Servicing six Hyster LO-series lift truck variants, from the LO1.0F through the LO7.0T, is the job of this 34-page Hyster LO1.0F service manual PDF, OEM number 4247932. Wiring diagrams and hydraulic schematics sit with periodic maintenance for safety decals, frame, motor, reduction unit, braking system, cab and controls instruments, electrical system, small mast and forks, linkage, scooter control, tow hook, wheels and battery. Hydraulic checks run from oil leaks and valve condition to tank oil level and flexible pipes, while battery work covers electrolyte density, electrolyte level and cable connections. Hold the optimal clamp height at 85 mm, and tighten your drive wheel fixing nuts to 210 Nm. Castor wheel assembly screws take 52 Nm with Loctite 243. Your order list might include a hydraulic oil filter or a steering thrust bearing for the control head. Bookmarked and text-searchable, the pages also print cleanly when you want a working copy.
What's Inside This Hyster LO1.0F–LO7.0T Manual
| System | Pages | Key Topics |
|---|---|---|
| Periodic Maintenance Manual | 1-2 | Safety Decals, Frame, Motor, Braking System, Hydraulic System, Battery |
| Motor Maintenance | 9-11 | Motor Insulation, Cable Connection, Fixing Nut, Bearing, Motor Cleaning |
| Hydraulic System Maintenance | 17-19 | Oil Leak, Hydraulic Valves, Oil Level, Flexible Pipes, Tank Oil, Oil Filter |
| Scooter Control Maintenance | 24-26 | Scooter Control Operation, Fastening Screws, Control Head, Steering Thrust Bearing |
| Battery Maintenance | 30-34 | Battery Charge, Cable Connection, Liquid Leaks, Electrolyte Density, Electrolyte Level, Battery Insulation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Drive wheel fixing nut torque | 210 Nm | p. 28 |
| Castor wheel pivoting nut torque | 85 Nm | p. 29 |
| Castor wheel assembly screw torque | 52 Nm | p. 29 |
| Pivoting wheel nut torque | 85 Nm | p. 29 |
| Optimal clamp height | 85 mm | p. 22 |
| Hydraulic oil operating temperature | 32 to 72 °C | p. 17 |
| Lift chain replacement interval (normal conditions) | 5000 hours | p. 21 |
Hyster LO1.0F–LO7.0T Common Problems This Manual Covers
Hyster LO series traction motor insulation test shows resistance below infinity between a phase wire and bodywork
Disconnect the battery with the key switch OFF and wear protective clothing, as page 9 requires. Disconnect phase wires U, V and W, then put one tester probe on each phase in turn and the other on unpainted bodywork. Any reading other than infinity means the motor is not insulated; replace it immediately. Check the power supply cable nuts following page 10.
Manual Section: Motor Maintenance p. 9Hydraulic oil spots under the parked truck or wet, dirt caked areas on hoses and pipes
Inspect the floor where the truck parks, then check pipes and hoses for damage, loose components and wear following page 18. Never hunt for a leak by running your hands along pressurized lines, because oil can be injected into the body (page 18). Oil runs 32 to 72 °C, so wear oil and heat resistant gloves to avoid burns (page 17).
Manual Section: Hydraulic System Maintenance p. 18Forks lift and lower roughly or drop too quickly during the valves operation check
Cycle the forks with and without load; they must move smoothly and not too fast, per page 17. Then check tank level with forks fully lowered, key switch OFF, battery disconnected, protective clothing on and oil at least 32 °C. Top up through the breather cap with Shell Tellus S2 V 46 (standard) to the full mark, do not overfill, and keep dirt out (page 18).
Manual Section: Hydraulic System Maintenance p. 17Electromagnetic parking brake does not stop the truck within a few inches, loaded or empty
Start on a flat surface with no load and keep everyone away from the truck during brake tests, as page 14 requires. Enable the electromagnetic brake while driving and confirm the truck stops in a few inches, then repeat with a load. Run the dynamic, reverse, normal (brake button) and emergency switch checks on a level, dry, clear stretch and inspect lining wear.
Manual Section: Braking System Maintenance p. 14Damaged wiring, broken connections or a loose battery plug and socket with electrical controls operating incorrectly
Disconnect the battery connector before any repair, per page 6. Check the battery plug is secure on the truck and the quick removal handle is fixed to the socket, then inspect connections and wiring for wear, looseness or breaks and tighten the fixing nut following page 16. Reconnect, turn the key switch on and enable each sensor to confirm it operates.
Manual Section: Electrical System Maintenance p. 16Contactor tips suspected welded after the truck was operated on a low battery
Check all contactors for welded tips before connecting a charged battery, as page 31 warns. Never connect the charger to the truck plug, which damages the electronic control circuit, and match charger voltage to battery voltage (page 30). Charge in a well ventilated room away from sparks, wearing gloves and safety glasses, and never let electrolyte temperature rise above 49 °C while charging (page 31).
Manual Section: Battery Maintenance p. 31Frequently Asked Questions
What is the required torque for the drive wheel fixing nuts on a Hyster LO1.0F-LO7.0T lift truck?
The traction wheel retaining nuts must be tightened using a torque wrench to a torque of 210 Nm. This check is performed as part of the wheel maintenance schedule. p. 28
What is the required torque for the castor wheel assembly screws on the Hyster LO1.0F-LO7.0T?
The screws fastening the castor wheel assembly to the truck base must be tightened using Loctite 243 with a torque setting of 52 Nm. p. 29
What torque does the nut securing the pivoting wheel need on a Hyster LO1.0F-LO7.0T lift truck?
The nut securing the pivoting wheel must be tightened using a torque of 85 Nm. p. 29
What is the optimal height for the clamps off the ground?
The optimal height for the clamps off the ground is 85 mm. If the height is greater or less than this, the tie rods must be adjusted. p. 22
When should the lift chains be replaced under normal working conditions?
Under normal working conditions, lift chains should be replaced every 3 years or 5000 hours. If the truck is used in cold rooms or corrosive environments, they must be replaced every 2 years or 3000 hours. p. 21
How will I receive this Hyster LO1.0F Service Manual?
Instant PDF download. You get the full 34-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this Hyster LO1.0F manual print-friendly?
Yes. Print the sections you need to take out to the shop for your own use. Standard letter or A4 paper works.
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