PERIODIC

MAINTENANCE
E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) [D098/E098]

PART NO. 1596603 8000 SRM 1201

 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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 1
How to Tow Lift Truck............................................................................................................................... 1
How to Put Lift Trucks on Blocks ................................................................................................................. 2
How to Raise Drive Tires .......................................................................................................................... 2
How to Raise Steering Tires ..................................................................................................................... 3
Maintenance Schedule....................................................................................................................................... 4
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 9
General ........................................................................................................................................................... 9
How to Make Checks With Key Switch OFF ............................................................................................... 9
Tires and Wheels ....................................................................................................................................... 9
Forks .......................................................................................................................................................... 9
Remove .................................................................................................................................................. 9
Inspect ................................................................................................................................................... 10
Install..................................................................................................................................................... 10
Adjust..................................................................................................................................................... 10
Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains ........................................................... 11
Safety Labels ............................................................................................................................................. 12
Steering Column Latch ............................................................................................................................. 12
Operator Restraint System....................................................................................................................... 12
Automatic Locking Retractor (ALR) .................................................................................................... 12
Emergency Locking Retractor (ELR) ................................................................................................... 12
Battery Restraint System ......................................................................................................................... 13
Battery ....................................................................................................................................................... 14
Hydraulic System ...................................................................................................................................... 15
How to Make Checks With Key Switch ON ................................................................................................. 16
Horn, Lights, and Alarm........................................................................................................................... 16
Steering System ........................................................................................................................................ 17
Service Brakes ........................................................................................................................................... 17
Parking Brake ........................................................................................................................................... 17
Seat Brake ................................................................................................................................................. 17
Control Levers and Pedals........................................................................................................................ 17
Direction and Speed Control Pedals......................................................................................................... 17
Lift System Operation............................................................................................................................... 18
Oil Leaks.................................................................................................................................................... 18
First Service After First 100 Hours of Operation ............................................................................................ 18
Change Hydraulic Oil and Filter .................................................................................................................. 18
Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (E098) ................................................................ 18
Remove .................................................................................................................................................. 18
Install..................................................................................................................................................... 20
Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098)................................................................ 21
Remove .................................................................................................................................................. 21
Install..................................................................................................................................................... 22
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 23
Wheel Nuts..................................................................................................................................................... 23
Header Hose Checks...................................................................................................................................... 23
Mast Lubrication ........................................................................................................................................... 23
Integral Sideshift Carriage ........................................................................................................................... 26
Brake Fluid .................................................................................................................................................... 27
Other Lubrication .......................................................................................................................................... 27
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 27

©2007 HYSTER COMPANY i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Differential and Speed Reducer .................................................................................................................... 27
Lift Chains ..................................................................................................................................................... 27
Wear Check................................................................................................................................................ 27
Lubrication ................................................................................................................................................ 27
Forks............................................................................................................................................................... 28
Parking Brake................................................................................................................................................ 28
Brake Linkage Shafts.................................................................................................................................... 28
Steering Spindles and Tie Rod Ends ............................................................................................................ 29
Seat Rails ....................................................................................................................................................... 29
Seat Plate Hinges .......................................................................................................................................... 29
Electrical Inspection...................................................................................................................................... 29
Contactors.................................................................................................................................................. 29
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 31
Brake Fluid .................................................................................................................................................... 31
Hydraulic System .......................................................................................................................................... 32
Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098) .................... 32
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models E3.50-5.50XL (E70-120Z,
E100ZS) (D098) ......................................................................................................................................... 32
Remove .................................................................................................................................................. 32
Install..................................................................................................................................................... 33
Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (E098) .................... 34
Remove .................................................................................................................................................. 34
Install..................................................................................................................................................... 34
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models E3.50-5.50XL
(E70-120Z, E100ZS) (E098) ...................................................................................................................... 34
Remove .................................................................................................................................................. 34
Install..................................................................................................................................................... 34
Differential and Speed Reducer .................................................................................................................... 36
Service Brakes ............................................................................................................................................... 36
Wheel Bearings.............................................................................................................................................. 37
Steer Wheels, Lubrication ........................................................................................................................ 37
Drive Wheels, Lubrication ........................................................................................................................ 37
Lift Chains ..................................................................................................................................................... 37
Battery Maintenance ......................................................................................................................................... 37
How to Charge Battery.................................................................................................................................. 37
How to Change Battery ................................................................................................................................. 38
Safety Procedures When Working Near Mast.................................................................................................. 41
Lift and Tilt System Leak Check ...................................................................................................................... 44
Check Lift Cylinders for Leaks ..................................................................................................................... 44
Check Tilt Cylinders for Leaks ..................................................................................................................... 44
Lift Chain Adjustments ..................................................................................................................................... 45
Welding Repairs ................................................................................................................................................. 46
Overhead Guard Changes ................................................................................................................................. 47
Wheels and Tires................................................................................................................................................ 47
General ........................................................................................................................................................... 47
Remove Wheels From Lift Truck .................................................................................................................. 47
Remove Tire From Wheel and Install Tire on Wheel .................................................................................. 47
Remove....................................................................................................................................................... 47
Install ......................................................................................................................................................... 47
Install Wheels ................................................................................................................................................ 48

ii
Periodic Maintenance Table of Contents

TABLE OF CONTENTS (Continued)

This section is for the following models:

E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 1201
General
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
WARNING
DO NOT make repairs or adjustments unless
you have both authorization and training. Re-
pairs and adjustments that are not correct can
make a dangerous operating condition.
WARNING
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If re-
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from
the key switch. Disconnect the battery connec-
tor.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance for your lift
truck. The service intervals are given in both oper-
ating hours recorded on the lift truck hourmeter, and
in calendar time. The recommendation is to use the
interval that comes first.
The recommendation for the time intervals are for
eight hours of operation per day. The time intervals
must be decreased from the recommendations in the
Maintenance Schedule for the following conditions:
• If the lift truck is used more than eight hours per
day.
• If the lift truck must work in dirty operating con-
ditions.
• Poor ground conditions.
• Intensive usage at high performance levels or
other abnormal conditions will require more fre-
quent servicing.
Your dealer for Hyster lift trucks has the equipment
and trained service personnel to do a complete pro-
gram of inspection, lubrication, and maintenance. A
regular program of inspection, lubrication, and main-
tenance will help your lift truck provide more effi-
cient performance and operate for a longer period of
time.
Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service Man-
uals are available from your dealer for Hyster lift
trucks to help users who do their own maintenance.
General
HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra caution when towing a lift truck if
any of the following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be moved on a steep
grade.
If the steering pump motor does not operate,
steering control of the lift truck can be slow
and difficult. DO NOT tow the lift truck if there
is no power. Poor traction can cause the dis-
abled lift truck or towing vehicle to slide. Steep
grades will require additional brake force to
stop the lift truck.
Never carry a disabled lift truck unless the lift
truck MUST be moved and cannot be towed.
The lift truck used to carry the disabled lift
truck MUST have a rated capacity equal to
or greater than the weight of the disabled
lift truck. The capacity must be for a load
center equal to half the width of the disabled
lift truck. See the nameplate of the disabled
lift truck for the approximate total weight.
The forks must extend the full width of the
disabled lift truck. Put the weight center of
the disabled lift truck on the load center of the
forks. DO NOT damage the underside of the
lift truck.
1. The towed lift truck must have an operator.
2. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Install a chain
to prevent the carriage and mast channels from
moving.
3. If disabled lift truck is equipped with a seat
brake, remove floor plate and pull up on handle
to release seat brake. See Figure 1.
1
General
1. HANDLE
2. LIFT TRUCK FRAME
3. TRACTION MOTOR
Figure 1. Release Seat Brake
4. Tow with another lift truck of equal or larger ca-
pacity than the disabled lift truck. Install a load
of approximately half-capacity on the forks of the
lift truck that is being used to tow the disabled
lift truck. The half-capacity load will increase the
traction of the lift truck. Keep the load as low as
possible.
5. Use a towing link made of steel that fastens to
the tow pins in the counterweights of both lift
trucks.
6. Release the parking brake.
7. Tow the lift truck slowly.
2
8000 SRM 1201
HOW TO PUT LIFT TRUCKS ON BLOCKS
How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, battery, or counterweight. When the lift
truck is put on blocks, put additional blocks in
the following positions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so that
the lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so that the
lift truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that
any blocks used to support the lift truck are
solid, one-piece units.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck. See Figure 2.
2. Put the mast in a vertical position. Put a block
under each outer mast channel.
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put additional blocks under the frame behind the
drive tires.
5. If the hydraulic system will not operate, use a
hydraulic jack under the side of the frame near
the front. Make sure that the jack has a capacity
equal to at least half the weight of the lift truck.
See the Nameplate.
8000 SRM 1201 General

How to Raise Steering Tires
1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to pre-
vent movement of the lift truck. See Figure 2.
2. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at least
2/3 of the total weight of the lift truck as shown
on the Nameplate.
3. Put the jack under the steering axle or frame to
raise the lift truck. Put blocks under the frame
to support the lift truck.

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

3
Maintenance Schedule 8000 SRM 1201

Maintenance Schedule

NOTE: HYDRAULIC SYSTEM COMPONENTS SHOWN, ITEMS NUMBER 18 AND 19, ARE FOR E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098) LIFT TRUCK MODELS ONLY. SEE FIGURE 4 FOR LOCATION OF HY-
DRAULIC SYSTEM COMPONENTS FOR LIFT TRUCK MODELS E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098).

Figure 3. Maintenance Points

4
8000 SRM 1201 Maintenance Schedule

Figure 4. Hydraulic System Components, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)

Table 1. Maintenance Schedule

Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or Specification
No. 1 day 3 mo 6 mo 1 yr Quantity
1 Battery X Check Condition
See NOTE 1
2 Brake Fluid X C 0.24 liter (0.5 pt) SAE J1703
(DOT 3)
2 Brake Linkage Shafts L See NOTE 3 and Multipurpose Grease
NOTE 4 See NOTE 2
3 Restraint System X Check Condition
4 Direction/Speed X Check Operation Multipurpose Grease
Controls Lubricate as See NOTE 2
Required
X=Check C=Change L=Lubricate

5
Maintenance Schedule 8000 SRM 1201

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or Specification
No. 1 day 3 mo 6 mo 1 yr Quantity
5 Steering System and X Check Operation Multipurpose Grease
Steering Column Latch Lubricate as See NOTE 2
Required
6 Horn, Lights, Alarm X Check Operation
7 Mast, Carriage, Header X Check Condition SAE 30W Engine
Hoses, Lift Chains, Lubricate as Oil or Hyster Chain
Attachment Required and Cable Lubricant
(Hyster P/N 171350)
7 Lift Chains X Check
Adjustment and
Length
7 Lift Chains L See NOTE 3 SAE 30W Engine
Oil or Hyster Chain
and Cable Lubricant
(Hyster P/N 171350)
7 Lift Chains L Remove, Clean, SAE 30W Engine Oil
and Lubricate
8 Mast and Mast Sliding X L Check Condition Multipurpose Grease
Surfaces See NOTE 2
8 Header Hoses X Check Condition
Check Lift System X Check Operation
of the Lift System
9 Parking Brake X L Check Operation Hyster Part No.
See NOTE 4 328388
10 Fork Guides and Locks X L See NOTE 3 Motor Oil
11 Integral Sideshift L 8 Fittings Multipurpose Grease
Carriage Sliding See NOTE 2
Surfaces
E3.50-4.00XL,
E4.50XLS (E70-80Z,
E100ZS)
11 Integral Sideshift L 12 Fittings Multipurpose Grease
Carriage Sliding See NOTE 2
Surfaces
E4.50-5.50XL,
(E100-120Z)
12 Differential/Speed X C 5.2 liter (5.5 qt) Multipurpose
Reducer Gear Oil
SAE 80W-90, GL-5
X=Check C=Change L=Lubricate

6
8000 SRM 1201 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or Specification
No. 1 day 3 mo 6 mo 1 yr Quantity
13 Mast Pivots X L 2 Fittings Multipurpose Grease
See NOTE 2
14 Forks X Check Condition
15 Drive Tires X Check Condition See Parts Manual
16 Wheel Nuts X Check Torque 680 N•m (500 lbf ft)
(Drive Wheels)
17 Service Brakes X Check Operation
17 Service Brakes X Check Condition Minimum liner
thickness 1.0 mm
(0.040 in.)
18 Hydraulic Oil, Tank X C 33.3 liter (8.8 gal) ISO VG 46
Capacity See NOTE 7 Hydraulic Oil
E4.50XLS 15 C (5 F) and
(E100ZS) Above
(Short Frame)
18 Hydraulic Oil, Tank X C 39.8 liter ISO VG 46
Capacity (10.5 gal) Hydraulic Oil
E3.50-5.50XL See NOTE 7 15 C (5 F) and
(E70-120Z) Above
(Long Frame)
18 Hydraulic Oil Filter C 1 See Parts Manual
E3.50-5.50XL See NOTE 3 and
(E70-120Z) NOTE 7
(D098)
19 Hydraulic Tank C 1 See Parts Manual
Breather See NOTE 3
20 Seat (Parking) Brake X Check Operation Must hold a full
Operation Check Adjust as capacity load on a
Required 15% grade
See Brake
System 1800
SRM 338 for
Adjustment
Procedures
21 Wheel Bearings L Multipurpose Grease
See NOTE 2
22 Tie Rod Ends L 2 Fittings Multipurpose Grease
See NOTE 3 and See NOTE 2
See NOTE 5
X=Check C=Change L=Lubricate

7
Maintenance Schedule 8000 SRM 1201

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or Specification
No. 1 day 3 mo 6 mo 1 yr Quantity
22 Steering Spindle L 4 Fittings Multipurpose Grease
See NOTE 3 and See NOTE 2
NOTE 5
23 Steer Tires X Check Condition See Parts Manual
24 Contactors X Check Condition
See NOTE 6
25 Hydraulic Oil Filter C 1 See Parts Manual
E3.50-5.50XL See NOTE 3 and
(E70-120Z) NOTE 7
(E098)
Battery Restraint X Check Operation
Latch
Safety Labels X Replace if See Parts Manual
Necessary
Hinges, Levers, Pedals, X L Check Operation Use Hyster Part
Pins Lubricate as No. 328388
Required
Seat Rails X L See NOTE 4 Multipurpose Grease
See NOTE 2
Seat Plate Hinge L See NOTE 3 and Use Hyster Part
NOTE 4 No. 328388
NOTE 1: Equalization Charge is required approximately each month.
NOTE 2: Multipurpose grease with 2 to 4% molybdenum disulfide.
NOTE 3: Under dusty or dirty conditions, change or clean and lubricate more frequently.
NOTE 4: Recommended service intervals are based on a normal application in a clean environment. Appli-
cations involving contaminated environment, poor ground conditions, intensive usage at high performance
levels or other abnormal conditions will require more frequent servicing. At your request, your Hyster dealer
will advise you of the appropriate service interval, based on an application survey.
NOTE 5: For outdoor or wet floor operations, lubricate at 500 hours.
NOTE 6: Replace contact tips when the tip thickness is 30% of thickness when new.
NOTE 7: Change hydraulic oil and filter after the first 100 hours of operation.
X=Check C=Change L=Lubricate

8
8000 SRM 1201
Maintenance Procedures Every 8 Hours or Daily
GENERAL
WARNING
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If
repair is necessary, put a DO NOT OPERATE
tag in operator’s area. Remove key from key
switch.
Inspect lift truck every eight hours or daily before
use. Put lift truck on a level surface. Lower carriage
and forks and turn key to OFF position. Apply
parking brake. Remove floor plates and inspect for
leaks and conditions that are not normal. Clean
any oil spills. Make sure that lint, dust, paper, and
other materials are removed from compartments.
Make additional checks as described in How to Make
Checks With Key Switch OFF and How to Make
Checks With Key Switch ON.
HOW TO MAKE CHECKS WITH KEY
SWITCH OFF
Tires and Wheels
CAUTION
Check all drive wheel nuts after 2 to 5 hours
of operation: when new lift trucks begin op-
eration and on all lift trucks when the drive
wheels have been removed and installed.
Tighten nuts in a cross pattern to correct
torque value shown in Maintenance Schedule.
When nuts stay tight for eight hours, interval
for checking torque can be extended to 500
hours.
Inspect tires for wire, rocks, glass, pieces of metal,
holes, cuts, and other damage. Remove any object
that will cause damage. See Figure 5. Check for loose
or missing hardware. Remove any wire strapping or
other material wrapped around axle. Make sure that
drive wheel nuts are tight. Tighten drive wheel nuts
in a cross pattern to correct torque value shown in
Maintenance Schedule.
Maintenance Procedures Every 8 Hours or Daily
1. CHECK FOR DAMAGE AND REMOVE NAILS,
GLASS, METAL, AND OTHER OBJECTS
2. MAKE EDGES SMOOTH
Figure 5. Tires Check
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 35 to 180 kg (80 to 395 lb).
NOTE: Forks are to be replaced only in pairs and not
individually.
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance. Slide a hook
fork to the fork removal notch on the carriage. See
Figure 6 and Figure 7. Lower the fork onto blocks so
that the bottom hook of the fork moves through the
fork removal notch. See Figure 7. Lower the carriage
further so that the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
from the fork, or use a lifting device to move the fork
away from the carriage.
9
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1201

slots in the top carriage bar. If pin does not remain

engaged in carriage slot, replace with new pin.

1. CARRIAGE BARS 3. BLOCKS

2. HOOK FORK

Figure 6. Hook Fork Removal

Inspect

WARNING
Do not try to correct fork tip alignment by
bending the forks or adding shims. Replace
bent forks. Never repair damaged forks by
heating or welding. Forks are made of special
steel using special procedures. Replace dam-
aged forks. Forks are to be replaced only in Fork Tip Alignment
sets and not individually. Length of Forks 3% Dimension
1. Inspect the forks for cracks and wear. Check that 914 mm (36 in.) 27 mm (1.10 in.)
the fork tips are aligned to within 13 mm (0.5 in.) 1057 mm (42 in.) 32 mm (1.16 in.)
of each other (see Figure 7). Check that the bot- 1220 mm (48 in.) 37 mm (1.45 in.)
tom of the fork is not worn (Item 4 in Figure 7). 1371 mm (54 in.) 40 mm (1.56 in.)
1524 mm (60 in.) 46 mm (1.80 in.)
2. Replace any damaged or broken parts that are
used to keep the forks locked in position. 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
Install 2. CRACKS
3. LATCH DAMAGE
Move the fork and carriage so that the top hook on 4. HEEL OF FORK (MUST BE 90% OF DIMENSION
the fork can engage the upper carriage bar. Raise X)
the carriage to move the lower hook through the fork 5. CARRIAGE
6. LOAD BACKREST EXTENSION
removal notch. Slide the fork on the carriage so that 7. MAXIMUM ANGLE 93
both upper and lower hooks engage the carriage. En- 8. FORK REMOVAL NOTCH
gage the lock pin with a notch in the upper carriage
bar. Figure 7. Carriage and Forks Check

Adjust Adjust the forks as far apart as possible for maxi-

NOTE: During 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 6 and Figure 8. The lock pins
are installed through the top fork hooks and fit into
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
the carriage bar. Make sure the lock pin is engaged
in the carriage bar to lock the fork in position after
the width adjustment is made.

10
8000 SRM 1201 Maintenance Procedures Every 8 Hours or Daily

parts for cracks and wear. Make sure the parts

that fasten the sideshift carriage or attachment
to the carriage are in good condition.

6. Visually inspect hoses/fittings for hydraulic

leaks; hose cover for cuts, cracks or exposed re-
inforcement; defective/broken clamping devices
or sheaves; proper tracking during operation.
Adjust/repair/replace hose/components as neces-
sary.

7. Check that the lift chains are correctly lubri-

cated. Use SAE 30W engine oil or Hyster Chain
1. FORK 5. WEDGE
2. LOCK PIN 6. KNOB and Cable Lubricant (Hyster P/N 171350) to lu-
3. SPRING 7. LOCK PIN bricate the lift chains. Inspect the lift chains for
4. WASHER ASSEMBLY cracks or broken links and pins. See Figure 9.

Figure 8. Fork Lock Pin Assembly 8. Inspect the chain anchors and pins for cracks and
damage.
Inspection of Mast, Mast Pivots, Header
9. Make sure the lift chains are adjusted so that
Hoses and Lift Chains
they have equal tension. Adjustments or re-
placement of the lift chains must be done
WARNING by authorized personnel. See Lift Chain Ad-
NEVER work under a raised carriage or forks. justments in this section.
Lower the carriage or use chains on the mast
weldments and carriage so they cannot move.
Make sure the moving parts are attached to a
part that does not move.

Do not try to correct fork tip alignment by

bending the forks or adding shims. Replace
bent forks.

Never repair damaged forks by heating or

welding. Forks are made of special steel using
special procedures. Replace damaged forks.

1. Inspect the welds on the mast and carriage for

cracks. Make sure that the capscrews and nuts
are tight.

2. Inspect the channels for wear in the areas where

the rollers travel. Inspect the rollers for wear or
damage.
1. WORN PIN 5. LOOSE LEAVES
3. Inspect the mast pivots for proper lubrication. 2. CRACKS 6. DAMAGED PIN
Lubricate if required at the grease fittings on the 3. EDGE WEAR 7. CORROSION
pivots or pivot pins. Use multipurpose grease. 4. HOLE WEAR

4. Inspect the load backrest extension for cracks Figure 9. Lift Chain Check
and damage. See Figure 7.

5. If the lift truck is equipped with an integral

sideshift carriage or attachment, inspect the

11
Maintenance Procedures Every 8 Hours or Daily
Safety Labels
WARNING
Safety labels are installed on the lift truck to
give information about operation and possible
hazards. It is important that all safety labels
are installed on the lift truck and can be read.
Check that all safety labels are installed in correct lo-
cation on lift truck. See Parts Manual or the service
manual section Frame 100 SRM 1200 for the correct
location of safety labels and installation procedures.
Steering Column Latch
Make sure latch for steering column operates cor-
rectly. Latch must NOT allow column to move unless
latch is released.
Operator Restraint System
There is an indicator light on the display panel for
the seat belt. The red light is ON as described in the
Operating Manual. The light can help the operator
remember to fasten the seat belt.
The seat belt, hip restraint brackets, seat and seat
rails, battery restraint (seat plate), and latch are all
part of the operator restraint system. See Figure 10
and Figure 11. Each item must be checked to make
sure it is attached securely, functions correctly, and
is in good condition.
Automatic Locking Retractor (ALR)
NOTE: Lift trucks produced before November 1, 2005
are equipped with the ALR type seat belts.
The seat belt must latch securely. Make sure the seat
belt extends and retracts smoothly and is not dam-
aged or torn. If the seat belt cannot be pulled from
the belt housing, the seat belt assembly must be re-
placed. Keep the belt straight so it pulls out and re-
tracts smoothly.
Make sure the seat rails are not loose. The seat rails
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached
to the mounting surface.
12
8000 SRM 1201
NOTE: NON-SUSPENSION SEAT SHOWN.
1. HIP RESTRAINT 2. SEAT BELT
BRACKETS 3. HOOD LATCH
Figure 10. Operator Restraint System With
ALR Seat Belt
Emergency Locking Retractor (ELR)
NOTE: Lift trucks produced after November 1, 2005
are equipped with the Emergency Locking Retractor
(ELR) style seat belt.
When the ELR style seat belt is properly buckled
across the operator, the belt will permit slight op-
erator repositioning without activating the locking
mechanism. If the truck tips over, travels of a dock,
or comes to a sudden stop, the locking mechanism
will be activated and hold the operator’s lower torso
in the seat.
A seat belt that is damaged or does not operate prop-
erly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if it is damaged or worn. See Figure 11.
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 as-
sembly. Make sure the seat belt pulls out and
retracts smoothly. If the seat belt does not pull
out of the retractor assembly, the internal latch
8000 SRM 1201
may be locked. Pull firmly on the seat belt and
hold for a moment to remove slack from the belt
in the retractor. Release the seat belt. Seat belt
will retract and the internal latch will unlock. If
the seat belt cannot be pulled from the retractor
assembly or the belt will not retract, replace the
seat belt assembly.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. make sure the
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, makes sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor with
the hood in the open position, replace the seat belt
assembly.
NOTE: FULL SUSPENSION SEAT SHOWN.
1. OPERATOR WEIGHT ADJUSTMENT
2. FORWARD BACKWARD ADJUSTMENT
3. SEAT BELT
4. HIP RESTRAINT
5. SEAT
6. SEAT RAIL
Figure 11. Operator Restraint System With
ELR Seat Belt
Maintenance Procedures Every 8 Hours or Daily
Battery Restraint System
The battery restraint system is a heavy steel seat
plate that has a hinge at the front of the battery com-
partment. Spacers are used inside the battery com-
partment to prevent horizontal movement of the bat-
tery. An additional battery retention bar is used on
all models where batteries can be longer. This bar
has a hinge fastened to the counterweight and is part
of the hood mechanism on lift trucks with hoods. The
bar is also installed on lift trucks without hoods.
WARNING
The battery restraint and its latch mechanisms
must operate correctly before a lift truck is op-
erated. A loose battery can cause serious in-
jury and property damage if the lift truck over-
turns. The battery retention bar must be down
and under the seat and battery restraint plate.
Make sure battery has a cover if lift truck does
not have a hood.
To operate correctly, the battery restraint plate must
be locked in the down position. The battery reten-
tion bar (and hood) must be lowered first, then the
battery restraint plate is locked in the down posi-
tion over the bar. The battery must have spacers to
prevent movement in any one horizontal direction of
13 mm (0.5 in.) maximum. Use knob near hinge to
release battery restraint plate (see Figure 12). Use
handle on restraint plate to raise plate and seat. A
spring brace will hold the assembly in the up posi-
tion. If installed, raise hood. Make sure that bat-
tery cannot move more than a total of 13 mm (0.5 in.)
in any one horizontal direction. Make sure correct
spacers are installed to prevent movement. See your
dealer for Hyster lift trucks to replace damaged or
missing spacers. If a smaller battery of the correct
weight (see Nameplate) is installed and spacers can-
not prevent movement, your dealer for Hyster lift
trucks has larger spacers. Push seat and battery re-
straint down until latch locks. Make sure battery re-
straint is locked securely. Lift up on battery restraint
to make sure it is latched and will not move.
13
Maintenance Procedures Every 8 Hours or Daily
1. SEAT
2. BATTERY RESTRAINT (SEAT PLATE)
3. KNOB FOR LATCH MECHANISM
4. HINGE
5. LATCH
Figure 12. Battery Restraint
If necessary, adjust battery spacer system as de-
scribed in Battery Maintenance in this manual. See
your dealer for Hyster lift trucks to replace damaged
or missing spacers.
Battery
WARNING
Never put tools or other metal on battery.
Metal on battery can cause a short circuit and
possible damage or injury.
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
area. Make acid neutral with a solution of
sodium bicarbonate (soda). Acid in the eyes
must be flushed with water immediately.
Batteries generate explosive fumes. Keep
vents in caps clean. Keep sparks or open
flames away from battery area. Do not make a
spark from battery connections.
14
8000 SRM 1201
6. SPRING BRACE
7. HOOD
8. BATTERY RETENTION BAR
9. COUNTERWEIGHT
Disconnect battery when doing maintenance.
NOTE: There can be one of two types of batteries.
One type has removable cell caps. The other type
has sealed cells. The sealed batteries require a dif-
ferent charger, the electrolyte level or specific gravity
cannot be checked, and water cannot be added to the
electrolyte.
Make sure the voltage and weight of battery are cor-
rect as shown on Nameplate. See Table 2 in the Bat-
tery Maintenance section in this SRM to check for
correct battery dimensions.
Keep battery case, top cover, and area for battery
clean and painted. Leakage from battery and cor-
rosion can cause a malfunction in electric controls of
lift truck. Use a water and sodium bicarbonate (soda)
solution to clean battery and battery area. Keep top
of battery clean, dry, and free of corrosion.
8000 SRM 1201 Maintenance Procedures Every 8 Hours or Daily

Make sure battery is charged and has correct volt- only as needed. If more hydraulic oil is added than
age and ampere hour rating for lift truck. See Name- FULL level, hydraulic oil will leak from breather dur-
plate. ing operation.

Inspect battery case, connector, and cables for dam- Inspect hydraulic system for leaks and damaged or
age, cracks, or breaks. See battery dealer in the area loose components.
to repair any damage.

On batteries with cell caps, check level of electrolyte

daily on a minimum of one cell. Add only distilled wa-
ter, as necessary, to all cells that do not have correct
electrolyte level. Correct level is halfway between top
of plates and bottom of fill hole.

Hydraulic System

WARNING
At operating temperature hydraulic oil is HOT.
Do not permit hot oil to contact skin and cause
a burn.

CAUTION 1. HYDRAULIC TANK

2. BRAKE FLUID RESERVOIR
Do not permit dirt to enter hydraulic system
when oil level is checked or filter is changed. Figure 13. Hydraulic and Brake Checks,
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
Never operate pump without oil in hydraulic (D098) Lift Truck Models
system. Operation of hydraulic pump without
oil will damage pump.

Check hydraulic oil level with mast vertical (90 ),

forks fully lowered, and key switch is in OFF posi-
tion. See Figure 13, and Figure 14. Add hydraulic oil

15
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1201

1. HYDRAULIC FILTER 3. DIPSTICK

2. HYDRAULIC TANK BREATHER 4. HYDRAULIC TANK

Figure 14. Hydraulic System Checks, E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098) Lift
Truck Models

HOW TO MAKE CHECKS WITH KEY Horn, Lights, and Alarm

SWITCH ON
WARNING
FASTEN YOUR SEAT BELT! The seat belt is
installed to help operator stay on truck if lift
truck tips over. IT CAN ONLY HELP IF IT IS
FASTENED.
Make sure area around lift truck is clear before mov-
ing lift truck. Always look in direction that you in-
tend to move lift truck. Be careful when making
checks.
1. Check the operation of the horn by pressing the
horn button on the steering column. The horn
will operate when the key is in any position.
2. Check the operation of the lights using the appro-
priate rocker switch, located on the right hand
side of the dash panel. The lights will operate
when the key is in any position.
3. Check the strobe light by turning the key in
the ON position and check the operation of the
light. The strobe light can also be operated with
a rocker switch

16
8000 SRM 1201
4. Check the backup alarm on lift trucks equipped
with a forward and reverse lever, by sitting in the
seat and turning the key to the ON position. Pull
back on the forward and reverse lever. The alarm
will sound.
5. Check the backup alarm on lift trucks equipped
with a MONOTROL pedal by sitting in the seat,
turning the key to the ON position and pressing
the reverse arrow on the MONOTROL pedal.
Steering System
WARNING
Because the lift truck has hydraulic power
steering, lift truck can be difficult to steer
when power steering pump is not operating.
Make sure that steering system operates smoothly
and provides good steering control.
Service Brakes
WARNING
Loss of fluid from brake fluid reservoir indi-
cates a leak. Repair brake system before us-
ing lift truck. Replace brake fluid in system if
there is dirt, water, or oil in system.
NOTE: Some lift trucks are used in operations where
automatic adjusters can be slow to adjust brake
shoes. If brakes need adjustment, operate lift truck
in forward and reverse 10 times. Apply brake pedal
firmly, but do not cause wheels to slide. If automatic
adjusters do not adjust brake shoes, a qualified
service person must check operation and condition
of brakes.
Check operation of service brakes. Push on brake
pedal. Brake pedal must stop firmly and must not
move slowly down after brakes are applied. Service
brakes must apply equally to both drive wheels. Ser-
vice brakes must not pull lift truck to either side of
direction of travel when they are applied. Service
brakes are automatically adjusted when brakes are
applied and lift truck changes direction.
Maintenance Procedures Every 8 Hours or Daily
Parking Brake
There is an indicator light on display panel for park-
ing brake. The red light is ON as described in the
Operating Manual. If light is ON after approxi-
mately one second, operator is not on the seat or the
key is in OFF position. An alarm will also make a
noise. ALWAYS apply parking brake when leaving
seat.
Make sure service brakes operate correctly before
checking operation of parking brake. The parking
brake, when correctly adjusted, will hold lift truck
with a capacity load on a 15% grade [a slope that
increases 1.5 m in 10 m (1.5 ft increase in 10 ft)].
Turn knob on end of hand lever to adjust parking
brake. Do not tighten adjustment so that brakes are
applied when hand lever is released.
Seat Brake
Some lift trucks are equipped with an additional
linkage that automatically actuates a separate brake
when the operator leaves the seat (seat brake). When
correctly adjusted, this brake will also hold the lift
truck with a capacity load on a 15% grade. If the
brake does not hold the lift truck on the grade, the
seat brake must be adjusted by authorized service
personnel according to the procedure in Brake Sys-
tem 1800 SRM 338.
Control Levers and Pedals
Check that levers for mast and attachment operate
as described in the Operating Manual. Check that
the direction and speed control levers and pedals op-
erate as described in the Operating Manual. Lu-
bricate pedals and levers as required.
Direction and Speed Control Pedals
Check that the direction and speed control pedals op-
erate as described in the Operating Manual. Lubri-
cate the direction lever and accelerator pedal joints
as needed. See the Maintenance Schedule.
17
First Service After First 100 Hours of Operation
Lift System Operation
WARNING
NEVER work under raised carriage or forks.
Lower carriage or use chains on mast weld-
ments and carriage so that they cannot move.
Make sure moving parts are attached to a part
that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
1. Check for leaks in hydraulic system. Check con-
dition of hydraulic hoses and tubes.
NOTE: Some parts of mast move at different speeds
during raising and lowering.
2. Slowly raise and lower mast several times with-
out a load. Mast components must raise and
lower smoothly in correct sequence. Carriage
First Service After First 100 Hours of Operation
CHANGE HYDRAULIC OIL AND FILTER
Lift Truck Models E3.50-5.50XL (E70-120Z,
E100ZS) (E098)
Remove
WARNING
To avoid injury to personnel, turn Key to the
OFF position, and remove key and unplug the
battery before removal of the hydraulic filter.
WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact 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 compo-
nents of the hydraulic system.
Never operate the pump without oil in the hy-
draulic system. The operation of the hydraulic
pump without oil will damage the pump.
18
8000 SRM 1201
raises first, then inner mast, and intermediate
mast (three-stage mast only).
3. Inner mast and carriage must lower completely.
4. Raise mast 1 m (3 ft), with a capacity load.
Inner mast and carriage must raise smoothly.
Lower mast. All moving components must lower
smoothly.
5. With load lowered, tilt mast backward and for-
ward. Mast must tilt smoothly and both tilt
cylinders must stop evenly.
6. Check that controls for attachment operate the
functions of attachment. See symbols by each of
the controls. Make sure all hydraulic lines are
connected correctly and do not leak.
Oil Leaks
Visually check the hydraulic system, steering sys-
tem, brake system, and differential for leaks.
1. Put lift truck on a level surface. Lower mast and
turn key to OFF position and remove key.
2. Remove the floor plate for access to hydraulic fil-
ter. See Figure 15.
3. Install a drain container, with enough capacity,
under drain plug of hydraulic tank. See the
Maintenance Schedule for the size of container
needed.
4. Remove drain plug and let oil drain from hy-
draulic tank. See Figure 15.
5. Remove the four socket head screws from filter
cover. See Figure 15. Remove O-ring seal from
filter cover and discard O-ring. See Figure 16.
6. Remove filter element from filter housing and
discard filter element. If debris cap was removed
with filter element, remove cap from filter ele-
ment. See Figure 16.
7. Remove debris cap from filter element and clean
and inspect.
8000 SRM 1201 First Service After First 100 Hours of Operation

NOTE: FLOOR PLATE NOT SHOWN FOR CLARITY.

1. HYDRAULIC PUMP AND MOTOR 7. FILTER COVER
2. STEERING PUMP AND MOTOR 8. HYDRAULIC BREATHER
3. HYDRAULIC FILTER 9. BREATHER ADAPTER
4. SOCKET HEAD SCREWS 10. HYDRAULIC TANK
5. ALIGNMENT PIN AND NOTCH 11. HYDRAULIC TANK SUCTION HOSE
6. FILTER HOUSING 12. HYDRAULIC TANK DRAIN PLUG

Figure 15. Hydraulic Filter Removal and Hydraulic Oil Change, Lift Truck Models E3.50-5.50XL
(E70-120Z, E100ZS) (E098)

19
First Service After First 100 Hours of Operation 8000 SRM 1201

Install

1. Lubricate oil seal on new filter element.

2. Install debris cap on filter element and install

filter element into filter housing. See Figure 16.

3. Lubricate new O-ring and install new O-ring into

filter cover. See Figure 16.

4. Place filter cover onto housing, making sure the

pin on the cover lines up with the notch on the
housing, and secure cover to housing with four
socket head screws. See Figure 15.

5. Install and hand tighten drain plug. Once the

drain plug has been hand tightened, tighten two
to three more turns. See Figure 15.

6. Fill hydraulic tank with new hydraulic oil as

specified in the Maintenance Schedule.

7. Install the floor plate.

8. Operate hydraulic system and check for leaks.

1. COVER O-RING 3. OIL SEAL

2. FILTER ELEMENT 4. DEBRIS CAP

Figure 16. Hydraulic Filter Components, Lift

Truck Models E3.50-5.50XL (E70-120Z, E100ZS)
(E098)

20
8000 SRM 1201 First Service After First 100 Hours of Operation

Lift Truck Models E3.50-5.50XL (E70-120Z,

E100ZS) (D098)
Remove

WARNING
To avoid injury to personnel, turn Key to the
OFF position, and remove key and unplug the
battery before removal of the hydraulic filter.

WARNING
The hydraulic oil is HOT at operating tempera-
ture. Do not permit hot oil to contact skin and
cause a burn.

CAUTION
Do not permit dirt to enter hydraulic system
when oil level is checked or filter is changed.
Dirt can cause damage to components of hy-
draulic system.

Never operate the pump without oil in the hy-

draulic system. The operation of the hydraulic
pump without oil will damage the pump.

1. Put lift truck on level surface. Lower mast. Turn

key to OFF position and remove key.

2. Install a drain container, with enough capacity,

under drain plug of hydraulic tank. See the
Maintenance Schedule.
1. O-RING 9. CLAMP
2. CAP 10. LOCKWASHER
3. Disconnect hoses that go to the control valve and 3. DIPSTICK 11. BREATHER
mast, from the filter head assembly. If truck 4. FILTER HEAD 12. FITTING
is equipped with a two-stage full free list mast, ASSEMBLY 13. FITTING (HOSE TO
there is no hose connection between filter head 5. FILTER CONTROL VALVE)
assembly and mast. There is a plug in place of 6. SCREW 14. PLUG*
7. NUT 15. FITTING (HOSE TO
the fitting. Drain oil from hoses into container. 8. SPACER MAST)
See Figure 17.
* PLUG USED ONLY ON LIFT TRUCKS WITH TWO-
4. Remove drain plug and let oil drain from hy- STAGE FULL FREE LIFT MAST.
draulic tank. See Figure 18.
Figure 17. Hydraulic Filter and Filter Head
5. Remove screw, nuts, spacers, and lockwasher Assembly, Lift Truck Models E3.50-5.50XL
and remove clamp that holds the filter and filter (E70-120Z, E100ZS) (D098)
head assembly to tank.

6. Remove filter from filter head assembly and in-

stall new filter. Be sure to install new O-ring be-
tween filter and filter head assembly.

21
First Service After First 100 Hours of Operation 8000 SRM 1201

Install 3. Connect hoses that go to the control valve and

NOTE: The hydraulic oil filter has a bypass relief
valve that is part of the filter. Make sure the cor-
rect replacement filter with a bypass relief valve is
installed. See the Parts Manual.
1. Install filter and filter head assembly into hy-
draulic tank. Install the screw, nuts, spacer, and
lockwasher for the clamp. Secure filter and filter
head assembly to tank with clamp.
mast, to the filter head assembly. If truck is
equipped with a two-stage full free list mast,
there is no hose connection between filter head
assembly and mast. There is a plug in place of
the fitting. See Figure 17.
4. Fill hydraulic tank with new hydraulic oil as
specified in the Maintenance Schedule.

2. Install and hand tighten drain plug. Once the

drain plug has been hand tightened, tighten two
to three more turns.

NOTE: THE HYDRAULIC FILTER IS INSIDE THE HYDRAULIC TANK AND ATTACHED TO THE FILTER HEAD
ASSEMBLY. IT IS NOT SHOWN HERE FOR CLARITY (SEE FIGURE 17). THE HYDRAULIC FILTER AND TANK
ARE ON THE RIGHT SIDE.
1. HYDRAULIC FILTER AND HEAD ASSEMBLY 4. HYDRAULIC FILTER
2. TRUCK FRAME 5. DRAIN PLUG
3. HYDRAULIC TANK 6. SUPPLY OUTLET

Figure 18. Hydraulic Tank, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098)

22
8000 SRM 1201
Maintenance Procedures Every 500 Hours or 3 Months
NOTE: Perform the 8-hour checks prior to performing
the procedures in this section.
WHEEL NUTS
Tighten drive wheel nuts as required to torque shown
in the Maintenance Schedule. See the Wheels and
Tires section for tire and wheel removal and instal-
lation procedures.
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.
MAST LUBRICATION
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow recommenda-
tions of manufacturer.
Parts of the lift mechanism can move and cause
serious injury. DO NOT allow anyone under
raised carriage or forks. DO NOT put any part
of your body in or through lift mechanism if
any part of lift mechanism can move.
Before you reach into the lift mechanism:
• Make sure that all parts of lift mechanism are
completely lowered.
• If lift mechanism cannot be lowered com-
pletely, use blocks or chains on mast weld-
ments and carriage so that they cannot move.
Use chain to attach each moving part of lift
mechanism to a part that does not move. If
blocks are used, make sure that blocks are
placed between each part that moves and the
ground. Operate lift/lower control to check
that all parts will not move, but do not allow
lift chains to become loose.
• Turn key switch to OFF. Remove key.
WARNING
Metal particles can fall into eyes during opera-
tion of mast. Failure to remove these particles
can cause eye injury. Remove metal particles
that are attached to the edge of the mast parts
Maintenance Procedures Every 500 Hours or 3 Months
with a disc sander if necessary. Always wear
eye protection when using a disc sander.
CAUTION
DO NOT use steam or high-pressure water to
clean load rollers or lift chains. Steam and
high-pressure water can remove lubrication
from bearings in load rollers. Water in bear-
ings of sheaves and link pins of chains can also
shorten service life of these parts.
1. Clean mast assembly. Inspect mast channels in
areas where rollers travel. If there are loose or
displaced metal particles, remove metal parti-
cles.
NOTE: Some applications will require more frequent
cleaning and lubrication of the mast assembly. DO
NOT use a lubricant-spray on surfaces of mast
channels where load rollers make contact. The use
of correct lubricant is important! Use multipurpose
grease (Hyster Part No. 3020381) or an equivalent
grease with 2% to 4% molybdenum disulfide. The
load rollers and sheaves have sealed bearings that
do not need additional lubrication.
2. Lubricate sliding surfaces and load roller sur-
faces along the full length of the channels as
shown in Figure 19. Apply lubricant to darker
areas like those indicated by 1 and 2.
A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 19. Lubricate Mast
23
Maintenance Procedures Every 500 Hours or 3 Months 8000 SRM 1201

NOTE: When lubricating the mast mounting/hanger

bushings, the load must be removed from the normal
contact surface to allow grease to properly lubricate
the normal contact surfaces of the mast bushings

3. Raise the carriage about 61 cm (2 ft), and tilt the

mast fully back. Place blocks under the outer
mast channels to within 13 mm (0.5 in.) of the
channels. See Figure 20.

4. Tilt the mast fully forward. See Figure 20.

5. Lubricate the mast hanger bushings at grease

fittings on outer mast. See Figure 21. Use multi-
purpose grease shown in the Maintenance Sched-
ule.

6. Tilt mast fully back. Remove the blocks from un-

der the channels.

A. MAST TILTED FULLY BACK

B. MAST TILTED FULLY FORWARD
1. BLOCK 2. MAST

Figure 20. Blocking the Mast

24
8000 SRM 1201 Maintenance Procedures Every 500 Hours or 3 Months

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 21. Mast Mounting Hanger Lubrication

25
Maintenance Procedures Every 500 Hours or 3 Months 8000 SRM 1201

INTEGRAL SIDESHIFT CARRIAGE with multipurpose grease as shown in the Mainte-

nance Schedule. See Figure 22.
If a integral sideshift carriage is installed, lubricate
the fittings for side load rollers and sliding surfaces

1. SIDE LOAD ROLLERS 2. LUBE FITTING 3. LUBE FITTING*

* LUBE FITTING NOT USED ON E3.50-4.00XL, E4.50XLS (E70-80Z, E100ZS) (D098) LIFT TRUCKS EQUIPPED
WITH INTEGRAL SIDESHIFT.

Figure 22. Integral Sideshift Carriage Lube Fittings

26
8000 SRM 1201
BRAKE FLUID
WARNING
Loss of fluid from master cylinder indicates a
leak. This condition can cause brake failure.
The result can be material damage or personal
injury. Repair brake system before lift truck is
used. Replace brake fluid in system if there is
dirt, water, or oil in system.
Maintenance Procedures Every 1000 Hours or 6 Months
NOTE: Do these procedures in addition to the 8-hour
and 500-hour checks.
DIFFERENTIAL AND SPEED REDUCER
WARNING
DO NOT work under raised carriage. Lower
carriage or use chain to prevent carriage and
inner or intermediate weldments from low-
ering when doing maintenance. Make sure
moving parts are attached to parts that cannot
move.
Check oil level at fill plug in differential housing. See
Figure 23. Oil level must be even with bottom of hole.
Add oil if oil level is low. Install and tighten plug to
122 N•m (90 lbf ft).
1. FILL PLUG
2. DRAIN PLUG
Figure 23. Differential
Maintenance Procedures Every 1000 Hours or 6 Months
Check brake fluid in reservoir for master cylinder.
Add brake fluid as necessary. Use brake fluid shown
in Maintenance Schedule.
OTHER LUBRICATION
Lubricate hinges, pins, linkages, cables, pedals, and
levers as necessary. Use multipurpose grease, or sil-
icone lubricant-spray (Hyster Part No. 328388) as
needed. See Maintenance Schedule.
LIFT CHAINS
Wear Check
WARNING
DO NOT repair worn or damaged lift chain.
Replace worn or damaged lift chain with new
chain. If a pair of lift chains is used in mast,
both lift chains must be replaced.
If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re-
placed. If a chain scale is available, check lift chains
as shown in Figure 24. If a chain scale is not avail-
able, measure 20 links of chain. Measure from center
of a pin to center of another pin 20 links away. Com-
pare length with chart in Figure 24. Replace chain
if length of 20 links of worn section is more than the
WEAR LIMIT.
NOTE: The lift chain must be under tension when
checking for wear.
Inspect lift chains for edge wear where they pass over
the chain sheaves. Make sure chain links are a min-
imum of 95% (5% wear) of a chain link that is not
worn. See Figure 9.
Lubrication
NOTE: Lubrication or cleaning (see Maintenance
Procedures Every 2000 Hours or Yearly) can be
needed more frequently in very dirty applications.
Correct lubrication helps provide normal service life
for these parts.
Lubricate lift chains with 30W engine oil or Hys-
ter Chain and Cable Lubricant (Hyster Part No.
171350).
27
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1201

2. Measure thickness of forks at a vertical section

where there is no wear. This is dimension X. Now
measure thickness at heel of fork. If thickness is
not more than 90% of dimension X, replace fork.

3. Use clean engine oil as specified in the Mainte-

nance Schedule, to lubricate guides and locks for
forks.

PARKING BRAKE
NOTE: Lubricate the parking brake at 1000 hours if
lift truck is used in a clean, dry warehouse environ-
ment. If lift truck is used in a more severe environ-
ment, lubricate at 500 hours.

Lubricate the parking brake pivot and slide with lu-

bricant specified in the Maintenance Schedule. See
Figure 25.

Pitch Total Length Wear Limit

of 20 Links The 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.) (15.6 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)

NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
1. CHAIN WEAR SCALE

Figure 24. Lift Chains Wear Check

1. PIVOT
2. APPLIED POSITION
FORKS 3. RELEASED POSITION
4. PARKING BRAKE SLIDE
WARNING
Figure 25. Parking Brake Lubrication
Never repair damaged forks. DO NOT heat,
weld, or bend forks. Forks are made of special
steel using special methods. Replace damaged
BRAKE LINKAGE SHAFTS
forks. NOTE: Lubricate the brake linkage shafts at 1000
hours if lift truck is used in a clean, dry warehouse
1. Check heel and attachment points of forks with
environment. If lift truck is used in a more severe
a penetrant or magnetic particle inspection. See
environment, lubricate at 500 hours.
Figure 7.

28
8000 SRM 1201 Maintenance Procedures Every 1000 Hours or 6 Months

NOTE: Under dusty or dirty conditions, clean and lu-
bricate the brake linkage shafts more frequently.
Lubricate rod end and pedal assembly with multipur-
pose grease as specified in the Maintenance Sched-
ule. See Figure 26.
Lubricate the pivot tube in the pedal assembly using
the following procedure:
1. Remove floor plate.
2. Remove capscrew, washer, and tube from pedal
assembly. Apply multipurpose grease, as speci-
fied in the Maintenance Schedule, on the outside
of the tube.
3. Install tube, washer, and capscrew into pedal as-
sembly. Tighten capscrew to 165 N•m (122 lbf ft).
4. Install floor plate.
rod ends, there are two fittings, one on each end of
the steering axle. For the steering spindles, there
are four lube fittings, one on the top and bottom on
each end of the steering axle.
SEAT RAILS
NOTE: Lubricate the seat rails at 1000 hours if lift
truck is used in a clean, dry warehouse environment.
If lift truck is used in a more severe environment,
lubricate at 500 hours.
Lubricate the seat rails with multipurpose grease, as
specified in the Maintenance Schedule.
SEAT PLATE HINGES
NOTE: Lubricate the seat plate hinges at 1000 hours
if lift truck is used in a clean, dry warehouse envi-
ronment. If lift truck is used in a more severe envi-
ronment, lubricate at 500 hours.

NOTE: Under dusty or dirty conditions, clean and lu-

bricate the seat plate hinges more frequently.

Lubricate the seat plate hinges with silicone lubri-

cant-spray as specified in the Maintenance Schedule.

ELECTRICAL INSPECTION
Contactors

WARNING
Disconnect battery connector to prevent injury
from electric shock before making any inspec-
tions or repairs.

CAUTION
Never clean components of electrical system
with steam or high pressure water.

The contactor contacts are made of special silver

1. CAPSCREW alloy (see Figure 27). The contacts will look black
2. WASHER and rough from normal operation. This condition
3. PIVOT TUBE does not cause problems with the operation of the lift
4. PEDAL ASSEMBLY
5. ROD END truck. Cleaning is not necessary. DO NOT USE A
6. ROD END PIN FILE ON CONTACTS. DO NOT LUBRICATE CON-
TACTS. Always replace contacts in sets. Check for
Figure 26. Brake Linkage Shafts equal spring tension if contacts do not wear evenly.
See section AC Motor Controllers/Display Panel,
STEERING SPINDLES AND TIE ROD ENDS Description, Checks, Adjustments, and Trou-
bleshooting 2200 SRM 1056 for replacement and
Use multipurpose grease, as specified in the Mainte- adjustment procedures.
nance Schedule, to lubricate the tie rod ends on the
steering axle and the steering spindles. For the tie

29
Maintenance Procedures Every 1000 Hours or 6 Months 8000 SRM 1201

1. FUSE 1 (15A) 8. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW) 9. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (15A) 10. POWER STEERING FUSE (40A)
4. FUSE 4 (5A) 11. LED INDICATOR
5. POWER STEERING CONTACTOR 12. LINE PUMP CONTACTOR
6. LINE TRACTION CONTACTOR
7. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)

Figure 27. AC Traction and Pump Motor Controllers

30
8000 SRM 1201
Maintenance Procedures Every 2000 Hours or Yearly
NOTE: Do these procedures in addition to the 8-hour,
500-hour, and 1000-hour checks.
BRAKE FLUID
Change the brake fluid every 2000 hours or yearly
using these procedures:
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. Remove old brake fluid from reservoir on master
cylinder.
2. Disconnect brake lines from special fittings
(bleed screw), located behind the wheel assem-
bly (see Figure 28). Drain old brake fluid from
the brake lines, into a container.
A. BRAKE ASSEMBLY
1. WHEEL CYLINDER ASSEMBLY
2. SPECIAL FITTING (BLEED SCREW, LOCATED ON BACK SIDE)
3. FLUID FILL HOLE AND PLUG
Figure 28. Change Brake Fluid
Maintenance Procedures Every 2000 Hours or Yearly
3. Connect brake lines to special fittings. Add new
brake fluid to reservoir on master cylinder. See
the Maintenance Schedule for the type and quan-
tity of brake fluid to use.
4. Remove air from brake system:
a. Put one end of a rubber hose on special fit-
tings at wheel cylinders.
b. Put other end of hose in a container with
clean brake fluid. Loosen special fittings.
c. Push slowly on brake pedal. Close special
fittings.
Repeat the procedure until no air bubbles are seen
in container. Check fluid level in reservoir. Keep
reservoir full of brake fluid during these procedures.
B. MASTER CYLINDER ASSEMBLY
31
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1201

HYDRAULIC SYSTEM
Hydraulic Tank Breather, Lift Truck Models
E3.50-5.50XL (E70-120Z, E100ZS) (D098)
Change the hydraulic tank breather every 2000
hours or yearly. The breather is on a fitting on the
hydraulic filter head assembly. See Figure 29.

Change Hydraulic Oil and Hydraulic Oil

Filter, Lift Truck Models E3.50-5.50XL
(E70-120Z, E100ZS) (D098)
Remove

WARNING
To avoid injury to personnel, turn Key to the
OFF position, and remove key and unplug the
battery before removal of the hydraulic filter.

WARNING
The hydraulic oil is HOT at operating tempera-
ture. Do not permit hot oil to contact skin and
cause a burn.

CAUTION
Do not permit dirt to enter hydraulic system
when oil level is checked or filter is changed.
Dirt can cause damage to components of hy-
draulic system.
1. O-RING 9. CLAMP
Never operate the pump without oil in the hy- 2. CAP 10. LOCKWASHER
3. DIPSTICK 11. BREATHER
draulic system. The operation of the hydraulic 4. FILTER HEAD 12. FITTING
pump without oil will damage the pump. ASSEMBLY 13. FITTING (HOSE TO
5. FILTER CONTROL VALVE)
1. Put lift truck on level surface. Lower mast. Turn 6. SCREW 14. PLUG*
key to OFF position and remove key. 7. NUT 15. FITTING (HOSE TO
8. SPACER MAST)
2. Install a drain container, with enough capacity,
under drain plug of hydraulic tank. See the * PLUG USED ONLY ON LIFT TRUCKS WITH TWO-
Maintenance Schedule. STAGE FULL FREE LIFT MAST.

3. Disconnect hoses that go to the control valve and Figure 29. Hydraulic Filter and Filter Head
mast, from the filter head assembly. If truck Assembly, Lift Truck Models E3.50-5.50XL
is equipped with a two-stage full free list mast, (E70-120Z, E100ZS) (D098)
there is no hose connection between filter head
4. Remove drain plug and let oil drain from hy-
assembly and mast. There is a plug in place of
draulic tank. See Figure 30.
the fitting. Drain oil from hoses into container.
See Figure 29.

32
8000 SRM 1201 Maintenance Procedures Every 2000 Hours or Yearly

5. Remove screw, nuts, spacers, and lockwasher lockwasher for the clamp. Secure filter and filter
and remove clamp that holds the filter and filter head assembly to tank with clamp.
head assembly to tank.
2. Install and hand tighten drain plug. Once the
6. Remove filter from filter head assembly and in- drain plug has been hand tightened, tighten two
stall new filter. Be sure to install new O-ring be- to three more turns.
tween filter and filter head assembly.
3. Connect hoses that go to the control valve and
Install mast, to the filter head assembly. If truck is
equipped with a two-stage full free list mast,
NOTE: The hydraulic oil filter has a bypass relief there is no hose connection between filter head
valve that is part of the filter. Make sure the cor- assembly and mast. There is a plug in place of
rect replacement filter with a bypass relief valve is the fitting. See Figure 29.
installed. See the Parts Manual.
4. Fill hydraulic tank with new hydraulic oil speci-
1. Install filter and filter head assembly into hy- fied in the Maintenance Schedule.
draulic tank. Install the screw, nuts, spacer, and

NOTE: THE HYDRAULIC FILTER IS INSIDE THE HYDRAULIC TANK AND ATTACHED TO THE FILTER HEAD
ASSEMBLY. IT IS NOT SHOWN HERE FOR CLARITY (SEE FIGURE 29). THE HYDRAULIC FILTER AND TANK
ARE ON THE RIGHT SIDE.
1. HYDRAULIC FILTER AND HEAD ASSEMBLY 4. HYDRAULIC FILTER
2. TRUCK FRAME 5. DRAIN PLUG
3. HYDRAULIC TANK 6. SUPPLY OUTLET

Figure 30. Hydraulic Tank, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098)

33
Maintenance Procedures Every 2000 Hours or Yearly
Hydraulic Tank Breather, Lift Truck Models
E3.50-5.50XL (E70-120Z, E100ZS) (E098)
Remove
1. Remove the floor plate for access to the hydraulic
tank breather.
2. Unscrew the breather from the breather adapter.
See Figure 31.
Install
1. Install new breather onto breather adapter. See
Figure 31.
2. Install the floor plate.
Change Hydraulic Oil and Hydraulic Oil
Filter, Lift Truck Models E3.50-5.50XL
(E70-120Z, E100ZS) (E098)
Remove
WARNING
To avoid injury to personnel, turn Key to the
OFF position, and remove key and unplug the
battery before removal of the hydraulic filter.
WARNING
The hydraulic oil is HOT at operating temper-
ature. Do not permit the hot oil to contact 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 compo-
nents of the hydraulic system.
Never operate the pump without oil in the hy-
draulic system. The operation of the hydraulic
pump without oil will damage the pump.
1. Put lift truck on a level surface. Lower mast and
turn key to OFF position and remove key.
34
8000 SRM 1201
2. Remove the floor plate for access to hydraulic fil-
ter. See Figure 31.
3. Install a drain container, with enough capacity,
under drain plug of hydraulic tank. See the
Maintenance Schedule for the size of container
needed.
4. Remove drain plug and let oil drain from hy-
draulic tank. See Figure 31.
5. Remove the four socket head screws from filter
cover. See Figure 31. Remove O-ring seal from
filter cover and discard O-ring. See Figure 32.
6. Remove filter element from filter housing and
discard filter element. If debris cap was removed
with filter element, remove cap from filter ele-
ment. See Figure 31.
7. Remove debris cap from filter element and clean
and inspect.
Install
1. Lubricate oil seal on new filter element.
2. Install debris cap on filter element and install
filter element into filter housing. See Figure 32.
3. Lubricate new O-ring and install new O-ring into
filter cover. See Figure 32.
4. Place filter cover onto housing, making sure the
pin on the cover lines up with the notch on the
housing, and secure cover to housing with four
socket head screws. See Figure 31.
5. Install and hand tighten drain plug. Once the
drain plug has been hand tightened, tighten two
to three more turns. See Figure 31.
6. Fill hydraulic tank with new hydraulic oil as
specified in the Maintenance Schedule.
7. Install the floor plate.
8. Operate hydraulic system and check for leaks.
8000 SRM 1201 Maintenance Procedures Every 2000 Hours or Yearly

NOTE: FLOOR PLATE NOT SHOWN FOR CLARITY.

1. HYDRAULIC PUMP AND MOTOR 7. FILTER COVER
2. STEERING PUMP AND MOTOR 8. HYDRAULIC BREATHER
3. HYDRAULIC FILTER 9. BREATHER ADAPTER
4. SOCKET HEAD SCREWS 10. HYDRAULIC TANK
5. ALIGNMENT PIN AND NOTCH 11. HYDRAULIC TANK SUCTION HOSE
6. FILTER HOUSING 12. HYDRAULIC TANK DRAIN PLUG

Figure 31. Hydraulic Filter Removal and Hydraulic Oil Change, Lift Truck Models E3.50-5.50XL
(E70-120Z, E100ZS) (E098)

35
Maintenance Procedures Every 2000 Hours or Yearly
1. COVER O-RING 3. OIL SEAL
2. FILTER ELEMENT 4. DEBRIS CAP
Figure 32. Hydraulic Filter Components, Lift
Truck Models E3.50-5.50XL (E70-120Z, E100ZS)
(E098)
DIFFERENTIAL AND SPEED REDUCER
Remove plug from bottom of differential housing to
drain oil. See Maintenance Schedule for correct lu-
bricant. Fill differential and speed reducer so that
oil level is even with fill plug. See Figure 23. Install
and tighten drain plug to 122 N•m (90 lbf ft).
36
8000 SRM 1201
SERVICE BRAKES
WARNING
Brake linings contain dangerous fibers.
Breathing the dust from these brake linings
is a cancer or lung disease hazard. Do not
create dust! Do not clean brake parts with
compressed air or by brushing. Use vacuum
equipment approved for asbestos dust or fol-
low the cleaning procedure in this section.
When brake drums are removed, do not create
dust.
Do not sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to brake linings must be done in a re-
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
Cleaning Procedures:
1. Do not release brake lining dust from brake lin-
ings into air when brake drum is removed.
2. Use solvent approved for cleaning of brake parts
to wet lining dust. Follow instructions and cau-
tions of manufacturer for use of solvent. If a sol-
vent spray is used, do not create brake lining dust
with spray.
3. When brake lining dust is wet, clean parts. Put
any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a DAN-
GEROUS FIBERS warning label on plastic bag
or airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
CAUTION
Do not use an oil solvent to clean wheel cylin-
der. Use solvent approved for cleaning of brake
parts. Do not permit oil or grease in brake fluid
or on brake linings.
Check brake lining and parts of brake assembly for
wear or damage. See the section Brake System
1800 SRM 338 for removal and installation proce-
dures of drive wheels and hubs. If brake linings or
brake shoes are worn or damaged, they must be re-
placed. Brake shoes must be replaced in complete
sets. Inspect brake drums for cracks or damage. Re-
place any damaged parts.
8000 SRM 1201
WHEEL BEARINGS
Steer Wheels, Lubrication
Lubricate wheel bearings in hubs for the steer wheels
with multipurpose grease. See Maintenance Sched-
ule. See the following Service Manual section for
the procedures to remove and install steer wheels
and hubs: Steering Axle 1600 SRM 326.
Drive Wheels, Lubrication
Lubricate inner wheel bearings in hubs with mul-
tipurpose grease. See Maintenance Schedule. See
the following Service Manual section for the proce-
dures to remove and install drive wheels and hubs:
Drive Axle, Speed Reducer, and Differential
1400 SRM 413.
LIFT CHAINS
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
Battery Maintenance
HOW TO CHARGE BATTERY
WARNING
If the lift truck was operated with a low bat-
tery, inspect all contactors for welded contacts
BEFORE connecting a charged battery. The
lift truck cannot be controlled if contacts are
welded. This condition can cause personal in-
jury when battery is connected.
WARNING
The acid in the electrolyte can cause injury.
Use water to flush area and make acid neutral
with a water and soda solution. Acid in eyes
must be flushed with water. Batteries generate
explosive fumes when they are being charged.
Keep fire, sparks, and burning material away
from battery charger area. Avoid sparks from
battery connections. Charge batteries only in
the special area for charging batteries. When
battery is being charged, keep vent caps clear.
Battery charger area must have ventilation
so that explosive fumes are removed. Open
Battery Maintenance
cleaning solvents, always follow recommenda-
tions of manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
eyes.
Remove lift chains. Clean lift chains by soaking
them in solvent that has petroleum base for at least
30 minutes. Use compressed air to completely dry
chains when they are clean.
Lubricate lift chains by soaking them in 30W engine
oil for at least 30 minutes. Remove chains from oil.
Hang chains for one hour so that excess oil will drain
from chains.
battery cover on a covered battery. Disconnect
battery when doing cleaning and maintenance.
CAUTION
Never connect battery charger plug to plug
of lift truck. You can damage electronic con-
troller. Make sure battery charger voltage is
correct voltage for battery.
NOTE: Many users have battery chargers that can
follow a program to automatically charge a battery
according to recommendations of the battery manu-
facturer. Use recommendations of battery manufac-
turer for charging battery.
Correct use of the hydrometer (Figure 33) and proper
operation of the battery charger is important. Fol-
low instructions of charger manufacturer. Never
let battery discharge below minimum value given
by battery manufacturer. A fully charged battery
will have a specific gravity of 1.265 to 1.310 at 25 C
(77 F). Never charge a battery at a rate that will
raise electrolyte temperature above 49 C (120 F).
Never let battery stay discharged for long periods.
37
Battery Maintenance 8000 SRM 1201

See the section Industrial Battery 2240 SRM 1 for

additional information on charging and maintenance
of a battery.

HOW TO CHANGE BATTERY

WARNING
Batteries are heavy and can cause an injury.
Use care to avoid injury. Do NOT put hands,
arms, feet, or legs between battery and a solid
object.

Make sure capacity of crane and spreader

bar is greater than weight of battery. Weight
of battery is normally shown on battery case.
Maximum battery weight is shown on lift truck
Nameplate. Spreader bar must NOT be made
of metal or it must have insulated straps.
Specific Correc-
Electrolyte Correct
Gravity tion Replacement battery must fit battery area cor-
Temp. Value
Reading Points rectly. See Table 2. Use spacers to prevent bat-
1.210 31 C (87 F) +0.003 1.213 tery from moving horizontally in battery com-
1.210 27 C (80 F) +0.001 1.211 partment.
1.210 25 C (77 F) 0.000 1.210
Make sure that battery voltage and weight of
1.210 18 C (64 F) 0.004 1.206
replacement battery is correct as shown on
+0.001 or 0.001 for each 2 C from the 25 C base Nameplate.
value.
Make sure battery restraint is locked in down
position and battery retention bar is lowered
Figure 33. Check Specific Gravity
and locked under seat before lift truck is oper-
1. NORMAL CHARGE: This charge is the charge ated.
that is normally given to a battery that is discharged
Before connecting battery, make sure key
from normal service. Many users give this charge at
switch is in OFF position and parking brake is
a regular interval based on usage. This practice will
set.
keep the battery fully charged if the battery is not
discharged below the limit. Always use a hydrometer
(Figure 33) to check battery if interval charge cycle CAUTION
is used. Frequent charging of a battery that has 2/3 Batteries must be discarded according to local
of a full charge or more can decrease battery life. environmental regulations.

2. EQUALIZING CHARGE: This charge is at a low
rate and balances the charge in all of the cells. The
equalizing charge is normally given approximately
once a month. It is a charge at a slow rate for three
to six hours in addition to the regular charging cycle.
DO NOT give an equalizing charge more than once
a week. The most accurate specific gravity mea-
surements for a charged battery will be after an
equalizing charge. If the specific gravity difference
is more than 0.020 between cells of the battery after
an equalizing charge, there can be a damaged cell.
Consult your battery dealer.
1. Disconnect battery. Move connector and cables
so that they will not be damaged when battery
is moved. Tilt steering column forward and
make sure detent engages to hold steering col-
umn. Slide seat to rear adjustment position.
Release lock on battery restraint and tilt battery
restraint and seat to up position. Make sure bat-
tery restraint and seat are locked in up position.
2. If lift truck has a hood, open hood from over bat-
tery. See Figure 34. If battery is not a covered
battery, put an insulating cover over battery. If
lift truck has a battery retention bar, secure bar
in UP position.

38
8000 SRM 1201 Battery Maintenance

3. Use a spreader bar and crane to lift battery battery from moving more than a total of 13 mm
from lift truck. See Figure 35. When a replace- (0.5 in.) in any one horizontal direction. See
ment battery is installed, make sure battery fits Figure 36.
battery compartment. Use spacers to prevent

Figure 34. Open Hood

Figure 35. Change Battery

39
Battery Maintenance 8000 SRM 1201

A. FRONT SPACERS
1. BATTERY COMPARTMENT 5. SHIM
2. BATTERY 6. STORE ADDITIONAL SHIMS IN FRONT OF
3. BULKHEAD BULKHEAD
4. SPACER

Figure 36. Battery Compartment Spacers

4. Lift trucks are equipped with adjustable spacers
WARNING
Correct operation of the battery restraint sys-
tem requires that the battery does not move
more than 13 mm (0.5 in.). Make sure battery
spacers are correctly adjusted. Use only spac-
ers supplied with truck.
WARNING
Make sure capacity of crane and spreader bar
is greater than weight of battery. Weight of
battery is normally shown on battery case.
Spreader bar must NOT be made of metal or it
must have insulated straps.
in battery compartment. See Figure 36. Add
or remove shims from under front spacer bar
to control movement of battery in forward and
backward directions. Install an equal num-
ber of shims at each capscrew. Install unused
shims under nuts of capscrews (outside battery
compartment). Spacers on each side of battery
can be adjusted to control movement of battery
from side to side. Access to nuts for spacers for
sides of battery is under frame near steer tires.
Tighten all capscrews. It can be necessary to
install side spacers facing opposite direction for
some batteries. If spacers cannot be adjusted
for a battery that is specified for this lift truck,

40
8000 SRM 1201 Safety Procedures When Working Near Mast

see your dealer for Hyster lift trucks for correct

spacers.

Table 2. Battery Specifications*

Minimum Battery Length Weight

Compartment
Model Volts
Size Length × Min./Max Min. Max.
Width
E3.50-4.00XL 841 × 987 mm 950 to 990 mm 1542 kg 2177 kg
36, 48, 80
(E70-80Z) (33.1 × 38.9 in.) (37.4 to 39.0 in.) (3400 lb) (4799 lb)
E4.50XLS 841 × 987 mm 950 to 990 mm 1633 kg 2177 kg
36, 48, 80
(E100ZS) (33.1 × 38.9 in.) (37.4 to 39.0 in.) (3600 lb) (4799 lb)
E4.50XL 694 × 1037 mm 1115 to 1150 mm 1814 kg 2517 kg
36, 48, 80
(E100Z) (27.3 × 40.8 in.) (43.9 to 45.3 in.) (4000 lb) (5681 lb)
E5.50XL 993 × 1146 mm 1115 to 1150 mm 1919 kg 2517 kg
36, 48, 80
(E120Z) (39.3 × 45.1 in.) (43.9 to 45.3 in.) (4231 lb) (5681 lb)
*BATTERY WIDTH
Batteries without cover: 950 to 1117 mm (37.4 to 44.0 in.)
Batteries with cover: 950 to 1143 mm (37.4 to 45.0 in.)
NOTE: Maximum tolerances are +0 and -13 mm (+0 and -0.5 in.) for the size of the battery compartment. The
battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a
battery compartment.

Safety Procedures When Working Near Mast

The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery on electric lift trucks and put a
tag or lock on the battery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• Do NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Do NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal
of the mast or carriage. Follow the repair
procedures in the correct Service Manual
section for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make
sure there is no movement in the mast. Make
sure that all parts of the mast that move are
fully lowered.
OR
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving parts
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:

41
Safety Procedures When Working Near Mast
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom cross-
member of the weldment that moves in the
outer weldment with a crossmember on the
outer weldment. On the two-stage and free-
lift mast, the moving part is the inner weld-
ment. On the three-stage mast, it is the
intermediate weldment. On the four-stage
mast, it is the first intermediate weldment.
See Figure 37.
c. Use a 3/8 inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
hook on the back side of the mast. Make sure
the hook is completely engaged with a link in
the chain. Make sure the safety chain does
not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
Legend for Figure 37
A. TWO-STAGE MAST
B. FREE-LIFT MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. FIRST INTERMEDIATE WELDMENT
42
8000 SRM 1201
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (free-
lift, three-stage, and four-stage masts only)
is completely retracted. Turn OFF power.
Apply the parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
e. Install another safety chain (3/8 inch mini-
mum) between the top or bottom crossmem-
ber of the carriage and a crossmember on the
outer weldment.
3. Apply the parking brake. After lowering or re-
straining the mast, shut off the power and re-
move the key. Put a DO NOT OPERATE tag in
the operator’s compartment. Disconnect the bat-
tery on electric lift trucks and put a tag or lock
on the battery connector.
C. THREE-STAGE MAST
D. FOUR-STAGE MAST
5. HOOK
6. FREE-LIFT CYLINDER
7. CROSSMEMBER
8. CROSSMEMBER
8000 SRM 1201 Safety Procedures When Working Near Mast

Figure 37. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

43
Lift and Tilt System Leak Check
Lift and Tilt System Leak Check
CHECK LIFT CYLINDERS FOR LEAKS
WARNING
Never allow any person under raised carriage.
Do not put any part of your body in or through
lift mechanism unless all parts of mast are com-
pletely lowered, key switch is in OFF position,
and key is removed.
Before making any repairs, use blocks and
chains on mast weldments and carriage so that
they cannot move. Make sure moving parts are
attached to parts that cannot move.
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 pressure.
During test procedures for hydraulic system,
fasten load to carriage with chains to prevent
it from falling. Keep all personnel away from
lift truck during tests.
1. Operate hydraulic system. Put a capacity load
on forks and raise and lower load several times.
Lower load and tilt mast forward and backward
several times. Check for leaks.
2. Raise carriage and load so that rods of main lift
cylinders extend at least 60 cm (2 ft). If carriage
lowers slowly with control valve in NEUTRAL
position, there are leaks inside hydraulic system.
The maximum speed that the carriage is allowed
to lower is 100 mm (3.90 in.) per 10 minutes
when hydraulic oil is 50 C (122 F).
3. Check lift cylinders for internal leaks. Remove
load from forks. Install a gate valve in supply
line between main control valve and mast. Put a
capacity load on forks again. Raise carriage and
load so that rods of main lift cylinders extend at
least 60 cm (2 ft). Close gate valve. If carriage or
mast weldments lower slowly, seals in lift cylin-
ders have leaks.
4. If carriage and mast weldments do not move,
open gate valve and check for movement again.
If carriage lowers when valve is open, check for
leaks in hydraulic lines or fittings. If no leaks
are found, main control valve can have damage.
Remove load from forks.
44
8000 SRM 1201
CHECK TILT CYLINDERS FOR LEAKS
WARNING
Never allow any person under raised carriage.
Do not put any part of your body in or through
lift mechanism unless all parts of mast are com-
pletely lowered, key switch is in OFF position,
and key is removed.
Before making any repairs, use blocks and
chains on mast weldments and carriage so that
they cannot move. Make sure moving parts are
attached to parts that cannot move.
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 pressure.
During test procedures for hydraulic system,
fasten load to carriage with chains to prevent
it from falling. Keep all personnel away from
lift truck during tests.
1. Put a capacity load on forks. Slowly tilt mast
forward. If mast continues to slowly tilt forward
when control valve is in NEUTRAL position,
there are leaks inside hydraulic system. The
maximum speed that the mast is allowed to
tilt forward when there are internal leaks in
lift system is 34 mm (1.3 in.) per 10 minutes
(measured at tilt cylinder). The maximum speed
is measured when hydraulic oil is 50 C (122 F).
2. If leak rate is greater than specifications, remove
load from mast. Install a gate valve between port
at front of tilt cylinder and hydraulic line. Put
load on forks again. Close gate valve. If mast
tilts slowly forward, cylinder seals are leaking.
Be sure to check both tilt cylinders.
3. If mast does not move, open gate valve and
check for movement again. If mast moves for-
ward when gate valve is open, check for leaks in
hydraulic lines or fittings. If no leaks are found,
main control valve can have damage. Remove
load from forks.
8000 SRM 1201 Lift Chain Adjustments

Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
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 power is OFF.
NOTE: Prior to performing adjustment procedures,
make sure the forklift truck is parked on a level sur-
face and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage
until the bottom of the fork heel is 6 ±3 mm (0.24
±0.12 in.) above floor level. See Figure 38.

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-

tem, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel
away from the lift truck during the tests.

When the lift chains are correctly adjusted:

• The tension will be the same on each chain of the
chain set. Check tension by pushing on both chains
at the same time.
• The chain length will be correct. 1. MAST
• The chains must travel freely through the complete 2. CARRIAGE
cycle. 3. FORK
4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
NOTE: When the chain adjustments are complete, ABOVE FLOOR LEVEL.
make sure the threads on the nuts of the chain an-
chors are completely engaged. Make sure all of the Figure 38. Lift Chain Adjustment, Hook- or
adjustment is not removed from the chain anchors. Pin-Type Forks
The chain anchors must be able to move on their 3. Adjust chain anchors which support the carriage
mounting. until the bottom of the lower carriage bar is above
1. When adjusting lift chains on forklift trucks the floor level as shown in Table 3. See Figure 39.
equipped with either pin- or hook-type forks in- Table 3. Hook-Type Carriage Chain Adjustment
stalled, go to Step 2. If forklift truck is normally
equipped with a hook-type carriage and has an Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)
attachment without forks, go to Step 3.
Class IV 133.5 ±3 mm (5.26 ±0.12 in.)

45
Welding Repairs
Figure 39. Lift Chain Adjustment, Hook-Type
Carriage
Welding Repairs
WARNING
Welding can cause a fire or an explosion. Al-
ways follow the instructions in the Frame sec-
tion of the Service Manual if a hydraulic tank
must be welded. Make sure there is no fuel, oil,
or grease near the weld area. Make sure there
is good ventilation in the area where the weld-
ing must be done.
Do not heat, weld, or bend forks. Forks are
made of special steel using special methods.
Get information from your dealer for Hyster
lift trucks before welding on a mast.
WARNING
Forklift frames and components may be
painted with a catalyzed paint, such as
polyurethane or a two-part primer. Weld-
ing, burning, or other heat sufficient to cause
thermal decomposition of the paint may re-
lease isocyanates. These chemicals are allergic
sensitizers to the skin and respiratory tract
and overexposure may occur without odor
warning. Should work be performed, utilize
good industrial hygiene practices including
removal of all paint (prime and finish coats) to
46
8000 SRM 1201
Legend for Figure 39
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
the metal around the area to be welded, local
ventilation, and/or supplied-air respiratory
protection.
CAUTION
When an arc welder is used, always disconnect
the battery connector on the lift truck. This
action will prevent damage to the motor con-
trollers.
Connect the ground clamp for the arc welder as
close as possible to the weld area. This action
will prevent damage to a bearing from the large
current from the welder.
NOTE: Remove all electronic controllers prior to arc
welding on these lift trucks. The removal procedures
for the electronic controllers are outlined in Electri-
cal System (Trucks With AC Controllers) 2200
SRM 1055.
Some welding repairs require special welding in-
structions and to get information from your dealer
for Hyster lift trucks before welding on truck. If an
acetylene or arc welder is used, do the procedures in
the previous WARNING and CAUTION.
8000 SRM 1201
Overhead Guard Changes
WARNING
DO NOT weld mounts for lights or accessories
to the legs of the overhead guard. The strength
of the overhead guard can be reduced by weld-
ing or heating.
Wheels and Tires
GENERAL
WARNING
The type of tires are shown on the lift truck
Nameplate. Make sure Nameplate is correct for
type of tires that are installed on lift truck.
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
These lift trucks use solid rubber tires. See Fig-
ure 40. Solid rubber tires made from softer or harder
material can be installed as optional equipment.
Tread on solid rubber tires can be either smooth
or it can have lugs. Electric compound tires are
recommended. DO NOT mix types of tires or tread
on lift truck. Make sure the type of tires that are
installed on lift truck are same as shown on lift truck
Nameplate.
1. SOLID RUBBER TIRE (PRESS-ON)
2. WHEEL
Figure 40. Wheel and Tire
Wheels and Tires
DO NOT operate lift truck without overhead
guard correctly fastened to the lift truck.
Observe previous WARNING before doing any
changes to overhead guard.
REMOVE WHEELS FROM LIFT TRUCK
WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
1. Raise lift truck as described in How to Put Lift
Trucks on Blocks in this manual.
2. Remove wheel nuts and remove wheel from lift
truck. Lift truck wheels are heavy.
REMOVE TIRE FROM WHEEL AND
INSTALL TIRE ON WHEEL
Remove
The correct tools, equipment, and a press ring must
be used for each size of wheel. Use a press to push
wheel from the tire assembly. The capacity of the
press must be approximately 36,000 to 181,600 kg
(80,000 to 400,000 lb).
Install
NOTE: Make sure tires are installed on wheels ac-
cording to dimensions shown in Figure 41. Tires
must be installed the same for both wheels (drive or
steer). Also check Nameplate of lift truck for correct
tread width.
The correct tools, equipment, and a press ring must
be used for each size of wheel. Use a press to push
the wheel into the tire assembly. The capacity of the
press must be approximately 36,000 to 181,600 kg
(80,000 to 400,000 lb).
47
Wheels and Tires 8000 SRM 1201

INSTALL WHEELS

CAUTION
Check all drive wheel nuts after 2 to 5 hours
of operation: when new lift trucks begin oper-
ation and on all lift trucks when drive wheels
have been removed and installed. Tighten
drive wheel nuts in a cross pattern to correct
torque value shown in the Maintenance Sched-
ule. When the drive wheel nuts stay tight
for eight hours, the interval for checking the
torque can be extended to 500 hours.

1. Install drive wheels on hubs. When drive wheels

are installed on lift truck, tighten wheel nuts
to torque shown in Specifications column in the
Offset* Maintenance Schedule.
Wheel Tire Width
Measurement A
2. Steering wheels are fastened to the spindle of the
229 mm (9 in.) 0 steering axle with a large castle nut. Make sure
Drive inner and outer bearings are correctly lubricated
304 mm (12 in.) 0
with grease. Install wheel and inner bearing as-
152 mm (6 in.) 0 sembly on spindle. Install outer bearing cone
Steer and castle nut. Tighten castle nut to 68 N•m
178 mm (7 in.) 12.7 mm (0.5 in.)
(50 lbf ft). Back off one quarter turn and tighten
*Offset is measured at the outside of the wheel. castle nut to 3 N•m (25 lbf in). Insert and bend
one prong of cotter pin.
A. STEER TIRE AND WHEEL
B. DRIVE TIRE AND WHEEL

Figure 41. Wheel and Tire Mounts

48
 TECHNICAL PUBLICATIONS

8000 SRM 1201 2/07 (11/06)(7/05)(3/05) Printed in U.S.A.