Manufacturing / Industrial • Maintenance

2015 HYSTER S40FT CUSHION TIRE 4 WHEEL SIT DOWN FORMS (Daily Maintenance)

The 2015 HYSTER S40FT CUSHION TIRE 4 WHEEL SIT DOWN Daily Maintenance Form ensures your equipment is running properly, avoiding costly downtime and extending the life cycle of the equipment. Ultimately, this form helps you save time and money.

MaintainX

04/26/2021

2015 HYSTER S40FT CUSHION TIRE 4 WHEEL SIT DOWN FORMS (Daily Maintenance)

Tires and Wheels

Check the tires for damage (see Figure 32).

Check the tread and remove any objects that will cause damage.

Check for bent or damaged rims.

Remove material that is wrapped around the axle.

wire
strapping
other material

Figure 32. Check the Tires

CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)

MAKE SMOOTH EDGES

CHECK THE TIRE PRESSURE (PNEUMATIC TIRES)

SAFETY LABELS

WARNING

Safety labels are installed on the lift truck to give infor- mation about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct location on the lift truck.

See the Parts Manual, the Model Description section in this Operating Manual, or the Frame section of the Service Manual 100 SRM 1120 for the correct location of the safety labels.

See the Parts Manual for the part numbers of the safety labels.

MAST, CARRIAGE, HEADER HOSES, LIFT CHAINS, AND ATTACHMENT

(See Figure 47 and Figure 33)

WARNING

Lower the lift mechanism completely. Never allow any person under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED.

Do not try to correct the alignment of the fork tips by bending the forks or adding shims. If either fork is damaged, replace the forks as a set.

Never repair damaged forks by heating or welding. Forks are made of special steel using special proce- dures. If either fork is damaged, replace the forks as a set.

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the cap screws and nuts are tight.

Adjust
Repair
Replace hose
Components as necessary

Inspect the channels for wear in the areas where the roll- ers travel. Inspect the rollers for wear or damage.

Adjust
Repair
Replace hose
Component as necessary

Inspect the load backrest extension for cracks and damage.

Adjust
Repair
Replace hose
Component as necessary

If the lift truck is equipped with a side shift 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.

Adjust
Repair
Replace hose
Component as necessary

Visually inspect hoses/fittings for hydraulic leaks;

Adjust
Repair
Replace Hose
Component as necessary

hose cover for cuts

Adjust
Repair
Replace Hose
Component as necessary

cracks

Adjust
Repair
Replace hose
Component as necessary

exposed reinforcement

Adjust
Repair
Replace hose
Component as necessary

defective/ broken clamping devices or sheaves

Adjust
Repair
Replace Hose
Component as necessary

proper tracking during operation

Adjust
Repair
Replace Hose
Component as necessary

Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains.

Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set. See Figure 33.

Inspect the chain anchors and pins for cracks and dam- age.

Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Figure 34. Hood and Seat Check

Legend for Figure 34

NOTE: NON-SWIVEL SEAT SHOWN.

SEAT BELT, HIP RESTRAINTS AND SEAT RAILS

NOTE: NON-SWIVEL SEAT SHOWN.

Automatic Locking Retractor (ALR)

NOTE: S40-70FT, S55FTS lift trucks produced before November 1, 2005 are equipped with the ALR type seat belts. See Figure 36

The seat belt must fasten securely.

Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced.

Figure 36. Seat Belts

A. AUTOMATIC LOCKING RETRACTOR (ALR)

B. EMERGENCY LOCKING RETRACTOR (ELR)

HOOD AND SEAT LATCHES

Make sure the seat rails and latch striker are not loose.

The seat rails must lock tightly in position, but move freely when unlocked (see Figure 34Figure 35 and Figure 37Fig- ure 38).

The seat rails must be correctly fastened to the hood and the hood fastened to the hinges on the frame.

Try to lift the hood to make sure it is fastened correctly and will not move. If adjustment is required, go to Hood Latch Check in the Periodic Maintenance section of the service manual.

AUTOMATIC LOCKING RETRACTOR

1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

B. EMERGENCY LOCKING RETRACTOR

3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
5. SEAT BELT

ENGINE COMPARTMENT

Figure 37. Swivel Seat Controls

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.

Paper Application

Vehicles used in paper applications require regular inspection and cleaning to minimize the risk of fire.

This should be done at least once every 8 hours or more frequently depending upon operating environment.

The paper application will help limit the contact of paper or tissue scraps to hot surfaces under the hood, but frequent maintenance is required.

WARNING:Engine and exhaust system components are hot to the touch. Be sure lift truck components are cool before starting inspection and cleaning, or personal injury may occur.

Ensure the truck engine cools properly by allowing it to idle for several minutes.

Shutting the truck down while hot will not allow the engine to cool quickly due to the loss of coolant circulation.

The heat trapped under the hood may actually increase the engine temperature because of no heat transfer through the radiator.

With engine OFF and lift truck components cooled, check and clean the radiator and if equipped, radiator screen.

Check engine, Clean as required

Manifold
Exhaust pipes
Muffler
Catalytic Converter for Paper Scarps

Check and clean

engine compartment components

transmission

fan shroud

belly pan

if equipped

inside frame ledges to avoid paper

dust

oil accumulation

Check axle and cowl openings for paper buildup and bailing wire. Remove any debris.

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 person- nel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION: Air pressure, nozzle, or extension tube may cause damage to exhaust wraps and radiator fins. Assure that air pressure, nozzle, or extension tube does not dam- age exhaust wraps or radiator fins.

Paper removal can generally be accomplished using a compressed air line and nozzle. An extension may be helpful to access hard to reach places.

Remove floor plates and side covers for better access to engine compartment. Open or remove belly pan, if equipped.

Clean components with compressed air.

Take care to maintain the integrity of the exhaust wraps when cleaning with compressed air and use caution to not force debris into openings.

WARNING: Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam.

If compressed air did not adequately remove debris, steam clean to remove any persistent accumulation of material or oil.

Protect electrical components from moisture when steam cleaning.

Do not spray exhaust wraps directly with high pressure steam. Allow lift truck to air dry before return- ing to work in a contaminated environment

Paper dust and scraps will adhere to wet surfaces.

Check the condition of exhaust

wraps for wear

proper fit

contamination with oil or antifreeze

gaps in coverage

failed fasteners

Replace as necessary

Do not reuse wraps if they have been removed for some other service operation.

Exhaust Wraps

Radiator

Radiator Screen

Belly Pan

CHECK FOR LEAKS - FUEL, OIL, WATER

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 dur- ing the repair. Do not

Make a visual check for leaks on and under the lift truck. If possible, find and report the leak to maintenance for repair.

Leaks often indicate a need for repair of damaged or worn components.

Leaks in the LPG fuel system are usually not visible unless ice is present. There is however, usually a strong odor.

Fuel leaks MUST be repaired IMMEDIATELY.

Check the fuel system for leaks and the condition of parts.

When fuel is added to the lift truck, see the section, How to Add Fuel to the Lift Truck.

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.

HYDRAULIC HOSES

Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the hydraulic hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

COOLANT HOSES

Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the coolant hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

FUEL TANK (GAS) S40-70FT, S55FTS (F187)

40.5 liter (10.7 gal) 85 Octane - Gasoline Minimum

FUEL TANK (GAS) H40-70FT (L177)

52 liter (13.7 gal) 85 Octane - Gasoline Minimum

FUEL TANK (LPG)

29.9 liter (7.9 gal) 15.2 kg (33.5 lb) LPG - HD 5, HD 10

FUEL TANK (DIESEL) H40-70FT (L177)

52 liter (13.7 gal) Diesel No. 2

Indicator Lights, Horn, Fuses, and Relays

If lift truck is equipped with a key switch, turn key to ON position.

If lift truck is equipped with a Power ON/OFF but- ton, press button to turn system power on.

Check all indica- tor lights for correct operation as described in Table 4

Check the operation of the horn.

Start the engine by turning the key switch to the START position, if truck is equipped with a key switch, or press the engine start button, if truck is equipped with this button.

If any of the indicator lights do not operate correctly, stop the engine and check the fuses.

The fuses are located in the Power Distribution Module (PDM) which is under the hood next to the battery on the right side. See Figure 48.

SERVICE BRAKES

Brake Fluid Level

WARNING: Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder area. Do not allow water entry, ensure that the sealed reservoir lid is properly replaced.

If the brake system has a power assist (or boost), brak- ing will be more difficult if the engine is not running.

On lift trucks with wet brake drive axles, only use Dex- ron III oil from sealed container in the master cylinder. On lift trucks with dry brake drive axles, only use SAE J-1703 (DOT 3) brake fluid in the master cylinder.

Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before using the lift truck. Replace the brake fluid in the system if there is dirt or water in the system.

Failure to observe the above warnings could result in death or serious injury.

There is an indicator light on the Display Switch Cluster for the brake fluid.

The red light is ON when the key switch is in the START position or the Power ON/OFF button is pressed, and must go OFF when the engine is running.

If the light is ON when the engine is running, the brake fluid level in the reservoir is too low.

Check the operation of the service brakes.

Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate.

The pedal must stop firmly and must not move slowly down after the brakes are applied.

The service brakes must apply equally to both drive wheels.

The service brakes must not pull the lift truck to either side of the direction of travel when they are applied.

The service brakes are automatically adjusted when the transmission is in reverse and the lift truck is moving and the brakes are firmly applied.

Full application of the inching/brake pedal applies the service brakes and puts the transmission in NEUTRAL.

Lift trucks with a pedal

when the inching/brake pedal is fully applied, the engine can be started.

Parking Brake

Make sure the service brakes are adjusted and the opera- tion of the automatic adjuster mechanism is correct before the parking brake is adjusted.

Lift trucks with a pedal:

A switch energizes the seat warning circuit when the hand lever is released.

This switch puts the transmission in NEU- TRAL by de-energizing the direction solenoid.

There is also a switch on the left-hand side of bracket. This switch pre- vents engine from starting unless parking brake is applied.

NOTE: Make sure parking brake is released before making adjustment.

To adjust the parking brake, do the following:

Turn the adjustment knob as shown in Figure 49. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parkin

For burnished brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 15% grade. A 15% grade is a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft).

Figure 49. Parking Brake Adjustment

1. LOCK BUTTON RELEASE
2. OFF POSITION
3. ON POSITION
4. ADJUSTMENT KNOB

STEERING CONTROLS AND STEERING COLUMN GAS CYLINDER

Make sure the gas cylinder for the steering column oper- ates correctly.

The cylinder must NOT allow the column to move unless the tilt lever is released. See Figure 39.

Figure 39. Steering Column Gas Cylinder and Tilt Lever

1. TILT LEVER

2. GAS CYLINDER

Transmission

Check the transmission for :

leaks

damage

components

HYDRAULIC OIL S40-70FT, S55FTS (F187)

ISO VG 46 Hydraulic Oil −15 °C (5 °F) and above See NOTE 17.

HYDRAULIC OIL H40-70FT (L177)

ISO VG 46 Hydraulic Oil −15 °C (5 °F) and above See NOTE 17.

HYDRAULIC OIL FILTER

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

CAUTION :Do not permit dirt to enter the hydraulic 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 system for leaks and damaged or loose components.

Heavy-duty or high-temperature operations can require more frequent checks.

HYDRAULIC TANK BREATHER

BATTERY AND CABLE TERMINALS

CAUTION: DO NOT try to start the engine by pushing or towing the lift truck. Damage to the transmission can occur if engine is started by pushing or towing lift truck.

If the battery becomes discharged and requires a booster battery to start the engine, follow these procedures care- fully when connecting the jumper cables:

Disconnect the negative battery terminal of the lift truck being started.

Always connect positive jumper cable to positive terminal of discharged battery and negative jumper cable to nega- tive terminal.

Always connect jumper cable, that is the ground cables, last.

Always connect jumper cables to discharged battery before connecting them to booster battery

ENGINE OIL Mazda 2.0L Engine (Gas/LPG)

ENGINE OIL Mazda 2.2L Engine (Gas/LPG)

ENGINE OIL GM 2.4L Engines (Gas/LPG)

ENGINE OIL FILTER Mazda 2.0L and 2.2L and GM 2.4L Engines

ENGINE OIL Yanmar 2.6L and 3.3L Engines (Diesel)

ENGINE OIL FILTER Yanmar 2.6L and 3.3L Engines (Diesel)

Engine Oil

After the engine has stopped, wait one minute before checking the oil level. See Figure 40, Figure 41, Fig- ure 42, or Figure 43.

Keep the oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule.

There is an indicator light for the engine oil pressure on the Display Switch Cluster.

During normal operation the red indicator light will illuminate when the key switch is turned to ON, if the truck is equipped with a key switch, or when the power ON/OFF button is pressed, if the truck is equip- ped with a keyless option, and will stay il

If the light continues to stay on when the engine is running, the engine oil pressure is low.

Stop the engine and check the oil level. See Figure 40, Figure 41, Figure 42, or Fig- ure 43. Do not restart the engine until the low pressure condition has been corrected.

Figure 40. Mazda 2.0Land 2.2L Engine Maintenance Points (Except 2007 Emission Compliant Engines)

A. GAS ENGINE

1. DIPSTICK ENGINE OIL

2. BATTERY

3. AUXILIARY COOLANT RESERVOIR

4. RADIATOR CAP

B. LPG ENGINE

5. ENGINE OIL FILL

6. DRIVE BELT

7. AIR FILTER

8. FUEL FILTER

9. ENGINE OIL FILTER

10. PCV VALVE

11. SPARK PLUGS

12. FUEL INJECTOR

Figure 41. Mazda 2.0Land 2.2L Engine Maintenance Points (2007 Emission Compliant Engines Only)

A. LPG ENGINE

1. DIPSTICK ENGINE OIL

2. BATTERY

3. AUXILIARY COOLANT RESERVOIR

4. RADIATOR CAP

B. GAS ENGINE

5. ENGINE OIL FILL

6. DRIVE BELT

7. AIR FILTER

8. FUEL FILTER

9. ENGINE OIL FILTER

10. PCV VALVE

11. SPARK PLUGS

12. FUEL INJECTOR (GAS ONLY)

Figure 42. GM Engine Maintenance Points

A. GAS ENGINE

1. DIPSTICK ENGINE OIL

2. BATTERY

3. AUXILIARY COOLANT RESERVOIR

4. RADIATOR CAP

5. ENGINE OIL FILL

6. DRIVE BELT

B. LPG ENGINE

7. AIR FILTER

8. FUEL FILTER

9. ENGINE OIL FILTER

10. PCV VALVE

11. SPARK PLUGS

12. FUEL INJECTOR

Figure 43. Yanmar 2.6L and 3.3L and 3.3L Diesel Engine Maintenance Points

1. BATTERY

2. AUXILIARY COOLANT RESERVOIR

3. RADIATOR CAP

4. DRIVE BELT

5. AIR FILTER

6. ENGINE OIL FILTER

7. DIPSTICK ENGINE OIL

8. FUEL FILTER

9. FUEL INJECTOR

10. ENGINE OIL FILL

AIR FILTER

The air filter canister should not be opened until an air filter element replacement is required. An air filter element replacement is required when one of the following occurs:

the optional air flow restriction indicator light on the dash illuminates

the optional manual air flow indicator button pops up

the specified number of hours has passed since the last filter element replacement

Do not operate the lift truck until the air filter element has been replaced.

COOLING SYSTEM

Mazda 2.0L and 2.2L Engines (Serpentine and Square Wave)

COOLING SYSTEM

Mazda 2.0L and 2.2L Engines (Square Wave with Air Oil Cooler)

COOLING SYSTEM

GM 2.4L Engines

COOLING SYSTEM

Yanmar 2.6L and 3.3L Engines

CLEAN DEBRIS FROM RADIATOR CORE

FORKS

NOTE: Forks must be removed or installed by trained per- sonnel only.

The identification of a fork describes how the fork is con- nected to the carriage. These lift trucks have hook forks.

Forks, Remove

NOTE: If lift truck is equipped with a fork positioner attach- ment, perform Step 1 first, before going to Step 2. If lift truck is not equipped with a fork positioner attachment, go to Step 2.

Lower the carriage and remove four capscrews from inner fork carriers. Remove inner fork carriers from fork positioner. See Figure 44.

Figure 44. Fork Positioner

1. OUTER FORK CARRIER

2. FORKS

3. INNER FORK CARRIER

4. SIDE SHIFT CARRIAGE

5. FORK POSITIONER

6. CAPSCREWS

7. FORK REMOVAL NOTCH

WARNING: Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (99 to 253 lb).

NOTE: Forks are to be replaced only in sets and not indi- vidually.

A fork can be removed from the carriage for replacement of the fork or other maintenance.

Slide a hook fork to the fork removal notch on the carriage. See Figure 45 and Fig- ure 47. Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch.

See Fig- ure 47. 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. See Figure 46.

Figure 45. Remove a Hook Fork

CARRIAGE BARS

HOOK FORK

BLOCKS

Figure 46. Fork Lock Pin Assembly

1. FORK

2. LOCK PIN

3. SPRING

4. WASHER

5. WEDGE

6. KNOB

7. LOCK PIN ASSEMBLY

Forks, Inspect

Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 47. Check that the bottom of the fork is not worn (Item 4 in Figure 47).

Replace any damaged or broken parts that are used to keep the forks locked in position.

Forks, Install

Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar.

Raise the carriage to move the lower hook through the fork removal notch.

Slide the fork on the carriage so that both upper and lower hooks engage the carriage.

Engage the lock pin with a notch in the upper carriage bar. See Figure 46.

If lift truck is equipped with a fork positioner, install inner fork carriers using four capscrews. Tighten capscrews to 35 N•m (25 lbf ft). See Figure 44.

Forks, Adjust

NOTE: During the adjustment of the forks, the heel of the forks should not be touching the ground.

The forks are connected to the carriage by hooks and lock pins. See Figure 45 and Figure 46.

The lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. If pin does not remain engaged in carriage Maintenance slot, replace with new pin. Adjust the forks as far apart as possible for maximum support of the lo

Hook forks will slide along the carriage bars to adjust for the load to be lif- ted.

Raise the lock pin in each fork to slide the fork on the carriage bar.

Make sure the lock pin is engaged in the car- riage bar to lock the fork in position after the width adjustment is made.

Figure 47. Forks Check

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH)

2. CRACKS

3. LATCH DAMAGE

4. HEEL OF FORK (MUST BE 90% OF DIMENSION “X”)

5. CARRIAGE

6. LOAD BACKREST EXTENSION

7. MAXIMUM ANGLE 93°

8. FORK REMOVAL NOTCH

MAST

Sideshift Carriage

BRAKE FLUID

WARNING :Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinder area. Do not allow water entry, ensure that the sealed reservoir lid is properly replaced. If the brake system has a power as

On lift trucks with wet brake drive axles, only use Dex- ron III oil from sealed container in the master cylinder. On lift trucks with dry brake drive axles, only use SAE J-1703 (DOT 3) brake fluid in the master cylinder.

Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before using the lift truck. Replace the brake fluid in the system if there is dirt or water in the system. Failure to observe the above warnings could result in death

There is an indicator light on the Display Switch Cluster for the brake fluid.

The red light is ON when the key switch is in the START position or the Power ON/OFF button is pressed, and must go OFF when the engine is running.

If the light is ON when the engine is running, the brake fluid level in the reservoir is too low.

Check the operation of the service brakes.

Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate.

The pedal must stop firmly and must not move slowly down after the brakes are applied. The service brakes must apply equally to both drive wheels.

The service brakes must not pull the lift truck to either side of the direction of travel when they are applied. The service brakes are automatically adjusted when the transmission is in reverse and the lift truck is moving and the brakes are firmly appli

Full appli- cation of the inching/brake pedal applies the service brakes and puts the transmission in NEUTRAL.

BRAKE OIL

Master Cylinder

Wet Brakes

Source: Hyster

Tires and Wheels

Check the tires for damage (see Figure 32).

Check the tread and remove any objects that will cause damage.

Check for bent or damaged rims.

Remove material that is wrapped around the axle.

wire

strapping

other material

Figure 32. Check the Tires

CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)

MAKE SMOOTH EDGES

CHECK THE TIRE PRESSURE (PNEUMATIC TIRES)

SAFETY LABELS

WARNING

Safety labels are installed on the lift truck to give infor- mation about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct location on the lift truck.

See the Parts Manual, the Model Description section in this Operating Manual, or the Frame section of the Service Manual 100 SRM 1120 for the correct location of the safety labels.

See the Parts Manual for the part numbers of the safety labels.

MAST, CARRIAGE, HEADER HOSES, LIFT CHAINS, AND ATTACHMENT

(See Figure 47 and Figure 33)

WARNING

Lower the lift mechanism completely. Never allow any person under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED.

Do not try to correct the alignment of the fork tips by bending the forks or adding shims. If either fork is damaged, replace the forks as a set.

Never repair damaged forks by heating or welding. Forks are made of special steel using special proce- dures. If either fork is damaged, replace the forks as a set.

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the cap screws and nuts are tight.

Adjust

Repair

Replace hose

Components as necessary

Inspect the channels for wear in the areas where the roll- ers travel. Inspect the rollers for wear or damage.

Adjust

Repair

Replace hose

Component as necessary

Inspect the load backrest extension for cracks and damage.

Adjust

Repair

Replace hose

Component as necessary

If the lift truck is equipped with a side shift 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.

Adjust

Repair

Replace hose

Component as necessary

Visually inspect hoses/fittings for hydraulic leaks;

Adjust

Repair

Replace Hose

Component as necessary

hose cover for cuts

Adjust

Repair

Replace Hose

Component as necessary

cracks

Adjust

Repair

Replace hose

Component as necessary

exposed reinforcement

Adjust

Repair

Replace hose

Component as necessary

defective/ broken clamping devices or sheaves

Adjust

Repair

Replace Hose

Component as necessary

proper tracking during operation

Adjust

Repair

Replace Hose

Component as necessary

Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains.

Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set. See Figure 33.

Inspect the chain anchors and pins for cracks and dam- age.

Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Figure 33. Lift Chain Check

WORN PIN