Part No.

: 1668891 Revision: 1 (03/2010)

Technical information for

Hyster customer care centres

This manual is addressed to the skilled technicians of Hyster

service network

C441..... S1.0 - S1.2

C456..... S1.4 - S1.6
S1.4 I.L. - S1.6 I.L.
 PREFACE SERVICE

IMPORTANT
This manual contains detailed information about the routine and preventive maintenance, troubleshooting,
disassembly/assembly of components, adjustment procedures for the following Hyster models:
S1.0 - S1.2 - S1.4 - S1.6 - S1.4 IL - S1.6 IL.
These procedures require specific technical knwoledge and they must be carried out only by qualified and
trained staff. Please read this manual carefully in order to prevent damage or accidents to people; it must
be kept in good conditions so that it is always readable and complete in all its parts.
This manual is an integral part of the use and maintenance manual and it does not replace it.

Product support group

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HOW TO USE THE MANUAL

SECTIONS
This manual is divided in the following sections:
Section1: Introduction
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Secttion 5: Hydraulic system
Sezione 6: Frame mechanics
Sezione 7: Mast assembly mechanics
Sezione 8: Reduction gear
Sezione 9: Braking system
Sezione 10: Ordinary maintenance

Always refer to the index with the numbered black bands in order to go to the desired section.

SYMBOLS

It indicates the presence of a danger that can cause accidents to people or damage to the
truck.

It indicates a danger due to high temperatures.

It indicates notes or important information to be taken into consideration.

It indicates that, in the electronic version of the manual, by clicking on this symbol it is possi-
ble to display a filmed sequence.

ASSEMBLY PROCEDURE
For the assembly carry out the disassembly procedure in the reverse order complying with the information
and the notes concerning the correct operation of the truck.

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GENERAL SAFETY STANDARDS

PERSONAL SAFETY
• Always use the personal protective equipment when it is required.
• Pay attention to the squashing risks due to moving parts, oscillations, not correctly fastened materials
when lifting operations are carried out or when the loads are moved.
• Do not wear rings, watches, jewels, unbuttoned or hanging clothes such as scarves, unbuttoned jackets
or smocks with open zips that can get entangled in the moving parts.
• Never carry out cleaning, lubrication or maintenance operations when the battery is connected.
• IIf you use compressed air to clean the parts, wear glasses with lateral guards. The air pressure must
not be higher than 1 bar.
SAFETY IN THE WORKPLACE
• Make sure that all working tools are perfectly efficient and ready to use. Keep the working surfaces
clean and free from the deposits that settle on the truck parts and cause damage.
• Keep sparks, free flames and cigarettes at a distance from fuels or flammable materials such as the
gas of the batteries.
• Make sure that the working area is well ventilated, illuminated, dry and clean. Remove any water pud-
dles or oil spots.
• Make sure that the lifting equipment, devices or machines can bear the load.
• ver use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and non-
flammable solvents.
• In case the interventions are carried out of the workshop, lay the truck flat and block it. If it is necessary
to carry out the work on slopes, block the truck and bring it in a flat area as soon as possible within a
certain safety limit.
• Disconnect the batteries and label all controls in order to indicate that an intervention is in progress.
Block the truck and any equipment to be lifted.
• Do not carry out any intervention on the truck when the operators are controlling it, except that they are
qualified operators and help to carry out the intervention.
• During towing operations use only the prescribed attachment points and make sure that the pins and/or
bolts are tightly secured. Lift and move all heavy components by means of a lifting device of proper
carrying capacity. Use the proper eyebolts. Make sure that nobody stays near the load to be lifted.
• Do not twist chains or metal ropes.
• Do not use damaged or bent chains or ropes: do not use them during lifting or towing operations. While
handling them always wear safety gloves.
• Do not accumulate cloths soaked with grease or oil: they represent a risk of fire. Always put them in a
closed metal container.
• The oil must be collected and not be let off in the drain pipes; the industrial oils must be disposed of by
specialized companies under the protection of the law in force in every Country.
• When welding operations are carried out, it is necessary to use proper accident-prevention protections:
protective glasses, helmet, overalls, shoes. The protective glasses must be worn also by the people
who do not carry out the works if they stay near a welding area.

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 SERVICE PREFACE

• Before using the batteries, make sure that the cables are connected to the terminals as described: (+)
with (+) and (-) with (-).
• Do not short-circuit the terminals.
• The gas emanated during a recharge is higly flammable. During the recharge of the battery leave the
battery compartment uncovered in order to use a more efficient ventilation and remove the plugs.
• Do not check the condition of the battery charge by means of “jumpers” obtained by placing metal
objects on the terminals.
• Before any intervention check if there are no short-circuit elements.
• Disconnect the batteries before acting on the electric system.
• For the battery chargers and similar equipment, use only auxiliary electric power supply sources in
order to avoid any electric shocks.
• A fluid passing through a very small hole can be almost invisible but strong enough to penetrate into
the skin; in these cases check the fluid by means of a card or a piece of wood.
• To chek the pressure of the plant use the proper devices.

• BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE

• Register all used hanging ropes, whose features and data are shown on the identification plate.
• Do not use bands, ropes or hanging ropes, whose identification plate has been lost.
• Always use bands, ropes or hanging ropes of proper dimensions. As far as the hanging ropes are con-
cerned, take into consideration the lifting angle and the unbalance of the load.
• The hooks of the hanging ropes must have a proper size according to the hook of the bridge crane and
they must move freely.
• Position the load in the hook mouth.
• Do not place the load on the point of the hook.
• During lifting, do not carry out sudden operations that could tear the ropes and the bands.
• Do not carry out lifting operations with twisted ropes and bands.
• Knots are forbidden.Always protect the ropes and the bands when they are near sharp edges.
• During the movements without load in order to avoid unintentional collisions or hooking, fasten the
hooks to the proper seats and lock them.

Use of hanging ropes with unbalanced load

If unbalanced loads must be lifted it is advisable to reduce the carrying capacity of the hanging ropes:
• Slings with 2 arms, consider them as the slings with 1 arm.
• Slings with 3 and 4 arms, consider them as the slings with 2 arms.
Suggestions for maintenance
Check the bands, the ropes and the hanging ropes according to the law in force in order to determine their
working conditions. Carry out the replacement in the following cases:
• When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on
them.
• When the wear of the components is higher than 10% of the initial dimensions.
• When the sling is overloaded.

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Rope capacity table

Colour

violet 1000 2000 1400 800

green 2000 4000 2800 1600
yellow 3000 6000 4200 2400
grey 4000 8000 5600 3200
red 5000 10000 7000 4000
brown 6000 12000 8400 4800
Working blue 8000 16000 11200 6400
capacity (kg)
orange 10000 20000 14000 8000
orange 12000 24000 16800 9600
orange 15000 30000 21000 12000
orange 20000 40000 28000 16000
orange 25000 50000 35000 20000
orange 30000 60000 42000 24000
Coefficient 1 2 1,4 0,8

Band capacity table

Width
Colour
(mm)

black 35 500 1000 700 400

violet 50 1000 2000 1400 800
black 50 1500 3000 2100 1200
green 60 2000 4000 2800 1600
Working yellow 75 3000 6000 4200 2400
capacity (kg) grey 120 4000 8000 5600 3200
red 150 5000 10000 7000 4000
browm 180 6000 12000 8400 4800
blue 240 8000 16000 11200 6400
orange 300 10000 20000 14000 8000
Coefficient 1 2 1,4 0,8

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SERVICE PREFACE

Hanging rope capacity table

Colour

violet 1000 1400 2100 2100

green 2000 2800 4200 4200
Working
yellow 3000 3800 6300 6300
capacity (kg)
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefficient 1 1,4 2,1 2,1

Working capacity: the working capacity is calculated with an angle in the centre of 90°.

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DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS

Before the disassembly of the various parts
Nominal DRIVING TORQUE Nm
and of the bolts and screws, read carefully
the instructions below. diameter
Class 8 Class 10
M3 4 5,2
To tighten the screws use the product LOCTITE 270 in M4 7 9,15
order to ensure the safety of the threaded couplings.
M5 12,14 14,8
If it is not possible to loosen the screws because this
M6 17,2 20,9
product is used, do not add extensions to the tools, but
heat the area (maximum 50°C) in oder to eliminate the M8 31,8 38,1
effect of LOCTITE 270. M 10 50,5 60,3
In the above-mentioned cases use a small quantity of M 12 74,2 88,5
LOCTITE 270 in the assembly phase (30% of the con- M 14 101,2 120,8
nection surface). M 16 138,2 164,9
The driving torque with which the threaded couplings M 18 176,6 203,5
are tightened is very important to ensure the safety of
M 20 225,4 259,7
the truck connection.
M 22 278,8 321,2
The bolts and nuts and the corresponding driving torques
are shown in the tables on this page. M 24 324,8 374,2
M 27 422,3 486,5
M 30 516,1 594,7

DRIVING TORQUE Nm
Preloading
Class 5.8 Class 8.8 Class 10.9
N

M4 0,7 7 3 2400 1,92 1,44 3,07 2,3 4,17 3,13

M5 0,8 8 4 3880 3,88 2,91 6,2 4,65 8,43 6,33
M6 1 10 5 5490 6,58 4,94 10,5 7,9 14,3 10,8
M8 1,25 13 6 9990 16 12 25,6 19,2 34,8 26,1
M8 1 13 6 10700 17,1 12,8 27,4 20,5 37,3 27,9
M 10 1,5 16 8 15825 31,7 23,8 51 38 69 52
M 10 1,25 16 8 16700 33,4 25,1 53 40,1 73 55
M 12 1,75 18 10 23025 55 41,4 88 66 120 90
M 12 1,25 18 10 25150 60 45,3 96 72 130 98
M 14 2 21 12 31400 88 66 140 105 190 145
M 14 1,5 21 12 34125 96 72 155 115 210 155
M 16 2 24 14 42850 135 105 220 165 300 225
M 16 1,5 24 14 45600 145 110 235 175 320 240
M 20 2,5 30 17 66875 270 200 430 320 580 435
M 20 1,5 30 17 74250 295 225 475 355 650 485

= with lubricant

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CORRECT METHOD TO APPLY THE FEMALE CONNECTORS

To ensure an optimum connection between the female connectors and the adapters mentioned in this ma-
nual, it is necessary to carry out the following procedure, which is different from the one for the assembly
of the rigid pipes.
Female connectors without gasket (metal/metal connection)
Screw the nut manually and then tigthen 1/4 turn by means of a spanner.
Female connectors with O-RING
Screw the nut manually and then tighten 1/4 turn by means of a spanner.
In any case make sure that the pipe is correctly aligned before tightening the nut to the adapter.

DRIVING TORQUE

ROTARY METRIC FEMALE CONNECTOR ROTARY METRIC FEMALE CONNECTOR jic

Driving torque Nm 37°
External
Thread Driving torque Nm
diameter
UNF Nominal torque min / max Thread
of the pipe Dimension
UNF Nominal torque min / max
M 12x1,5 6 20 15 -25
M 14x1,5 8 38 30 - 45 7/16-20 -4 15 9 - 21

8 1/2-20 -5 20 13 - 27
M 16x1,5 45 38 - 52
10 9/16-18 -6 30 18 - 42

10 3/4-16 -8 50 30 - 70
M 18x1,5 51 43 - 85
12 7/8-14 -10 69 44 - 94

M 20x1,5 12 58 50 - 65 1.1/16-12 -12 98 63 - 133

14 1.3/16-12 -14 118 73 - 163

M 22x1,5 74 60 - 88
15 1.5/16-12 -16 140 90 - 190

M 24x1,5 16 74 60 - 88 1.5/8-12 -20 210 135 - 285

M 26x1,5 18 105 85 - 125 1.7/8-12 -24 290 200 - 380

20 2.1/2-12 -32 450 300 - 600

M 30x2 135 115 - 155
22
25
M 36x2 166 140 - 192
28
M 42x2 30 240 210 - 270
M 45x2 35 290 255 - 325
38
M 52x2 330 280 - 380
42

ROTARY FEMALE CONNECTOR ROTARY FEMALE CONNECTOR ORFS

BSP Driving torque Nm
Driving torque Nm Thread
Dimension
Thread UNF Nominal torque max.
UNF Nominal torque max
9/16-18 -4 14 16
G1/4 20 15 - 25 11/16-16 -6 24 27
G3/8 34 27 - 41 13/16-16 -8 43 47
G1/2 60 42 - 76 1-14 -10 60 68
G5/8 69 44 - 94 1.3/16-12 -12 90 95
G3/4 115 95 - 135 1.3/16-12 -14 90 95
G1 140 115 - 165 1.7/16-12 -16 125 135
G1.1/4 210 140 - 280 1.11/16-12 -20 170 190
G1.1/2 290 215 - 365 2-12 -24 200 225
G2 400 300 - 500 2-1/2-20 -32 460 490

The values shown in the tables refer to to galvanized steel connectors. Different values
correspond to connectors of different materials.

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 PREFACE SERVICE

HYDRAULIC SYSTEM MAINTENANCE INSTRUCTIONS

Before servicing the hydraulic system you must eliminate any residual circuit pressure.
Using the Allen key provided, open valve “A” to discharge any residual pressure from the fork lifting circu-
it.
Close the valve on completion of the maintenance operations.

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INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS

Visual check of hoses and connectors: if one of the following conditions occurs, the hose must be im-
mediately disconnected and replaced:
• movement of the connector on the hose;
• there are damage, cuts or abrasions on the surface;
• hardening or stiffness of the hose, burned parts or cracks due to heat;
• cracks, damage or corroded parts on the connector;
• leakages from the hose or connector;
• the hose has permanent folds, squashed or twisted parts;
• presence of bubbles, softening and wear of the external surface.

Pre-installation inspection: before installing a hose it is necessary to check the conditions of the pipes.
First of all check if the type, the size, the reference code and the length are correct and then make sure that
there are no impurities, obstructions, bubbles, external layer peeling-off or other visible defects.

Installation:
Do not twist the hose, otherwise it could break due to pressure.
Consider a proper radius of curvature in order to avoid the bending or breaking. If the radius of curvature
is lower than the minimum radius of curvature allowed, the life of the hose is considerably reduced.
The pressure can change the length of the hose, up to + 2%. Therefore it is advisable to consider a length
which is higher than the required one in order to compensate for such changes.

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SECTION INDEX

Introduction 1

Installation and settings 2

Diagnostics and measurements 3

Electrical system 4

Hydraulic system 5

Frame mechanics 6

Mast assembly mechanics 7

Reduction gear 8

Braking system 9

Routine maintenance 10
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 SERVICE PRESENTATION

presentation
TRUCK PRESENTATION������������������������������������������������������������������������������������������������������������������������������������������� 2
TRUCK VIEWS������������������������������������������������������������������������������������������������������������������������������������������������������������ 3
TRUCK AND LOAD IDENTIFICATION DATA������������������������������������������������������������������������������������������������������������ 4
TRUCK IDENTIFICATION DATA PLATE��������������������������������������������������������������������������������������������������������������������� 4
RESIDUAL LOAD PLATE ������������������������������������������������������������������������������������������������������������������������������������������� 4
TRUCK AND MAST SERIAL NUMBER STAMP��������������������������������������������������������������������������������������������������������� 5
DATA LOCATION��������������������������������������������������������������������������������������������������������������������������������������������������������� 5
GENERAL SPECIFICATIONS������������������������������������������������������������������������������������������������������������������������������������ 6

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 PRESENTATION SERVICE

TRUCK PRESENTATION
The new range of tiller lift trucks is made up of four models, with nominal loads of 1000kg - 1200kg - 1400kg
- 1600kg:
• S1.0
• S1.2
• S1.4
• S1.6
• S1.4 IL
• S1.6 IL

Electrical system
The traction motor benefits from the use of alternate current three phase AC technology.
The high battery efficiency is guaranteed by the regenerative nature of the breaking system and the energy
retrieval achieved during the cab lowering stage with the forks loaded.
The Combi AcO electronic control system communicates via the CAN-Bus system (Controller Area Network
Bus).

Hydraulic system
The 2 kW and 3 kW pump motors guarantee excellent performance thanks to the technology with ON/OFF or
proportional solenoid valves for the fork lifting/lowering operations with fluid movements of the actuators.

Guidance system
These are lift systems with ground operators. The tiller is mounted on the traction assembly. The low
anchor point of the tiller enables no effort steering. Thanks to the SNAIL function one can also operate in
tight corners.

Mast
The masts can be in one, two or three stages.
The rigidity and stability characteristics of the masts allow the forks to reach heights of over 4 meters.
The lift cylinders are of the type with a simple lift effect with an end point slowing system and a simple
plunger effect with a full shaft.

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SERVICE PRESENTATION

TRUCK VIEWS

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 PRESENTATION SERVICE

TRUCK AND LOAD IDENTIFICATION DATA

TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located on the truck

base.

• Manufacturer's name. • Max. weight battery

• Model • Min weight battery
• Serial number • Battery voltage
• Weight without battery • Nominal Load capacity
• Year of manufacture • Persons on board

RESIDUAL LOAD PLATE

The load plate is located on the mast crossbar

The load plate bears the following data:

• Model
• Liftable load values up to varying heights up to the maximum load with different distances from the
load centre of gravity of the forks.

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SERVICE PRESENTATION

Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.

TRUCK AND MAST SERIAL NUMBER STAMP

The truck Serial number is located in side the The mast serial number is located on the side
engine compartment. of the external mast.

DATA LOCATION

The truck documentation located in the bat-

tery compartment.