PERIODIC

MAINTENANCE
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL 2,
H155XLS) [F006, G006]

PART NO. 897123

8000 SRM 341

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 ...............................................................................................................................................................
Serial Number Data ......................................................................................................................................
How to Move Disabled 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.................................................................................................
Hydraulic System Oil ................................................................................................................................
Engine Oil ..................................................................................................................................................
Drive Belts .................................................................................................................................................
Intake Manifold Rubber Cap ....................................................................................................................
Cooling System ..........................................................................................................................................
Air Filter ....................................................................................................................................................
Fuel System ...............................................................................................................................................
Primary Fuel Filter, Diesel Engine ..........................................................................................................
Battery .......................................................................................................................................................
Tires and Wheels .......................................................................................................................................
Forks ..........................................................................................................................................................
Adjust.....................................................................................................................................................
Remove and Install ...............................................................................................................................
Forks, Mast, and Lift Chains, Inspect .....................................................................................................
Operator Restraint System.......................................................................................................................
Safety Labels .............................................................................................................................................
How to Make Checks With Engine Running................................................................................................
Gauges, Lights, Horn, and Fuses .............................................................................................................
Oil Level, Powershift Transmission .........................................................................................................
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL).....................................................................
Control Levers and Pedals........................................................................................................................
Lift System Operation...............................................................................................................................
Inching/Brake Pedal..................................................................................................................................
Service Brakes ...........................................................................................................................................
Parking Brake ...........................................................................................................................................
Steering System ........................................................................................................................................
Maintenance Procedures Every 250 Hours or 6 Weeks ...................................................................................
Engine Oil and Filter, GM V-6 Engine .........................................................................................................
Lift Chains, Lubrication................................................................................................................................
Drive Shafts ...................................................................................................................................................
Mast Lubrication ...........................................................................................................................................
Crankcase Breather, GM V-6 ........................................................................................................................
Air Filter, GM V-6 EPA Compliant Engine .................................................................................................
Maintenance Procedures Every 350 Hours or 2 Months .................................................................................
Engine Oil and Filter, Perkins 4.2482 Diesel Engine..................................................................................
Drive Belts .....................................................................................................................................................
Perkins Diesel Engine...............................................................................................................................
GM V-6 Engine (Early Models).................................................................................................................
GM V-6 Engine (Late Models) ..................................................................................................................
Brake Fluid ....................................................................................................................................................
Lift Chains Wear Check ................................................................................................................................

2003 HYSTER COMPANY

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Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued)

Forks Wear and Damage Check....................................................................................................................
Steering Axle Lubrication .............................................................................................................................
Fuel System, Checks and Adjustments ........................................................................................................
Diesel Fuel System....................................................................................................................................
LPG Carburetor (Early Models) ...............................................................................................................
Gasoline Carburetor (Early Models) ........................................................................................................
Fuel Injection (Late Models).....................................................................................................................
Crankcase Breather, Perkins 4.2482 Diesel Engine....................................................................................
Hydraulic Tank Breather ..............................................................................................................................
Cooling System, Clean Debris from Radiator Core .....................................................................................
Maintenance Procedures Every 500 Hours or 3 Months .................................................................................
Engine Oil and Filter, Perkins Diesel Engine..............................................................................................
Crankcase Breather, Perkins Diesel Engine................................................................................................
PCV Valve, GM V-6 .......................................................................................................................................
Maintenance Procedures Every 1000 Hours or 6 Months ...............................................................................
Manifold Heat Valve, GM V-6 (Early Models) .............................................................................................
Ignition System, GM V-6...............................................................................................................................
Valve Clearance Adjustment.........................................................................................................................
Fuel Filter, Replace (Diesel Engine) .............................................................................................................
Fuel System Air Removal (Perkins 1004-4 Diesel Engine) .........................................................................
Fuel Injection Pump With Vent Tube .......................................................................................................
Fuel Injection Pump With Vent Screw .....................................................................................................
Fuel System Air Removal (Perkins 4.2482 Diesel Engine) .........................................................................
Oil Level Check in Transmission ..................................................................................................................
Manual Transmission, H3.50-5.00XL (H70-110XL) ................................................................................
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110XL)............................................
Manual Transmission, H6.00-7.00XL (H135-155XL) ..............................................................................
Differential and Drive Axle for Powershift Transmission, H6.00-7.00XL (H135-155XL,
H135-155XL 2, H155XLS)..........................................................................................................................
Differential, Speed Reducer, and Drive Axle for Manual Transmission, H6.00-7.00XL
(H135-155XL) ............................................................................................................................................
Control Levers and Pedals, Lubricate ..........................................................................................................
Crankcase Breather, Replace ........................................................................................................................
Cooling System, GM V-6 EPA Compliant Engine........................................................................................
Spark Plug Replacement ...............................................................................................................................
Remove.......................................................................................................................................................
Install .........................................................................................................................................................
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace .........................................................................
Inspect Engine Electrical System, Connectors, and FCVS Connection .....................................................
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................
Hydraulic System ..........................................................................................................................................
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace .............................................................
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2, H155XLS), Replace ................
Oil Change and Oil Filter Replacement, Powershift Transmission, All Units ..........................................
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)................................................................
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL) .............................................................
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL (H70-110XL) ................................
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110XL)....................................................
Oil Change, Differential and Drive Axle, Powershift Transmission, H6.00-7.00XL (H135-155XL,
H135-155XL 2, H155XLS) ..............................................................................................................................

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