breather. CAUTION

Install new transmission breather and hand Before adding oil, ensure the truck is parked
tighten. and on level ground.
6. Remove and discard old oil filter. Apply clean oil 2. Add oil at the fill/level port for the center body
to gasket of new filter. Install new filter and hand until the oil/fill level port has overflowed. The
tighten. correct oil is shown in the Maintenance Sched-
ule. For lift truck models S4.0, 4.5, 5.50FT;
64
S5.5FTS (G004) see Figure 67. For lift truck

models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (N005, P005) see Figure 68.
3. Install oil fill/level plug. Tighten to 30 to 50 N•m

(22 to 37 lbf ft).
BRAKE OIL (MASTER CYLINDER),

CHANGE
1. Remove the dashboard from the cowl.
CAUTION
2. Remove the brake oil reservoir from the bracket

on the cowl. See Figure 69.
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.
1. RESERVOIR CAP 8. NIPPLE
2. BRAKE OIL 9. MASTER
CAUTION RESERVOIR CYLINDER
3. RESERVOIR 10. CYLINDRICAL
Do NOT use "DOT" fluid, only use Dexron III MOUNTING BLOCK DRAIN
oil from a sealed container to prevent possible BRACKET PLUG
damage to the brake system. 4. COWL 11. CYLINDRICAL
5. UPPER BRAKE OIL BLOCK
3. Remove the brake oil reservoir cover and cylin- SUPPLY HOSE 12. CYLINDRICAL
drical block drain plug. Pour the oil into a 6. CYLINDRICAL BLOCK MOUNTING
suitable container with a 0.35 liter (0.74 pt) BLOCK OUTLET BRACKET
FITTING CAPSCREW
minimum capacity. Install the cylindrical block 7. LOWER BRAKE
drain plug. Refill the reservoir with clean oil OIL SUPPLY HOSE
from a sealed container and install the cover on
the reservoir. The correct oil is shown in the Figure 69. Brake Oil Change
Maintenance Schedule.
4. Install the reservoir into the bracket located on

the cowl.
65
BRAKE OIL (DRY BRAKE), REMOVE replaced in complete sets. Inspect brake drums for
cracks or damage. Replace any damaged parts.
Perform the following procedure to remove used
brake oil from the remainder of the brake system.
WARNING
1. Ensure that the master cylinder reservoir is Brake linings can contain dangerous fibers.
filled with brake oil. Breathing the dust from these brake linings
is a cancer or lung disease hazard. Do not
NOTE: This procedure cannot be performed by one create dust! Do not clean brake parts with
person. compressed air or by brushing. Follow the
2. Put one end of a rubber hose on the bleed screw cleaning procedure in this section. When the
of the wheel cylinder. Put the other end of the brake drums are removed, do not create dust.
hose into a empty container. Do not sand, grind, chisel, hammer, or change
3. Loosen the bleed screw at the wheel cylinder one linings in any way that will create dust. Any
turn so that the used brake oil can be removed changes to brake linings must be done in a re-
from the brake system. Slowly push the brake stricted area with special ventilation. Protec-
pedal and hold it at the end of its stroke. Close tive clothing and a respirator must be used.
the bleed screw. Release the brake pedal. Brake cleaning procedures are as follows:
NOTE: The new brake oil will be easily recognized, as
the color will be more clear than the used oil which CAUTION
will be darker. Do not use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
4. Repeat Step 1 through Step 3 until there is new
of brake parts. Do not permit oil or grease in
brake oil in the container.
the brake fluid or on the brake linings.
5. Check the level of the brake oil in the reservoir
1. Do not release brake lining dust from brake lin-
for the master cylinder during the procedure.
ings into the air when brake drum is removed.
Make sure to keep the brake oil at the correct
level. 2. Use a solvent approved for cleaning of brake
parts to wet lining dust. Follow the instructions
6. Repeat the procedure for the other wheel cylin-
and cautions of the manufacturer for the use of
der.
the solvent. If a solvent spray is used, do not
create brake lining dust with the spray.
SERVICE BRAKES (DRY BRAKE)
3. When the brake lining dust is wet, clean parts.
Check brake lining and parts of the brake assembly
Put any cloth or towels in a plastic bag or an
for wear or damage. The minimum acceptable brake
airtight container while they are still wet. Put
lining thickness is 1.0 mm (0.040 in.). If the brake
a DANGEROUS FIBERS warning label on the
linings are worn thinner than the specification, re-
plastic bag or airtight container.
place the brake linings. See the section Brake Sys-
tem 1800 SRM 1247 for the removal and installation 4. Any cleaning cloths that will be washed must be
procedures of the drive wheels and brake drums. If cleaned so that fibers are not released into the
the brake linings or brake shoes are worn or dam- air.
aged, they must be replaced. Brake shoes must be
66
DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential can
be found in the section Drive Axle and Differential
Assembly Repair, (Dry Brake) 1400 SRM 1245.
1. Place the 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 capac-
ity of 5 liter (5.3 qt) under the differential. Re-
move the drain plug located in the bottom of the
differential and drain the oil from the differential
completely. Install the drain plug.
3. The fill hole is on the front of the differential

housing. Add oil shown in the Maintenance
Schedule until the oil level is at the lower edge of 1. CHECK/FILL PLUG
the fill hole. Install fill plug and rotate the drive 2. DRAIN PLUG
wheels in order to get oil pumped into the axle. 3. DRIVE AXLE
Remove the fill plug and check the oil level. Add
oil, as necessary. Install the fill plug and check Figure 71. Drive Axle (Dry Brake) Fluid Fill
for leaks. See Figure 70 and Figure 71. for Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (N005, P005)
TEST LPG/GAS REGULATOR PRESSURE

For more information regarding the Test LPG/GAS
Regulator Pressure, see the section LPG Fuel Sys-
tem, GM 4.3L Engine 900 SRM 1242
CHECK THROTTLE SHAFT FOR STICKING

Check Throttle body return action to ensure throttle
shaft is not sticking. Repair if necessary.
INSPECT EXHAUST MANIFOLD AND

PIPING FOR LEAKS
To check the exhaust manifold and piping for leaks,
perform the following:
• Check the exhaust manifold at the cylinder head

for leaks. Ensure that all bolts and shields are in
place.
• Check exhaust pipe fasteners to manifold for leaks
1. DRIVE AXLE to ensure they are tight. Repair if necessary.
2. CHECK/FILL PLUG
3. DRAIN PLUG • Check all exhaust pipe extension connectors for
leaks and tighten, if necessary.
Figure 70. Drive Axle (Dry Brake) Fluid Fill • Visually inspect converter for correct muffler
for Lift Truck Models S4.0, 4.5, 5.50FT; S5.5FTS mounting and tail pipe mounting.
(G004) • Check for any leaks at the inlet and outlet of the
converter.
67
VALVE CLEARANCE, CHECK AND

ADJUST FOR CUMMINS QSB 3.3L DIESEL
ENGINE
The Cummins QSB 3.3L engine does not require
valve clearance adjustments during normal service.
See the Maintenance Schedule for valve clearances.
Check the valve clearance and make adjustments as

needed. To adjust the valve clearances do the follow-
ing:
1. Align the TDC mark on the crankshaft pulley

with the engraved mark on the block. See Fig- 1. EXHAUST VALVE 4. CYLINDER 2
ure 72. 2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4
Figure 73. Cummins Valve Adjustment
3. Tighten the lock nut to 24 N•m (18 lbf in) and

measure valve lash.
4. Mark the vibration damper and rotate the crank-

shaft 360 degrees. See Figure 74.
2. DRIVE BELT
3. ENGRAVE TIMING MARK
Figure 72. Cummins QSB 3.3L TDC Mark

1. TIMING PIN 2. VIBRATION
2. Adjust ONLY the valves shown in Figure 73, by DAMPER
loosening the locknut with a wrench and adjust- Figure 74. Cummins Vibration Damper
ing the valve clearance using a screwdriver or
Allen wrench. 5. Perform Step 2 and Step 3 to adjust ONLY the
valves shown in Figure 75. See the Maintenance
Schedule for valve clearances.
68
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years

1. EXHAUST VALVE 4. CYLINDER 2
2. INTAKE VALVE 5. CYLINDER 3
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 500-hour, 1000-hour, and NOTE: Replace the hydraulic oil filter at the same
2000-hour checks prior to performing the procedures time the oil is changed.
in this section.
1. Place a container with a minimum capacity of
HYDRAULIC OIL, REPLACE 39.4 liter (42 qt) under the drain plug at the
bottom of the hydraulic tank. To drain the oil,
remove the drain plug from the bottom of the
WARNING hydraulic tank. See Figure 76. When the tank
At operating temperature the hydraulic oil is is empty, inspect the inside of the tank for any
HOT. Do not permit the hot oil to touch the skin foreign matter or possible fungus. If necessary,
and cause a burn. clean the inside of the tank in accordance with
the instructions found in the section Frame 100
CAUTION SRM 1243. When either the inspection or the
Do not permit dirt to enter the hydraulic sys- cleaning of the tank is completed, install the
tem when the oil level is checked or the filter drain plug in the bottom of the hydraulic tank.
is changed. Dirt can cause damage to the com-
ponents of the hydraulic system. CAUTION
Never operate the hydraulic pump without oil Additives may damage the hydraulic system.
in the hydraulic system. The operation of the Before using additives, contact your local Hys-
hydraulic pump without oil will damage the ter dealer.
pump. 2. Fill hydraulic tank with oil specified in the Main-
tenance Schedule.
CAUTION
3. When the oil level is correct, operate system and
check for leaks.
NOTE: Heavy-duty or contaminated applications will

require hydraulic oil change at 2000 hours.
69
Maintenance Procedures Every 4000 Hours or 2 Years 8000 SRM 1248
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 76. Hydraulic Oil Change
VALVE CLEARANCE, CHECK AND 2. Adjust ONLY the valves shown in Figure 78, by
ADJUST FOR CUMMINS 4.5L DIESEL loosening the lock nut with a wrench and adjust-
ENGINE ing the clearance using a screwdriver or Allen
wrench.
The Cummins 4.5L engine does not require valve
clearance adjustments during normal service. See 3. Tighten the lock nut to 24 N•m (18 lbf in) and
the Maintenance Schedule for valve clearances. measure valve lash.
Check the valve clearance and make adjustments as 4. Remove the timing pin. See Figure 77.
needed. To adjust the valve clearance, do the follow- 5. Mark the vibration damper and rotate the crank-
ing: shaft 360 degrees. See Figure 79.
1. Rotate the engine until it is at TDC for cylinder 6. Perform Step 2 and Step 3 to adjust ONLY the
number one (intake and exhaust valves closed). valves shown in Figure 80.
Insert timing pin. See Figure 77.
70
8000 SRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
1. INSERT TIMING PIN HERE

2. FUEL/WATER SEPARATOR FILTER
3. TIMING BELT
Figure 77. Timing Pin Location, Cummins 4.5L Diesel Engine

3. CYLINDER 1 6. CYLINDER 4 1. TIMING PIN
2. VIBRATION DAMPER
Figure 79. Cummins Vibration Damper
71
Safety Procedures When Working Near Mast 8000 SRM 1248

Safety Procedures When Working Near Mast

The following procedures must be used when inspect- • DO NOT use blocks to support the mast weld-
ing or working near the mast. Additional precautions ments nor to restrain their movement.
and procedures can be required when repairing or re- • Mast repairs require disassembly and re-
moving the mast. See the correct Service Manual sec- moval of parts and can require removal of
tion for the specific mast being repaired. the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WARNING
Mast parts are heavy and can move. Distances NOTE: If there is no power to lower the mast on lift
between parts are small. Serious injury or trucks equipped with Electronic Hydraulic System,
death can result if part of the body is hit by there is an emergency load lowering valve located
parts of the mast or the carriage. on the hoist/lower valve section of the main control
valve. See the Operating Manual for the proce-
• Never put any part of the body into or under dures to lower a load using the emergency load low-
the mast or carriage unless all parts of the ering valve.
mast are completely lowered or a safety chain
is installed. Also make sure that the power is 1. Lower mast and carriage completely. Push lift/
off and the key is removed. Put a DO NOT OP- lower control lever forward and make sure there
ERATE tag in the operator’s compartment. is no movement in the mast. Make sure all parts
• Be careful of the forks. When the mast is of the mast that move are fully lowered.
raised, the forks can be at a height to cause
an injury. OR
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
72
8000 SRM 1248 Safety Procedures When Working Near Mast
2. If parts of the mast must be in a raised position, the chain. Make sure the safety chain does
install a safety chain to restrain the moving parts not touch lift chains or chain sheaves, tubes,
of the mast. Connect moving parts to a part that hoses, fittings, or other parts on the mast.
does not move. Follow these procedures:
d. Lower the mast until there is tension in the
a. Put mast in vertical position. safety chain and the free-lift cylinder (free-
lift, three-stage, and four-stage masts only)
b. Raise mast to align bottom crossmember is completely retracted. If running, stop en-
of weldment that moves in outer weldment gine. Apply parking brake. Install a DO
with a crossmember on outer weldment. NOT REMOVE tag on the safety chain(s).
On the two-stage and free-lift mast, the
moving part is the inner weldment. On e. Install another safety chain (3/8-in. mini-
the three-stage mast, it is the intermediate mum) between the top or bottom crossmem-
weldment. See Figure 81. ber of the carriage and a crossmember on the
outer weldment.
c. Use a 3/8-in. minimum safety chain with a
hook to fasten the crossmembers together so 3. Apply parking brake. After lowering or restrain-
the movable member cannot lower. Put the ing the mast, shut off power and remove key. Put
hook on the back side of the mast. Make sure a DO NOT OPERATE tag in the operator’s com-
the hook is completely engaged with a link in partment.
73
Safety Procedures When Working Near Mast 8000 SRM 1248
Figure 81. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
74
8000 SRM 1248 Fuel Filter Water Removal

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
Fuel Filter Water Removal

NOTE: The following procedure only pertains to lift
trucks equipped with Cummins 4.5L and QSB 3.3L
diesel engines.
1. Shut off the engine.
NOTE: The drain valve is located on the bottom of

fuel filter element.
2. To access the fuel filter element and drain valve,

remove the air inlet elbow. See Figure 82.
CAUTION
Drain water/fuel into a container and dispose
in accordance with local environmental regu-
lations.
3. Turn the drain valve clockwise approximately

3 1/2 turns. Drain fuel filter until clear fuel is
visible.
CAUTION 1. AIR INLET ELBOW

Do not overtighten when closing the drain 2. FUEL FILTER ELEMENT
valve. Overtightening can damage the threads. 3. DRAIN VALVE
Close the drain valve by lifting and turning clock- Figure 82. Engine Fuel Filter Drain Valve
wise until it is hand-tight. Location (Cummins 4.5L Shown)
75
Hood Latch Check 8000 SRM 1248
Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is
The hood, hood latch, and latch striker must be fully closed after two clicks of the latch.
correctly adjusted for the correct operation of
the operator restraint system. 4. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center
1. Install hood latch on frame of hood. See Fig- of hood latch. Open hood and tighten capscrews
ure 83. Tighten capscrews so that hood latch can for latch.
still move when hood is closed.
5. Check operation of hood latch. Have an operator
2. Install latch striker in highest slot position. sit in the seat. Make sure hood is fully closed
Check that latch striker is in center of jaws of (two clicks). Also check that hood touches rubber
hood latch when hood closes. bumper. If necessary, repeat Step 4.
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME
Figure 83. Hood Latch Check
76
8000 SRM 1248 Lift Chain Adjustments
Lift Chain Adjustments

WARNING
section.
Never allow anyone 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 find hydraulic leaks by putting

your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.
During test procedures for the hydraulic sys-

1. MAST
tem, fasten the load to the carriage with chains 2. CARRIAGE
to prevent it from falling. Keep all personnel 3. FORK
away from the lift truck during the tests. 4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE THE FLOOR LEVEL.
When lift chains are correctly adjusted:
• Tension will be the same on each chain of chain Figure 84. Lift Chain Adjustments With Forks
set. Check tension by pushing on both chains at Installed
the same time.
• Chain length will be correct.
• Chains must travel freely through complete cycle.
NOTE: When chain adjustments are complete, make

sure the threads on the nuts of the chain anchors
are completely engaged. Make sure all adjustment is
not removed from the chain anchors. Chain anchors
must be able to move on their mounting.
1. When adjusting lift chains on forklift trucks

equipped with the forks installed, go to Step 2.
If forklift truck is equipped with an attachment
without forks, go to Step 3.
NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage 1. MAST

2. CARRIAGE
until bottom of the fork heel is 6 ±3 mm (0.24 3. DISTANCE FROM FLOOR TO LOWER
±0.12 in.) above floor level. See Figure 84. CARRIAGE BAR
3. Adjust chain anchors which support carriage un- Figure 85. Lift Chain Adjustment Without
til the bottom of lower carriage bar is above the Forks Installed
floor level as shown in Table 2. See Figure 85.
77
Jump-Starting the Lift Truck 8000 SRM 1248
In Table 2, the masts are divided by class. Each Table 2. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK
CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by push- touching.
ing or towing lift truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these DO NOT try to start the engine by pushing or
procedures carefully when connecting the jumper towing the lift truck. Damage to the hydraulic
cables: system can occur if engine is started by push-
ing or towing lift truck.
1. Disconnect the negative battery terminal of the
lift truck being started. 1. Always connect positive jumper cable to positive
terminal of discharged battery and negative
2. Always connect positive jumper cable to positive jumper cable to negative terminal.
terminal of discharged battery and negative
jumper cable to negative terminal. 2. Always connect jumper cable, that is the ground
cable, last.
3. Always connect jumper cable, that is the ground
cable, last. 3. Always connect jumper cables to discharged lift
truck battery before connecting them to the fully-
4. Always connect jumper cables to discharged bat- charged lift truck battery.
tery before connecting them to booster battery.
78
8000 SRM 1248 Overhead Guard Changes
Welding Repairs
and overexposure may occur without odor
WARNING warning. Should work be performed, utilize
Welding can cause a fire or an explosion. Al- good industrial hygiene practices including
ways follow the instructions in the Frame sec- removal of all paint (prime and finish coats) to
tion if a fuel or hydraulic tank must be welded. the metal around the area to be welded, local
Make sure there is no fuel, oil, or grease near ventilation, and/or supplied-air respiratory
the weld area. Make sure there is good venti- protection.
lation in the area where the welding must be
done.
CAUTION
Do not heat, weld, or bend forks. Forks are When an arc welder is used, always disconnect
made of special steel using special methods. the ground cable from the battery in the lift
The strength of the overhead guard can be re- truck. This action will prevent damage to the
duced by welding or heating. Get information alternator or the battery.
from your dealer for Hyster lift trucks before
welding on a mast. Connect the ground clamp for the arc welder as
close as possible to the weld area. This action
Forklift frames and components may be will prevent damage to a bearing from the large
painted with a catalyzed paint such as current from the welder.
polyurethane or a two-part primer. Weld-
ing, burning, or other heat sufficient to cause Some repairs require welding. If an acetylene or arc
thermal decomposition of the paint may re- welder is used, make sure procedures in previous
lease isocyanates. These chemicals are allergic WARNING and CAUTION are done.
sensitizers to the skin and respiratory tract
Overhead Guard Changes

See your dealer for Hyster lift trucks BEFORE
WARNING performing any changes to the overhead
DO NOT weld mounts for lights or accessories guard.
to the legs of the overhead guard. Changes that
are made by welding or by drilling holes that No welding or drilling on legs of overhead guard is
are too big or in the wrong location can reduce permitted as per previous WARNING.
the strength of the overhead guard.
79
Wheel and Tire Replacement 8000 SRM 1248
Wheel and Tire Replacement

GENERAL Always wear safety glasses.
The S series lift trucks have solid rubber tires (often 1. Raise lift truck as described in How to Put Lift
called cushion tires) that are pressed onto the rim. Truck on Blocks in this manual.
The H series lift trucks have pneumatic tires or solid
rubber tires that look like pneumatic tires. These 2. Remove wheel nuts and remove wheel from lift
variations in tires also cause a variation in the types truck. Lift truck wheels are heavy.
of wheels and the disassembly and assembly proce-
dures. Remove and Install Tire on Wheel
NOTE: Make sure the tires are installed on the
SOLID RUBBER TIRE, CHANGE
wheels so that the outside edges of the tire and
(S SERIES) wheel are as shown in Figure 86. Also, check the
Nameplate of the lift truck for the correct tire size
NOTE:
and tread width.
Solid rubber tires made from softer or harder ma-
1. The correct tools, equipment, and a press ring
terial can be installed as optional equipment. The
must be used for each size of wheel. Use a press
tread on the sold rubber tires can be either smooth
to push wheel from rim and tire. The capacity of
or it can have lugs. Do not mix types of tires or tread
the press must be approximately 355 to 1779 kN
on lift truck. See Figure 86.
(80,000 to 400,000 lbf). For the tire sizes, see the
Nameplate.
WARNING
The type of solid rubber tire is shown on the 2. When the drive wheels are installed on the lift
Nameplate. Make sure the Nameplate is cor- truck, tighten wheel nuts to a torque value of 618
rect for the type of tires on the lift truck. The to 680 N•m (456 to 502 lbf ft).
12000 lb. capacity solid rubber tired fork lift
3. The steering wheels are fastened to the spindle of
must be equipped with high load capacity
the steering axle with a large castle nut. Make
steering tires.
sure inner and outer bearings are correctly lubri-
Wheels must be changed and tires repaired by cated with grease. Install inner bearing assem-
trained personnel only. bly and wheel on spindle. Install outer bearing
cone and castle nut.
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER 2. WHEEL
TIRE 3. OVERHANG
Figure 86. Tires and Wheels for S4.0, 4.5, 5.50FT; S5.5FTS (G004) Lift Trucks
80
8000 SRM 1248 Wheel and Tire Replacement
Tighten castle nut up to 203 N•m (150 lbf ft) Deflate tire completely before removing the
while rotating hub in both directions to prop- wheel from the lift truck. If dual wheels are
erly seat the bearings, loosen the castle nut until used, deflate both tires. Air pressure in the
wheel hub turns freely with no end play. Tighten tires can cause the tire and rim parts to ex-
castle nut to 34 N•m (25 lbf ft). If the cotter plode, causing serious injury or death.
pin cannot be installed, loosen the castle nut to
the first position where the cotter pin can be in- Always wear safety glasses.
stalled. Install cap for bearings.
Never loosen the nuts that hold the inner and
outer wheel halves together when there is air
PNEUMATIC TIRE WITH TUBE, REPAIR
pressure in the tire.
Remove Wheels From Lift Truck 1. Put lift truck on blocks as described in How to
Put Lift Truck on Blocks at the beginning of this
WARNING section.
A solid rubber tire that is the same shape as
a pneumatic tire can be installed on a three- 2. Remove air from tire. Remove valve core to make
piece or four-piece wheel for a pneumatic tire. sure all air is out of inner tube. Push a wire
DO NOT make changes in the parts of the rim if through valve stem to make sure valve stem does
this type of solid rubber tire is installed instead not have a restriction.
of a pneumatic tire. Changes to the parts of the
3. Remove wheel nuts and remove wheel and tire
rim can cause a failure of the wheel and cause
from lift truck. Lift truck tires and wheels are
an accident.
heavy.
WARNING Remove Tire From Wheel

The type of tire and the tire pressure (pneu-
matic tires) are shown on the nameplate. Make NOTE: When you disassemble the wheels, see Fig-
sure the nameplate is correct for the type of ure 87. There are several types of wheels used on
tires on the lift truck. this series of lift trucks.
WARNING
Wheels must be changed and tires repaired by
trained personnel only.
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 87. Types of Pneumatic Wheels
81
Remove Tire From Two-Piece Wheel
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.
STEP 1.
Remove nuts that fasten wheel rims together.
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.
82
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure
in the tires can cause the tire and rim parts to explode, causing serious injury or death.
to cause an injury.
STEP 1.
Loosen tire bead from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen bead from other side of wheel rim. Remove
valve stem from wheel.
STEP 4.
Remove wheel from tire.
83
Install Wheel in Tire 1. Clean and inspect all parts of wheel. Paint any
parts that have rust or corrosion.
WARNING 2. Install new inner tube in tire. Used tubes and
Damage to the tire and wheel assembly and in- flaps can cause tire failure.
jury or death can occur if you do not do the fol-
lowing procedures: 3. Apply a rubber lubricant or a soap solution to the
• Clean and inspect all parts of the wheel be- tire bead and tube.
fore installing the tire.
• DO NOT use any damaged or repaired wheel 4. Install new tire flap.
parts.
5. Make sure rim is the correct size for tire. Lubri-
• Make sure all parts of the wheel are the cor-
cate part of wheel that contacts bead and flap.
rect parts for that wheel assembly.
• DO NOT mix parts between different types or
manufacturers of wheels. CAUTION
• DO NOT mix types of tires, type of tire tread, Do not use pneumatic-shaped, solid tires on
or wheel assemblies of different manufactur- two-piece bolt together drive wheels. Spinning
ers on any one lift truck. may occur.
Do not use a steel hammer on the wheel. Use 6. Install the three-piece or four piece wheel in the
a rubber, lead, plastic, or brass hammer to put tire a shown in Install Three-Piece or Four-Piece
parts together. Make sure the side ring is in the Wheel in Tire.
correct position. The ends of the side ring must
not touch. The clearance at the ends of the lock 7. Install the two-piece wheel in the tire as shown
ring will be approximately 13 to 25 mm (0.5 to in Install Tire on Two-Piece Wheel.
1.0 in.) after it is installed. If the clearance is
wrong, the wrong part has been used.
Install Three-Piece or Four-Piece Wheel in Tire
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause an injury.
STEP 1.
Install inner tube and rubber flap in tire.
84
STEP 2.
Install wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
STEP 3.
Turn over rim and tire. Put blocks under rim so rim
is 8 to 10 cm (3 to 4 in.) above floor. Install flange
seat (if used) and lock ring.
STEP 4.
Put lock ring in the correct position on rim. Add air
pressure to tire as described in Install Wheel in Tire.
Install Tire on Two-Piece Wheel Do not use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
WARNING parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
Wheels can explode and cause injury or death
not touch. The clearance at the ends of the lock
if the following procedures are not followed:
ring will be approximately 13 to 25 mm (0.5 to
• Clean and inspect all parts of the wheel be-
1.0 in.) after it is installed. If the clearance is
fore installing the tire.
wrong, the wrong part has been used.
• DO NOT use any damaged or repaired wheel
parts.
• Make sure all parts of the wheel are the cor- CAUTION
rect parts for that wheel assembly. Do not use pneumatic-shaped solid tires on
• DO NOT mix parts between different types or two-piece bolt together drive wheels. Spin-
manufacturers of wheels. ning may occur.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different manufactur- 1. Clean and inspect all parts of wheel. Paint any
ers on any one lift truck. parts that have rust or corrosion.
85
2. Install new inner tube in tire. Used tubes and 3. Apply a rubber lubricant or a soap solution to tire
flaps can cause tire failure. bead and tube.
4. Install new tire flap.

WARNING
Do not lubricate the tire bead with antifreeze 5. Make sure rim is the correct size for tire. Lubri-
or petroleum-based liquid. Vapors from these cate part of wheel that contacts bead and flap.
liquids can cause an explosion during inflation
or use.
Install Two-Piece Wheel in Tire
STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (130 lbf ft). Add air pressure to tire (see
nameplate).
ADD AIR TO PNEUMATIC TIRES WITH 2. Add 20 kPa (3 psi) of air pressure to tire. See
TUBE Figure 88.
3. Check that all wheel parts are correctly installed.

WARNING Hit lock ring lightly to make sure it is in the seat.
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before 4. If installation is correct, add air pressure to tire
use. When air pressure is added, use a chuck to the specified pressure.
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit 5. Check that all wheel parts are correctly installed.
the operator to stand away from the safety cage If installation is not correct, remove all air pres-
when air pressure is added to the tire. sure from tire. Remove valve core to make sure
all air pressure has been removed and then make
Do not sit or stand by the safety cage. Do not adjustments. The clearance at the ends of the
use a hammer to try and correct the position of lock ring will be approximately 13 to 25 mm (0.5
the side flange or lock ring when the tire has to 1.0 in.) when the tire has the correct air pres-
air pressure greater than 20 kPa (3 psi). sure.
1. Put tire in a safety cage.
86
(332 to 369 lbf ft). If the wheels are the two-piece

rims, make sure nuts that fasten rim halves
together are toward brake drum when they are
installed.
4. Install the valve extension bracket and tighten

the attaching nut to 8 N•m (70 lbf in). Install
the valve extension hose into the bracket. See
Figure 89.
Figure 88. Add Air to Tires
Install the Wheels

Install wheel on the hub. Tighten nuts in a cross
pattern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 618 to 680 N•m
(456 to 502 lbf ft) for steer wheel nuts. If the wheels
are the two-piece rims, make sure nuts that fasten
rim halves together are toward brake drum when
they are installed.
Dual Drive Wheels, Install

NOTE: Some lift trucks have dual drive wheels. The
following procedures describe the steps to install the
dual sets of wheels.
1. Install inner wheel on hub. If the wheels are

the two-piece rims, make sure nuts that fasten
1. TIRE
rim halves together are toward brake drum when 2. DUAL HUB ASSEMBLY
they are installed. 3. WHEEL NUT
4. WHEEL
2. Install wheel adapter spacers on the inner wheel 5. WHEEL ADAPTER SPACER
studs and tighten spacers to 100 to 125 N•m (74 6. VALVE EXTENSION
to 92 lbf ft). Install the dual hub assembly and 7. BRACKET
inner wheel nuts on the spacers and tighten the
Figure 89. Dual Drive Wheels Installation
wheel nuts to 450 to 500 N•m (332 to 369 lbf ft).
See Figure 89.
3. Install outer wheel on dual hub assembly.

Tighten nuts to a torque value of 450 to 500 N•m
87
PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be
Remove Wheels From Lift Truck used with a tube.
The main component of a TBS is a special rubber

WARNING
ring that fits inside the tire between the tire beads
Wheels must be changed and tires repaired by to ensure the air tightness of the existing wheel and
trained personnel only. the tubeless tire assembly. See Figure 87.
Deflate tire completely before removing the 1. Put lift truck on blocks as described in How to
wheel from the lift truck. If dual wheels are Put Lift Truck on Blocks at beginning of this sec-
used, deflate both tires. Air pressure in tires tion.
can cause the tire and rim parts to explode
causing serious injury or death. 2. Remove the valve cap and core to remove all air
from the tire.
Always wear safety glasses.
3. Remove the wheel nuts and remove the wheel
Never loosen the nuts that hold the inner and and tire from the lift truck. Lift truck tires and
outer wheels halves together when there is air wheels are heavy.
pressure in the tire.
Remove Tire From Wheel
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
to cause injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 87.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.
88
STEP 2.
Put wheel and tire assembly on the press. Position
the feet of the press on the loose flange. Press down
on loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel only)
from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove
it.
89
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
WARNING
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together.
WARNING
Do not lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids
can cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubri-
cate tire beads and the inside of the tire, up to the
tire shoulders. Apply lubricant to the entire under-
side of the TBS.
NOTE: If the wheel rim width is less than six inches, the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than six inches, the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve
slot. The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and remov-
ing the lubricated valve several times. If a three- or
four-piece wheel is being used, remove the valve. If
a two-piece wheel is being used, leave valve in valve
hole.
If the TBS has two-valve holes, lubricate the plastic

plug and insert into valve hole that will not be used.
90
STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in the
TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot
in the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
91
STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.
Push down on the press to depress the tire beads un-

til locking ring groove is fully exposed.
STEP 8.
Insert tire tool into the locking ring groove, and a
vise grip on other end. Remove vise grip. Release
the press and check that all component parts are
correctly positioned. Replace the valve core.
STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to ensure all components are correctly sealed. Remove
the press from wheel and tire assembly.
Add Air to Pneumatic Tubeless Tire
WARNING
Add air pressure to tires only in safety cage.
Inspect safety cage for damage before use.
When air pressure is added, use a chuck that
fastens onto valve stem. Make sure there is
enough hose to permit operator to stand away
from safety cage when air pressure is added to
tire.
Do not sit or stand by safety cage.
1. Put tire in safety cage. See Figure 90.
2. Add air to tire to the recommended air pressure

that is shown on the Nameplate. Install valve Figure 90. Add Air to Tires
cap to ensure air stays in the tire.
92
Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
Install wheel on hub. Tighten nuts in a cross pat-
tern to a torque value of 450 to 500 N•m (332 to
369 lbf ft) for drive wheel nuts and 155 to 175 N•m WARNING
(114 to 129 lbf ft) for steer wheel nuts. If wheels Wheels must be changed and tires repaired by
are two-piece rims, make sure nuts that fasten rim trained personnel only.
halves together are toward brake drum when they
are installed. Always wear safety glasses.
1. Put lift truck on blocks as described in How to

section.
2. Remove wheel nuts and remove wheel and tire

heavy.
Remove Wheel From Tire

NOTE: When you disassemble the wheels, see Figure 87. There are several types of wheels used on these series
of lift trucks.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury. Always wear safety glasses.
STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.
93
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
94
Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 87. There are several types of wheels used on these series
of lift trucks. Do not use a two-piece pneumatic wheel for solid rubber tires.
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following
procedures.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not
touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
95
STEP 3.
Remove cage and put flange seat (if used), side ring,
and lock ring in position on wheel rim. Install cage
on tire. Use press to push tire onto wheel rim so side
flange and lock ring can be installed.
STEP 4.
While the cage is holding the tire on the wheel rim,
install lock ring. Use a tire tool to make sure lock
ring is in the correct position.
SNAP-ON-TIRE, CHANGE 2. Remove wheel nuts and remove wheel and tire
heavy.
WARNING
Wheels must be changed and tires repaired by NOTE: When you disassemble the wheels, see Fig-
trained personnel only. ure 91. There are several types of wheels used on
these series of lift trucks.
Always wear safety glasses.
1. Put lift truck on blocks as described in How to

section.
96
Figure 91. Snap-On-Tire and Rim Configurations
Remove Snap-On-Tire, Solid Tire From Wheel
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury.
STEP 1.
Put a support under wheel rim. Make sure wheel rim
is at least 150 to 200 mm (6 to 8 in.) from bed of press.
STEP 2.
Put cage in position on tire. Use press to push tire
from wheel rim.
97
Install Snap-On-Tire, Solid Tire on Wheel

NOTE: When you assemble the wheels, see Figure 91. There are several types of wheels used on these series
of lift trucks. Do not use a two-piece pneumatic wheel for solid rubber tires.
WARNING
Failure to follow these procedures will cause damage to the tire and wheel assembly and can cause
an injury.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix types of tires, types of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant.
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
98
8000 SRM 1248 Adhesives and Sealants
Adhesives and Sealants

Loctite®
Hyster Part No. Description Size
Part No.
360387 222 Small Screw Threadlock (Purple) 50 ml
318702* 242 Removable Threadlock (Blue) 10 ml
226414* 271 High Strength Threadlock (Red) 10 ml
318996 277 High Viscosity Threadlock (Red) 50 ml
318650 290 Low Viscosity Threadlock (Green) 0.02 oz
251099 290 Low Viscosity Threadlock (Green) 50 ml
355844* 422 SuperBonder® Adhesive 3 ml
350830 515 Gasket Eliminator (Purple) 6 ml
313022* 515 Gasket Eliminator (Purple) 50 ml
273338* 567 Pipe Sealant with Teflon® 50 ml
318705 595 Super Flex® Silicone 100 ml
318701* 609 Retaining Compound 10 ml
341959 680 Retaining Compound 50 ml
226415 Primer T - Aerosol 6 oz
251979 767 Antiseize Compound 1 lb
360053-10 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
318700 Adhesive and Sealant Kit (Contains one each of *
items)
*Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700.
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.
99
NOTES
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100
TECHNICAL PUBLICATIONS
8000 SRM 1248 5/08 (10/07)(7/07)(3/07)(10/06)(8/06)(6/06)(4/06)(3/06) Printed in United Kingdom

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PERIODIC

PART NO. 1624760 8000 SRM 1248

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

S4.0, 4.5, 5.50FT; S5.5FTS [G004];

5. If lift trucks are equipped with a tow pin in the

A. COUNTERWEIGHT WITHOUT TOW PIN (LEADED COUNTERWEIGHT)

Figure 1. Counterweight Types

1. Put blocks on each side (front and back) of steer-

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

Figure 3. GM 4.3L LPG Trucks;S4.0, 4.5, 5.50FT; S5.5FTS (G004) Shown

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 6. Tire Check

Safety Labels or sheaves; proper tracking during operation.

1. Inspect the welds on the mast and carriage for

2. Inspect the channels for wear in the areas where

Emergency Locking Retractor (ELR) Legend for Figure 8

The following seat belt operation checks must be per-

Figure 9. Swivel Seat Controls

Hood and Seat Latches

Figure 8. Hood and Seat Check

Engine Compartment fins. Assure that air pressure, nozzle or exten-

Also check the condition of the radiator or heater WARNING

Never operate the engine without oil. The op-

After the engine has stopped, wait one minute before

Legend for Figure 11

Figure 11. Cummins 4.5L Diesel Engine

A. RIGHT SIDE FRONT VIEW B. LEFT SIDE FRONT VIEW

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

A fork can be removed from the carriage for replace-

2. Replace any damaged or broken parts that are

The air filter canister should not be opened until an

Figure 14. Hook Fork Removal

Move the fork and carriage so that the top hook on

NOTE: During the adjustment of the forks, the heel

The forks are connected to the carriage by hooks and

1. TIP ALIGNMENT (MUST BE WITHIN 3%

Integral Sideshift Carriage HOW TO MAKE CHECKS WITH ENGINE

Item Warning and Indicator Light

Figure 18. Warning and Indicator Lights

NOTE: HOOD REMOVED FOR CLARITY.

Figure 19. PDM Showing Fuses and Relays

Check the operation of the service brakes. Push on