H230HD Manut - Periodica PDF

PERIODIC
MAINTENANCE
H8.00-12.00XM (H170-280HD) [F007];
H13.00-16.00XM (H300-360HD) [E019];
H10.00-12.00XM-12EC (H360HD-EC) [E019]
PART NO. 1494144
8000 SRM 934
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
Keep the unit clean and the working area clean and orderly.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
Be sure to follow the WARNING and CAUTION notes in the instructions.
Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a 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 ...............................................................................................................................................................
How to Move Disabled Lift Truck .................................................................................................................
How to Tow Lift Truck...............................................................................................................................
How to Put Lift Truck on Blocks...................................................................................................................
How to Raise Drive Tires ..........................................................................................................................
How to Raise Steering Tires .....................................................................................................................
Maintenance Schedule.......................................................................................................................................
Maintenance Procedures Every 8 Hours or Daily............................................................................................
How to Make Checks with Engine Stopped .................................................................................................
Tires and Wheels .......................................................................................................................................
Forks ..........................................................................................................................................................
Adjust.....................................................................................................................................................
Remove ..................................................................................................................................................
Install.....................................................................................................................................................
Forks, Mast, and Lift Chains, Inspect .....................................................................................................
Safety Labels .............................................................................................................................................
Operator Restraint System.......................................................................................................................
Steering Column Latch .............................................................................................................................
Drive Belts .................................................................................................................................................
Cooling System ..........................................................................................................................................
Fuel, Oil, or Coolant Leaks, Check...........................................................................................................
Cab Hydraulic System ..............................................................................................................................
Hydraulic System ......................................................................................................................................
Engine Oil ..................................................................................................................................................
Fuel System ...............................................................................................................................................
Primary Fuel Filter ...................................................................................................................................
Battery .......................................................................................................................................................
Air Filter ....................................................................................................................................................
How to Make Checks with Engine Running ................................................................................................
Gauges, Lights, Horn, and Fuses .............................................................................................................
Control Levers and Pedals ........................................................................................................................
Transmission Oil .......................................................................................................................................
Lift System Operation...............................................................................................................................
Brakes ........................................................................................................................................................
Steering System ........................................................................................................................................
Maintenance Procedures Every 250 Hours or Every 2 Months ......................................................................
Engine Oil and Filter - Cummins Engine ....................................................................................................
Empty Container Handler ............................................................................................................................
Maintenance Procedures Every 500 Hours or Every 2 Months ......................................................................
Lift Chains .....................................................................................................................................................
Lubrication ................................................................................................................................................
Adjust .........................................................................................................................................................
Drive Shaft .....................................................................................................................................................
Steering Axle..................................................................................................................................................
Wheel Nuts.....................................................................................................................................................
Shafts for Brake Actuators ...........................................................................................................................
Drive Axle and Differential...........................................................................................................................
Hydraulic Tank Breather ..............................................................................................................................
Air Filter, Engine, and Air Compressor .......................................................................................................
Cabin Air Filter, Heater ................................................................................................................................
Engine Oil and Filter - Perkins Engine........................................................................................................
2002 HYSTER COMPANY
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Table of Contents
Periodic Maintenance
TABLE OF CONTENTS (Continued)

Drive Belts .....................................................................................................................................................
Mast................................................................................................................................................................
General Lubrication ......................................................................................................................................
Forks Wear and Damage Check....................................................................................................................
Lift Chains Wear Check ................................................................................................................................
Fuel System ...................................................................................................................................................
Idle Speed ..................................................................................................................................................
Governor Speed (Diesel)............................................................................................................................
Maintenance Procedures Every 1000 Hours or 6 Months ...............................................................................
Transmission Oil and Filter, Change............................................................................................................
Final Fuel Filters, Diesel ..............................................................................................................................
Diesel Fuel System Air Removal ..............................................................................................................
Fuel Injection Pump Without Vent Tube..................................................................................................
Fuel Injection Pump Timing .........................................................................................................................
Valve Adjustment ..........................................................................................................................................
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................
Hydraulic System ..........................................................................................................................................
Hydraulic Oil Filter, Change ....................................................................................................................
Hydraulic Oil, Change ..............................................................................................................................
Differential and Drive Axle...........................................................................................................................
Wheel Bearings..............................................................................................................................................
Steer Wheels ..............................................................................................................................................
Drive Wheels .............................................................................................................................................
Service Brakes ...............................................................................................................................................
Cleaning Procedures (Dry Brake Axle) ....................................................................................................
Safety Procedures When Working Near Mast..................................................................................................
Fuel Injectors Check ..........................................................................................................................................
Lift and Tilt System Leak Check ......................................................................................................................
Lift System.....................................................................................................................................................
Tilt System .....................................................................................................................................................
Welding Repairs .................................................................................................................................................
Wheel and Tire Replacement ............................................................................................................................
Remove Wheels from Lift Truck ...................................................................................................................
Pneumatic Tires.............................................................................................................................................
Remove Tire from Wheel...........................................................................................................................
Remove Tire from Three- and Four-Piece Wheel ................................................................................
Install Tire on Wheel.................................................................................................................................
Install Three- or Four-Piece Wheel in Tire..........................................................................................
Add Air to Tires .............................................................................................................................................
Solid Rubber Tires .........................................................................................................................................
Remove Tire from Wheel...........................................................................................................................
Install Tire on Wheel.................................................................................................................................
Wheels, Install ...............................................................................................................................................
This section is for the following models:
H8.00-12.00XM (H170-280HD) [F007];
H13.00-16.00XM (H300-360HD) [E019];
H10.00-12.00XM-12EC (H360HD-EC) [E019]
ii
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8000 SRM 934
General
General
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can make
a dangerous operating condition.
WARNING
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag
in the operators area. Remove the key from
the key switch.
WARNING
Disposal of lubricants and fluids must meet local environmental regulations.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance of your
lift truck. The recommended time intervals are for
8 hours of operation per day. Shorten the recommended time intervals in the Maintenance Schedule
for the following conditions:
If the lift truck is used more than 8 hours per day
If the lift truck must work in dirty operating conditions
Your dealer for Hyster lift trucks has the equipment
and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A
regular program of inspection, lubrication, and maintenance will help your lift truck give more efficient
performance and operate for a longer period of time.
Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster lift
trucks to help users who do their own maintenance.
HOW TO MOVE DISABLED LIFT TRUCK

WARNING
Use caution when towing a lift truck if there is
a problem with any of the following:
Brakes do not operate correctly.
Steering does not operate correctly.
Tires are damaged.
Traction conditions are bad.

The lift truck must be towed on a steep grade.
If the engine cannot run, there is no power
available for the hydraulic steering system
and the service brakes. This condition can
make the lift truck difficult to steer and stop.
Poor traction can cause the disabled lift truck
or towing vehicle to slide. A slope will also
make the lift truck more difficult to stop.
Never lift and move a disabled lift truck unless
the disabled lift truck MUST be moved and
cannot be towed. A lift truck used to move
a disabled lift truck MUST have a capacity
rating equal to or greater than the weight of
the disabled lift truck. The capacity of the lift
truck used to move a disabled lift truck must
have a load center equal to half the width of
the disabled lift truck. See the capacity plate
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. Be careful not to damage
the underside of the lift truck.
NOTE: For lift trucks equipped with air brakes, if
there is no air pressure in the brake system, the parking brake must be manually released. To manually
release the parking brake, use the release bolt at
each air chamber to compress the spring that applies
the brake. Tighten the release bolt (or nut) until the
brake is released.
H8.00-12.00XM models: the release bolt, washer,
and nut are in a receptacle on the side of the air
chamber. Make sure the release bolt is engaged in
the piston before the nut is tightened.
H13.00-16.00XM models: the release bolt is permanently installed in the piston of the park brake.
How to Tow Lift Truck

1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. 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.
General
4. If another lift truck is used to tow the disabled lift
truck, that lift truck must have a weight equal
or greater than the weight of the disabled lift
truck. Install approximately 1/2 capacity load on
the forks of the lift truck that is being used to tow
the disabled lift truck. This 1/2 capacity load will
increase the traction of the lift truck. Travel with
the load as low as possible.
5. Use a towing link made of steel that attaches to
the tow pins in the counterweights of both lift
trucks.
HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and the counterweight. When the lift truck is put on blocks,
put additional blocks in the following positions to maintain stability:
1. Before removing the mast and drive axle,
put blocks under the counterweight so that
the lift truck cannot fall backward.
2. 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. Put a steel plate on top
of the block.
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 1.
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.
8000 SRM 934

4. Put additional blocks under the frame behind the
drive tires. Make sure the blocks are under the
frame and not under the hydraulic or fuel tanks.
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 capacity plate.
How to Raise Steering Tires

WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and the counterweight. When the lift truck is put on blocks,
put additional blocks in the following positions to maintain stability:
1. Before removing the mast and drive axle,
put blocks under the counterweight so that
the lift truck cannot fall backward.
2. 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. Put a steel plate on top
of the block.
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 the mast in the vertical position.
2. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 1.
3. Use a hydraulic jack to raise the steering tires.
Put the jack under the steering axle or frame to
raise the lift truck. 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 capacity plate.
4. Put blocks under the frame and counterweight to
support the lift truck. Make sure the blocks are
under the frame and not under the hydraulic or
fuel tanks.
8000 SRM 934
1. STEERING TIRES
Maintenance Schedule
2. DRIVE TIRES
Figure 1. Put Lift Truck on Blocks
Figure 2. Maintenance Points - Perkins Engine
8000 SRM 934
Figure 3. Maintenance Points - Cummins Engine

Table 1. Maintenance Schedule
Item
No.
Item
8 hr/
1 day
Hydraulic System
Dry Axle
Wet Axle
Engine Oil and Filter
Perkins (Turbo)
Perkins (Nonturbo)
Cummins
Air Filter, Engine and
Air Compressor
2
3
3
4
250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

hr/
2 mo 6 mo
1 yr
Quantity
2 mo
C
139 liter (37 gal)
C 1,2
C 1,2
C 1,2
X
X=Check
C=Change
Specification
10 W HCE - 4
J20C HCE - 102
17.5 liter (18 qt)
CG - 4
2 Filters
See Parts Manual
15.1 liter (16 qt)
CG - 4
1 Filter
See Parts Manual
16.3 liter (17.2 qt)
CG - 4
1 Filter
See Parts Manual
Clean or replace See Parts Manual
(See Note 3)
L=Lubricate
*Heavy-duty applications involving contaminated environment, poor ground conditions, intensive usage at
high performance levels, or other abnormal conditions will require more frequent servicing, in particular
lubricating points. At your request, your Hyster dealer will advise you of the appropriate service interval
based on an application survey.
NOTE:
1
Change filters after first 100 hours of operation on a new lift truck.
2
Change engine oil and filters every 500 hours (250 hours for Cummins Engine).
3
Very dirty conditions will require a more frequent clean and check.
4
Multipurpose grease with 2 to 4% molybdenum disulfide.
5
Lift chains must be lubricated after the first 100 hours of service.
8000 SRM 934
Table 1. Maintenance Schedule (Continued)
Item
No.
5
Item
Transmission Oil
8 hr/
1 day
X

hr/
2 mo 6 mo
1 yr
Quantity
2 mo
C
28 liter (30 qt)
Specification
Hyster Part
336831
Hyster Part
336832
Hyster Part
336833
Diesel No.
No.
No.
No.
Fuel Tank
Cooling System
Perkins 1006
Nonturbo
Cooling System
Perkins 1006T
Turbo
Cooling System
Cummins
Drive Belts
26.0 liter (27.4 qt) 50% Water with 50%

Ethylene Glycol
31.0 liter (32.8 qt) 50% Water with 50%

Ethylene Glycol
25.5 liter (27 qt) 50% Water with 50%

Ethylene Glycol
Check condition See Parts Manual
Check tension
Check condition See Parts Manual
7
8
120 liter (32 gal)
9 Radiator Hoses
10 Battery
Electrolyte Level
11 Primary Fuel Filter
12 Windshield Washer
Fluid
13 Tires
Tire Pressure
14 Brakes,
Service and Parking
15 Mast, Carriage,
Attachment
Transmission
Safety Belt and Seat

Rails
X
X
X
Clean
Check level
Drain water
Check level
X
X
Check condition
See capacity
plate
Check operation
Check condition
Check condition
and operation
Check operation
Check condition
X=Check
C=Change
See Parts Manual

2 Batteries
See Parts Manual
See Parts Manual
L=Lubricate
NOTE:
1
2
3
4
5
8000 SRM 934

Item
No.
Item
8 hr/
1 day
Engine Compartment
Safety Labels
Horn, Gauges, Lights,

Alarms, and Mirrors
Wet Brake System
Radiator
Steering

hr/
2 mo 6 mo
1 yr
Quantity
2 mo
Remove
combustible
materials
Replace if
necessary
Check operation
Inspect and clean
Check operation
16 Forks
17 Brake Filter
Wet Brake System
18 Lift Chains
X, L 5
X
Bleed the system

and adjust the
park brake every
6 months
Check condition
and lubrication
Check
adjustment
Check length
3 Fittings
19 Drive Shaft
20 Hydraulic Tank
Breather
1
Clean as
necessary
L
L
4 Fittings
2 Fittings
X=Check
See Parts Manual
Check condition
C
X
Steering Axle
21
Tie Rods
22 Lower Spindle
Bearings
Specification
C=Change
See Brake SRM
Engine Oil
Multipurpose
Grease 4
See Parts Manual
Multipurpose
Grease 4
Multipurpose
Grease 4
L=Lubricate
NOTE:
1
2
3
4
5
8000 SRM 934
Item
No.
Item
23 Drive Axle and

Differential
Dry Brake System
H8.00-12.00XM
H13.00-16.00XM
Wet Brake System
H8.00-12.00XM
H13.00-16.00XM
24 Wheel Nuts
Drive Wheels
Steer Wheels
Mast
25
Pivots
26
Sliding Surfaces
27
Sideshift Carriage
28
Fork Guides
Tilt Cylinder
Pivot Pins
Chain Anchors (Top
of Mast)
8 hr/
1 day

hr/
2 mo 6 mo
1 yr
Quantity
2 mo
X
Specification
SAE 85W-140
24.4 liter (26 qt)

22.5 liter (24 qt)
25.6 liter (27 qt)
23.5 liter (25 qt)
X
X
Check torque
Check torque
640 to 680 Nm
(472 to 502 lbf ft)
L
L
L
L
L
L
L
2 Fittings
As Necessary
4 Fittings
As Necessary
2 Fittings
4 Fittings
2
As necessary
Multipurpose
Grease 4
Multipurpose
Grease 4
Multipurpose
Grease 4
Engine oil
Multipurpose
Grease 4
Multipurpose
Grease 4
Multipurpose
Grease 4
Engine oil
Pedals, Levers,
Linkages, Cables,
Hinges, Seat Rails
Air Tank
Air Filter, Heater
X
X=Check
C=Change
Drain moisture
1
See Parts Manual
Clean (See Note 3)
L=Lubricate
NOTE:
1
2
3
4
5
8000 SRM 934

Item
No.
Item
8 hr/
1 day

hr/
2 mo 6 mo
1 yr
Quantity
2 mo
Engine Speed
Idle Speed
Perkins
Cummins
Governed Speed
Perkins 1006
Perkins 1006T
Cummins
29 Final Fuel Filters
30 Transmission Oil
Filter
Valve Adjustment,
Perkins
Inlet (Cold)
Exhaust (Cold)
Cummins
Inlet (Cold)
Exhaust (Cold)
Timing, Injection
Pump
Perkins
31 Hydraulic System Oil
Filter
32 Grease in Hub
Bearings, Steer
Wheels
Air Dryer
Adjust as
necessary
X
X
Adjust as
necessary
X
X
X
725 to 775 rpm

925 to 975 rpm
2200 rpm
2300 rpm
2780 rpm
See Parts Manual
1 (See Note 1)
See Parts Manual
Adjust as
required
X=Check
Specification
C=Change
Adjust as
required
0.20 mm (0.008 in.)

0.45 mm (0.018 in.)
0.25 mm (0.1 in.)
0.51 mm (0.2 in.)
23 BTDC static
1 (See Note 1)
See Parts Manual
As necessary
Multipurpose
Grease 4
As necessary
See Parts Manual
L=Lubricate
NOTE:
1
2
3
4
5
8000 SRM 934
Figure 4. Maintenance Points

Table 2. Maintenance Schedule (Empty Container Handler Model 553)
Item
Item
No.
1 Wear Pads for Main
Beams and Extended
Beams
Extension Cylinder
Support Wear Pads
Upper Sideshift Slider

Pads
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

1 day 2 mo
6 mo
1 yr
X,L
X=Check
Procedure or
Specification
Quantity
Check for wear of the Multipurpose
14 nylon wear pads
Grease 1
and replace before
metal to metal contact
between carriage and
frame occurs. Apply
grease to new pads or
in cases where there is
screeching noise.
Check for wear of the
4 nylon wear pads
and replace before
frame occurs.
nylon wear pads and
replace before metal to
metal contact between
carriage and frame
occurs.
L=Lubricate
NOTE:
1
8000 SRM 934
Table 2. Maintenance Schedule (Empty Container Handler Model 553) (Continued)

Item
Item
No.
4 Twistlock Housings
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

1 day 2 mo
6 mo
1 yr
X
Lower Sideshift Slider

Pads
End Beam Slider Pads
X=Check
Procedure or
Specification
Quantity
Check for wear and
possible damage of the
twistlock and the nose of
the twist lock housing.
Replace if damaged.
nylon wear pads and
carriage and frame
occurs.
nylon wear pads and
end beam and extension
beam occurs.
L=Lubricate
NOTE:
1
Item
Item
No.
Beams and Extended
Beams
Extension Cylinder
Support Wear Pads
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

Procedure or
Specification
1 day 2 mo
6 mo
1 yr
Quantity
X,L
14 nylon wear pads
Grease 1
and replace before
frame occurs. Apply
screeching noise.
X
4 nylon wear pads
and replace before
frame occurs.
X=Check L=Lubricate
NOTE:
1
10
8000 SRM 934

Item
Item
No.
3 Upper Sideshift Slider
Pads
Lifting Hooks

Pads
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

Procedure or
Specification
1 day 2 mo
6 mo
1 yr
Quantity
X
nylon wear pads and
carriage and frame
occurs.
X
Check for hooks for wear
and cracking. If any
sign of either defect
is suspected the hooks
should either be replaced
or nondestructive
crack tested.
X
nylon wear pads and
carriage and frame
occurs.
X
nylon wear pads and
beam occurs.
X=Check L=Lubricate
NOTE:
1
Item
Item
No.
Beams and Extended
Beams
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

1 day 2 mo
6 mo
1 yr
X,L
X=Check
Procedure or
Specification
Quantity
14 nylon wear pads
Grease 1
and replace before
frame occurs. Apply
screeching noise.
L=Lubricate
NOTE:
1
11
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 934

Item
Item
No.
2 Extension Cylinder
Support Wear Pads
8 hr/ 250 hr/ 1000 hr/ 2000 hr/

1 day 2 mo
6 mo
1 yr
X
Upper Sideshift Slider

Pads
Twistlock Assemblies
1 Grease Nipple per
Sleeve
1 Grease Nipple per
Twistlock
X,L

Pads
X=Check
Procedure or
Specification
Quantity
4 nylon wear pads
and replace before
frame occurs.
nylon wear pads and
carriage and frame
occurs.
Check for wear and
Multipurpose
possible damage of the
Grease 1
twistlock and twistlock
sleeve. Replace if in
doubt.
4 Fittings
nylon wear pads and
carriage and frame
occurs.
nylon wear pads and
beam occurs.
L=Lubricate
NOTE:
1

HOW TO MAKE CHECKS WITH ENGINE
STOPPED
Put the lift truck on a level surface. Lower the
carriage and forks, stop the engine, and apply the
12
parking brake. Open the hood and check for leaks

and conditions that are not normal. Clean any oil
or fuel spills. Make sure that lint, dust, paper,
and other materials are removed from the engine
compartment.
8000 SRM 934
Tires and Wheels

WARNING
Air pressure in tires can cause tire and wheel
parts to explode. The explosion of wheel parts
can cause serious injury or death.
Remove all of the air from the tires before the
tires are removed from the lift truck.
If the air pressure is less than 80% of the correct pressure, the tire must be removed before
air is added. Put the tire in a safety cage when
adding air pressure to the tire. Follow the procedures under Add Air to Tires.
When air is added to the tires, a remote air
chuck must be used so that the person adding
air can stand to the side and not in front of the
tire.
Keep the tires at the correct air pressure. (See the
capacity plate.) Check the air pressure with a gauge
when the tires are cold. See Figure 5. If it is necessary to add air to a tire that is warm, check one of
the other tires on the same axle and add air to the
tire that has low pressure so that the air pressures
are equal. The air pressure of warm tires must always be equal to or greater than air pressures specified for cold tires.
Check the tires for damage. Check the tread and remove any objects that will cause damage. Check for
bent or damaged rims. Check for loose or missing
hardware. Remove any wire, strapping, or other material that is wrapped around the axle.
Replace solid tires when the wear line at the side
of the tire has reached the tread surface. Extended
usage beyond the wear limit affects the stability of
the lift truck.
1. CHECK FOR DAMAGE (REMOVE NAILS,

GLASS, AND OTHER OBJECTS FROM TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 5. Tires Check
CAUTION
When the wheels have been installed, check
all wheel nuts after 2 to 5 hours of operation.
Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance
Schedule table. When the nuts stay tight after
8 hours, the interval for checking the torque
can be extended to 150 hours.
NOTE: Whenever a wheel is removed, it will be necessary to lubricate the wheel nuts and studs. See
Figure 34. Put two drops of engine oil (or other lubricant) between the flange and body of the wheel nut.
Also put two drops of oil on the threads of the studs.
Make sure the wheel nuts are tight. Tighten the
wheel nuts in a cross pattern (see Figure 34) to
the correct torque value shown in the Maintenance
Schedule.
13
Forks
The identification of a fork is determined by how it
is connected to the carriage. These lift trucks have
pin forks. Pin forks are fastened to the carriage with
large fork pins.
Adjust
A lock pin for each fork fits into the top carriage bar
and a slot in the fork. These lock pins hold the fork in
position. Adjust the forks as far apart as possible for
maximum support of the load. Make sure the lock pin
is engaged in the carriage bar and the fork. The fork
must be locked into position after the adjustment is
made.
8000 SRM 934

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 nuts and bolts are
tight.
2. Inspect the channels for wear in the areas where
the rollers travel. Inspect the rollers for wear or
damage.
3. Inspect the forks for cracks and wear. Check that
the fork tips are aligned (Figure 6). Check that
the bottom of the fork is not worn (Figure 6).
Remove
WARNING
Do not try to move a fork without a lifting device. The forks can weigh up to 370 kg (800 lb)
each.
Put the lift truck on a level surface and lower the
forks. Tilt the mast so that the forks have stability.
Remove the retainers for the fork pins and push the
pins from the carriage. Move the lift truck away from
the forks.
Install
1. Put the forks approximately 1 m (3 ft) in front of
the carriage.
2. Slowly move the lift truck toward the forks until
the fork pins can be installed. Install the fork
pins and the retainers.
Forks, Mast, and Lift Chains, Inspect

WARNING
Never work under a raised carriage, forks,
or mast channel. Lower the carriage or use
blocks and chains on the mast weldments and
carriage so that they cannot move. Make sure
the moving parts are attached to a part that
does not move.
Do not try to correct fork tip alignment by
bending the forks or adding shims. Replace
damaged forks.
14
Fork Tip Alignment

Length of Forks
3% Dimension
1220 mm (48 in.)

1830 mm (72 in.)
2440 mm (96 in.)
37 mm (1.45 in.)
55 mm (2.17 in.)
74 mm (2.91 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. FORK PIN DAMAGE
4. MUST BE 90% OF DIMENSION X
5. FORK WEAR
Figure 6. Forks Check
8000 SRM 934
4. Replace any damaged or broken parts that are

used to keep the forks locked in position.
hazards. It is important that all safety labels

are installed on the lift truck and can be read.
5. Check that the lift chains are correctly lubricated. Use engine oil to lubricate the chains.
Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the Frame section of the Service Manual for
the correct location of the safety labels.
6. If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks
and wear. Make sure the parts that fasten the
sideshift carriage or attachment to the carriage
are in good condition.
7. Inspect the lift chains for cracks or broken links
and pins. See Figure 7.
8. Inspect the chain anchors and pins for cracks and
damage.
9. Make sure the lift chains are adjusted so that
they have equal tension. If the lift chains need
repair or adjustment, it must be done by authorized personnel. See the section, Mast 4000 SRM
445, for adjustment procedures.
If new labels must be installed, use the following procedure:
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint with a cleaning solvent.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface. Make sure that all air is removed from
under the label and the corners and edges are
tight.
Operator Restraint System

The seat belt, seat, and mounting are all part of the
operator restraint system. See Figure 8. Each item
must be checked to make sure it is attached securely,
functions correctly, and is in good condition. The seat
belt must latch securely. Make sure the seat belt extends and retracts smoothly and is not damaged or
torn.
1.
2.
3.
4.
WORN PIN
CRACKS
EDGE WEAR
HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
Figure 7. Lift Chains Check
Make sure that the area around the lift truck is clear
before starting the engine or making any operational
checks. Be careful when making the checks. If the
lift truck is stationary during a check, apply the
parking brake and put the transmission in Neutral
(N). Proceed carefully.
Safety Labels
WARNING
Safety labels are installed on the lift truck to
give information about operation and possible
15
8000 SRM 934
A. AIR SEAT
B. MECHANICAL SEAT
1. SEAT BELT
2. SEAT RAIL
3. SEAT BELT RETRACTOR
Figure 8. Seat Check
Steering Column Latch

Make sure the latch for the steering column operates
correctly. The latch must NOT allow the column to
move unless the latch is released.
is heated and the level in the auxiliary coolant reservoir will increase.
Drive Belts
Check the drive belts for wear or damage.
Cooling System
WARNING
DO NOT remove the radiator cap when the engine is hot. When the pressure cap is removed
from the radiator, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
Check the coolant level at the auxiliary coolant reservoir. See Figure 9. Make sure the coolant level is
between the FULL and the ADD mark on the auxiliary coolant reservoir. The coolant will expand as it
16
1. AUXILIARY COOLANT RESERVOIR

2. RADIATOR
Figure 9. Auxiliary Coolant Reservoir
8000 SRM 934
If coolant is added, use the correct mixture of water

and ethylene glycol. See the Maintenance Schedule.
Fuel, Oil, or Coolant Leaks, Check

WARNING
All fuels are very flammable and can burn or
cause an explosion. Do not use an open flame
to check the fuel level or to check for leaks in
the fuel system. If there is a leak in the fuel system, extra care must be used during the repair.
Do not operate the lift truck until a leak is repaired.
Make a visual check for leaks on and under the lift
truck. If possible, find and repair the leak at the
source. Leaks often indicate a need for repair of damaged or worn components.
Check the fuel system for leaks and the condition of
parts. Also check the condition of the radiator or
heater hoses that are not leaking. Soft or cracked
hoses need to be replaced before a major leak occurs.
Cab Hydraulic System

The hydraulic system for the cab tilt device has a
separate reservoir.
If the cab does not tilt completely, the oil level may
be low and require filling.
Lock the cab in the half open position. Place the
pump mechanism in the full down position, and remove the filler plug from the hand pump reservoir.
See Figure 10. Add 0.2 liter (0.4 pt) of hydraulic oil
to the hand pump reservoir. Install the plug in the
hand pump reservoir.
CAUTION
Place oil absorbing material around the opening of the hand pump reservoir before lowering the cab. This will prevent any accidental
spillage of hydraulic oil when the cab is lowered.
Lower the cab to the fully lowered position.
1. PUMP
MECHANISM
2. FILLER PLUG
3. HAND PUMP
RESERVOIR
Figure 10. Cab Tilt Device
Hydraulic System
WARNING
At operating temperature the hydraulic oil is
HOT. Do not permit the oil to touch the skin and
cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter
is changed.
Never operate the hydraulic pump without oil
in the hydraulic system. The operation of the
hydraulic pump without oil will damage the
pump.
Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered, and the
engine is stopped. See Figure 11. Add hydraulic oil
only as needed. If more hydraulic oil is added than
the FULL level, the hydraulic oil will leak from the
breather during operation.
17

To add hydraulic oil, remove dipstick and add hydraulic oil through the dipstick opening with the return filter installed. When adding large volumes of
oil, use a pump with a filter assembly. The filter assembly should filter to at least three micron. To insert the filler hose of the pump with the filter assembly into the hydraulic tank, the hydraulic return filter must be removed.
8000 SRM 934

Do not operate the lift truck until a leak is repaired.
Check the fuel system for leaks and the condition of
the parts. When fuel is added to the lift truck, see the
section How to Add Fuel to Lift Truck procedures
in the Operating Manual.
Check the hydraulic system for leaks and damaged

or loose components.
1. DIPSTICK FOR HYDRAULIC OIL

2. HYDRAULIC OIL FILTER
3. BATTERY
1.
2.
3.
4.
ENGINE OIL DIPSTICK

ENGINE OIL FILTER
PRIMARY FUEL FILTER
FINAL FUEL FILTER
Figure 12. Perkins Engine Maintenance
Figure 11. Maintenance Points
Engine Oil
WARNING
Long term exposure to used engine oil can
cause skin damage or cancer. Wash with detergent and water.
After the engine has stopped, wait 1 minute before
checking the oil level. See Figure 12 or Figure 13.
Keep the oil at the correct level as indicated on the
dipstick. Use the correct oil as shown in the Maintenance Schedule.
Fuel System
WARNING
All fuels are very flammable and can burn or
cause an explosion. Do not use an open flame
to check the fuel level or to check for leaks in
the fuel system. If there is a leak in the fuel system, extra care must be used during the repair.
18
1. ENGINE OIL DIPSTICK

2. FUEL FILTER
3. WATER SEPARATOR
Figure 13. Cummins Engine Maintenance
8000 SRM 934
Primary Fuel Filter

Drain the water from the primary fuel filter. See Figure 12 or Figure 13.
1. Open the valve on the bottom of the filter canister. Drain some fuel (and any water) into a cup
until clean fuel flows from the filter.
2. Close the valve.
Battery
WARNING
The acid in the electrolyte can cause injury.
If the electrolyte is spilled, use water to flush
the area. Use a solution of sodium bicarbonate
(baking soda) to make the acid neutral. Acid
in the eyes must be flushed with water immediately.
Wear eye protection. Batteries generate explosive fumes. Keep the vents in the caps
clean. Keep sparks or open flame away from
the battery area. Do not make sparks from the
battery connections. Disconnect the battery
ground cable when doing maintenance.
CAUTION
Disposal of batteries must meet local environmental regulations.
Keep the battery and cable terminals clean. See Figure 11. Check the electrolyte level (unless a maintenance-free battery). Keep the electrolyte level above
the separators and plates. Use distilled water. Do
not fill the battery past the bottom of the internal
filler neck.
If the battery becomes discharged and requires a
booster battery to start the engine, follow these
procedures carefully when connecting the jumper
cables:
1. Always connect the positive jumper cable to the
positive terminal of the discharged battery and
the negative jumper cable to the negative terminal.

3. Always connect the jumper cables to the discharged battery before connecting them to the
booster battery.
Air Filter
NOTE: If the indicator light is on, the air filter must
be replaced.
There are air filters for the engine and the air compressor.
Clean the inside of the canister when changing filters.
HOW TO MAKE CHECKS WITH ENGINE

RUNNING
WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if
the lift truck tips over. IT CAN ONLY HELP IF
IT IS FASTENED.
Make sure that the area around the lift truck is clear
before starting the engine or making any operational
checks. Be careful when making the checks. If the
lift truck is stationary during a check, apply the
parking brake and put the transmission in NEUTRAL. Proceed carefully.
Gauges, Lights, Horn, and Fuses

Start the engine. Check the gauges and lights for correct operation as described in the Operating Manual. Check the operation of the horn.
The fuse and relay panels are located under the instrument console on the RIGHT SIDE of the operators seat. See Figure 14. To access the fuse and relay
panels, remove four knurled screws and the cover.
NOTE: Not all trucks may be equipped with the same
fuses and/or relays (e.g., trucks not equipped with the
cold start feature will not have the cold start fuses or
relays).
The fuse and relay positions and titles are as shown
in Figure 15 and Figure 16.
2. Always connect the ground jumper cable last.
19
8000 SRM 934

Legend for Figure 15
1. KNURLED KNOBS
2. COVER
Figure 14. Fuse Panel Location
1. FUSE PANEL #1 LOCATOR

1. HYDRAULIC CONTROLS
2. TRANSMISSION
3. ATTACHMENT CONTROLS
4. TRANSMISSION B+
5. TRANSMISSION B+
6. PARK BRAKE
7. FRONT END GROUND
8. FRONT WINDOW WASHER/WIPER
9. ROOF WINDOW WASHER/WIPER
10. REAR WINDOW WASHER/WIPER
11. FRONT INNER FLOODLIGHTS
12. FRONT OUTER FLOODLIGHTS
13. REAR DRIVE LIGHTS
14. BEACON/STROBE
15. STOPLIGHTS
16. MAST LIGHTS
17. HAZARD LIGHTS
18. DIRECTION INDICATORS
19. SIDE/TAILLIGHTS
20. FRONT DRIVE LIGHTS
21. ENGINE START
22. ENGINE COLD START (PERKINS)
23. INSTRUMENTATION/SHUTDOWN
24. CAB TILT POWER ASSIST
25. HORN
26. INTERIOR LIGHTING
27. SEAT SUSPENSION COMPRESSOR
28. HEATER/AC VENTILATION FAN
29. OIL COOLER/AIR DRIER
30. REVERSE LIGHTS/ALARM
31. CONSOLE ACCESSORY SOCKET
32. RADIO/CB/INTERCOM
33. OPEN
34. OPEN
35. OPEN
36. ENGINE STOP SOLENOID
37. OPEN
38. OPEN
39. OPEN
40. ENGINE COLD START (PERKINS)
Control Levers and Pedals

Check that the control levers for the transmission,
mast and attachment, and the pedals operate as described in the Operating Manual.
Transmission Oil
Figure 15. Fuse Panel
20
Apply the parking brake. Check the oil level in the

powershift transmission when the engine is running
at idle speed and, if equipped, the direction control
lever is in the NEUTRAL position. See Figure 17.
Use the correct oil as shown in the Maintenance
Schedule. Keep the oil level at the FULL mark on
the dipstick.
8000 SRM 934

lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
WARNING
Before making any repairs, use blocks and
chains on the mast weldments and carriage so
that they cannot move. Make sure the moving
parts are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
Do the following checks and inspections:
1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the mast several times
without a load. Raise the mast to its full extension height at least once. The mast components
must raise and lower smoothly in the correct sequence.
Figure 16. Relays (Located Left of Fuse Panel)
NOTE: Some parts of the mast move at different

speeds during raising and lowering.
3. The inner weldment and the carriage must lower
completely.
4. Raise the mast 1 m (3 ft) with a capacity load.
The inner weldment and the carriage must raise
smoothly. Lower the mast. All moving components must lower smoothly.
5. Lower the load to approximately 0.3 m (1 ft) from
the floor. Tilt the mast forward and backward.
The mast must tilt smoothly and both tilt cylinders must stop evenly.
1. TRANSMISSION OIL DIPSTICK

2. FUEL CAP
Figure 17. Transmission Oil
Lift System Operation

WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not
put any part of your body in or through the
6. Check that the controls operate the functions of

the attachment correctly. (See the symbols next
to each of the controls.) Make sure all of the hydraulic lines are connected correctly and do not
leak.
Brakes
Check that the service and parking brakes operate
correctly. The service brakes must apply when the
brake pedal is depressed. The parking brake must
apply when the knob for the parking brake is pulled.
The parking brake must release when the knob is
21
Maintenance Procedures Every 500 Hours or Every 2 Months
8000 SRM 934
pushed. On lift trucks with a Monotrol pedal, applying the parking brake puts the transmission in Neutral.
Steering System
NOTE: Full application of the inching/brake pedal

applies the service brakes and disengages the transmission.
The lift truck has hydraulic power steering.

The steering can be difficult if the engine is
not running.
WARNING
Make sure the steering system operates smoothly

and gives good steering control.

NOTE: Do the 8-hour checks before beginning these
procedures.
ENGINE OIL AND FILTER - CUMMINS

ENGINE
CAUTION
Long-term exposure to used engine oil can
cause skin irritation or cancer. Wash with
detergent and water.
CAUTION
Never run the engine without oil.
NOTE: Change the oil filter for the engine after the
first 100 hours on new lift trucks.
Change the filter at the same time engine oil is
changed. See Figure 13. Use the correct oil according to the specifications. Install a new filter. Apply
clean oil to the gasket of the new filter. Turn the

filter until the gasket touches, then tighten 1/2 to
3/4 turn with your hand.
CAUTION
To prevent possible engine damage if the engine starts before sufficient oil pressure is
reached, turn the ignition key to the stop position.
Turn the ignition key to the start position and crank
the engine until either the oil pressure warning light
extinguishes or oil pressure is registered on the oil
pressure gauge.
EMPTY CONTAINER HANDLER

See Table 2, Table 3, and Table 4 and Empty Container Handling Attachment 5000 SRM 969.

NOTE: Do the 8-hour and 250-hour checks before
beginning these procedures.
LIFT CHAINS
Lubrication
WARNING
Do not repair a worn or damaged lift chain. Replace a worn or damaged lift chain with a new
chain. If a pair of lift chains is used in the mast,
both lift chains must be replaced.
Lubricate the lift chains with SAE 30 engine oil. The
best procedure is to remove the chains from the lift
truck and soak them in oil.
22
Adjust
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain
anchors are completely engaged. Make sure that all
of the adjustment is not removed from the chain anchors. The chain anchors must be able to move in
their sockets.
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.
The chains must travel freely through the complete
cycle.
8000 SRM 934
1. Put a load equal to 80 to 90% of the capacity load

on the forks. Lower the forks as much as possible. Tilt the mast fully backward.
2. Check the amount that the bottom carriage roller
extends below the inner channel of the mast. See
Figure 18. The carriage roller must not extend
more than 34 mm (1.3 in.) below the inner channel. If the adjustment is not correct, adjust the
chain anchors. Make sure each anchor is adjusted the same amount.
STEERING AXLE
Raise the steering axle as directed in How to Raise
Steering Tires in this SRM.
Lubricate the grease fittings on the tie rods and the
lower spindle bearings with multipurpose grease.
See Figure 19.
3. Remove the load from the forks. Check the clearance of the carriage when the mast is fully extended. The carriage must not touch the top
crossmember of the inner weldment. The chains
are too tight if the carriage touches the crossmember. Put the mast in a vertical position and
lower the carriage completely. If the forks do not
just touch the surface, the chains are too tight.
If the chains are too tight, adjust the chain anchors. Make sure each anchor is adjusted the
same amount.
1. TIE ROD
2. LOWER SPINDLE BEARING
Figure 19. Steering Axle
WHEEL NUTS
Check the torque of the wheel nuts. Tighten the nuts
to 640 to 680 Nm (470 to 500 lbf ft) in the sequence
shown in Figure 34.
SHAFTS FOR BRAKE ACTUATORS

Lubricate the grease fitting on the shafts for the
brake actuator arms.
1.
2.
3.
4.
TILT MAST FULLY BACKWARD

CARRIAGE ROLLER
FORK
CARTRIDGE ROLLER MUST NOT EXTEND
MORE THAN 34 mm (1.3 in.) BELOW MAST
CHANNEL
Figure 18. Lift Chain Adjustments
DRIVE SHAFT
Lubricate the three fittings on the transmission drive
shaft with multipurpose grease.
DRIVE AXLE AND DIFFERENTIAL

The drive axle and differential use the same oil supply. The oil level in the drive axle is correct when the
oil is even with the plug in the planetary cover. Be
sure to check both planetary covers and the differential when checking the oil level. Make sure the level
line on the planetary cover is parallel to the floor.
The oil level in the differential is correct when the
oil is even with the plug in the front of the housing.
Add the correct oil as specified in the Maintenance
Schedule.
23
HYDRAULIC TANK BREATHER

The hydraulic tank breather is located behind the
right hand cover. Remove cover or raise cab. See
Raising and Lowering Cab, 100 SRM 935, and replace. See Figure 2.
AIR FILTER, ENGINE, AND AIR

COMPRESSOR
Replace the air filter.
CABIN AIR FILTER, HEATER

Remove the four screws and the air intake cover at
the left rear of the vehicle and replace the air filter.
ENGINE OIL AND FILTER - PERKINS

ENGINE
8000 SRM 934
a pair. When a pair of drive belts is used, adjust the

tension for the tightest belt.
A gauge is available that will indicate the tension
in the drive belt. Fit the gauge at the center of the
longest length of the drive belt and measure the tension. See Figure 20. The correct tension is approximately 355 N (80 lbf).
The tension can also be checked by pushing on the
drive belt as shown in Figure 21. Push on the drive
belt with approximately 10 kg (20 lb) force between
the alternator and crankshaft pulleys. When the tension is correct, the drive belt will move approximately
13 mm (0.5 in.).
Loosen the capscrew on the alternator mount to adjust the tension of the drive belts.
CAUTION
Long-term exposure to used engine oil can
cause skin irritation or cancer. Wash with
detergent and water.
CAUTION
Never run the engine without oil.
NOTE: Change the oil filter for the engine after the
first 100 hours on new lift trucks.
Change the filter at the same time engine oil is
changed. See Figure 12. Use the correct oil according to the specifications. Install a new filter. Apply
clean oil to the gasket of the new filter. Turn the
filter until the gasket touches, then tighten 1/2 to
3/4 turn with your hand.
CAUTION
To prevent possible engine damage if the engine starts before sufficient oil pressure is
reached, turn the ignition key to the stop position.
Turn the ignition key to the start position and crank
the engine until either the oil pressure warning light
extinguishes or oil pressure is registered on the oil
pressure gauge.
DRIVE BELTS
Check the drive belts for wear and damage. When a
pair of drive belts is used, they must be replaced as
24
Figure 20. Gauge to Check Drive Belt Tension
MAST
WARNING
Lower the lift mechanism completely. 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
STOPPED.
parts are attached to a part that does not move.
To lower the mast, there must be 24-volt system
power available to energize the solenoids that operate the control valve. Turn the ignition key to the
on position and operate the mast lowering lever or
joystick to lower the mast.
8000 SRM 934

1. Lubricate the sliding surfaces for the bearing
blocks along the full length of the channels as
shown in Figure 23. Apply lubricant only to the
indicated surfaces.
1. PIVOT FASTENER
2. ADJUSTMENT
LINK
Figure 21. Check and Adjust Drive Belt Tension

(Diesel)
If for any reason 24 volts are not available, the cab
must be tilted and the manual valve on the front of
the control valve must be turned to allow the mast to
be lowered manually. See Figure 22.
1.
2.
3.
4.
5.
6.
7.
LOAD ROLLER
BEARING BLOCK
LUBRICATE BEARING BLOCK SURFACES
LUBRICATE STRIP BEARINGS
OUTER WELDMENT
INNER WELDMENT
CARRIAGE
Figure 23. Lubricate Mast
NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.
NOTE: The drive wheels must be lifted off the ground
while lubricating the mast pivot pins.
2. Lubricate the pivot pins for the mast at the
grease fittings on the pivot pins. Use multipurpose grease.
3. Lubricate the pivot pins for the tilt cylinders.
There is a grease fitting on each pivot pin. Use
multipurpose grease.
1. MANUAL VALVE
2. CONTROL VALVE
4. If a sideshift carriage is installed, lubricate the

fittings and the sliding surfaces with multipurpose grease.
Figure 22. Manual Lowering Valve
25
8000 SRM 934
GENERAL LUBRICATION
Inspect all hinges, pins, linkages, cables, pedals, and
levers for wear and damage. Lubricate these parts
as necessary with engine oil.
FORKS WEAR AND DAMAGE CHECK
Legend for Figure 24

NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
Pitch
Total Length
of 20 Links
(Pitch) of New
Chain
Wear Limit
- Maximum
Length of 20
Links
31.8 mm
(1.25 in.)
38.1 mm
(1.50 in.)
44.5 mm
(1.75 in.)
635 mm
(25.0 in.)
762 mm
(30.0 in.)
889 mm
(35.0 in.)
654 mm
(25.7 in.)
785 mm
(30.9 in.)
915 mm
(36.0 in.)
WARNING
Never repair damaged forks. Do not heat, weld,
or bend the forks. Forks are made of special
steel using special methods. Replace damaged
forks.
1. Check the heel and attachment points of the
forks with a penetrant or magnetic particle inspection. See Figure 6.
2. Measure the thickness of the forks at a vertical
section where there is no wear. This is dimension
X. Now measure the thickness at the heel of the
fork. If the thickness is not more than 90% of
dimension X, replace the fork.
LIFT CHAINS WEAR CHECK

If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. Measure the chain for wear where it moves
over the sheaves. If a chain scale is available, check
the lift chains as shown in Figure 24.
1. CHAIN WEAR SCALE

If a chain scale is not available, measure 20 links of
chain. Measure from the center of a pin to the center
of another pin 20 pitches away. Compare the length
with the chart in Figure 24. Replace the chain if the
length of 20 links of the worn section is more than
the WEAR LIMIT.
FUEL SYSTEM
With the engine at normal operating temperature,
adjust engine speed as follows:
Idle Speed
Loosen the lock nut and turn the idle speed screw until the idle speed is within the specifications shown in
the Maintenance Schedule. See Figure 25. Tighten
the lock nut.
Governor Speed (Diesel)

1. Adjust the idle speed to 725 to 775 rpm.
2. Disconnect the throttle cable at the throttle lever
on the fuel injection pump. See Figure 26. Push
the throttle or MONOTROL pedal until it stops
against the floor plate. Hold the pedal in this
position with a rod.
Figure 24. Lift Chains Check
26
3. Connect the end of the throttle cable to the rod

end on the throttle lever. Make sure the end of
the cable is connected securely with the rod end,
but the cable is not tight. Tighten the jam nut to
hold the cable to the rod end.
8000 SRM 934
4. Adjust the cable housing at the bracket on the engine to obtain full throttle at the engine. Tighten
the jam nuts on the cable housing.
5. Remove the rod from holding the pedal in the
open position. If necessary, adjust the pedal stop
so that there is approximately 3 mm (0.12 in.)
free pedal when the engine is at idle speed.
6. On units with a Monotrol pedal, move the pedal
from FORWARD to REVERSE and REVERSE
to FORWARD several times. The pedal must
shift to the opposite direction before the throttle
opens.
1. IDLE SPEED SCREW

Figure 25. Fuel Injection Pump
1.
2.
3.
4.
5.
THROTTLE OR MONOTROL PEDAL

FLOOR PLATE
PEDAL STOP
BRACKET
JAM NUT
6.
7.
8.
9.
CABLE END
JAM NUT
ROD END
THROTTLE LEVER
Figure 26. Diesel Throttle Adjustment
27
Maintenance Procedures Every 1000 Hours or 6 Months
8000 SRM 934

NOTE: Do the 500-hour checks before beginning
these procedures.
TRANSMISSION OIL AND FILTER,

CHANGE
WARNING
The transmission oil can be hot after operation
of the lift truck.
WARNING
Disposal of lubricants and fluids must meet local environmental regulations.
NOTE: Change the oil filter for the transmission after
the first 100 hours on new lift trucks.
Change the oil and filter for the transmission. The
drain plugs for the transmission are at the front of
the housing, below the drive shaft. Put a container
under the transmission. Remove the drain plug,
spring, and screen at the rear of the transmission
housing. Clean the screen. After the oil has drained,
install the screen, spring, and plug. Install the
drain plugs. Replace the filter when the oil in the
transmission is changed. Remove and discard the
old filter. Apply clean oil to the gasket of the new
filter. Install the new filter and tighten it with your
hand. When starting the engine, DO NOT exceed
the idle level during the first 5 seconds. Check for
leaks during operation.
1.
2.
3.
4.
ENGINE OIL DIPSTICK

ENGINE OIL FILTER
PRIMARY FUEL FILTER
FINAL FUEL FILTERS
Figure 27. Perkins Engine Maintenance
FINAL FUEL FILTERS, DIESEL

Remove and discard the filter elements. See Figure 27 or Figure 28. Put oil on the seal of the new
filter and install it. Remove air from the fuel system.
Diesel Fuel System Air Removal

The engine cannot be started if there is air in the fuel
system. The air must be removed from the fuel system if any part of the fuel system has been disconnected. Also remove the air if there was a leak in the
low-pressure part of the fuel system while the engine
was running.
28
1. ENGINE OIL DIPSTICK

2. FUEL FILTER
3. WATER SEPARATOR
Figure 28. Cummins Engine Maintenance
8000 SRM 934
Fuel Injection Pump Without Vent Tube

1. Make sure there is fuel in the fuel tank. Refer to
the "How to Add Fuel to Lift Truck" procedures
in the Operating Manual.
2. Loosen the banjo bolt on the top of the filter head.
See Figure 29. If a vent plug has been installed,
loosen the vent plug instead.
NOTE: If the drive cam of the fuel lift pump is at the
point of maximum lift, it will not be possible to operate the priming lever. In this situation, the crankshaft must be rotated one revolution.
3. Operate the priming lever of the fuel lift pump
until fuel without air bubbles comes out of the
banjo bolt. Tighten the banjo bolt.
CAUTION
The starting aid must be held in place with an
open end wrench while loosening and tightening the union nut in Step 4.
CAUTION
Do not tighten the union nuts of the high-pressure pipes more than the recommended torque.
If there is leakage from the union nut, ensure
that the pipe is correctly aligned with the atomizer inlet. Do not tighten the atomizer union
nut more, as this can cause a restriction at the
end of the pipe which can affect fuel delivery.
7. Turn the ignition key to the ON position. Operate the starter motor until fuel, free from
air, comes from the high-pressure connections.
Tighten the high-pressure pipe connections to
22 Nm (16 lbf ft). Turn the ignition key to the
OFF position.
8. The engine is now ready to start. If the engine
runs correctly for a short period of time and then
stops or runs roughly, check for air in the fuel
system. If there is air in the fuel system, there is
probably a leak in the low-pressure system.
FUEL INJECTION PUMP TIMING
4. Loosen the start aid union nut at the cold start

aid and operate the priming lever until fuel,
free of air, comes from the start aid union nut.
Tighten the start aid union nut at the cold start
aid.
See the section Perkins Diesel Engines 600 SRM

705 for the procedures to check the injection pump
timing.
5. Loosen the fuel inlet union nut of the fuel inlet

pipe. Operate the priming lever until fuel, free of
air, comes from the fuel inlet union nut. Tighten
the fuel inlet union nut at the fitting.
See the section Perkins Diesel Engines 600 SRM

705 for the procedures to adjust the valves.
VALVE ADJUSTMENT
6. Loosen the high-pressure connections at two of

the atomizers.
29
1. BANJO BOLT
2. START AID UNION NUT
3. COLD START AID
8000 SRM 934
4. FUEL INLET UNION NUT

5. HIGH-PRESSURE CONNECTIONS
Figure 29. Remove Air from Diesel Fuel System
30
8000 SRM 934
Maintenance Procedures Every 2000 Hours or Yearly
Maintenance Procedures Every 2000 Hours or Yearly

NOTE: Do the 1000-hour checks before beginning
these procedures.
HYDRAULIC SYSTEM
NOTE: Change the oil filter for the hydraulic system
after the first 100 hours on new lift trucks.
differential and drive axle. To drain the oil, remove

the plugs from the planetary covers and the plug at
the bottom of the differential housing. Operate the
lift truck to make sure the oil level is even. Check
the oil level again and check for leaks.
Hydraulic Oil Filter, Change

Remove the filter head from the hydraulic tank. Remove and discard the filter. Install a new filter. Install the filter head, making sure it is tight against
the tank. Operate the system and check for leaks.
Hydraulic Oil, Change

WARNING
At operating temperature, the hydraulic oil is
HOT. Do not permit the oil to touch the skin and
cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter
is changed.
1. Put the lift truck on a level surface and lower the
carriage. Put a container under the hydraulic
tank. Remove the drain plug to drain the oil.
2. When the hydraulic oil has drained, install the
drain plug. Fill the hydraulic tank with the correct oil.
1. LEVEL LINE
2. DRAIN PLUG
Figure 30. Drive Axle
WHEEL BEARINGS
Steer Wheels
Lubricate the wheel bearings in the hubs for the steer
wheels with multipurpose grease. Install the hubs as
follows:
1. Install the hub and bearings on the spindle.
3. To add hydraulic oil, remove the dipstick and add

hydraulic oil through the dipstick opening with
the return filter installed. When adding large
volumes of oil, use a pump with a filter assembly.
The filter assembly should filter to at least three
micron. To insert the filler hose of the pump with
the filter assembly into the hydraulic tank, the
hydraulic return filter must be removed.
2. Install the washer and the castle nut. Tighten

the castle nut to 200 Nm (150 lbf ft) while rotating the wheel and hub. Loosen the nut to
less than 25 Nm (20 lbf ft). Tighten the nut to
35 Nm (25 lbf ft). Tighten the castle nut until
the cotter pin can be installed. Install the cotter
pin and grease cap.
DIFFERENTIAL AND DRIVE AXLE
Drive Wheels
The drive axle and differential use the same oil supply. The oil level in the drive axle is correct when the
oil is even with the plug in the planetary cover.
Lubricate the inner and outer wheel bearings in the

hubs for the drive wheels with multipurpose grease.
Refer to the Drive Axle or Brake System section for
the removal and installation procedures of the drive
wheels and hubs.
Make sure the level line on the planetary cover is parallel to the floor. See Figure 30. Change the oil for the
31
Safety Procedures When Working Near Mast
SERVICE BRAKES
Cleaning Procedures (Dry Brake Axle)
WARNING
Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings
is a cancer or lung disease hazard. Do not
create dust! Do not clean brake parts with
compressed air or by brushing. Use vacuum
equipment approved for dangerous fibers or
follow the cleaning procedure in this section.
When the brake drums are removed, do not
create dust.
Do not sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used.
1. Do not release brake lining dust from the brake
linings into the air when the brake drum is removed.
8000 SRM 934

2. Use a solvent approved for cleaning of brake
parts to wet the brake lining dust. Follow the
instructions and cautions of the manufacturer
for the use of the solvent. If a solvent spray is
used, do not create brake lining dust with the
spray.
3. When the brake lining dust is wet, clean the
parts. Put any cloth or towels in a plastic bag
or an airtight container while they are still wet.
Put a DANGEROUS FIBERS warning label on
the plastic bag or airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
5. Check the brake lining and brake assembly
parts for wear or damage. See the section Brake
System for the removal and installation procedures of the drive wheels and hubs. If the
linings or shoes are worn or damaged, replace
the brake shoes. It is recommended that brake
shoes be replaced in complete sets. Inspect the
brake drums for cracks or damage. Replace any
damaged parts. See Wet Brake System 1800
SRM 951.
Safety Procedures When Working Near Mast

The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
Never put any part of the body into or under
the mast or carriage unless all parts are completely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a DO NOT OPERATE tag
in the operators compartment.
Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
Do NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
32
Do NOT use blocks to support the mast weldments nor to restrain their movement.
Mast repairs require disassembly and removal of parts and can require removal
of the mast or carriage. Follow the repair
procedures in the correct Service Manual
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:
a. Put the mast in a vertical position.
8000 SRM 934
Fuel Injectors Check
b. Raise the mast to align the bottom of the inner weldment to below the anchor for the tilt
cylinders. See Figure 31.
c. Use a 13 mm (0.5 in.) minimum safety chain
with a hook to fasten the weldments together
so that the inner weldment cannot lower. Install the chain on both sides of the mast.
1. INNER WELDMENT
Make sure the hooks are completely engaged

with a link in the chain.
d. Lower the mast until there is tension in the
safety chain. If the engine is running, stop
the engine. Apply the parking brake. Install a DO NOT REMOVE tag on the safety
chain. Put a DO NOT OPERATE tag in the
operators compartment.
2. TILT CYLINDER ANCHOR
3. HOOK
Figure 31. Mast
Fuel Injectors Check

For trucks with Perkins Engines, see Perkins Diesel Engines 600 SRM 705 for the procedures to check injector pump timing.
33
Lift and Tilt System Leak Check
8000 SRM 934
Lift and Tilt System Leak Check

LIFT SYSTEM
WARNING
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
stopped.
parts are fastened to the 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 the pressure.
During test procedures for the hydraulic system, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel
away from the lift truck during the tests.
1. Slowly raise and lower the mast several times
without a load. Put a capacity load on the forks
and raise and lower the load several times.
Lower the load and tilt the mast forward and
backward several times. Check for leaks and
repair as necessary.
2. Raise the carriage and the capacity load 1 m
(3 ft). If the carriage lowers slowly with the
control valve in a NEUTRAL position, there
are leaks inside the hydraulic system. The
maximum speed that the carriage is allowed
to lower is shown in Table 5. For example, the
maximum speed that the carriage is allowed to
lower is 33 mm (1.3 in.) per 10 minutes when
the hydraulic oil is 30 C (86 F).
3. Check the lift cylinder for internal leaks. Remove
the load from the forks. Install a gate valve in
34
each of the supply lines between the main control

valve and the mast. Put a capacity load on the
forks again. Raise the carriage 1 m (3 ft). Close
both gate valves. If the carriage or inner mast
lowers slowly, the seals in the lift cylinders have
leaks.
4. If the carriage does not move, open both gate
valves and check the movement again. If the carriage lowers when the gate valves are open, check
for leaks in the hydraulic lines and fittings. If no
leaks are found, the main control valve can have
a defect. Remove the load from the forks.
TILT SYSTEM
1. Put a capacity load on the forks and raise the
forks approximately 30 cm (12 in.). Slowly tilt
the mast forward. If the mast continues to slowly
tilt forward when the control valve is in a NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the
mast is allowed to tilt forward is shown in Table 5. For example, the maximum speed that the
mast is allowed to tilt forward is 29 mm (1.1 in.)
per 10 minutes when the hydraulic oil is 30 C
(86 F).
2. If the leak rate is greater than specified, remove
the load from the forks. Install a gate valve between the port at the front of each tilt cylinder
and the hydraulic line. Put the load on the forks
again. Close one valve. If the mast tilts slowly
forward, the cylinder connected to the closed gate
valve has leaking seals. Check the other cylinder
using the same procedure.
3. If the mast does not move, open one of the gate
valves and check for movement again. If the
mast moves forward with the valve open, check
for leaks in the hydraulic lines or fittings. Check
the other tilt cylinder using the same procedure.
If no leaks are found, the main control valve can
have a defect. Remove the load from the forks.
8000 SRM 934
Welding Repairs
Table 5. Allowable Mast Movement from Internal Leakage
Hydraulic Oil
Temperature
Maximum Vertical
Movement at Carriage
Maximum Horizontal Movement

at Tilt Cylinder
Tilt Cylinder Stroke
in./10 min
mm/10 min
degrees/10 min
in./10 min
mm/10 min
68
20
0.9
22
1.1
0.73
18.6
86
30
1.3
33
1.7
1.1
28.8
104
40
2.5
63
3.1
2.1
52.6
122
50
3.9
100
5.0
3.3
84.8
140
60
5.7
146
7.3
4.9
123.7
Welding Repairs
WARNING
Forklift truck frames and components may
be painted with a catalyzed paint such as
polyurethane or a two-part primer. Welding,
burning, or other heat sufficient to cause thermal decomposition of the paint may release
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
the metal around the area to be welded, local
ventilation, and/or supplied-air respiratory
protection.
WARNING
Welding can cause a fire or an explosion. Always follow the instructions in the section
Frame if a fuel or 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 welding
must be done.
Do not heat, weld, or bend forks. Forks are

made of special steel using special methods.
The strength of the overhead guard can be reduced by welding or heating. Get information
from your dealer for Hyster lift trucks before
welding on a mast.
CAUTION
When an arc welder is used, always disconnect
the ground cable from the battery in the lift
truck. This action will prevent damage to the
alternator or the battery.
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.
Some repairs require welding. If an acetylene or arc
welder is used, make sure the procedures in the previous WARNINGS and CAUTION are done.
35
Wheel and Tire Replacement
8000 SRM 934

REMOVE WHEELS FROM LIFT TRUCK
WARNING
The type of tire and tire pressure (pneumatic
tires) are shown on the capacity plate. Make
sure the capacity plate is correct for the type
of tires on the lift truck.
WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
Completely remove the air pressure from the
tire before it is removed from the lift truck. If
dual wheels are installed, remove the air from
both tires. Air pressure in the tires can cause
the tire and wheel parts to explode, causing serious injury or death.
PNEUMATIC TIRES
Remove Tire from Wheel
WARNING
Completely remove the air pressure from the
tire before it is removed from the lift truck. If
dual wheels are installed, remove the air from
both tires. Air pressure in the tires can cause
the tire and wheel parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel.
If the tool slips, it can move with enough force
to cause serious injury.
See Figure 32 when disassembling the wheels. There
are two types of wheels used on this series of lift
trucks.
1. Raise the lift truck as described in How to Put

Lift Truck on Blocks in this section.
2. Remove the air from the tire. Remove the valve
core to make sure that all of the air is out of the
inner tube. Push a wire through the valve stem
to make sure that the valve stem does not have a
restriction. If dual tires are used, remove the air
pressure from both tires.
3. Remove the wheel nuts then remove the wheel
from the lift truck. Be careful not to damage
the studs when removing the wheels. Lift truck
wheels are heavy.
NOTE: IF SOLID RUBBER TIRES ARE INSTALLED,

THE FOUR-PIECE WHEEL ASSEMBLIES MUST BE
USED.
1. WHEEL RIM
2. SIDE RING
3. WEDGE BAND
4. LOCK RING
Figure 32. Wheel Types
36
8000 SRM 934
Remove Tire from Three- and Four-Piece Wheel

STEP 1.
Loosen tire bead from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen the bead from the other side of wheel rim. Remove valve stem from wheel.
STEP 4.
Remove wheel from tire.
37
Install Tire on Wheel

WARNING
8000 SRM 934

NOTE: See Figure 32 when assembling the wheels.
There are two types of wheels used on this series of
lift trucks.
Failure to follow these procedures can cause

the wheel assembly to explode and cause injury
or death.
1. Clean and inspect all parts of the wheel. If the

wheel has rust or corrosion, remove loose rust
and corrosion and paint the parts.
Clean and inspect all parts of the wheel before

installing the tire. DO NOT use any damaged
or repaired wheel parts. Wheels that have
been repaired can explode when air pressure
is added to the tire or during operation. Make
sure that all parts of the wheel are the correct
parts for the wheel assembly. Do not mix parts
between different types or manufacturers of
wheels. Do not mix type of tires, type of tire
tread, or wheel assemblies of different manufacturers on any one lift truck.
2. Install a new flap and inner tube in the tire. Inner tubes and flaps that have been used in earlier
service can cause tire failure. (Some inner tubes
also require a backup washer on the valve stem.)
Do not use a steel hammer on the wheel. Use a

rubber, lead, plastic, or brass hammer to put
parts together. Make sure that the side ring
and/or the lock ring are in the correct position.
The ends of the lock ring or side ring must not
touch. The clearance at the ends of the side
ring and/or the lock ring must be 2.5 to 6.5 mm
(0.1 to 0.26 in.) after air pressure is added to
the tire. If the clearance is wrong, the wrong
part has been used.
3. Apply a rubber lubricant or a soap solution to the

tire bead and tube.
Install Three- or Four-Piece Wheel in Tire

STEP 1.
Install inner tube and rubber flap in tire.
STEP 2.
Install wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
38
WARNING
Do not lubricate the tire bead with antifreeze
or petroleum-based liquid. Vapors from these
liquids can cause an explosion when air pressure is added or when the tire is in use.
4. Make sure that the rim is the correct size for the
tire. Lubricate the parts of the rim that engage
the bead and flap.
8000 SRM 934
STEP 3.
Turn over rim and tire. Put blocks under rim so that
rim is 8 to 10 cm (3 to 4 in.) above floor. Install flange
seat (if used) and side flange. Hold them in correct
position.
STEP 4.
Put lock ring in correct position on rim. Add air pressure to tire as described in Add Air to Tires.
ADD AIR TO TIRES

WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before use. When air pressure is added to the tire,
use a chuck that fastens onto the valve stem of
the inner tube. Make sure there is enough hose
to permit the operator to stand away from the
safety cage when air pressure is added to the
tire.
5. Check that all wheel parts are correctly installed.

If installation is not correct, remove all of the air
pressure from the tire. Remove the valve core
to make sure all of the air pressure has been removed and make adjustments. The clearance at
the ends of the side ring and/or lock ring will be
2.5 to 6.5 mm (0.1 to 0.26 in.) when the tire has
the correct air pressure.
Do not sit or stand by the safety cage. Do not

use a hammer to try and correct the position of
the side ring and/or lock ring when the tire has
air pressure greater than 20 kPa (3 psi).
1. Put the tire in a safety cage. See Figure 33.
2. Add 20 kPa (3 psi) air to the tire.
3. Check that all wheel parts are correctly installed.
Hit the side ring and/or lock ring lightly to make
sure that it is in the seat.
4. If installation is correct, add air to the tire to the
correct pressure. (See the capacity plate.)
Figure 33. Add Air to Tires
39
8000 SRM 934
SOLID RUBBER TIRES

Remove Tire from Wheel
WARNING
Keep tire tools in firm contact with wheel parts. If the tool slips, it can move with enough force to
cause serious injury.
NOTE: See Figure 32 when disassembling the wheels. There are two types of wheels used on this series of lift
trucks.
STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side ring.
STEP 2.
Put tire tool into slot between side ring and/or lock
ring and wheel rim. Remove side ring, lock ring, and
wedge band.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
40
8000 SRM 934
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
Install Tire on Wheel

WARNING
Failure to follow these procedures will cause damage to the tire and wheel assembly and cause
injury or death.
Clean and inspect all parts of the wheel before installing the tire. DO NOT use any damaged or
repaired wheel parts. Make sure that all parts of the wheel are the correct parts for the wheel
assembly. Do not mix parts between different types or manufacturers of wheels. Do not mix type
of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure that the side ring is in the correct position. The ends of the side ring must not
touch. The clearance at the ends of the side ring must be 2.5 to 6.5 mm (0.1 to 0.26 in.) after it is
installed. If the clearance is wrong, the wrong part has been used.
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury.
CAUTION
Too much lubricant can cause tire to slide and move around wheel rim.
NOTE: See Figure 32 when assembling the wheels. There are two types of wheels used on this series of lift
trucks. The four-piece wheel assemblies must be used with the solid rubber tires. Some solid rubber tires will
not allow the wedge band to be installed. If necessary, install the side ring and the lock ring only.
STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.
41

STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
STEP 3.
Remove cage and put wedge band (if used), side ring,
and lock ring in position on wheel assembly. Install
cage on tire. Use press to push tire onto wheel rim so
that wedge band and side ring can be installed.
STEP 4.
While cage is holding tire on wheel rim, install lock
ring. Use a tire tool to make sure lock ring is in correct position.
42
8000 SRM 934
8000 SRM 934
WHEELS, INSTALL
WARNING
When the wheels have been installed, check
all wheel nuts after 2 to 5 hours of operation.
Tighten the nuts to the correct torque. When
the nuts stay tight for 8 hours, the interval for
checking can be extended to 150 hours.
1. Install the wheel on the hub. When dual wheels
are used, install the inner wheel so that it is
tight against the brake drum. Install the outer
wheel. Be careful not to damage the threads on
the studs.
2. Lubricate the studs and nuts as shown in Figure 34. Do not get any oil on the outer surfaces
of the wheel or the flange of the nut.
3. Start with the wheel nut at the top and tighten
the nuts to 68 to 136 Nm (50 to 100 lbf ft) in the
sequence shown. Check to make sure that the
wheel(s) is tight against the hub, then tighten the
nuts to 640 to 680 Nm (470 to 500 lbf ft).
X. NO LUBRICANT
1. WHEEL RIM
2. HUB
3. WHEEL STUD
4. WHEEL NUT
5. FLANGE
6. LUBRICATE
Figure 34. Wheels Installation
43
NOTES
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44
TECHNICAL PUBLICATIONS
8000 SRM 934
8/01 (5/01)(2/01) Printed in U.S.A.

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H230HD Manut - Periodica PDF

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PERIODIC

PART NO. 1494144

8000 SRM 934

2002 HYSTER COMPANY

TABLE OF CONTENTS (Continued)

8000 SRM 934

HOW TO MOVE DISABLED LIFT TRUCK

Traction conditions are bad.

How to Tow Lift Truck

HOW TO PUT LIFT TRUCK ON BLOCKS

8000 SRM 934

How to Raise Steering Tires

8000 SRM 934

Figure 2. Maintenance Points - Perkins Engine

8000 SRM 934

Figure 3. Maintenance Points - Cummins Engine

250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

8000 SRM 934

250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

26.0 liter (27.4 qt) 50% Water with 50%

31.0 liter (32.8 qt) 50% Water with 50%

25.5 liter (27 qt) 50% Water with 50%

120 liter (32 gal)

Safety Belt and Seat

See Parts Manual

See Parts Manual

8000 SRM 934

Horn, Gauges, Lights,

250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

Inspect and clean

Bleed the system

See Parts Manual

See Brake SRM

8000 SRM 934

23 Drive Axle and

250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

24.4 liter (26 qt)

Air Filter, Heater

8000 SRM 934

250 500 hr/ 1000 hr/ 2000 hr/ Procedure or

725 to 775 rpm

See Parts Manual

0.20 mm (0.008 in.)

See Parts Manual

See Parts Manual

8000 SRM 934

Figure 4. Maintenance Points

Upper Sideshift Slider

8 hr/ 250 hr/ 1000 hr/ 2000 hr/

8000 SRM 934

Table 2. Maintenance Schedule (Empty Container Handler Model 553) (Continued)

8 hr/ 250 hr/ 1000 hr/ 2000 hr/

Lower Sideshift Slider

End Beam Slider Pads

8 hr/ 250 hr/ 1000 hr/ 2000 hr/

8000 SRM 934

Table 3. Maintenance Schedule (Empty Container Handler Model 555) (Continued)

Lower Sideshift Slider

End Beam Slider Pads

8 hr/ 250 hr/ 1000 hr/ 2000 hr/

8 hr/ 250 hr/ 1000 hr/ 2000 hr/

Maintenance Procedures Every 8 Hours or Daily