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com

OPERATING MANUAL

H2.0-3.0XT (A380)

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4150903 12/17

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Spacer

LIFT TRUCK MODEL SERIAL NUMBER

ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE SERIAL NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE GROUP NUMBER

DRIVE TYRE SIZE STEERING TYRE SIZE

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2017. All Rights Reserved.

HYSTER, , FORTENS, and MONOTROL are Registered Trademarks of Hyster-Yale Group, Inc. DURAMATCH, UNISOURCE, and are Trademarks
in the United States and certain other jurisdictions.
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FOREWORD

FOREWORD
To OWNERS, USERS, and OPERATORS: It is the responsibility of the employer to make sure that the
operator can see, hear, and has the physical and mental
The safe and efficient operation of a lift truck requires ability to operate the equipment safely.
skill and alertness on the part of the operator. To develop
the skill required the operator must: NOTE: A comprehensive operator training program is
available from Hyster Company. For further details, con-
• Receive training in the proper operation of THIS lift tact your dealer for Hyster lift trucks.
truck.
This Operating Manual is the original instruction and con-
• Understand any potential hazards that may exist in the tains information necessary for the operation and mainte-
work place where the lift truck is intended to be used. nance of a basic fork lift truck. Optional equipment is
• Understand the capabilities and limitations of the lift sometimes installed that can change some operating char-
truck. acteristics described in this manual. Make sure the neces-
sary instructions are available and understood before
• Become familiar with the construction of the lift truck and operating the lift truck.
see that it is maintained in good condition.
Some of the components and systems described in this
• Read and properly understand the warnings, instruc- Operating Manual will NOT be installed on your unit. If
tions, and operating procedures in this manual. you have a question about any item described, contact
In addition, a qualified person, experienced in lift truck your dealer for Hyster lift trucks.
operation, must guide a new operator through several driv- The following additional information is provided as speci-
ing and load handling operations before the new operator fied in Machinery Directive 98/37 EC and/or 2006/42/EC:
attempts to operate the lift truck alone.

©HYSTER COMPANY 2017 4150903 - ENGLISH-UK 1

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FOREWORD
• Dimensional Details: Certain information is shown on — Measured whole-body vibration at the operator position,
the truck Nameplate. For additional dimensional details based upon standard production truck with full-suspen-
on this or any other specific truck, consult your dealer. sion or comfort-suspension seat is listed below.
• Noise Levels: In accordance with standards EN 12053 — Declared whole-body vibration emission value is in
and EN ISO 4871, the equivalent sound pressure level accordance with EN 12096.
(Lpaz) at the operator position is in the range of:
• Full-suspension seat measured vibration emission value
— Without Cab, with PSI Engines – 79.0 dB(A) aw,z = 0.6 m/s2
— Without Cab, with Yanmar Engines – 79.0 dB(A) • Comfort-suspension seat measured vibration emission
— With Cab, with PSI Engines – 80.0 dB(A) value aw,z = 0.8 m/s2
— With Cab, with Yanmar Engines – 81.0 dB(A) • Uncertainty, K = 0.2 m/s2
• Human Vibration (Whole Body and Hand-Arm Vibra- — Values determined according to EN 13059
tion).
Hand-arm vibration:
Note:The whole-body vibration level is measured
according to standard EN 13059 which contains specific — Hand-arm vibration emission value = < 2.5 m/s2
test criteria (load, speed, roadway surface, etc.). Work- • Hazardous Atmosphere: Before any truck within the
site vibration levels may vary depending on actual oper- European Community can be operated in a Potentially
ating and surface conditions. Explosive Atmosphere, it is necessary that the truck is
Whole-body vibration: suitably converted for the application. Conversions
should only be carried out by a Hyster approved sup-
plier. Confirmation of the conversion can be made by
referring to the truck Declaration of Conformity which will

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FOREWORD
confirm compliance with European Directive 94/9/ce. If NOTE: The following symbols and words indicate safety
you are in doubt, please contact your Hyster dealer for information in this manual.
assistance.
WARNING
• Manufacturer: Hyster Europe, Centennial House, Build-
Indicates a hazardous situation which, if not avoided,
ing 4.5, Frimley Business Park, Frimley, Surry GU16
could result in death or serious injury.
7SG, United Kingdom
• The EC Conformity: Each lift truck ships with a unique CAUTION
EC Declaration of Conformity certificate. See the end of Indicates a hazardous situation which, if not avoided,
this section for a sample EC Declaration of Conformity could result in minor or moderate injury and property
certificate which complies with Machinery Directive damage.
2006/42/EC.
On the lift truck, the WARNING symbol is on orange
CAUTION background. The CAUTION symbol is on yellow back-
ground.
Disposal of lubricants and fluids must meet local envi-
ronmental regulations.
NOTE: Hyster lift trucks are not intended for use on public
roads.

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FOREWORD

Atmospheric Conditions
This range of fork lift trucks is designed to work in the following atmospheric conditions:

Average ambient temperature for continuous duty: +25°C

Maximum ambient temperature (with reduced performance): +50°C
Lowest ambient temperature for trucks intended for use in normal indoor conditions: +5°C
Lowest ambient temperature for trucks intended for use in normal outdoor conditions: −20°C
Altitude: Up to 2000m
From 30% to 95%
Relative humidity:
(non-condensing)

Lifting
When transporting the truck, should lifting be
required, please use the points indicated on the
truck by the hook symbols.

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FOREWORD

Truck Modification 2. Maintain a permanent record of the design, test(s),

and implementation of the modification or alteration;
Unauthorized truck modification is not permitted. To obtain
authorization contact your Hyster dealer. 3. Approve and make appropriate changes to the
capacity plate(s), decals, tags and instruction hand-
Only in the event that the truck manufacturer is no longer in book;
business and there is no successor in the interest of the
business, the user may arrange for a modification or altera- 4. Affix a permanent and readily visible label to the truck
tion to a powered industrial truck, provided, however, that stating the manner in which the truck has been modi-
the user shall: fied or altered together with the date of modification or
alteration, and the name and address of the organiza-
1. Arrange for the modification or alteration to be tion that accomplished the tasks.
designed, tested, and implemented by an engineer(s)
expert in industry trucks and their safety;

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6
FOREWORD

EC DECLARATION OF CONFORMITY

WE HYSTER EUROPE
CENTENNIAL HOUSE
BUILDING 4.5
FRIMLEY BUSINESS PARK
FRIMLEY, SURRY GU16 7SG
UNITED KINGDOM

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT IC ENGINE POWERED

TYPE

SERIAL NUMBER(S)

YEAR OF CONSTRUCTION

IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC. COMPLIANCE WITH

THIS DIRECTIVE IS ESTABLISHED BY MEETING THE TECHNICAL REQUIREMENTS OF
THE RELEVANT STANDARDS, INCLUDING EN ISO 3691-1

OTHER APPLICABLE DIRECTIVES:

2014/30/EU - EMC EMISSIONS
2000/14/EC - SOUND POWER FOR IC ENGINED FORKLIFT AS AMMENDED
BY 2005/88/EC.
TYPICAL VALUE dB
GUARANTEED VALUE, dB
CONFORMITY ASSESSMENT PROCEDURE: INTERNAL CONTROL OF PRODUCTION AND
RESULTS OBTAINED BY FOLLOWING TEST PROCEDURE TEP 361, IN LINE WITH THE
REQUIREMENTS OF DIRECTIVE 2000/14/EC
TECHNICAL FILE CONTROLLED BY THE ENGINEERING MANAGER, HYSTER-YALE UK
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LIMITED/NEDERLAND B.V., CRAIGAVON, NORTHERN IRELAND/NIJMEGEN, THE

NETHERLANDS.

NAME
POSITION PLANT MANAGER
(BLOCK LETTERS)

SIGNATURE
DATE
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Contents

Contents
FOREWORD ................................................................ 1 OPERATING TECHNIQUES ...................................... 54
TO OWNERS, USERS, AND OPERATORS: ............. 1 Basic Operating Procedures .................................... 54
ATMOSPHERIC CONDITIONS .................................. 4 Driving and Direction Changes ................................. 59
LIFTING ...................................................................... 4 General ................................................................... 60
TRUCK MODIFICATION ............................................ 5 Normal Operations ................................................. 60
Warning ....................................................................... 10 Standard Operator Presence System .................... 61
Model Description ...................................................... 13 Basic Powershift or Electronic Powershift
GENERAL .................................................................. 15 Transmission .................................................... 61
OPERATOR PROTECTION EQUIPMENT ................ 15 Inching Control ......................................................... 62
NAMEPLATE .............................................................. 16 Steering (Turning) .................................................... 63
SAFETY LABELS ....................................................... 17 Load Handling, General ........................................... 64
CONTROLS ................................................................ 21 Load Handling, Lifting, Lowering, and Tilting ........... 66
DASH DISPLAY ......................................................... 38 Load Handling, How to Engage and Disengage a
Operating Procedures ................................................ 46 Load ..................................................................... 68
GENERAL .................................................................. 46 Load Handling, Traveling ......................................... 71
Know Your Lift Truck ................................................ 46 LORRY, FREIGHT WEGONS, AND DOCKS ............. 75
Stability and Center of Gravity .................................. 47 ATTACHMENTS ......................................................... 76
Capacity (Weight and Load Center) ......................... 49 STOPPING ................................................................. 76
INSPECTION BEFORE OPERATION ........................ 50 PARKING ................................................................... 77
Checks With the Engine Stopped ............................. 50 DISCONNECTING ATTACHMENT HYDRAULIC
Mounting and Dismounting ....................................... 51 QUICK-DISCONNECT HOSES ............................... 77
Lift Truck Interlocks .................................................. 51 CONNECTING ATTACHMENT HYDRAULIC QUICK-
Starting Procedure ................................................... 52 DISCONNECT HOSES ............................................ 78
Checks With the Engine Running ............................. 53 Maintenance ................................................................ 80

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Contents
GENERAL .................................................................. 80 Hydraulic System Oil ................................................ 114
Serial Number Data .................................................. 81 Engine Oil ................................................................. 115
HOW TO MOVE A DISABLED LIFT TRUCK ............. 81 Air Filter .................................................................... 120
How to Tow the Lift Truck ......................................... 81 Forks ........................................................................ 120
HOW TO PUT A LIFT TRUCK ON BLOCKS ............. 82 Forks, Remove ......................................................... 120
How to Raise the Drive Tyres ................................... 82 Forks, Inspect ........................................................... 122
How to Raise the Steering Tyres .............................. 83 Forks, Install ............................................................. 125
HOW TO CLEAN A LIFT TRUCK ............................... 85 Forks, Adjust ............................................................ 126
Maintenance Schedule ............................................... 85 Brake Fluid ............................................................... 126
Maintenance Procedures Every 8 Hours or Daily .... 104 HOW TO MAKE CHECKS WITH THE ENGINE
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING ................................................................. 128
STOPPED ................................................................ 104 Indicator Lights, Horn, Fuses, and Relays ............... 128
Tyres and Wheels .................................................... 104 Service Brakes ......................................................... 130
Safety Labels ............................................................ 105 Brake Fluid Level .................................................... 130
Mast, Carriage, Header Hoses, Lift Chains, and Operation, Check ................................................... 130
Attachment ........................................................... 105 Parking Brake ........................................................... 131
Operator Restraint System ....................................... 106 Engine Oil Pressure ................................................. 131
Emergency Locking Retractor (ELR) ...................... 110 Cooling System ........................................................ 131
Bonnet and Seat Latches ......................................... 110 Steering System ....................................................... 133
Engine Compartment ............................................... 111 Control Levers and Pedals ....................................... 133
Earth Static Strap ..................................................... 111 Lift System Operation ............................................... 133
Fuel, Oil, and Coolant Leaks, Check ........................ 113 HOW TO ADD FUEL TO THE LIFT TRUCK .............. 134
Hydraulic Hoses ....................................................... 113 Liquefied Petroleum Gas (LPG) ............................... 134
Coolant Hoses .......................................................... 113 LPG Tank, Removal ............................................... 135
Transmission ............................................................ 113 LPG Tank, Fill ......................................................... 137

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Contents
LPG Tank, Install .................................................... 138 SNAP-ON TYRE, CHANGE ....................................... 159
Petrol and Diesel Fuel .............................................. 138 Remove Tyre, Solid Tyre From Wheel ..................... 161
WHEELS AND TYRES ............................................... 139 Install Snap-On-Tyre, Solid Tyre on Wheel .............. 162
General ..................................................................... 139 OPERATING PROCEDURES FOR A NEW OR
PNEUMATIC TYRE WITH TUBE, REPAIR ................ 139 REBUILT ENGINE ................................................... 163
Remove Wheels From Lift Truck .............................. 139 JUMP-STARTING THE LIFT TRUCK ........................ 163
Remove Tyre From Wheel ....................................... 140 Jump-Starting Using a Battery Charger ................... 163
Tyre Removal, Two-Piece Wheel ........................... 142 Jump-Starting Using Another Lift Truck ................... 164
Tyre Removal, Three- and Four-Piece Wheels ...... 143 CHANGES TO THE OVERHEAD GUARD ................ 164
Install Wheel in Tyre ................................................. 144 HOW TO PUT INTERNAL COMBUSTION ENGINE
Tyre Installation Three- or Four-Piece Wheel ........ 145 (ICE) TRUCKS IN STORAGE .................................. 164
Tyre Installation Two-Piece Wheel ......................... 146 Short-Term Storage .................................................. 165
Add Air to Pneumatic Tyres With Tube .................... 147 Long-Term Storage .................................................. 165
Install the Wheels ..................................................... 148 While the Lift Truck is in Storage .............................. 166
PNEUMATIC TUBELESS TYRE, REPAIR ................. 148 How to Put Batteries in Storage ............................... 166
Remove Tyre From Lift Truck ................................... 148 Putting a Stored Lift Truck Back Into Service ........... 167
Remove Tyre From Wheel ....................................... 149 HOW TO MOVE A LIFT TRUCK ON A
Install Tyre on Wheel ................................................ 150 TRANSPORT ........................................................... 167
Add Air to Pneumatic Tubeless Tyre ........................ 154 Loading ..................................................................... 168
Install the Wheels ..................................................... 154 Unloading ................................................................. 169
SOLID RUBBER TYRES ON PNEUMATIC WHEELS, PREPARATION FOR USE ......................................... 169
CHANGE .................................................................. 155 Preparation After Transport ...................................... 169
Remove Tyre From Wheel ....................................... 155 Maintenance Register ................................................ 170
Install Tyre on Wheel ................................................ 156

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Warning

WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!

KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

• ALWAYS use 3 points of contact when getting on and • IF YOU CAN'T SEE, DON'T GO.
off the truck.
• TRAVEL in reverse if load blocks forward vision.
• KNOW operating, inspection, and maintenance instruc-
• MAKE SURE tail swing area is clear.
tions in this Operating Manual.
• SOUND horn at intersections or where vision is blocked.
• DO NOT operate or repair truck unless trained and
authorized. • WATCH clearances, especially overhead.
• INSPECT truck before use. KNOW YOUR LOADS:
• DO NOT operate if truck needs repair. Tag truck and • HANDLE only stable loads within specified weight and
remove key. Repair truck before use. Always use Hys- load center. See Nameplate on truck.
ter Approved parts when making repairs. Replacement
• DO NOT handle loose loads higher than load backrest.
parts must meet or exceed the specifications of the origi-
nal equipment manufacturer. • SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
• USE auxiliary equipment (attachments) for intended pur-
pose only. USE COMMON SENSE:
• VERIFY truck is equipped with overhead guard and load • DO NOT use truck to lift people unless there is no other
backrest adequate for the load. practical option. Then, use only a securely attached

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Warning

WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!

special work platform. Follow instructions in this Operat- KNOW THE AREA:
ing Manual.
• NEVER enter a trailer or railroad car unless its wheels
• OBEY traffic rules. Yield right-of-way to pedestrians. are blocked.
• BE in complete control at all times. • CONFIRM floor strength.
• ALLOW NO ONE under or near lift mechanism or load. • FILL fuel tank or charge battery only in designated area.
• OPERATE truck only from operator's seat. • TURN OFF engine when fueling.
• KEEP arms, legs, and head inside operator's compart- • AVOID sparks or open flame. Provide ventilation.
ment.
• DO NOT start if fuel is leaking.
• DO NOT move truck if anyone is between truck and sta-
• KEEP vent caps clear when charging battery.
tionary object.
• DISCONNECT battery during servicing.
• BEFORE DISMOUNTING, neutralize travel control,
lower carriage, and set brake. • CHECK dockboard width, capacity, and security.
• WHEN PARKING, also shut off power, close LPG fuel PROTECT YOURSELF FASTEN YOUR SEAT BELT!
valve, block wheels on inclines.
• AVOID bumps, holes, and loose materials.
• AVOID sudden starts or stops.

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Warning

WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!

• NEVER turn on or angle across an incline. • SLOW DOWN before turning, especially without load.
• TRAVEL on inclines with load uphill or when unloaded FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
with lift mechanism downhill. CAUSE THE LIFT TRUCK TO TIP.
• TILT mast slowly and smoothly. LIFT or LOWER with DO NOT JUMP off if the truck tips over. HOLD steering
upright vertical or tilted slightly back. Use minimum tilt wheel firmly. BRACE your feet. LEAN FORWARD and
when stacking elevated loads. AWAY from point of impact.
• TRAVEL with carriage as low as possible and tilted
back.

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Model Description
Model Description

Figure 1. Model View Showing Major Components of H2.0-3.0XT

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Model Description
Legend for Figure 1
1. OVERHEAD GUARD 8. CARRIAGE
2. TAIL, BRAKE, AND REVERSE LIGHTS 9. FORKS
3. SEAT 10. LOAD BACKREST EXTENSION
4. COUNTERWEIGHT 11. PARKING BRAKE
5. STEERING AXLE 12. STEERING WHEEL
6. SEAT BELT AND HIP RESTRAINT 13. MAST
7. DRIVE AXLE 14. OPERATING MANUAL (BEHIND SEAT)

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Model Description

Model Description
General Operator Protection Equipment
This Operating Manual is for the following models of lift The LOAD BACKREST EXTENSION is installed to keep
trucks: loose parts of the load from falling back toward operator. It
must be high enough, with vertical openings small enough,
H2.0-3.0XT (A380)
to prevent parts of the load from falling backward. If a load
These lift trucks are available with the following engine: backrest extension that is different from the one installed
on your lift truck is required, contact your Hyster lift truck
• PSI 2.4L engine which uses LPG fuel
dealer.
• PSI 2.4L bi-fuel engine which uses Petrol and LPG fuels
The OVERHEAD GUARD is intended to offer reasonable
• Yanmar 2.6L engine which uses diesel fuel protection to the operator from falling objects, but cannot
protect against every possible impact. Therefore, it must
• Yanmar 3.3L engine which uses diesel fuel
not be considered a substitute for good judgment and care
These lift truck models are equipped with a Basic Power- when handling loads. DO NOT remove the overhead
shift or Electronic Powershift transmission. guard.
The H2.0-3.0XT lift trucks are equipped with pneumatic NOTE: The seat belt can be either black or red.
tyres or solid rubber tyres that look like pneumatic tyres.
The SEAT BELT AND HIP RESTRAINT provide additional
See Wheels and Tyres in the Maintenance Section for a
means to help the operator keep the head and torso sub-
description of these tyres.
stantially within the confines of the lift truck frame and over-
head guard if a tipover occurs. This restraint system is
intended to reduce the risk of the head and torso being
trapped between the lift truck and the ground, but it cannot

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Model Description
protect the operator against all possible injury in a tipover. The capacity is specified in kilograms (kg) and pounds (lb).
The hip restraint will help the operator resist side move- The capacity is the maximum load that the lift truck can
ment. It is not a substitute for the seat belt. Always fasten handle for the load condition shown on the Nameplate.
the seat belt.
The maximum capacity for the lift truck, at full load height,
This lift truck is equipped with one of the three seat belt must be shown on the Nameplate. Special capacities with
configurations. the load height reduced or with optional load centers, may
also be shown on the Nameplate.
• Seat belt with no operation interlock.
The lift truck serial number code is on the Nameplate. The
• Seat belt with operation interlock. Seat belt must be fas-
serial number code is also stamped on the right-hand side
tened for lift truck to start or to travel.
of the lift truck frame, under the floorplate.
Nameplate When a lift truck is shipped incomplete from the factory, the
Nameplate is covered by an INCOMPLETE label as shown
WARNING in Figure 2. If the equipment on the truck is changed, the
DO NOT add to or modify the lift truck. Any modifica- Nameplate is covered by a NOTICE label as shown in Fig-
tion that affects the safe operation of the truck cannot ure 2. If your lift truck has either of these labels, do not
be undertaken without the written authorization of Hys- operate the lift truck. Contact your dealer for Hyster lift
ter Company. trucks to obtain a complete correct Nameplate.
Any change to the lift truck, the tyres, or its equipment
can change the lifting capacity. The lift truck must be
rated as equipped and the Nameplate must show the
new capacity rating.

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Model Description

Safety Labels
Safety labels are installed on the lift truck to provide infor-
mation about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 3.
All possible label configurations that can be on the lift
trucks covered in this Operating Manual are not shown in
Figure 3. See the Parts Manual for label part numbers
and a complete listing of all labels that are available for the
lift trucks covered in this Operating Manual.

A. NAMEPLATE (CE NAMEPLATE SHOWN)

B. NOTICE LABEL
C. INCOMPLETE LABEL

Figure 2. Nameplate and Labels

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Model Description

Figure 3. Warning and Safety Labels (Sheet 1 of 3)

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Model Description

Figure 3. Warning and Safety Labels (Sheet 2 of 3)

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Model Description

Figure 3. Warning and Safety Labels (Sheet 3 of 3)

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Model Description
Legend for Figure 3
1. FLAMMABLE LP-GAS 11. DIESEL FUEL LABEL (NOT SHOWN)
2. TIPOVER WARNING 12. TRANSMISSION LABEL (EXAMPLE ONLY)
3. OPERATION WARNING 13. LIFT AND TILT LABEL
4. NO RIDERS 14. BORON-FREE ANTIFREEZE
5. WARNING FOR PARKING BRAKE 15. ANTIFREEZE WARNING
6. MAST WARNING 16. LPG TANK WARNING
7. NAMEPLATE 17. LOCKING GAS SPRING
8. NO ONE ON OR UNDER FORKS 18. BONNET OPENING CAUTION
9. MAST WARNING 19. ETHER WARNING (DIESEL ONLY)
10. FAN WARNING 20. SPLIT WHEEL WARNING (PNEUMATIC TYRES ONLY)

Controls problem immediately. DO NOT operate the lift truck

until the problem is corrected.
WARNING Not all lift trucks have all of the controls shown in Figure 4
If any of the instruments, levers, or pedals do not oper- and Table 1.
ate as described in the following tables, report the

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Model Description

Figure 4. Controls

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Model Description
Legend for Figure 4
1. PARKING BRAKE LEVER 10. LIFT/LOWER LEVER
2. DIRECTION CONTROL LEVER 11. TILT LEVER
3. STEERING COLUMN TILT LEVER 12. 3RD AUXILIARY LEVER
4. STEERING WHEEL 13. 4TH AUXILIARY LEVER
5. HORN 14. BRAKE PEDAL
6. DASH DISPLAY 15. INCHING/BRAKE PEDAL (NOT SHOWN)
7. CONTROL BUTTON PANEL 16. ACCELERATOR PEDAL
8. KEY SWITCH 17. MONOTROL PEDAL (NOT SHOWN)
9. LIGHT SWITCH/INDICATOR 18. TRACTION SPEED LIMITER LIGHT

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Model Description
Table 1. Controls

Item
Item Function
No.
1 Parking Brake to be on when lift truck is parked. Pull parking brake lever backward
all the way to set it.
Push the top button to release the lock, while pulling on the lever, and push lever
forward to release parking brake.

Parking Brake Lever

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
2
CAUTION
This lift truck has a neutral switch. The engine will not start at a position
other than neutral.
Always change the shift lever from forward/reverse when the lift truck is
stopped to protect the equipment and for safety.
Direction Control Lever
NOTE: This truck series has a safety alarm. If the operator leaves the operator
seat with the Direction Control lever not in neutral, an alarm will sound even with
the key switch OFF.
This lever is used to change from forward to reverse travel. This truck is equipped
with a travel interlock system as a standard feature. If the operator is not in the
operator seat, the direction control does not work and the transmission will stay in
neutral.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
3
CAUTION
Adjust the steering wheel when the lift truck is stopped, as adjustment dur-
ing travel is dangerous.
Adjust steering wheel as needed.

Lever For Steering Column

Tilt
A. Lock
B. Release Lock
4 Steering Wheel The steering wheel controls the position of the steer tyres.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
5 Horn The horn button controls the operation of the horn.

6 Dash Display The screen shows icons for the warning and indicator lights. The display also
shows operator messages for the different functions. All programmed warning and
indicator lights will light up for two seconds (Start Check) when System Power is
turned ON.
7 Control Button Panel These buttons are used to change items shown on the dash display. See Operat-
ing Procedures section of this manual for instructions.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
8 Key NOTE: The key switch has a function of anti-restart, so if the engine does not start
even when the key is turn to ST, return the key to OFF once, and then try again
after 5 to 10 seconds. Turn key OFF before removing it.
The key switch is on the right side of the steering column near the cowl. The key
switch has three positions:
1) OFF position: De-energizes all electrical circuits except for the horn
2) ON position: Energizes all electrical circuits except the start circuit. The key
Switch switch will be in this position during normal operations.
3) START position: Energizes the starter motor for starting the engine. A spring
returns the key to ON position when the key is released.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
9 Light The light switch is integrated with the indicator lever. When the switch is turned
forward the light is turned ON. When the switch is turned backward the light is
turned OFF.

Switch

9 To indicate the turning direction of the lift truck, push the indicator lever forward for
the left indicator to blink or pull the indicator lever backward for the right indicator to
blink.

Lindicator Lever

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
10 Lift/Lower Con- NOTE: If the operator is not in the seat or leaves the seat, hydraulic controls are
trol Lever not active to avoid unintentional movement of front end equipment.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual.
The lift/lower control lever is the first manual lever to the right of the operator's
seat. Pull backward toward the operator to raise the carriage and forks. Push for-
ward to lower the carriage and forks.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
11 Tilt Control NOTE: If the operator is not in the seat or leaves the seat, hydraulic controls are
Lever not active to avoid unintentional movement of front end equipment.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual.
NOTE: To operate the mini-levers, the operator must be on the seat.
The tilt control lever is the second manual lever to the right of the operator's seat.
Push the lever forward to tilt the mast and forks forward. Pull the lever backward
toward the operator to tilt the mast and forks backward. To tilt the mast to the rear,
pull the tilt lever backward. To tilt the mast forward, push the tilt lever forward. The
speed of the tilt can be adjusted by the pull/push stroke. There is a built-in tilt-lock
mechanism which prevents the mast from tilting forward when the key switch is
OFF.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
11 These trucks can be equipped with Return to Set Tilt (RTST) option if truck has
manual hydraulic levers. The vertical stop position will be set at the factory. Push
the tilt lever knob switch while moving the mast forward or backward, with a light
load, the mast will return to vertical position. To stop RTST, release the tilt lever
knob switch.
RTST is intended as an operator aid in positioning forks or attachments for their
application to minimize product damage and facilitate load handling. Care should
Tilt Control Lever With RTST be taken to operate the truck in accordance with load handling instructions as
described in Operating Techniques on the Operating Procedures section of this
Operating Manual.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
12
WARNING
A manual control lever with a detent must be installed when an attachment
with a clamp is installed. See your dealer for Hyster lift trucks to get the cor-
rect control lever.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual.
NOTE: If truck is equipped with only three levers and clamp attachments, the last
Manual Control Lever for 3rd (3rd) lever controls clamp functions.
Auxiliary Functions
The third control lever is installed to the right of the tilt control lever. This lever can
have two methods of operation, depending on the attachments. The lever is oper-
ated by moving forward and backward.
Control Lever with a Detent - Attachments with a clamp action:: The lever is
spring-loaded toward the operator. The lever is operated by moving it to the right,
then forward and back.
Control Lever without a Detent - Attachments without a clamp action: The
lever is operated by moving it forward and back.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
13 NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual.
NOTE: If truck is equipped with four levers and clamp attachment, the last (4th)
lever controls clamp functions.
The fourth control lever is installed to the right of the third manual control lever.
This lever can have two methods of operation, depending on the attachments.
Control Lever with a Detent - Attachments with a clamp action:: The lever is
Manual Control Lever for 4th spring-loaded toward the operator. The lever is operated by moving it to the right,
Auxiliary Functions then forward and back.
Control Lever without a Detent - Attachments without a clamp action: The
lever is operated by moving it forward and back.
14 Brake Pedal This pedal, controlled by the operators right foot, controls the application of the
service brakes.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
15 Inching/ By varying the position of the inching/brake pedal, the operator can move the lift
Brake Pedal truck slowly while a high engine speed is used for lifting loads. Completely
(Not Shown depressing the pedal disengages the transmission and applies the service brakes.
in Figure 4) The engine can be started when the inching/brake pedal is fully depressed and
Direction Control Lever is in neutral.

16 Accelerator This pedal controls the speed of the engine and is operated by the operator right
Pedal foot.

17 MONOTROL® The MONOTROL® Pedal controls the speed and direction of the lift truck. Pushing
Pedal (Not on the right side of the pedal causes the lift truck to move in reverse. Pushing on
Shown in Fig- the left side of the pedal causes the lift truck to move in forward. The speed of the
ure 4) engine increases as the pedal is depressed. The reverse lights and the optional
reverse alarm will be on in the reverse position during normal operation.

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Model Description
Table 1. Controls (Continued)

Item
Item Function
No.
18 For lift trucks equipped with a Yanmar engine and traction speed limiter, this light
will illuminate if the traction speed limiter is not working properly.

Traction Speed Limiter Light

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Model Description

Direction of Movement
Function
Load or Equipment Control Lever
1. REACH Retract/Extend Backward/Forward
2. SIDESHIFT Right/Left Backward/Forward
3. PUSH-PULL Backward/Forward Backward/Forward
4. ROTATE Clockwise/Anticlockwise Backward/Forward
5. UPENDER Up/Down Backward/Forward
6. SCOOP Up/Down Backward/Forward
7. LOAD STABILIZER Down (Clamp)/Up (Release) Backward/Forward
8. SWING (FORKS) Right/Left Backward/Forward
9. FORK SPREAD Together/Apart Backward/Forward
10. CLAMP Clamp/Release Backward/Forward

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Model Description

Dash Display may not contain all the warning and indicator lights shown
in Figure 5 and Table 2. When the warning lights and indi-
WARNING cators are on, the operator will see the appropriate symbol.
If any of the instruments, levers, or pedals do not oper- When the warning lights and indicators are off, the operator
ate as described in the following tables, report the will see a black panel. Unless noted in Table 2, all pro-
problem immediately. DO NOT operate the lift truck grammed warning and indicator lights will light up for one
until the problem is corrected. second when System Power is turned ON.

Depending on the equipment installed on the lift truck,

warning and indicator lights on the Display will vary and

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Model Description

Figure 5. Dash Display - Warning and Indicator Lights

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Model Description
Legend for Figure 5
1. FUEL GAUGE 10. DISPLAY CHANGE BUTTON FOR HOUR METER
2. SEDIMENTER (DIESEL ONLY) 11. MODE CHANGE BUTTON
3. ENGINE OIL PRESSURE 12. CONTROL BUTTON PANEL
4. GLOW LAMP 13. COOLANT TEMPERATURE
5. BATTERY CHARGE 14. ALARM SET
6. TORQUE CONVERTER OIL TEMPERATURE 15. HOUR METER, CALENDAR
7. WARNING 16. CLOCK, SPEED, MESSAGE
8. MAINTENANCE REQUIRED 17. SEAT BELT
9. DISPLAY CHANGE BUTTON FOR CLOCK

Table 2. Dash Display - Warning and Indicator Lights (See Figure 5)

Item
Item Function
No.
1 NOTE: There is no LPG fuel gauge or indicator light. When a lift truck with an LPG
engine has low fuel, a warning buzzer beeps.
This gauge indicates the amount of remaining fuel in the fuel tank.
Always refill fuel before the gauge reaches the bottom bar. If the fuel level reaches the
Fuel Gauge bottom bar, a warning buzzer beeps.
2 Sedimenter This amber indicator light will illuminate if the fuel-water separator sensor indicates
(Diesel Only) that water must be drained. Not on at Start Check.

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Model Description
Table 2. Dash Display - Warning and Indicator Lights (See Figure 5) (Continued)

Item
Item Function
No.
3 Glow Lamp This amber indicator light will illuminate for up to 10 seconds after engine start up sig-
nifying that the glow plugs are functioning properly at temperatures up to 80 °C
(176 °F) coolant temperature.
4 Battery Charge This icon will be ON when the key switch is ON and the engine is not running. The
Lamp icon must go OFF when the engine is running.

5 Engine Oil
CAUTION
Pressure
Stop the engine immediately if this icon is ON while the engine is running.
This icon is ON when the key switch is in the ON position and must go OFF when the
engine is running.
6 Torque Con-
CAUTION
verter Oil Tem-
Do not continue to operate the lift truck if the icon is ON when the engine is
perature
running. Make sure the oil level is correct and add fluid as needed. Let the
Warning
transmission cool before operating the lift truck.
The icon must go OFF when the engine is running.

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Model Description
Table 2. Dash Display - Warning and Indicator Lights (See Figure 5) (Continued)

Item
Item Function
No.
7 Warning

8 Maintenance This amber light will illuminate when a fault that is not engine related and requires
Required immediate attention occurs.

9 Display Each time you press a button the display changes to show operating information
Change But- about the truck. Each screen will show either the date and the hours recorded on that
ton - Center date, or a fault and the hourmeter reading at which it occurred.
Figures

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Model Description
Table 2. Dash Display - Warning and Indicator Lights (See Figure 5) (Continued)

Item
Item Function
No.
10 Display Press this button while the calendar date is showing to update the date and time
Change But- shown on the display.
ton - Bottom
Figures

11 Mode Change Pressing this button at the same time as the Display Change Buttons will activate a
Button different item on the display for adjustment. The item will blink until changed. Pressing
this button once will return the display to normal mode.

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Model Description
Table 2. Dash Display - Warning and Indicator Lights (See Figure 5) (Continued)

Item
Item Function
No.
12 Control But- The panel contains the Display Change and Mode Change Buttons.
ton Panel

13
CAUTION
Do not continue to operator the lift truck when the gauge indicates that the
engine is too hot (full bars indicated, and warning buzzer beeping).
This gauge indicates the temperature of the engine cooling water. Start operation after
the engine has been warmed up and the bare gauge starts raising. When the bar
Coolant Temperature
gauge reaches around the middle bar, the water temperature is optimum.
Gauge
14 Alarm Set The icon is ON when the alarm is on.

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Model Description
Table 2. Dash Display - Warning and Indicator Lights (See Figure 5) (Continued)

Item
Item Function
No.
15 Hourmeter - The hour meter operates when the key switch is in the ON position. Peri-
odic Maintenance recommendations are based on these hours.

Hour Meter
16 Clock The clock displays the current time.

17 Seat Belt
WARNING
Always fasten the seat belt when operating the lift truck.
The icon flashes for 10 seconds anytime the key switch is put in the ON position. If the
seat belt interlock option is equipped, the icon goes OFF immediately after fastening
the seat belt.

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Operating Procedures

Operating Procedures
General If engines are operated in confined spaces, maintain
adequate ventilation or vent exhaust to the outside. Do
Know Your Lift Truck not exceed applicable air contaminant limits.
Follow the inspection and maintenance schedule and
WARNING procedures in this manual. Do not alter exhaust, igni-
Always make sure the parking brake is fully applied tion, or fuel systems.
before leaving the lift truck. If the operator leaves the
lift truck without applying the parking brake, a seat WARNING
activated switch will shift the transmission to neutral. If FIRE HAZARD
the lift truck is left on a grade, without the parking The hot engine surfaces and exhaust of internal com-
brake fully applied, the lift truck will free-wheel down bustion engine powered lift trucks can present fire haz-
the grade, possibly causing injury or property damage. ards when operating in areas containing flammable
gases, vapors, liquids, dusts, fibers, or paper debris.
WARNING Engine and exhaust component surface temperatures
EXHAUST GASES can exceed the ignition temperatures of common sol-
Exhaust from internal combustion engines contains vents, fuels, oil, paper, and other organic materials
carbon monoxide and other harmful chemicals. Carbon (wood, wheat, cotton, etc.). Exhaust emitted sparks
monoxide is a colourless, odorless poison and can can ignite these materials as well. Engine and exhaust
cause unconsciousness or death without warning. surface temperatures increase after engine shutoff,
Long-term exposure to exhaust or chemicals in the presenting increased fire hazard. Check the engine
exhaust can cause cancer, birth defects, and other compartment frequently in areas containing combusti-
reproductive harm. Avoid exposure to engine exhaust. ble dust, fibers, or paper and remove any foreign mate-
rials. Contact your local Hyster dealer for forklift

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Operating Procedures
modifications that may be appropriate in environments
with fire hazards.
Operate the lift truck only in areas that have been
approved for lift truck operation.
Only the designated types of approved lift trucks may
be used in areas classified as hazardous by the author-
ity having jurisdiction. Areas classified as hazardous
The lift truck is based on the principle of two weights bal-
must be identified by signs to show the type of
anced on opposite sides of a pivot (fulcrum). This is the
approved lift truck required for operation in the area.
same principle used for a seesaw. In order for this principle
Modifications or poor maintenance can result in the lift
to work for a lift truck, the load on the forks must be bal-
truck being unsuitable for operation in areas classified
anced by the weight of the lift truck. The location of the
as hazardous.
center of gravity of both the truck and the load is also a fac-
The fork lift truck is designed to pickup, move, and tier tor.
materials. The basic lift truck has a lift mechanism and
This basic principle is used for picking up a load. The ability
forks on the front to engage the load. The lift mechanism
of the lift truck to handle a load is discussed in terms of
lifts the load so that it can be moved and stacked.
center of gravity and both forward and side stability.
In order to understand how the fork lift truck can pick up a
load, you must first know some basic things about the lift Stability and Center of Gravity
truck. The center of gravity (CG) of any object is the single point
about which the object is balanced in all directions.
Every object has a CG. When the lift truck picks up a load,
the truck and load have a new combined CG.

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Operating Procedures

A. CG LOAD B. CG TRUCK C. COMBINED CG

The stability of the lift truck is determined by the location of

its CG, or if the truck is loaded, the combined CG. A. CG LOAD B. COMBINED CG C. CG TRUCK
The lift truck has moving parts and therefore has a CG that
The center of gravity, and therefore the stability of the loa-
moves. The CG moves forward and back as the mast is til-
ded lift truck, is affected by a number of factors such as
ted forward and back. The CG moves up and down as the
size, weight, shape, and position of the load; the height to
mast moves up and down.
which the load is raised; the amount of forward and back-
ward tilt; tyre pressure and the dynamic forces created
when the truck is moving. These dynamic forces are
caused by things like acceleration, braking, turning, and
operating on uneven surfaces or on an incline. These fac-
tors must be considered when traveling with an unloaded
truck, as well, because an unloaded truck will tip over to
the side easier than a loaded truck with its load in the low-
ered position.

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Operating Procedures
In order for the lift truck to be stable (not tip over forward or center is specified in millimeters and inches. The capacity
to the side), the CG must stay within the area of the lift is the maximum load that the lift truck can handle, with the
truck represented by a triangle drawn between the drive mast vertical, for the load condition shown on the Name-
axle and the pivot of the steering axle. plate.

A. DRIVE AXLE B. STEERING AXLE C. TRUCK WILL TIP OVER

If the CG moves forward of the drive axle, the lift truck will
tip forward. If the CG moves outside of the line represented
by the lines drawn between the drive wheels and the steer-
ing axle pivot, the lift truck will tip to that side. The load center of a load is determined by the location of
Capacity (Weight and Load Center) its center of gravity. The load center is measured from the
front face of the forks, or the load face of an attachment, to
The capacity of the lift truck is shown on the Nameplate. the center of gravity of the load. Both the vertical and hori-
The capacity is listed in terms of weight and load center. zontal load centers are specified on the Nameplate.
The weight is specified in kilograms and pounds. The load

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Operating Procedures
Loads should be transported while centered on the center- • Condition of forks, carriage, chains, header hoses, mast,
line of the lift truck. The operator must know whether or not attachment, and overhead guard.
a load is within the maximum capacity of the lift truck
• Condition of wheels and tyres.
before the load is handled.
• Seat belt fastens correctly.
Inspection Before Operation
• Seat is correctly fastened to its mounts. Bonnet is cor-
WARNING rectly latched.
Report damage or faulty operation immediately. Do not • Condition of the engine compartment. Ensure all surfa-
operate a lift truck that needs repair. A lift truck will ces are free of oils, lubricants, fuel, and organic dusts or
only do its job when it is in proper working order. If fibers (paper, wood, cotton, agricultural grass/grain, etc).
repairs are required, install a tag in the operator's area Remove all foreign materials.
stating "DO NOT OPERATE" and remove the key from
the key switch if truck is equipped with key switch • Coolant level in the cooling system and condition of the
option. drive belts.
• Condition of the radiator and screen. Clean if necessary.

Checks With the Engine Stopped • Fuel level.

Inspect the lift truck before use and every eight hours or • Oil level in the engine.
daily as described in the Maintenance section of this • Oil level in the hydraulic tank.
Operating Manual. Inspect more frequently if used in
severe operating conditions. • Leaks from the engine, transmission, hydraulic system,
and fuel system.
Before using the lift truck, make the following checks:
• Loose or missing hardware.

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Operating Procedures
• Check transmission oil level. traction will be disabled. To reactivate traction, the operator
must return to the seat. Once the needed actions are com-
Mounting and Dismounting pleted, traction will be enabled and the operator can con-
tinue to load and unload material.
WARNING
To avoid serious injury when entering or exiting the lift HYDRAULIC INTERLOCKS: The hydraulic functions are
truck, ALWAYS USE 3 POINTS OF CONTACT. Maintain enabled when the operator is in the seat (occupancy sen-
contact simultaneously with two hands and one foot or sor), seat belt should be fastened, and the engine is run-
with two feet and one hand while climbing on or off the ning. If any of the above actions are not performed while
lift truck. operating the lift truck, the hydraulic functions will be disa-
bled. The LCD screen on the display panel will provide a
Place feet carefully. Always face the lift truck when climb- non-service fault message "Hydraulic Interlock Engaged."
ing on or off. Use added care when surfaces are slippery. To reactivate hydraulics, the operator must return to the
Keep hands free of any obstacles such as food, beverages, seat. Once the needed actions are completed, the
or tools. hydraulic function will be enabled and the operator can
continue to load and unload material.
Lift Truck Interlocks
Certain operator actions, if not performed correctly while
operating the lift truck, will cause traction and the hydraulic
functions to become disabled.
DRIVE INTERLOCKS: Traction is enabled when the oper-
ator is in the seat (occupancy sensor), seat belt should be
fastened, a direction of travel is selected, engine is running,
and the parking brake is released. If any of the above
actions are not performed while operating the lift truck,

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Operating Procedures

Starting Procedure 5. Turn key to the ON position. If lift truck is equipped with
a diesel engine and engine is cold, the cold start indicator
DO NOT start or operate the lift truck, light will illuminate and the cold start circuit will be ener-
including any of its functions or attach- gized.
ments, from any place other than the des-
ignated operator's position. 6. On lift trucks equipped with a LPG engine, turn the key
to the START position to engage the starter.
WARNING On lift trucks equipped with a diesel engine, if cold start
LPG is very flammable. An odor of LPG delay is required, the cold start indicator will be illuminated
fuel can indicate a leak in the fuel sys- and a countdown time of ten seconds is displayed. When
tem. DO NOT start the engine until the fuel leak is countdown reaches 0, turn the key to the START position
repaired and the atmosphere is free of LPG. to engage the starter.
NOTE: Lift trucks have a "Clear Flood Mode" programmed For all engine types, if engine fails to start after 30 sec-
into the ECU. When accelerator is depressed more than onds, the starter will shut down for 60 seconds to cool off.
80% during cranking, the ECU will not allow any fuel into A 60-second countdown timer will appear on the LCD
the engine. This allows the engine to clear any excess fuel screen showing the time remaining before a restart attempt
out of the intake manifold and cylinders. can be tried. To restart engine, repeat Step 5 and Step 6.
1. If the lift truck uses LPG fuel, open fuel valve on LPG
tanks.
2. Make sure that parking brake is applied.
3. Put direction control lever for transmission in NEUTRAL
position.
4. Make sure lift truck bonnet is closed.

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Operating Procedures
stantially within the confines of the truck frame and over-
Checks With the Engine Running head guard if a tipover occurs. This protection system is
intended to reduce the risk of the head and torso being
trapped between the truck and the ground, but it can not
WARNING protect the operator against all possible injury in a tipover.
FASTEN SEAT BELT
If Lift Truck Tips Over Make sure that the area around the lift truck is clear before
starting the engine or making any operational checks. Be
• DO NOT Jump – Stay On Truck
careful when making the checks. If the lift truck is station-
• Hold Firmly To Steering Wheel – Brace ary during a check, apply the parking brake and make sure
Feet – Lean Forward And Away From the direction control is in NEUTRAL. Proceed carefully.
Impact
Check the operation of the following functions as described
The seat belt is installed to help the opera- in the Maintenance section:
tor stay on the truck if the lift truck tips
• Check the operation of the horn, gauges, and indicator
over. IT CAN ONLY HELP IF IT IS FAS-
lights.
TENED.
• Operate the LIFT, TILT, and auxiliary functions to check
The operator must be aware that the lift truck
for correct operation of the mast, carriage, and attach-
can tip over. There is a great risk that the oper-
ments.
ator or someone else can be killed or injured if
trapped or hit by the truck as it tips over. The • Check the operation of direction control lever and accel-
risk of injury can be reduced if the operator stays on the erator pedal.
truck. If the truck tips over, do not jump off!
• Check the operation of the service brakes and parking
THE SEAT BELT AND HIP RESTRAINT bracket provides brake.
a means to help the operator keep the head and torso sub-

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Operating Procedures
• Check the operation of the steering system. Basic Operating Procedures
• Check the oil level in the transmission when the oil is at Many people make the mistake of thinking that operating a
operating temperature 50 °C (120 °F). Turn the truck off lift truck is the same as driving an automobile. This is not
and wait one minute. Then check the transmission oil true. A lift truck is a special machine designed to do a
level. much different job than an automobile. Because of the
Operating Techniques close areas in which a lift truck operates and its other oper-
ating characteristics (like rear wheel steering and tail
swing), every operator must receive additional training,
WARNING
even if they have a license to drive an automobile.
Before operating the lift truck,
FASTEN YOUR SEAT BELT. The following discussion lists basic procedures applicable
to lift truck operation.
There are a number of opera-
tions, if not performed carefully, 1. AUTHORIZED AND TRAINED
that can cause the lift truck to tip. If you have not read OPERATOR ONLY. This means
the WARNING page in the front of this Operating Man- the operator must be trained to
ual, do so NOW. As you study the following informa- drive the lift truck and it means that
tion about how to properly operate a lift truck, the operator must thoroughly
remember the WARNINGS. understand the procedures for lift
truck operation. It also means that
NOTE: When the Emergency Locking Retractor (ELR) seat
a qualified person experienced in lift truck operation must
belt is properly buckled across the operator, the belt will
guide the operator through several driving and load han-
permit slight operator repositioning without activating the
dling operations before the operator attempts to operate
locking mechanism. If the truck tips, travels off a dock, or
the lift truck alone. A basic education in proper driving and
comes to a sudden stop, the locking mechanism will be
load handling techniques is absolutely necessary to
activated and hold the operator's lower torso in the seat.

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Operating Procedures
prepare the new operator for proper defensive driving and The combined weight of the platform, load, and per-
to expect the unexpected. sonnel is not to exceed one-half of the capacity as indi-
cated on the Nameplate of the truck on which the
WARNING platform is used.
This lift truck is designed for handling materials. A lift
Before anyone is allowed in the platform, lift and lower
truck is not designed to lift people. DO NOT use a lift
the mast slowly with the platform in place to make sure
truck to lift people unless it has been determined that
the mast functions properly. Apply the parking brake.
there is no other practical option (scaffolds, elevated
DO NOT travel with people in the platform. The opera-
work platforms, aerial baskets, etc.) to perform the
tor must remain at the controls. Watch for overhead
needed work.
obstructions.
2. NO RIDERS. A lift truck is built for only
one person – the operator. It is danger-
ous for anyone to ride on the forks or any-
where else on the lift truck.

If a lift truck is used to elevate a worker, a safety plat-

form must be attached to the forks and carriage. It
must have a solid floor with a surface to prevent the 3. ADJUST SEAT - INTERNAL SUSPENSION
feet of the worker from slipping, hand rail, toe board,
and screen or shield at least 2 m (7 ft) high between
the people on the platform and the lift mechanism.

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Operating Procedures
Seat Position Adjustment (Semi-Suspension) Seat Position Adjustment
• Fore and aft adjustment - It is recommended that the • Fore and aft adjustment - It is recommended that the
seat be adjusted so that the thigh is horizontal to the seat be adjusted so that the thigh is horizontal to the
ground so that the best ergonomic position is achieved. ground so that the best ergonomic position is achieved.
See Figure 6. See Figure 6.
Seat Adjustment for Operator Weight (Semi-Suspen- Seat Adjustment for Operator Weight
sion)
CAUTION
CAUTION A major cause for high Whole Body Vibration is
A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to
caused by the operator not adjusting the seat to his/her weight.
his/her weight.
NOTE: It is important to adjust the weight setting for each
NOTE: It is important to adjust the weight setting for each operator.
operator.
NOTE: The seat is designed for a maximum weight of
NOTE: The seat is designed for maximum weight of 130 kg 135 kg (298 lb).
(287 lb) for semi-suspension seat.
• The target is for the "ride indicator" to fall between the
• The weight adjustment knob can be turned to increase arrows when the operator sits upright in the seat with the
or decrease the weight resistance. As the weight adjust- feet positioned on the pedals. This ensures that the
ment knob is turned the "stiffness" of the suspension operator is set at the midpoint of the 80 mm (3.15 in.)
canb e felt to increase or decreaseon which way the suspension. See Figure 6.
weight adjustment knob is turned. See Figure 6.
• The handle can be turned anticlockwise to increase or
4. ADJUST SEAT - STANDARD FULL SUSPENSION. clockwise to decrease the weight resistance, pull handle

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Operating Procedures
out before turning. As the handle is turned, the "stiff- NOTE: It is important to adjust weight setting for each
ness" of the suspension can be felt to increase or operator.
decrease depending on which way the handle is turned.
NOTE: The seat is designed for maximum weight of 145 kg
See Figure 6.
(320 lb) for premium full suspension seat.
5. ADJUST SEAT - PREMIUM FULL SUSPENSION
• The target is for the "ride indicator" to fall between the
Seat Position Adjustment arrows when opertaor sits upright in seat with feet posi-
tioned on pedals. This ensures that the operator sits
• Fore and aft adjustment - It is recommended that the
upright in seat with feet positioned on pedals. This
seat be adjusted so that the thigh is horizontal to the
ensures that the opertor is set at the midpoint of the
ground so that the best ergonomic position is achieved.
80 mm (3.15 in.) suspension
See Figure 6.
• The handle can be turned as shown to increase or
Seat Adjustment for Operator Weight
decrease weight resistance. Pull handle out before turn-
ing. As the handle is turned the "stiffness" of the suspen-
CAUTION
sion can be felt to increase or decrease on which way
A major cause for high Whole Body Vibration is
handle is turned. See Figure 6.
caused by the operator not adjusting the seat to
his/her weight.

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Operating Procedures

Figure 6. Seat Adjustment

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Operating Procedures
Legend for Figure 6
A. STANDARD NON-SUSPENSION SEAT C. SEMI-SUSPENSION SEAT
B. PREMIUM FULL SUSPENSION SEAT D. STANDAR FULL SUSPENSION SEAT
1. SEAT BELT 4. FORWARD/BACKWARD ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 5. BACKREST ANGLE ADJUSTMENT LEVER
3. RIDE POSITION INDICATOR 6. ARMREST

6. DO NOT drive a lift truck into an lift unless authorized to 7. Drive carefully, observe traffic rules, and be in
do so. Approach the lift slowly. After the lift is properly lev- full control of the lift truck at all times. Be com-
eled, the lift truck must be centered so that the lift is bal- pletely familiar with all the driving and load han-
anced. dling techniques contained in this Operating Manual.
Driving and Direction Changes
KNOW YOUR TRANSMISSION.These lift truck models are
equipped with a Basic Powershift or Electronic Powershift
transmission. See Table 3 and Figure 7. Read the follow-
ing section carefully.
Table 3. Transmissions

Basic Powershift or
Operational Feature Electronic Power-
When the lift truck is in the proper position in the lift, set the shift
brakes, put the controls in NEUTRAL and shut off the
Electronic Inching Yes
power. It is advisable that all other personnel leave the lift
before the lift truck enters or leaves.

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Table 3. Transmissions (Continued) REVERSE. If the lift truck has a Direction Control Switch,
rock the switch toward the palm rest to go FORWARD and
Basic Powershift or toward the base to go in REVERSE. If the truck has a
Operational Feature Electronic Power- direction control lever, move the lever toward the front of
shift the lift truck to go FORWARD and toward the rear of the lift
Electronic Control of Direction truck to go in REVERSE.
Yes
Changes
Normal Operations
In normal operating conditions, either at start or while driv-
ing the lift truck can only be maintained at a stopped posi-
tion by applying the service brake or parking brake.
When moving away from a stop:
1. Select direction while maintaining braking.

1. BASIC POWERSHIFT TRANSMISSION

2. Depress the accelerator or MONOTROL® Pedal.
2. ELECTRONIC POWERSHIFT
3. Release the brakes (parking and/or service brake).
Figure 7. Transmission Labels Depress the accelerator or MONOTROL® Pedal to ensure
General the lift truck will move in the selected direction when the
brakes are released.
The lift truck can have either a MONOTROL® Pedal, a
Direction Control Lever, or a Direction Control Switch to Due to variable load and grade conditions, this procedure
control the transmission. If the lift truck has a MONO- minimizes the possibility of the lift truck traveling in a direc-
TROL® Pedal, push on the left side of the pedal to go tion opposite to the one selected.
FORWARD, or the right side of the pedal to go in

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Standard Operator Presence System tor leaves the seat of the lift truck with the engine running
and without applying the parking brake.
WARNING
Basic Powershift or Electronic Powershift
Always make sure the parking brake is fully applied
Transmission
before leaving the lift truck. If the operator leaves the
lift truck without applying the parking brake, a seat
WARNING
activated switch will shift the transmission to neutral. If
DO NOT select the travel direction if the accelerator is
the lift truck is left on a grade, without the parking
depressed. The lift truck will move rapidly and can
brake fully applied, the lift truck will freewheel down
cause damage or injury.
the grade, possibly causing injury or property damage.
These lift trucks are equipped with an Operator Presence
System (OPS). The OPS feature has an electrical sensor in
the seat which senses the presence of the operator. This
allows the transmission in internal combustion engine
trucks to be engaged only when the operator is in the seat.
This feature also locks out lift and tilt functions. The OPS is
designed with slight delay in the seat sensor to allow the
operator to reposition himself without disengaging the A. MONOTROL® pedal
transmission. When the seat sensor disengages the trans- B. ACCELERATOR
C. DIRECTION CONTROL LEVER
mission (neutral position), the operator must select neutral, D. MLM DIRECTION CONTROL
then re-select a direction to re-engage the traction (travel
mode).
A switch in the operator's seat will automatically shift the
transmission to neutral within 1-2 seconds when the opera-

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CAUTION
The drive train can be damaged if the lift truck is travel-
ing too fast when the controls are changed to the
opposite direction of travel.
The operator can change the direction of travel at slow
travel speeds (less than a walking speed), but the mast
must not be in a raised position. If the lift truck is moving
rapidly, slow to a walking speed before changing the direc- A. FAST B. SLOW
tion of travel. The inching/brake pedal is used to control the inching oper-
Inching Control ation. During operation as the inching/brake pedal is
applied, the clutch in the transmission gradually disen-
WARNING gages while the brakes engage.
Inching requires coordinated movement of the inching/
brake pedal and the accelerator pedal. New operators
must practice this procedure before attempting to han-
dle loads.
Inching is the movement of a lift truck that allows a slow
travel speed while keeping the engine speed high for fast
operation of the lift mechanism or prevents rollback on an
incline.

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Steering (Turning) ground will aggravate these conditions and cause the fork-
lift to become unstable.
WARNING
TRAVEL SLOWLY WHEN TURN- WARNING
ING. Lift trucks can tip over even Failure to observe the tail swing area when making a
at very slow speeds. The combi- turn can injure or kill someone.
nation of speed and the sharp-
ness of a turn can cause a
tipover. A lift truck is less stable
when the forks are elevated, with
or without a load.

WARNING
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR
FEET, AND LEAN FORWARD AND AWAY FROM THE A. TAIL SWING
POINT OF IMPACT.
Because lift trucks are designed to work in a relatively
Most operators can understand the need to be careful small space, they can turn sharper than some other vehi-
when handling loads. But some operators do not realize cles. Most lift trucks are steered by the rear wheels and the
that a tipover can occur with an empty lift truck because rear of the lift truck can move to the side very fast during a
similar dynamic forces are present. In fact, the lift truck will turn. This movement is called "tail swing". An operator
actually tip over easier when empty, than when loaded with must be aware of tail swing and always check to make sure
the load lowered. Mast tilt, off-center loads, and uneven the tail swing area is clear before turning. Failure to

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observe the tail swing area when making a turn can lead to Load Handling, General
injury or death.
1. The capacity is the maximum
DO NOT turn on an incline. To load that the lift truck can handle for
reduce the possibility of a tipover, a the load condition shown on the
lift truck must not be driven across Nameplate. The operator must
an incline. know whether or not a load is within
When possible, keep both hands on the maximum capacity of the lift
the steering wheel. During most truck before the load is handled.
loading or unloading operations, the However, factors such as weak floors or uneven terrain,
operator steers with the left hand. loads with a high center of gravity, unevenly distributed
The right hand is used to operate the lift, tilt, and attach- loads, or tyre condition can mean that the safe working
ment controls. load is less than the capacity shown on the Nameplate.
When such conditions exist, the operator must reduce the
load so the lift truck will remain stable.

WARNING
DO NOT handle a load if any loose part of it is above
the load backrest or any part of the load is likely to fail.
2. Handle only stable loads. A load can have unstable
When turning the lift truck from a wide aisle into a narrow items that can easily shift and fall on someone.
aisle, start the turn as close to the opposite stock pile as
tail swing will permit. This action permits the lift truck to
enter the narrow aisle going straight ahead.

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WARNING
If the fork/locking pin is not fully engaged, the fork
could become unintentionally disengaged.

3. Position each fork the same distance from the center of

the carriage. This action will help center the load on the
carriage. Set the forks as far apart as possible for maxi-
mum support of the load. Center the weight of the load
between the forks.
If the weight of the load is not centered between the forks,
the load can fall from the forks when you turn a corner or
hit a bump. An off-center load will increase the possibility of
the truck tipping over to the side. Make sure the pins that
keep the forks in position are engaged so that the forks
cannot move.
4. Check the condition of the driving surface. Make sure
the floor will support the weight of the lift truck and the load.

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Operating Procedures

Load Handling, Lifting, Lowering, and Tilting

The LIFT and TILT functions are controlled by separate
levers. See the Controls section in the Model Description
section for the correct operation.
The speed of the hydraulic functions is controlled by the
position of the control levers. The farther the hand lever is
moved from the NEUTRAL position, the faster the speed of
the hydraulic function.
DO NOT lift or hit anything that can fall on the operator or a
bystander. Remember, a lift truck equipped with a Hyster
overhead guard and load backrest extension provides rea-
sonable protection to the operator from falling objects, but
can not protect against every possible impact.
A lift truck without an overhead guard provides no such
protection and other personnel have no overhead protec-
tion. Avoid hitting objects such as stacked material that
could become dislodged and fall.
The operator must exercise care while working near such
objects. Whether the lift truck is loaded or empty, DO NOT
travel with the load or carriage in a raised position.

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applies not only to the operator but also a helper. A
WARNING
helper must not be near the load or lift mechanism
while the operator is attempting to handle a load. The
lift mechanism has moving parts with close clearances
that can cause serious injury.
Lift and lower with the mast vertical or tilted slightly back-
ward from vertical. Tilt elevated loads forward only when
directly over the unloading place.

Keep yourself and all others clear of the lift mecha-

nism. Never allow anyone under or on the forks.

WARNING

NEVER put hands, arms, head, or legs through the

mast or near the carriage or lift chains. This warning

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WARNING
The lift truck can tip over forward when the load is
raised. Forward tipping is even more likely when tilting
forward, braking when traveling forward, or accelerat-
ing in reverse.
If the lift mechanism is raised to pick up or deposit a load,
keep the tilt angle in either direction to a minimum. Back-
ward and forward tilt are helpful, but they affect side and
forward stability. DO NOT tilt in either direction more than
Load Handling, How to Engage and
necessary when handling a load that is raised. The lift truck Disengage a Load
can tip forward if the mast is tilted forward with a load in the
raised position.
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR
FEET, AND LEAN FORWARD AND AWAY FROM POINT
OF IMPACT.

1. Avoid fast starts. Sudden movement can cause the lift

truck to tip. People can be hurt or killed and material can
be damaged.

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Approach the load carefully. Make sure that the truck is
perpendicular to the load. Raise the forks to the proper
height for engaging the load.

A. BE CAREFUL OF FORKS BEYOND THE LOAD

If the forks are longer than the load, move the forks under
the load so that the tips of the forks do not extend beyond
2. Move forward slowly until the forks are in position under
the load. Lift the load from the surface. Move backward a
the load. The forks must support at least two-thirds (2/3) of
few inches, then lower the load onto the surface and inch
the length of the load.
forward to engage the load against the carriage. Tilt the
Make sure that the load is centered between the forks. mast backward just far enough to lift the load from the sur-
Make sure that the forks do not extend past the load so face.
that loads or equipment that are behind the load being lif-
ted are not damaged. Lift the load a small distance from
the floor to make sure the lift truck has the capacity to lift
the load.

3. When a load is put on the floor, tilt the mast forward to a

vertical position and lower the load. Tilt the mast forward to

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permit smooth removal of the forks. Carefully move the lift
WARNING
truck backward to remove the forks from under the load.
Move carefully and smoothly when the load is raised
over a stack. When the load is elevated the center of
gravity of the lift truck and the load is much higher.
The lift truck can tip over when the load is raised.
5. To put the load on a stack, align the lift truck with the
stack. Raise the load higher than the point where it will be
placed. DO NOT raise the load to a point below where the
load is to be placed and "jog" the load up into position. This
operation uses added energy. Be careful not to damage or
move adjacent loads.

4. If the load is being removed from a stack, slowly move

the lift truck away from the stack. When the load is clear of
the stack, lower the load for traveling. Always travel with
the load as low as possible and tilted backward. Lowering
speed is controlled by the position of the control lever.
Lower slowly and smoothly. Slowly return the control lever
to the neutral position so that the load is not dropped or
that the lift truck is not tipped over due to the rapid stop of
the load.

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IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE NOTE: Not every load can be lifted using only the forks of
OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO a lift truck. Some loads will require a special attachment.
STEERING WHEEL, BRACE YOUR FEET, AND LEAN
6. When lifting round objects, use a block behind the
FORWARD AND AWAY FROM THE POINT OF IMPACT.
object. Tilt the mast forward so that the forks can slide
along the floor under the object to be lifted. Tilt the mast
fully backward to help keep the load on the forks.

Move forward slowly. When the load is in position, lower

the load on to the stack or the rack. Lower the forks just
enough to remove them from under the load. DO NOT
lower the forks so that they will drag on the surface under
the load. Tilt the mast forward just enough to permit Load Handling, Traveling
smooth removal of the forks from under the load. Carefully
move the lift truck backward to remove the forks from 1. When traveling with the load lowered, keep the load
under the load. Lower the forks when traveling. against the carriage and the mast tilted fully backward. This
action will help keep the load on the forks and provide good
forward and side stability.

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Always look in the direction of travel to avoid damage
to something or injury to someone.
3. For better visibility with large loads, travel with the load
trailing, but always keep a proper lookout in the direction of
travel. Normally, direction of travel is determined by the
best visibility available to the operator. If the lift truck must
travel in a direction where visibility is obstructed, a lookout
2. Travel with the lift mechanism raised only enough to
helper is required. Never drive when visibility is obstructed.
clear the ground or obstacles.
When the mast, carriage, or load is in a raised position, the
stability of the lift truck is reduced. This is also critical when
the lift truck is not carrying a load. The ability of the lift truck
to resist side tipping can be less on a lift truck without a
load than it is on a lift truck with a load in the lowered
(travel) position. Therefore, a lift truck without a load is
more likely to tip sideways, especially in a turn, than a lift
truck with a load carried in the lowered position.
4. When traveling up or down grades in excess of 5% with
WARNING a heavily loaded lift truck, keep the load upgrade to main-
tain control.
Some lift trucks have mirrors for viewing along the
side to observe the tail swing area. These mirrors are
an aid to the driver, but are NOT driving mirrors and
must NOT be used as such when operating in reverse.

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6. Anytime the lift truck is moving
keep arms, legs, etc., inside the
operator's compartment. Arms and
legs outside the machine can be
injured when passing obstructions.
When operating an unloaded lift truck on a grade in 7. Avoid bumps, holes, mud, slick
excess of 5%, keep the counterweight upgrade. spots, and loose materials that
may cause the lift truck to swerve
5. Watch out for pedestrians at all times.
or tip. If unavoida-
DO NOT drive up to anyone standing in
ble, slow down.
front of an object. Use extra care at
cross-aisles, doorways, and other loca- Different models of
tions where pedestrians can step into lift trucks are
the path of travel of the lift truck. designed to operate
under different con-
Slow down when approaching blind
ditions. Solid rubber
intersections or turns and sound the
tyre models are
horn. The horn is to warn pedestrians that there is a vehicle
designed to operate
in the area and to be alert to possible danger.
on relatively
smooth, firm surfa-
ces. Lift trucks with pneumatic tyres can adapt to more
uneven ground. Always make sure you pick the smoothest
route for your lift truck.

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8. Watch clearances, especially forks, mast, overhead 10. DO NOT pass another lift truck traveling in the same
guard, and tail swing. A lift truck is designed to perform a direction at intersections, blind spots, or at other dangerous
wide variety of functions within limited space. locations.

The operator must be aware that the forks can sometimes 11. Stay away from the edge of the road. Keep the wheels
extend beyond the front of the load. If the forks extend of the lift truck on the roadway. If the wheels are allowed to
beyond the load, the operator can hit an object or lift run off the edge of the travel surface onto soft ground, the
another load. Serious accidents can be caused by mast lift truck can tip over.
and overhead guards hitting pipes and beams near the
ceiling.

9. DO NOT indulge in stunt driving or horseplay.

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12. Under all travel conditions, operate the lift truck at a • DO NOT use a lift truck to move a freight wagons.
speed that will permit it to be brought to a stop in a safe
• DO NOT use a lift truck to open or close the door on a
manner.
freight wagons unless the lift truck has an attachment
Lorry, Freight Wegons, and Docks that is specifically designed for opening and closing
freight wagons doors and the operator is trained in its
WARNING use.
Maintain a safe distance from the
edge of docks, ramps, platforms
and other similar working surfa-
ces. Watch the “tail swing.”
Remember when traveling in the
forward direction and the steering
wheel is turned to move the lift
truck away from the edge of the
dock, the rear will swing toward
the edge. This action can cause
the lift truck to fall off the dock.
IF THE LIFT TRUCK FALLS OFF
THE DOCK, DO NOT JUMP OFF! HOLD FIRMLY TO • Check to make sure that the brakes on the lorry are set
STEERING WHEEL, BRACE YOUR FEET, AND LEAN and that wheel blocks have been placed on both sides
FORWARD AND AWAY FROM THE POINT OF IMPACT. of the rear wheels (unless a dock locking mechanism is
Before operating in a lorry or freight wagons observe the engaged). Fixed jacks may be necessary to support the
following:

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Operating Procedures
front and rear of a lorry trailer to prevent it from moving
or tipping during loading or unloading.
• Make sure that the freight wagons brakes are set and
the wheels are blocked while loading or unloading. Do
this check so that the freight wagons will not move due
to the movement of the lift truck in and out of the freight
wagons. If an attachment is installed on the lift truck, make sure the
operating instructions are available and understood before
• Check the condition of the driving surface. Make sure
operating the attachment. For the operation of attachment
the floor will support the weight of the lift truck and the
control levers, see Figure 4 and Table 1.
load.
Attachments must be removed or installed by trained per-
• Make sure the dock board is secured, in good condition,
sonnel only.
and of the proper capacity.
• When entering a freight wagons, the operator can enter Stopping
at an angle (if the dock plate or bridge is wide enough).
This will reduce the turning required after entering.
• Never leave a parked truck on a dock plate.
Attachments

WARNING
Make sure the Nameplate is correct if an attachment
has been installed.

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Stop the lift truck as gradually as possible. Hard braking See FIRE HAZARD WARNING at the beginning of this
and wheel sliding can cause the forklift to tip or the load to section.
fall off of the forks and damage the load or hurt someone.
8. If the lift truck is not in active use, close the fuel valve at
Parking the tank. If the lift truck is going to be left over night or lon-
ger, the truck must be parked outside or the LPG tank must
The operator must never leave a lift truck in a condition so be removed and stored outside.
that it can cause damage and injury. When parking the lift
truck, do the following operations: DO NOT park the lift truck so that it limits access to fire
aisles, stairways, and fire equipment.
1. Stop the lift truck and apply the parking brake.
Disconnecting Attachment Hydraulic Quick-
2. Fully lower the forks or carriage. Tilt mast forward until
the tips of the forks touch the ground.
Disconnect Hoses
3. If equipped, move the Direction Control Lever to the 1. Turn the key switch or keyless switch to the OFF posi-
NEUTRAL position. tion.

4. Turn the key to the OFF position to stop the engine. 2. Disconnect the negative terminal of the battery.

5. To release seat belt, press red release button and guide 3. Move the manual hydraulic levers forward and backward
belt carefully back into retractor with your hand. to relieve the system hydraulic pressure.

6. If the lift truck must be left on an incline, put blocks on 4. Disconnect the Quick-Disconnect hose connections. See
the down hill side of the wheels so that the lift truck can not Figure 8.
move.
7. Check engine compartment, if operating in areas con-
taining combustible material, and remove foreign debris.

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Connecting Attachment Hydraulic Quick- 3. Turn the key switch or keyless switch to the ON position
Disconnect Hoses and start the engine.
4. Move the manual hydraulic levers forward and back-
1. Connect the Quick-Disconnect hose connections. See
ward, and check the hydraulic system for leaks.
Figure 8.
2. Connect the negative terminal of the battery.

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1. QUICK-DISCONNECT FITTINGS 2. HYDRAULIC TUBES

Figure 8. Quick-Disconnect Hoses Connections

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Maintenance

Maintenance
General The Maintenance Schedule has time intervals for inspec-
tion, lubrication, and maintenance for your lift truck. The
WARNING service intervals are given in both operating hours recorded
DO NOT make modifications to the lift truck that affect on the lift truck hour meter, and in calendar time. Use the
the safe operation of the lift truck. Don't add parts or interval that occurs first.
components that affect visibility. The recommendation for the time intervals are for eight
DO NOT make repairs or adjustments unless you have hours of operation per day. The time intervals must be
both authorization and training. Repairs and adjust- decreased from the recommendations in the Maintenance
ments that are not correct can make a dangerous oper- Schedule for the following conditions:
ating condition. • If the lift truck is used more than eight hours per day.
DO NOT operate a lift truck that needs repairs. Report • If the lift truck must work in dirty operating conditions.
the need for repairs immediately. If repair is necessary,
put a "DO NOT OPERATE" tag in the operator's area • Poor ground conditions.
and remove the key. • Intensive usage at high performance levels on other
abnormal conditions will require more frequent servicing.
CAUTION
Disposal of lubricants and fluids must meet local envi- Your dealer for Hyster lift trucks has the equipment and
ronmental regulations. trained service personnel to do a complete program of
inspection, lubrication, and maintenance. A regular pro-
This section contains a Maintenance Schedule and the gram of inspection, lubrication, and maintenance will help
instructions for maintenance and inspection. your lift truck provide more efficient performance and oper-
ate for a longer period of time.

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Maintenance
Some users have service personnel and equipment to do make the lift truck difficult to steer. Poor traction can
the inspection, lubrication, and maintenance shown in the cause the disabled lift truck or towing vehicle to slide.
Maintenance Schedule. Service Manuals are available A slope will also make the lift truck more difficult to
from your dealer for Hyster lift trucks to help users who do stop.
their own maintenance.
Never lift and move a disabled lift truck unless the dis-
Serial Number Data abled lift truck MUST be moved and cannot be towed.
A lift truck used to move a disabled lift truck MUST
The serial number for the lift truck is on the Nameplate. It is have a capacity rating equal to or greater than the
also on the right side of the frame, under the floor plate. weight of the disabled lift truck. The capacity of the lift
truck used to move a disabled lift truck must have a
How to Move a Disabled Lift Truck
load center equal to half the width of the disabled lift
truck. See the Nameplate of the disabled lift truck for
WARNING the approximate total weight. The forks must extend
Use extra caution when towing a lift truck if any of the the full width of the disabled lift truck. Put the weight
following conditions exist: center of the disabled lift truck on load center of the
1. Brakes do not operate correctly. forks. Be careful to not damage the under side of the
lift truck.
2. Steering does not operate correctly.
3. Tyres are damaged.
How to Tow the Lift Truck
4. Traction conditions are bad. 1. The towed lift truck must have an operator.

5. The lift truck must be towed on a slope. 2. Tow the lift truck slowly.

If the engine cannot run, there is no power available for 3. Using a lift truck or a lifting device that can be attached
the hydraulic steering system. This condition can to the mast (i.e., come-a-long), raise the carriage and forks

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Maintenance
approximately 30 cm (12 in.) from surface. Install a chain 1. Before removing the mast and drive axle, put
around a mast crossmember and the carriage, to prevent blocks under the counterweight so that the lift
carriage and mast channels from moving. truck cannot fall backward.
4. If another lift truck is used to tow the disabled lift truck, 2. Before removing the counterweight, put blocks
that lift truck must have an equal or larger capacity than the under the mast assembly so that the lift truck can-
disabled lift truck. Install approximately 1/2 of a capacity not fall forward.
load on the forks of the lift truck that is being used to tow
The surface must be solid, even, and level when the lift
the disabled lift truck. This 1/2 capacity load will increase
truck is put on blocks. Make sure that any blocks used
the traction of the lift truck. Keep the load as low as possi-
to support the lift truck are solid, one piece units.
ble.
NOTE: Some lift trucks have lifting eyes. These lifting eyes
5. Use a towing link made of steel that fastens to the tow
can be used to raise the lift truck so that blocks can be
pins in the counterweights of both lift trucks.
installed.
How to Put a Lift Truck on Blocks How to Raise the Drive Tyres
(See Figure 9)
WARNING
The lift truck must be put on blocks for some types of 1. Put blocks on each side (front and back) of the steering
maintenance and repair. The removal of the following tyres to prevent movement of the lift truck.
assemblies will cause large changes in the center of 2. Put the mast in a vertical position. Put a block under
gravity: mast, drive axle, engine and transmission, and each outer mast channel.
the counterweight. When the lift truck is put on blocks,
put additional blocks in the following positions to 3. Tilt the mast fully forward until the drive tyres are raised
maintain stability: from the surface.

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Maintenance
4. Put additional blocks under the frame behind the drive 2. Use a hydraulic jack to raise the steering tyres. Make
tyres. sure that the jack has a capacity of at least 2/3 of the total
weight of the lift truck as shown on the Nameplate.
5. If the hydraulic system will not operate, use a hydraulic
jack under the side of the frame near the front. Make sure 3. Put the jack under the steering axle or frame to raise the
that the jack has a capacity equal to at least half the weight lift truck. Put blocks under the frame to support the lift
of the lift truck. See the Nameplate. truck.
How to Raise the Steering Tyres
(See Figure 9)
1. Apply the parking brake. Put blocks on both sides (front
and back) of the drive tyres to prevent movement of the lift
truck.

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Maintenance

1. DRIVE TYRES 2. STEERING TYRES

Figure 9. Put a Lift Truck on Blocks

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Maintenance Schedule

How to Clean a Lift Truck battery area, and dash display during the cleaning
process.
CAUTION Portions of your lift truck may be washed with a non-heated
Your lift truck may be damaged if water or cleaning pressure washer. Steam cleaning is not recommended in
agents come in contact with electrical components. DO most instances, as condensation may form in electrical
NOT directly spray any electrical components, espe- components causing damage or erratic behavior. For
cially connectors, switches, electro-hydraulic controls, cleaning guidelines and components to avoid, see the Peri-
odic Maintenance section of the Service Manual for your
Maintenance Schedule
lift truck.

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Maintenance Schedule

Figure 10. Maintenance and Lubrication Points, PSI 2.4L LPG Trucks

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Maintenance Schedule

Figure 11. Maintenance and Lubrication Points, Yanmar 2.6L and 3.3L Diesel Trucks

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Maintenance Schedule

Figure 12. Maintenance and Lubrication Points, PSI 2.4L Bi-Fuel Trucks

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Maintenance Schedule

Maintenance Schedule
(See Figure 10, Figure 11, and Figure 12)

8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
30 TYRES AND WHEELS X Check See Nameplate.
Condition.
SAFETY LABELS X Replace as Neces- See Parts Manual.
sary.
31, 33, MAST, CARRIAGE, X Check See Parts Manual.
34, 35 HEADER HOSES, Condition
LIFT CHAINS, AND and
ATTACHMENT Lubrication.
SEAT BELT, HIP X Check
RESTRAINTS, AND Condition
SEAT RAILS and
Operation.
BONNET AND SEAT X Check
LATCHES Condition
and
Operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
ENGINE COMPARTMENT X Remove
Combustible
Materials.
See NOTE 5 and
NOTE 15.
CHECK FOR LEAKS - X Check for Leaks.
FUEL, OIL, WATER See NOTE 1.
HYDRAULIC HOSES X Check See Parts Manual.
Condition.
See NOTE 15.
9 COOLANT HOSES X Check See Parts Manual.
Condition.
See NOTE 15.
16 FUEL TANK CIL 29.9 liter (7.9 gal) LPG - HD 5
PSI 2.4L LPG Engine
17 FUEL TANK CIL 69 liter (18.2 gal) No. 2 Diesel
Yanmar Diesel Engines
17 FUEL TANK CIL 69 liter (18.2 gal) 86 Octane Petrol
Petrol - PSI 2.4L Bi-Fuel Minimum
Engine
HORN, LIGHTS, ALARMS, X Check
FUSES, AND RELAYS Operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
37 SERVICE BRAKES X Check
Operation.
37 SERVICE BRAKES X Check Lining 1.0 mm (0.04 in.)
Thickness. Minimum
26 PARKING BRAKE X Check
Operation.
ACCELERATOR CABLE C 1 Cable See Parts Manual.
36 DRIVE AXLE X Check for Leaks.
Check Operation.
36 DIFFERENTIAL AND X C 6.5 liter (6.9 qt) SAE 80W-90
DRIVE AXLE OIL See NOTE 14. API GL-5
STEERING CONTROLS X Check
Operation
and
Condition.
24 TRANSMISSION X Check for Leaks
and Operation.
25 TRANSMISSION OIL DIP- X Check Oil Level. John Deere
STICK See NOTE 15. JDM J20C
25 TRANSMISSION OIL C 8.3 liter (8.8 qt) John Deere
See NOTE 15. JDM J20C
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
28 TRANSMISSION OIL C 1 Filter See Parts Manual.
FILTER See NOTE 4 and
NOTE 15.
27 TRANSMISSION OIL C 1 Breather See Parts Manual.
BREATHER See NOTE 15.
4 HYDRAULIC OIL X X C 30.0 liter (31.7 qt) ISO VG 46Hydraulic Oil
See NOTE 2, −20 °C (-4 °F) and Above
NOTE 3, NOTE 13
and NOTE 15.
8 HYDRAULIC OIL RETURN C 1 Filter See Parts Manual.
FILTER See NOTE 13 and
NOTE 15.
7 HYDRAULIC TANK X C Inspect and See Parts Manual.
BREATHER Replace as Neces-
sary.
See NOTE 13 and
NOTE 15.
5 BATTERY AND CABLE X Clean.
TERMINALS
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
14 ENGINE OIL X C 4.9 liter (5.2 qt) –20 to 30 °C (20 °F) and
PSI Engines CIL Every 6 mo See NOTE 4, Below SAE 5W-20
NOTE 5, and 16 °C (60 °F) and Below SAE
NOTE 15. 5W-30
–18 °C (0 °F) and Above SAE
10W-30
API SL
ILSAC GF3
SAE J2362
15 ENGINE OIL FILTER C 1 Filter See Parts Manual.
PSI Engines Every 6 mo See NOTE 4,
NOTE 5, and
NOTE 15.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
14 ENGINE OIL C 10.2 liter (10.8 qt) 20 °C (68 °F) and Over SAE
Yanmar Diesel Engines See NOTE 4, 40
NOTE 5, and 10 to 30 °C (50 to 86 °F) SAE
NOTE 15. 30
0 to 20 °C (32 to 68 °F) SAE
20
-16 to 40 °C (3 to 103 °F) SAE
15W-40
–20 to 30 °C (-4 to 86 °F) SAE
10W-30
-10 to 10 °C (14 to 50 °F) SAE
20W
-20 to 10 °C (-4 to 50 °F) SAE
10W
API CG-4 or Better
15 ENGINE OIL FILTER C 1 Filter See Parts Manual.
Yanmar Diesel Engines See NOTE 4,
NOTE 5, and
NOTE 15.
19 AIR FILTER X C 1 Filter See Parts Manual.
CIL See NOTE 5,
NOTE 6, and
NOTE 11.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
13 DRIVE BELT X Check for Wear
PSI Engines and Damage.
Adjust as
Needed.
13 DRIVE BELT X Check for Wear
Yanmar Diesel Engines and Damage.
Adjust as
Needed.
6 LPG REGULATOR X Drain Tar.
PSI Engine See NOTE 5.
6 LPG REGULATOR FILTER C 1 Filter See Parts Manual.
PSI Engine
20 LPG VAPORIZER X
PSI Engine
ENGINE IDLE SPEED X 850 ±25 RPM
PSI Engine
ENGINE GOVERNED X 2700 ±25 RPM
SPEED (No Load)
PSI Engine
ENGINE IDLE SPEED X 850 ±50 RPM
Yanmar Engine
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
ENGINE GOVERNED X 2625 ±25 RPM
SPEED (No Load)
Yanmar Engine
PCV Valve C Replace as Neces- See Parts Manual.
PSI 2.4L Engine sary.
23 VALVE ADJUSTMENT Not
PSI Engine Adjustable.
23 VALVE ADJUSTMENT X Adjust as Needed. Intake (cold)
Yanmar Engine 0.20 ±0.05 mm (0.008 to
0.002 in.)
Exhaust (cold)
0.20 ±0.05 mm (0.008 to
0.002 in.)
TIMING X Adjust as Needed. Preset at 4° ATDC
Yanmar 2.6L Engine
TIMING X Adjust as Needed. Preset at 6° ATDC
Yanmar 3.3L Engine
21 LPG FUEL FILTER C 1 Filter See Parts Manual.
PSI Engines
18 GASOLINE FUEL FILTER C 1 Filter See Parts Manual.
PSI Bi-Fuel Engine
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
21 FUEL WATER CIL C 1 Filter See Parts Manual.
SEPARATOR FILTER Drain Water from
Yanmar Diesel Filter as Required..
21 IN-LINE FUEL STRAINER C 1 Filter See Parts Manual.
Yanmar Diesel
3 FUEL INJECTORS X Check and Replace See Parts Manual.
PSI Engines if Necessary.
4 Injectors
See NOTE 7 and
NOTE 15.
3 FUEL INJECTORS X Check and Replace See Parts Manual.
Yanmar Diesel Engines if Necessary.
4 Injectors
See NOTE 15.
3 SPARK PLUGS C Change Spark Torch P/N DK7RTC
PSI Bi-Fuel Engine Plugs. 0.9 mm (0.035 in.)
4 Plugs
12 COOLING SYSTEM X C 11.0 liter (11.6 qt) See NOTE 12.
PSI Engine CIL
12 COOLING SYSTEM X C 11.5 liter (12.2 qt) See NOTE 12.
Yanmar Engines CIL
CLEAN DEBRIS FROM X See NOTE 5.
RADIATOR CORE
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
32 FORKS X X X Check
Condition.
32 FORK LATCHES L Lubricate as Multipurpose Grease
Required. See NOTE 8.
LIFT SYSTEM, OPERATE X Check
Operation.
31 MAST L Lubricate as Multipurpose Grease
Sliding Surfaces and Required. See NOTE 8.
Load Roller Surfaces See NOTE 9.
35 HEADER HOSES X Check
Condition.
34 LIFT CHAINS X L L, X Check Engine Oil
Condition. SAE 30W
Lube as Required.
See NOTE 10.
MAST L 2 Fittings Multipurpose Grease
Pivots See NOTE 8.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
MAST X L X C Lubricate as Multipurpose Grease
Sideshift Carriage Required. See NOTE 8and NOTE 10.
(Upper and Lower Bear- 2 Fittings 0 mm (0 in.) Minimum Thick-
ing Strips) for Upper ness.
Bearings and
2 Lower
Bearing
Strips.
Check Lower Bear-
ing Strips for Wear.
MAST X L X Lubricate as Multipurpose Grease
Fork Positioner Required. See NOTE 8.
2 Fittings
MAST X L X Lubricate as Multipurpose Grease
Fork Positioner Cylinder Required. See NOTE 8.
Rod Anchors 2 Anchors
MAST X Check
Fork Positioner and Torque.
Lower Hook Capscrews 8 Capscrews
TILT CYLINDER ENDS L 4 Fittings Multipurpose Grease
See NOTE 8.
BRAKE MASTER L Use Silicone Spray
CYLINDER ROD Hyster Part No. 328388.
END PIN
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
MANUAL HYDRAULIC L API SM
HAND LEVERS ILSAC GF4
SAE J2362
29 BRAKE FLUID CIL X C 0.2 liter (0.21 pt) SAE J-1703 (DOT 3)
Master Cylinder
1 DRIVE AXLE L Check Grease. Multipurpose Grease
Wheel Bearings See NOTE 8.
10 STEERING AXLE L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 8.
11 STEERING AXLE L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 8 and NOTE 17.
STEERING AXLE L 4 Fittings Multipurpose Grease
King Pins See NOTE 8 and NOTE 17.
STEERING AXLE L Check Grease. Multipurpose Grease
Wheel Bearings See NOTE 8.
2 PEDALS, LEVERS, SEAT L Lubricate as Use Silicone Spray
RAILS, CABLES, HINGES, Required. Hyster Part No. 328388.
LINKAGES
26 PARKING BRAKE X Adjust as Neces- Must Hold a Full Capacity
ADJUSTMENT sary. Load on a 15% Grade.
26 PARKING BRAKE L Lubricate as Use Silicone Spray
Required. Hyster Part No. 328388.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
30 WHEEL NUTS X Check Torque. 450 to 500 N•m (332 to
Drive Wheels 369 lbf ft)
30 WHEEL NUTS X Check Torque. 155 to 175 N•m (114 to
Steer Wheels 129 lbf ft)
TIMING BELT C Replace. See Parts Manual.
See See NOTE 16.
PSI Engine
NOTE 5.
See
NOTE 15.
INSPECT ENGINE x
ELECTRICAL SYSTEM,
CONNECTORS
INSPECT ENGINE X
VACUUM AND
FUEL LINES
AND FITTINGS
INSPECT LOCK-OFF FOR X
LEAKS AND ENSURE
LOCK-OFF CLOSING
TEST LPG X
REGULATOR
PRESSURE
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
CHECK AIR INDUCTION X
SYSTEM FOR LEAKS
CHECK MANIFOLD FOR X
VACUUM LEAKS
CHECK THROTTLE X
SHAFT FOR STICKING
CHECK INJECTORS AND X
RAILS FOR LEAKS
INSPECT EXHAUST X
MANIFOLD AND
PIPING FOR LEAKS
INSPECT CATALYST X
INLET AND OUTLET
INSPECT MUFFLER INLET X Replace as Nee-
AND OUTLET ded.
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours of operation.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance Schedule
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving contaminated environments
such as high levels of airborne debris (dust and waste paper); chemical or abrasive compounds; poor ground conditions; intensive usage at high perform-
ance levels; or other abnormal conditions will require more frequent servicing. At your request, your Hyster dealer will advise you of the appropriate
service intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Check fuel injectors at 5000 hours or 7 years. See PSI 2.4L Engine0600 SRM 1755 for procedures.
NOTE 8: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 9: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 10: Lubricate if dry or at first sign of visible surface rust.
NOTE 11: Do not open the air filter canister except to change the air filter element. See the Periodic Maintenance Manual for your lift truck for the correct
procedure to change air filter element.
NOTE 12: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized
water.
NOTE 13: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures 1900 SRM 1620 for oil cleanliness
and water content guidelines. For lift trucks operating in heavy duty applications or highly contaminated environments, take oil samples every 500 hours.
Normal operating conditions may allow for less frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
NOTE 14: Change differential/drive axle oil at 2400 hours. Use hour interval only.
NOTE 15: Turn lift truck engine OFF prior to performing maintenance or checks in engine compartment.
NOTE 16: Change timing belt every 6000 hours. Use hour interval only. Use Kit-Service 6000 hours specified in the Parts Manual for your lift truck.
NOTE 17: Lubricate tie rod ends and king pins at 300 hours. Use hour interval only.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

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Maintenance

Maintenance Procedures Every 8 Hours or Daily

How to Make Checks With the Engine Check for bent or damaged rims. Check for loose or miss-
Stopped ing hardware. Remove any wire, strapping, or other mate-
rial that is wrapped around the axle.
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 operator's area and
remove the key.
Put the lift truck on a level surface. Lower the carriage and
forks, stop the engine, and apply the parking brake. Open
the bonnet and check for leaks and conditions that are not
normal. Clean any oil or fuel spills. Ensure all surfaces are
free of oils, lubricants, fuel and organic dust or fibers
(paper, wood, cotton, agricultural grass/grain, etc.). 1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER
OBJECTS FROM THE TREAD)
Tyres and Wheels 2. MAKE SMOOTH EDGES
3. CHECK THE TYRE PRESSURE (PNEUMATIC TYRES)
Check the tyres for damage (see Figure 13). Check the
tread and remove any objects that will cause damage. Figure 13. Check the Tyres

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Maintenance

Safety Labels DO NOT try to correct the alignment of the fork tips by
bending the forks or adding shims. If either fork is
WARNING damaged, replace the forks as a set.
Safety labels are installed on the lift truck to give infor- Never repair damaged forks by heating or welding.
mation about operation and possible hazards. It is Forks are made of special steel using special proce-
important that all safety labels are installed on the lift dures. If either fork is damaged, replace the forks as a
truck and can be read. set.
Check that all safety labels are installed in the correct loca- DO NOT operate fork lift without lateral fork stops in
tion on the lift truck. See the Parts Manual, the Model place. Forks may disengage from fork carriage.
Description section in this Operating Manual, or the
Frame section of the Service Manual 100 SRM 1984 for 1. Inspect the welds on the mast, cylinders, and carriage
the correct location of the safety labels. See the Parts for cracks. Make sure that the capscrews and nuts are
Manual for the part numbers of the safety labels. tight.
2. Inspect the carriage to be sure fork stops are in place.
Mast, Carriage, Header Hoses, Lift Chains,
Fork stops prevent forks from laterally disengaging from
and Attachment the carriage.
(See Figure 25 and Figure 14)
3. Inspect the channels for wear in the areas where the roll-
WARNING ers travel. Inspect the rollers for wear or damage.
Lower the lift mechanism completely. Never allow any 4. Inspect the load backrest extension for cracks and dam-
person under a raised carriage. DO NOT put any part of age.
your body in or through the lift mechanism unless all
parts of the mast are completely lowered and the 5. If the lift truck is equipped with a sideshift carriage or
engine is STOPPED. attachment, inspect the parts for cracks and wear. Make

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Maintenance
sure the parts that fasten the sideshift carriage or attach- Figure 15 and Figure 16). Each item must be checked to
ment to the carriage are in good condition. make sure it is fastened correctly, functions correctly, and
is in good condition.
6. Visually inspect hoses/fittings for hydraulic leaks; hose
cover for cuts, cracks, or exposed reinforcement; defective/
broken clamping devices or sheaves; and proper tracking
during operation. Adjust/repair/replace hose/components
as necessary.
7. Check that the lift chains are correctly lubricated. Use
SAE 30 engine oil to lubricate the lift chains.
8. Inspect the lift chains for cracks or broken links and worn
or turned pins. Lift chains must be replaced as a set. See
Figure 14.
9. Inspect the chain anchors and pins for cracks and dam-
age.
10. Make sure the lift chains are adjusted so that they have
equal tension. Adjustments or replacement of the lift 1. WORN PIN 5. LOOSE LEAVES
chains must be done by authorized personnel. 2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. CORROSION
Operator Restraint System 4. HOLE WEAR

The seat belt, hip restraint, seat, bonnet, and bonnet Figure 14. Lift Chain Check
latches are all part of the operator restraint system (see

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Maintenance

Figure 15. Seat Check

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Maintenance
Legend for Figure 15
A. STANDARD NON-SUSPENSION SEAT C. SEMI-SUSPENSION SEAT
B. PREMIUM FULL SUSPENSION SEAT D. STANDARD FULL SUSPENSION SEAT
1. SEAT BELT 4. FORWARD/BACKWARD ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 5. BACKREST ANGLE ADJUSTMENT LEVER
3. RIDE POSITION INDICATOR 6. HIP RESTRAINT

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Maintenance
1. LATCH STRIKER
2. BUMPER
3. BONNET
4. BONNET RELEASE HANDLE
5. BONNET LATCH
6. LIFT TRUCK FRAME
7. BOOT

Figure 16. Bonnet and Bonnet Latch Check

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Maintenance
Emergency Locking Retractor (ELR) be pulled from the retractor assembly or the belt will not
retract, replace the seat belt assembly.
When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposition- • With the bonnet closed and in the locked position, pull
ing without activating the locking mechanism. If the truck the seat belt with a sudden jerk. Make sure the seat belt
tips over, travels off a dock, or comes to a sudden stop, the will not pull from the retractor assembly. If the seat belt
locking mechanism will be activated and hold the opera- can be pulled from the retractor when it is pulled with a
tor's lower torso in the seat. See Figure 15. sudden jerk, replace the seat belt assembly.
A seat belt that is damaged, worn, or does not operate • With the bonnet in the open position, make sure the seat
properly will not provide protection when it is needed. The belt will not pull from the retractor assembly. If the seat
end of the belt must fasten correctly in the latch. The seat belt can be pulled from the retractor, with the bonnet in
belt must be in good condition. Replace the seat belt if it is the open position, replace the seat belt assembly.
damaged or worn.
Bonnet and Seat Latches
NOTE: The following seat belt operation checks must be
performed three times before replacing the seat belt Make sure the seat rails and latch striker are not loose. The
assembly. seat rails must lock tightly in position, but move freely when
unlocked (see Figure 15). The seat rails must be correctly
• With the bonnet closed and in the locked position, pull fastened to the bonnet and the bonnet fastened to the
the seat belt slowly from the retractor assembly. Make hinges on the frame. Try to lift the bonnet to make sure it is
sure the seat belt pulls out and retracts smoothly. If the fastened correctly and will not move. If adjustment is
seat belt does not pull out of the retractor assembly, the required, go to Bonnet Latch Check in the Periodic Main-
internal latch may be locked. Pull firmly on the seat belt tenance section of the service manual.
and hold for a moment to remove slack from the belt in
the retractor. Release the seat belt. Seat belt will retract
and the internal latch will unlock. If the seat belt cannot

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Maintenance

Engine Compartment place and in contact with the ground. Check attaching
hardware. If worn, missing or not in contact with the
Check for the presence of any combustible material such ground, replace strap and mounting hardware as required.
as paper, leaves etc. Remove any combustible materials.
Earth Static Strap
If lift truck is equipped with a Earth Static Strap (see Fig-
ure 17), check to be sure Earth Static Strap is securely in

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Maintenance
1. FRAME
2. PDM
3. EARTH STATIC STRAP
4. BATTERY

Figure 17. Earth Static Strap

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Maintenance

Fuel, Oil, and Coolant Leaks, Check Hydraulic Hoses

Check the condition of the hydraulic hoses for serviceability
WARNING
by inspecting for cracks or other obvious damage. Check to
All fuels are very flammable and can burn or cause an
insure that the hydraulic hoses are not leaking. If any hose
explosion. DO NOT use an open flame to check the fuel
is leaking, report it to maintenance for repair.
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- Coolant Hoses
ing the repair. DO NOT operate the lift truck until a leak
is repaired. Check the condition of the coolant hoses for serviceability
by inspecting for cracks or other obvious damage. Check to
Make a visual check for leaks on and under the lift truck. If insure that the coolant hoses are not leaking. If any hose is
possible, find and report the leak to maintenance for repair. leaking, report it 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 Transmission
visible unless ice is present. There is however, usually a
Check the transmission for leaks, damage, and loose com-
strong odor. Fuel leaks MUST be repaired IMMEDIATELY.
ponents. Heavy-duty or high-temperature operations can
Check the fuel system for leaks and the condition of parts. require more frequent checks.
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.

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Maintenance

Hydraulic System Oil

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.
After the engine has stopped, wait one minute before
checking the oil level. Keep hydraulic oil at the correct level
as indicated on the dipstick, located on top of right frame
channel. See Figure 18. Use the correct oil as shown in
the Maintenance Schedule.
Check the hydraulic system for leaks and damaged or
loose components. Heavy-duty or high-temperature opera-
tions can require more frequent checks. Figure 18. Hydraulic System Oil Check

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Maintenance
Legend for Figure 18 There is an indicator light for the engine oil pressure on the
1. DIPSTICK 4. BREATHER/FILLER NECK
Dash Display. During normal operation the red indicator
2. RETURN FILTER 5. RIGHT FRAME CHANNEL light will illuminate when the key switch is turned to ON and
3. SUCTION FILTER will stay illuminated until correct oil pressure is obtained, at
which time the light will go off.
Engine Oil If the light continues to stay on when the engine is running,
After the engine has stopped, wait one minute before the engine oil pressure is low. Stop the engine and check
checking the oil level. See Figure 19, Figure 20, Fig- the oil level. See Figure 19, Figure 20, Figure 21, and
ure 21, and Figure 22. Keep the oil at the correct level as Figure 22. DO NOT restart the engine until the low pres-
indicated on the dipstick. Use the correct oil as shown in sure condition has been corrected.
the Maintenance Schedule.

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Maintenance
1. BATTERY
2. AUXILIARY COOLANT RESERVOIR
3. DRIVE BELT
4. RADIATOR CAP
5. AIR FILTER
6. FUEL FILTER
7. DIPSTICK ENGINE OIL
8. ENGINE OIL FILTER
9. ENGINE OIL FILL
10. FUEL INJECTOR

Figure 19. Yanmar 2.6L Diesel Engine Maintenance Points

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1. BATTERY
2. DRIVE BELT
3. RADIATOR CAP
4. AUXILIARY COOLANT RESERVOIR
5. AIR FILTER
6. ENGINE OIL FILTER
7. FUEL FILTER
8. DIPSTICK ENGINE OIL
9. FUEL INJECTOR
10. ENGINE OIL FILL

Figure 20. Yanmar 3.3L Diesel Engine Maintenance Points

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1. BATTERY
2. PCV VALVE
3. SPARK PLUGS
4. DRIVE BELT
5. ENGINE OIL FILL
6. RADIATOR CAP
7. AUXILIARY COOLANT RESERVOIR
8. FUEL FILTER
9. ENGINE OIL FILTER
10. AIR FILTER
11. ENGINE OIL DRAIN PLUG
12. DIPSTICK ENGINE OIL

Figure 21. PSI 2.4L LPG Engine Maintenance Points

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1. BATTERY
2. PCV VALVE
3. SPARK PLUGS
4. ENGINE OIL FILL
5. DRIVE BELT
6. RADIATOR CAP
7. LPG FUEL FILTER
8. AUXILIARY COOLANT RESERVOIR
9. ENGINE OIL FILTER
10. AIR FILTER
11. PETROL FUEL FILTER
12. ENGINE OIL DRAIN PLUG
13. DIPSTICK ENGINE OIL
14. INJECTOR

Figure 22. PSI 2.4L Bi-Fuel Engine Maintenance Points

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Air Filter NOTE: Forks are to be replaced only in sets and not indi-
vidually.
The air filter canister should not be opened until an air filter
element replacement is required. An air filter element NOTE: If lift truck is equipped with fork positioner attach-
replacement is required when one of the following occurs: ment, perform Step 1 and Step 2. If lift truck is not equip-
ped with a fork positioner attachment, go to Step 2.
• the specified number of hours has passed since the last
filter element replacement 1. Lower carriage and remove four capscrews from inner
fork carriers. Remove inner fork carriers from integral side
DO NOT operate the lift truck until the air filter element has shift carriage. See Figure 23.
been replaced.
2. A fork can be removed from the carriage for replacement
Forks of the fork or other maintenance. Slide a hook fork to the
fork removal notch on the carriage. See Figure 24 .
The identification of a fork describes how the fork is con-
nected to the carriage. These lift trucks have hook forks. Lower the fork onto blocks so that the bottom hook of the
fork moves through the fork removal notch. See Figure 24.
Forks, Remove
Lower the carriage further so that the top hook of the fork is
WARNING disengaged from the top carriage bar. Move the carriage
away from the fork, or use a lifting device to move the fork
DO NOT try to move a fork without a lifting device.
away from the carriage.
Each hook fork for these lift trucks can weigh 45 to
115 kg (99 to 253 lb).

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Figure 23. Fork Positioner

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Legend for Figure 23
1. OUTER FORK CARRIER 5. FORK POSITIONER
2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. SIDESHIFT CARRIAGE

Legend for Figure 24

1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK

Forks, Inspect

WARNING
DO NOT try to correct for tip alignment by bending the
forks or adding shims. Replace bent forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
dures. Replace damaged fork. Forks are to be replaced
only in sets and not individually.
1. Inspect the forks for cracks and wear. Check that the
fork tips are aligned as shown in Figure 25. Check that the
bottom of the fork is not worn (Item 4 in Figure 25).
Figure 24. Remove a Hook Fork

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b. Position caliper at end of heel internal radius (item 4,
CAUTION
Figure 25) with opening corresponding to measured
Remove fork latch pins if adding a fork positioner
thickness of fork shank in Step a above. (e.g. for N 1.75
attachment. Damage to forks and other carriage com-
use N 1.75 opening). This is typically the section of fork
ponents can occur if fork latch poins are not removed
where wear is greatest. Note that opening distance has
prior to using attachment.
been reduced by 10% from nominal thickness.
2. Replace any damaged or broken parts that are used to
c. If fork enters opening, it is mandatory to replace it.
keep the forks locked in position.
DANGER OF BREAKING. Furthermore, a 10% reduc-
3. Inspect fork wear. Ensure heel wear is not more than tion in fork blade thickness results in 20% reduction in
10% of original thickness. if fork wear is more than 10%, operating capacity.
fork must be replaced or rerated. Perform fork wear inspec-
tion using a BOL256N1 caliper ruler Hyster P/N 4092984
as follows. See Figure 26.
a. Determine normal thickness of "N" of fork using scale
or ruler portion of caliper ruler. Measurement has to be
done on fork shank using caliper ruler.

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Fork Tip Alignment

Length of Forks 3% Dimension
1000 mm (39.5 in) 30 mm (1.17 in)
1016 mm (40 in) 30 mm (1.2 in)
1100 mm (43 in) 33 mm (1.29 in)
1200 mm (47 in) 36 mm (1.42 in)

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

Figure 25. Forks Check

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Forks, Install
1. Move the fork and carriage so that the top hook on the
fork can engage the upper carriage bar. Raise the carriage
to move th 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 27.
2. If lift truck is equipped with a fork positioner attachment,
install fork carriers using four capscrews. Tighten cap-
screws to 35 N•m (25 lbf ft). See Figure 23.

Figure 26. Fork Wear

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slot, replace with new pin. Adjust the forks as far apart as
possible for maximum support of the load. 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 adjust-
ment is made.
Brake Fluid

WARNING
1. FORK 5. WEDGE Small amounts of water in the brake system can cause
2. LOCK PIN 6. KNOB reduced braking performance if the water reaches the
3. SPRING 7. LOCK PIN ASSEMBLY wheel cylinder areas. DO NOT allow water entry.
4. WASHER
Ensure that the sealed reservoir lid is properly
replaced.
Figure 27. Fork Lock Pin Assembly
Replace the brake fluid in the system if there is dirt or
Forks, Adjust water in the system.
NOTE: During the adjustment of the forks, the heel of the On lift trucks with dry brakes, only use SAE J-1703
forks should not be touching the ground. (DOT 3) brake fluid in the master cylinder.
The forks are connected to the carriage by hooks and lock Open cover to brake fluid reservoir. Open reservoir and
pins. See Figure 24 and Figure 27. The lock pins are check fluid lever. If fluid is low, fill to within 2.5 mm (0.1 in.)
installed through the top fork hooks and fit into slots in the of max line on reservoir. See Figure 28.
top carriage bar. If pin does not remain engaged in carriage

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Figure 28. Brake Fluid Reservoir Cover

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Legend for Figure 28
A. COVER CLOSED B. COVER OPEN
1. COVER 4. BRAKE FLUID RESERVOIR
2. CAPSCREW 5. MOUNTING BRACKET
3. NUT

How to Make Checks With the Engine Be careful when making the checks. If the lift truck is sta-
Running tionary during a check, apply the parking brake and put the
transmission in NEUTRAL. Make the checks carefully.
WARNING Indicator Lights, Horn, Fuses, and Relays
DO NOT operate a lift truck that needs repairs. Report
the need for repair immediately. If repair is necessary, Turn key to ON position. Check all indicator lights for cor-
put a DO NOT OPERATE tag in the operator's area and rect operation as described in Table 1. Check the opera-
remove the key. tion of the horn. Start the engine by turning the key switch
to the START position. If any of the indicator lights do not
WARNING operate correctly, check the fuses. The fuses are located in
FASTEN YOUR SEAT BELT! The seat belt is installed the Power Distribution Module (PDM) which is under the
to help the operator stay on the truck if the lift truck bonnet next to the battery on the right side. See Figure 29.
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 checks of the operation.

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Figure 29. PDM Showing Fuses and Relays

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Legend for Figure 29
NOTE: BONNET REMOVED FOR CLARITY.
1. BATTERY 12. REAR WORK LIGHT (20 AMP)
2. POWER DISTRIBUTION MODULE (PDM) 13. FRONT WORK LIGHT RELAY
3. START RELAY 14. BACKUP RELAY
4. STARTER (30 AMP) 15. BATTERY+ (25 AMP)
5. RESISTOR (68 OHM) 16. FRONT WORK LIGHT (20 AMP)
6. IGNITION 3 RELAY 17. BATTERY+ (20 AMP)
7. TRANZORB 18. BACKUP (20 AMP)
8. IGNITION 1 RELAY 19. IGNITION 3+ (30 AMP)
9. REAR WORK LIGHT RELAY 20. FUEL/RUN (20 AMP)
10. BATTERY (25 AMP) 21. FUEL/RUN RELAY
11. IGNITION 1+ (20 AMP)

Service Brakes Operation, Check

Brake Fluid Level Check the operation of the service brakes. Push on the
inching/brake pedal. The service brakes must be applied
WARNING before the inching/brake pedal reaches the floor plate. The
If the brake system has a power assist (or boost), brak- pedal must stop firmly and must not move slowly down
ing will be more difficult if the engine is not running. after the brakes are applied. The service brakes must apply
equally to both drive wheels. The service brakes must not
Loss of fluid from the brake fluid reservoir indicates a pull the lift truck to either side of the direction of travel when
leak. Repair the brake system before using the lift they are applied. The service brakes are automatically
truck. Replace the brake fluid in the system if there is adjusted when the transmission is in reverse and the lift
dirt, water, or oil in the system. truck is moving and the brakes are firmly applied. Full

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application of the inching/brake pedal applies the service tinues to stay on when the engine is running, the engine oil
brakes and puts the transmission in NEUTRAL. pressure is low. Stop the engine and check the oil level.
See Engine Oil section in this manual. DO NOT restart the
Parking Brake engine until the low pressure condition has been corrected.
If the operator leaves the seat without setting the parking Cooling System
brake and the key is in the OFF position for a period of 3
minutes or less, an audible alarm will sound for 1 minute.
WARNING
Make sure the service brakes operate correctly before DO NOT remove the radiator cap from the radiator
checking the operation of the parking brake. Check the when the engine is hot. When the radiator cap is
operation of the parking brake. The parking brake, when in removed, the pressure is released from the system. If
good condition and correctly adjusted, will hold a lift truck the system is hot, the steam and boiling coolant can
with a full capacity load on a 15% grade [a slope that cause burns.
increases 1.5 meters in 10 meters (1.5 feet increases in 10
There is a coolant temperature gauge on the Dash Display.
feet)]. If parking brake requires adjustment, notify service
When the bar gauge reaches the middle bar, the tempera-
personnel.
ture is optimum. If the gauge shows full bars, the engine is
Engine Oil Pressure too hot and a warning buzzer will sound.

There is an indicator light for the engine oil pressure on the Make sure the coolant level is between the ADD and FULL
Dash Display. During normal operation the red indicator marks on the auxiliary coolant reservoir (See Figure 30).
light will illuminate when the key switch is turned to ON and The coolant will expand as it is heated and the level in the
will stay illuminated until correct minimum oil pressure is auxiliary coolant reservoir will increase.
obtained, at which time the light will go off. If the light con-

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CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
If coolant is added, use the correct mixture of water and
ethylene glycol shown in the Maintenance Schedule.

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.
Check the radiator fins. Clean the radiator with compressed
air or water as needed.
Check for and remove any debris on the radiator core. If
the indicator light turns on again after restarting, shut down
the lift truck and do not operate the lift truck until the prob- 1. RADIATOR CAP
lem is corrected. 2. FILL CAP
3. FULL MARK
4. AUXILIARY COOLANT RESERVOIR
5. ADD MARK (LOW)

Figure 30. Auxiliary Coolant Reservoir

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Steering System parts of the mast are completely lowered and the
engine is STOPPED.
WARNING If the mast cannot be lowered, use chains on the mast
The lift truck has hydraulic power steering. The steer- weldments and carriage so that they can not move.
ing can be difficult if the engine is not running. Make sure the moving parts are attached to a part that
Make sure the steering system operates smoothly and pro- does not move. See the Periodic Maintenance section
vides good steering control. Make sure the steering column of the service manual for additional information.
can be adjusted and the gas cylinder function is correct. DO NOT try to find hydraulic leaks by putting hands on
pressurized hydraulic components. Hydraulic oil can
Control Levers and Pedals
be injected into the body by the pressure.
Check that the control levers for the transmission, mast, Perform the following checks and inspections:
and attachment operate as described in Table 1. Check
that the pedals operate correctly as described in Table 1. 1. Check for leaks in the hydraulic system. Check the con-
dition of the hydraulic hoses and tubes.
Lift System Operation
NOTE: Some parts of the mast move at different speeds
WARNING during raising and lowering.
When working on or near the mast, see Safety Proce- 2. Slowly raise and lower the mast several times without a
dures When Working Near the Mast in the Periodic load. Raise the mast to its full height at least once. The
Maintenance for your lift truck. mast components must raise and lower smoothly in the
correct sequence. Hose must track properly during opera-
Lower the lift mechanism completely. Never allow any
tion.
person under a raised carriage. DO NOT put any part of
your body in or through the lift mechanism unless all

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3. The inner weldments and the carriage must lower com- LPG is extremely flammable. When checking or filling
pletely. an LPG tank: No smoking. Stop engine.
4. Raise the mast 1 m (3 ft) with a capacity load. The inner Frost on the surface of the tank, the valves or fittings
weldments and the carriage must raise smoothly. Lower and the odor of LPG fuel indicates a leak. Inspect the
the mast. All moving components must lower smoothly. LPG system and repair a leak immediately. An LPG fuel
leak creates an explosion and fire hazard. Do not
5. Lower the load to approximately 0.3 m (1 ft). Tilt the
attempt to start the engine if there is a leak in the LPG
mast forward and backward. The mast must tilt smoothly
fuel system.
and both tilt cylinders must stop evenly.
Only trained and authorized personnel are permitted to
6. Check that the controls for the attachment operate the
operate filling equipment.
functions of the attachment. See the symbols by each of
the controls. Make sure all of the hydraulic lines are con- Use only the LPG tank indicated on the label on the
nected correctly and do not leak. tank bracket. DO NOT use an LPG tank that is dam-
aged. A damaged LPG tank must be removed from
How to Add Fuel to the Lift Truck service.
Liquefied Petroleum Gas (LPG)
WARNING
LPG tanks are heavy. The weight of an LPG tank can
WARNING exceed the maximum recommended weight for safe
Close the fuel valve on the tank when the lift truck is lifting by an individual. Get assistance when lifting or
not in active use. DO NOT park the lift truck near heat lowering an LPG tank. Use correct lifting procedures.
or ignition sources.
LPG can cause an explosion. DO NOT cause sparks or
For complete instructions on the storage of LPG fuels permit flammable material near the LPG system. LPG
and the refueling of LPG tanks, refer to NFPA 58 & 505. fuel systems can be disconnected indoors only if the

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lift truck is at least 8 m (26 ft) from any open flame, flame, motor vehicles, electrical equipment, or ignition
motor vehicles, electrical equipments, or ignition source. Move lift truck to an area where LPG tanks are
source. changed.
Removable LPG tanks must be removed from the fork 2. Turn the shutoff valve clockwise until the valve is com-
lift before filling. If the lift truck is equipped with a non- pletely closed.
removable LPG tank, make sure all components
3. Run the engine until it stops, then turn the key switch to
(engine, transmission, muffler, catalytic muffler) have
the OFF position.
surface temperatures that have cooled to below 427 °C
(800 °F). 4. Disconnect the quick-disconnect fitting on the LPG tank.
See Figure 31.
LPG Tank, Removal
5. Unlatch the tank strap and remove the LPG tank from
1. Removable LPG tanks can be replaced indoors only if
the bracket.
the lift truck is a minimum of 8 m (26 ft) from any open

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NOTE: FABRIC TANK STRAP SHOWN.
1. LPG TANK
2. TANK STRAP
3. QUICK DISCONNECT FITTING
4. HYDROSTATIC RELIEF VALVE
5. LPG BULKHEAD BRACKET
6. FITTING
7. HOSE ASSEMBLY
8. LPG TANK BRACKET
9. LPG TANK PIN
10. TANK LATCH

Figure 31. LPG Tank and Bracket

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LPG Tank, Fill hose to this fitting. Make sure the correct adapter is used to
connect the supply hose to the auxiliary fill fitting.
WARNING
5. Open the vent valve on the liquid level indicator.
Read and follow all the refueling precautions and
instructions under Liquefied Petroleum Gas (LPG). 6. Open the fuel valve on the LPG tank.
Removable LPG tanks must be removed from the fork
7. Open the valve on the end of the supply hose.
lift before filling.
8. Watch for a discharge from the vent valve on the liquid
NOTE: The following instructions are general procedures.
level indicator. When a cloud of visible vapor appears, the
There is a variation in equipment for filling LPG tanks. The
LPG tank is full. Do not fill the LPG tank to more than the
local authorities that have jurisdiction have specific rules
maximum level indicated by the liquid level indicator.
and regulations for filling LPG tanks. Make sure these rules
Immediately close the valve at the end of the supply hose.
and regulations are available and understood.
9. Close the vent valve on the LPG tank.
1. Check the gauge on tank to make sure it needs filling.
During the fill operation, the LPG tank must be in a position 10. Close the fuel valve on the LPG tank.
so that the liquid level indicator will always be in the vapor
11. Disconnect the hose supply.
space above the liquid level.
12. Stop the pump.
2. Open the liquid outlet valve and bypass return valve on
the storage tank. 13. Close the liquid outlet and the bypass return valve on
the storage tank.
3. Start the pump.
4. Connect the supply hose to the quick disconnect fitting
on the LPG tank (see Liquefied Petroleum Gas (LPG)). If
the LPG tank has an auxiliary fill fitting, connect the supply

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LPG Tank, Install b. Smell - LPG has a very distinctive odor. If you smell
LPG, DO NOT start the engine.
WARNING
c. Soapy Water - This method is used in conjunction
Make sure the alignment pin extends through the cor-
with Step b above. If the odor of LPG is present but
rect hole in the rim of the LPG tank. The hose or fit-
escaping fuel cannot be heard, apply soapy water to the
tings can be damaged if the LPG tank is not installed in
fittings and observe for bubbles.
the correct position. A damaged hose or fitting can
release LPG fuel and cause an explosion and fire haz- d. Frost - If the amount of LPG escaping is sufficient,
ard. frost may appear on the fittings.
1. Install the LPG tank into the bracket so that the LPG Petrol and Diesel Fuel
tank pin is in the correct hole in the bracket. Replace LPG
tank pin if damaged. Close the tank strap latches. WARNING
2. Connect the quick disconnect fitting to the shutoff valve When fuel is added, keep the funnel or fuel nozzle in
on the tank. Hand-tighten the vale to the fitting. See Fig- contact with the metal of the fuel tank to reduce the
ure 31. possibility of static electric sparks. Clean any spilled
fuel.
3. Turn the fuel valve anticlockwise to open the fuel valve.
1. Remove the fuel cap. Make sure the fuel tank is filled
4. Inspect the fuel system for leaks when the fuel valve is with the correct fuel for the type of engine in the lift truck.
open. There are four methods used to inspect the fuel sys- Clean the fuel cap and make sure vent is clear.
tem for leaks:
2. Replace the fuel cap.
a. Sound - Listen for sound of LPG escaping from a
tank fitting or hose connection.

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Wheels and Tyres ply rating listed on the Nameplate is the minimum ply
rating that must be installed. tyre with ply ratings
General greater than or equal to the Nameplate listed ply rating
may be acceptable. Check with your Hyster dealer
This series of lift trucks have pneumatic tyres or solid rub- whether a specific bias-ply tyre is approved for use on
ber tyres that look like pneumatic tyres. These variations in Hyster trucks.
tyres also cause a variation in the types of wheels and the
disassembly and assembly procedures. WARNING
Pneumatic Tyre With Tube, Repair Wheels must be changed and tyres repaired by trained
personnel only.
Remove Wheels From Lift Truck Deflate tyre completely before removing the wheel
from the lift truck. If dual wheels are used, deflate both
WARNING tyres. Air pressure in the tyres can cause the tyre and
A solid rubber tyre that is the same shape as a pneu- rim parts to explode causing serious injury or death.
matic tyre can be installed on a three-piece or four-
piece wheel for a pneumatic tyre. DO NOT make Always wear safety glasses.
changes in the parts of the rim if this type of solid rub- Never loosen the nuts that hold the inner and outer
ber tyre is installed instead of a pneumatic tyre. wheel halves together when there is air pressure in the
Changes to the parts of the rim can cause a failure of tyre.
the wheel and cause an accident.
The type of tyre and the tyre pressure (pneumatic CAUTION
tyres) are shown on the Nameplate. Make sure the Not all makes of radial tyres have sufficient sidewall
Nameplate is correct for the type of tyres on the lift strength for successful use on forklift trucks. This can
truck. If the truck is equipped with bias-ply tyres, the affect stability and ride quality. Check with your dealer

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whether a specific radial tyre is approved for use on 3. Remove the wheel nuts and remove the wheel and tyre
Hyster trucks. from the lift truck. Lift truck tyres and wheels are heavy.
1. Put the lift truck on blocks as described in How to Put a Remove Tyre From Wheel
Lift Truck on Blocks at the beginning of this section.
When disassembling wheels, see Figure 32. There are
2. Remove the air from the tyre. Remove the valve core to several types of wheels used on this series of lift trucks.
make sure that all of the air is out of the inner tube. Push a See Tyre Removal, Two-Piece Wheel and Tyre
wire through the valve stem to make sure that the valve Removal, Three- and Four-Piece Wheels.
stem does not have a restriction.

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A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT

Figure 32. Types of Pneumatic Wheels

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Tyre Removal, Two-Piece Wheel

WARNING
Make sure all of the air pressure is removed from the
tyre before a wheel is disassembled. Air pressure in
the tyres can cause the tyre and rim parts to explode
causing serious injury or death.
Keep tyre tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
an injury.
1. Remove the nuts that fasten
the wheel rims together.

2. Loosen the tyre bead from the wheel rim.

3. Remove the wheel rims from

tyre. Remove the inner tube and
flap.

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Tyre Removal, Three- and Four-Piece Wheels 2. Put the tyre tool into the slot
between the lock ring and wheel
WARNING rim. Remove the lock ring and
Make sure all of the air pressure is removed from the side flange. If there is a flange
tyre before a wheel is disassembled. Air pressure in seat, remove it.
the tyres can cause the tyre and rim parts to explode
causing serious injury or death.
Keep tyre tools in firm contact with the wheel parts. If 3. Loosen the bead from the other
the tool slips, it can move with enough force to cause side of the wheel rim. Remove the
an injury. valve stem from the wheel.
1. Loosen the tyre bead from
the side flange.

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4. Remove the wheel rim from the • DO NOT mix types of tyres, type of tyre tread, or
tyre. wheel assemblies of different manufacturers on any
one lift truck.
DO NOT use a steel hammer on the wheel. Use a rub-
ber, 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 will be approxi-
Install Wheel in Tyre mately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If
the clearance is wrong, the wrong part has been used.
WARNING 1. Clean and inspect all parts of the wheel. Paint any parts
Damage to the tyre and wheel assembly and injury or that have rust or corrosion.
death can occur if you do not do the following proce-
dures: 2. Install a new inner tube in the tyre. Used tubes and flaps
can cause tyre failure.
• Clean and inspect all parts of the wheel before
installing the tyre. WARNING
• DO NOT use any damaged or repaired wheel parts. DO NOT lubricate the tyre bead with antifreeze or
petroleum-based liquid. Vapors from these liquids can
• Make sure that all parts of the wheel are the correct cause an explosion during inflation or use.
parts for that wheel assembly.
3. Apply a rubber lubricant or a soap solution to the tyre
• DO NOT mix parts between different types or manu- bead and tube.
facturers of wheels.
4. Install a new tyre flap.

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• DO NOT mix parts between different types or manu-
WARNING
facturers of wheels.
DO NOT lubricate the tyre bead with antifreeze or
petroleum-based liquid. Vapors from these liquids can • DO NOT mix types of tyres, type of tyre tread, or
cause an explosion during inflation or use. wheel assemblies of different manufacturers on any
one lift truck.
5. Make sure the rim is the correct size for the tyre. Lubri-
cate the part of the wheel that contacts the bead and flap. DO NOT use a steel hammer on the wheel. Use a rub-
ber, lead, plastic, or brass hammer to put parts
6. Install the three-piece or four-piece wheel in the tyre as
together. Make sure that the side ring is in the correct
shown in Tyre Installation Three- or Four-Piece Wheel.
position. The ends of the side ring must not touch. The
7. Install the two-piece wheel in the tyre as shown in Tyre clearance at the ends of the side ring will be approxi-
Installation Two-Piece Wheel. mately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If
the clearance is wrong, the wrong part has been used.
Tyre Installation Three- or Four-Piece Wheel
1. Install the inner tube and the rubber flap
WARNING in the tyre.
Damage to the tyre and wheel assembly and injury or
death can occur if you do not do the following proce-
dures:
• Clean and inspect all parts of the wheel before
installing the tyre.
• DO NOT use any damage or repaired wheel parts.
• Make sure that all parts of the wheel are the correct
parts for that wheel assembly.

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2. Install the wheel rim in the 4. Put the lock ring in the correct
tyre. Make sure the stem of position on the rim. Add air pres-
the inner tube is aligned with sure to the tyre as described in
the slot in the rim. Add Air to Pneumatic Tyres
With Tube.

3. Turn over the rim and tyre. Put Tyre Installation Two-Piece Wheel
blocks under the rim so that the
rim is 8 to 10 cm (3 to 4 in.) above CAUTION
the floor. Install the flange seat (if DO NOT use pneumatic-shaped, solid tyres on two-
used) and the lock ring. piece bolt together drive wheels. Spinning may occur.
1. Install the inner tube and the
rubber flap in the tyre. Install both
halves of the wheel rim in the
tyre. Make sure the stem of the
inner tube is aligned with the slot
in the rim.

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2. Tighten the nuts that hold the 1. Put the tyre in a safety cage. See Figure 33.
rim halves together to 175 N•m
2. Add 20 kPa (3 psi) of air pressure to the tyre.
(130 lbf ft). Add air pressure to
the tyre as described in Add 3. Check that all wheel parts are correctly installed. Hit the
Air to Pneumatic Tyres With lock ring lightly to make sure that it is in the seat.
Tube.

Add Air to Pneumatic Tyres With Tube

WARNING
Add air pressure to the tyres only in a safety cage. See
Figure 33. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make sure
there is enough hose to permit the operation to stand
away from the safety cage when air pressure is added
to the tyre.

WARNING
DO NOT sit or stand by the safety cage. DO NOT use a
Figure 33. Add Air to Tyres With Tube
hammer to try and correct the position of the side
flange or lock ring when the tyre has air pressure 4. If installation is correct, add air pressure to the tyre to the
greater than 20 kPa (3 psi) of air pressure to the tyre. specified pressure. See Nameplate.

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5. Check that all wheel parts are correctly installed. If the first position where the cotter pin can be installed.
installation is not correct, remove all of the air pressure Install cap for bearings.
from the tyre. Remove the valve core to make sure all of
the air pressure has been removed and then make adjust- Pneumatic Tubeless Tyre, Repair
ments. The clearance at the ends of the lock ring will be
Remove Tyre From Lift Truck
approximately 13 to 25 mm (0.5 to 1.0 in.) when the tyre
has the correct air pressure.
WARNING
Install the Wheels Wheels must be changed and tyres repaired by trained
personnel only.
Install the wheel on the hub. On the drive wheels tighten
the nuts in a cross pattern to a torque value of 450 to Deflate tyres completely before removing the wheel
500 N•m (332 to 369 lbf ft). If the wheels are the two-piece from the lift truck. If dual wheels are used, deflate both
rims, make sure the nuts that fasten the rim halves tyres. Air pressure in the tyres can cause the tyre and
together are toward the brake drum when they are instal- rim parts to explode causing serious injury or death.
led. Always wear safety glasses.
The steering wheels are fastened to the spindle of the Never loosen the nuts that hold the inner and outer
steering axle with a large castle nut. Make sure inner and wheels halves together when there is air pressure in
outer bearings are correctly lubricated with grease. Install the tyre.
inner bearing assembly and wheel on spindle. Install outer
bearing cone and castle nut. Tighten castle nut to 60 N•m The Tubeless Bead Seal (TBS) enables tubeless tyres to
(44 lbf ft) while wheel is rotated. Loosen castle nut until hub be used on wheel rims that were designed to be used with
turns freely with no end play. Tighten castle nut to 3.0 to a tube.
6.0 N•m (425 to 850 lbf in). Install cotter pin in castle nut. If The main component of the TBS is a special rubber ring
the cotter pin cannot be installed, loosen the castle nut to that fits inside the tyre between the tyre beads to ensure

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the airtightness of the existing wheel and the tubeless tyre 1. If wheel rim is a three- or
assembly. See Figure 32. four-piece rim, turn the valve
1/4 turn and remove valve
1. Put the lift truck on blocks as described in How to Put a
from wheel.
Lift Truck on Blocks at the beginning of this section.
2. Remove the valve cap and core to remove all air from
the tyre.
3. Remove the wheel nuts and remove the wheel and tyre
from the lift truck. Lift truck tyres and wheels are heavy.
Remove Tyre From Wheel
2. Put wheel and tyre assem-
WARNING bly on the press. Position the
Make sure all of the air pressure is removed from the feet of the press on the loose
tyre before a wheel is disassembled. Air pressure in flange. Push press down on
the tyres can cause the tyre and rim parts to explode loose flange to expose the
causing serious injury or death. locking ring.
Keep tyre tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
an injury.
NOTE: There are several types of wheels used on these lift
trucks. When disassembling wheels, see Figure 32.

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3. Remove the loose flange 5. Push the TBS toward the
locking ring and the advance inside of the tyre to remove it.
band (four-piece wheel only)
using a tyre tool.

4. Remove the press and Install Tyre on Wheel

remove the loose flange lock-
ing ring and the advance WARNING
band (four-piece wheel only)
Damage to the tyre and wheel assembly and injury or
from the tyre and wheel
death can occur if you do not do the following proce-
assembly.
dures:
• Clean and inspect all parts of the wheel before
installing the tyre.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct
parts for that wheel assembly.

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• DO NOT mix parts between different types or manu- 1. Clean interior and exte-
facturers of wheels. rior bead area of the tyre.
Lubricate tyre beads and
• DO NOT mix types of tyres, type of tyre tread, or
the inside of the tyre, up to
wheel assemblies of different manufacturers on any
the tyre shoulders. Apply
one lift truck.
lubricant to entire under-
side of the TBS.
WARNING
DO NOT use a steel hammer on the wheel. Use a rub-
ber, lead, plastic, or brass hammer to put parts
together.

WARNING NOTE: If the wheel rim width is less than six inches, the
TBS will contain one valve hole to accommodate the nee-
DO NOT lubricate the tyre bead with antifreeze or
dle valve. If the wheel rim width is greater than six inches,
petroleum-based liquid. Vapors from these liquids can
the TBS will have two holes for the needle valve.
cause an explosion during inflation or use.
One hole is centrally located and the other is offset, to
ensure the correct positioning of the valve in the valve slot.
The valve hole that is not used should be sealed with a
small plastic plug.

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2. Apply lubricant to the nee- 4. Apply lubricant to the rim. If a four-piece wheel is being
dle valve and the valve hole used, lubricate the advance band. Slide the tyre and TBS
that will be used (see NOTE onto the wheel.
in Step 1), by inserting and
Line up the valve hole in the
removing the lubricated valve
TBS with the valve slot in the
several times. If a three- or
wheel. Lubricate and insert
four-piece wheel is being
the valve into the valve hole.
used, remove the valve. If a
Make sure it is fully inserted.
two-piece wheel is being
used, leave valve in valve
hole.

If the TBS has two valve holes, lubricate the plastic plug
and insert into valve hole that will not be used.
3. Place the TBS inside the
tyre, making sure that the
wings of the TBS are not fol-
ded over. Make a mark on
the tyre to note the position of
the valve hole in the TBS.

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5. Place the wheel and tyre 7. Position the advance band. Ensure that it does not go in
assembly on a flat surface. too far and damage the valve. Position the arms of the
Turn the valve a 1/4 turn to press onto the loose flange.
lock the collar under the
Push down on press to
edges of the rim valve slot.
depress the tyre beads until
the locking ring groove is fully
exposed.
8. Insert tyre tool into the
locking ring groove, and a
vise grip on other end.
Remove vise grip. Release
6. Raise the tyre and position the press and check that all
the base and threaded stem component parts are correctly
of the press through the hole positioned. Replace the valve
in the center of the wheel. core.
Insert in wheel assembly, the
following parts: 9. Inflate tyre to 103 kPa
(15 psi). Tap wheel with a
• Advance band (four-piece mallet to ensure all compo-
wheel only) nents are correctly sealed.
• Loose flange Remove the press from
wheel and tyre assembly.
• Locking ring

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Add Air to Pneumatic Tubeless Tyre

WARNING
Add air pressure to the tyres only in a safety cage. See
Figure 34. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck that fas-
tens onto the valve stem. Make sure there is enough
hose to permit the operator to stand away from the
safety cage when air pressure is added to the tyre. DO
NOT sit or stand by the safety cage.
Add air to tyre to the recommended pressure that is shown
on the Nameplate. Install valve cap to ensure air stays in
the tyre.
Install the Wheels
Figure 34. Add Air to Tubeless Tyre
Install the wheel on the hub. On the drive wheels tighten The steering wheels are fastened to the spindle of the
the nuts in a cross pattern to a torque value of 450 to steering axle with a large castle nut. Make sure inner and
500 N•m (332 to 369 lbf ft). If the wheels are the two-piece outer bearings are correctly lubricated with grease. Install
rims, make sure the nuts that fasten the rim halves inner bearing assembly and wheel on spindle. Install outer
together are toward the brake drum when they are instal- bearing cone and castle nut. Tighten castle nut to 60 N•m
led. (44 lbf ft) while wheel is rotated. Loosen castle nut until hub
turns freely with no end play. Tighten castle nut to 3.0 to
6.0 N•m (425 to 850 lbf in). Install cotter pin in castle nut. If

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the cotter pin cannot be installed, loosen the castle nut to NOTE: When disassembling wheels, see Figure 32. There
the first position where the cotter pin can be installed. are several types of wheels used on these series of lift
Install cap for bearings. trucks.
Solid Rubber Tyres on Pneumatic Wheels, WARNING
Change Wheels must be changed and tyres repaired by trained
personnel only.
WARNING
Always wear safety glasses.
Wheels must be changed and tyres repaired by trained
personnel only. 1. Put the wheel rim on the
bed of the press. Put the
Always wear safety glasses.
cage in position on the tyre.
1. Put the lift truck on blocks as described in How to Put a Use the press to push the
Lift Truck on Blocks at the beginning of this section. tyre away from the side
flange.
2. Remove the wheel nuts and remove the wheel and tyre
from the lift truck. Lift truck tyres and wheels are heavy.
Remove Tyre From Wheel

WARNING
Keep tyre tools in firm contact with the wheel. If the
tool slips, it can move with enough force to cause seri-
ous injury.

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3. Turn the tyre over. Put a support under the wheel rim.
Make sure the wheel rim is at least 150 to 200 mm (6 to
8 in.) from the bed of the press.

2. Put the tyre tool into the slot between the lock ring and
the wheel rim. Remove the lock ring and side flange.

4. Put the cage in position on the tyre. Use the press to

push the tyre from the wheel rim.
Install Tyre on Wheel

WARNING
Damage to tyre and wheel assembly and injury or
death can occur if you do not do the following proce-
dures:

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• Clean and inspect all parts of the wheel before
CAUTION
installing the tyre.
Too much lubricant can cause the tyre to slide and
• DO NOT use any damaged or repaired wheel parts. move around the wheel rim.
• Make sure that all parts of the wheel are the correct 1. Lubricate the wheel rim
parts for the wheel assembly. and the inner surface of the
tyre with tyre lubricant or
• DO NOT mix parts between different types or manu-
soap.
facturers of wheels.
• DO NOT mix type of tyres, type of tyre tread, or
wheel assemblies of different manufacturers on any
one lift truck.
DO NOT use a steel hammer on the wheel. Use a rub-
ber, lead, plastic, or brass hammer to put parts
together. Make sure that the lock ring is in the correct
position. The ends of the lock ring must not touch. The
clearance at the ends of the side ring will be approxi-
mately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If
the clearance is wrong, the wrong part has been used.
NOTE: When disassembling wheels, see Figure 32. There
are several types of wheels used on these series of lift
trucks.

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2. Put the wheel rim on the bed of the press. Put the tyre 3. Remove the cage and put the flange seat (if used), the
over the wheel rim. Put the cage in position on the tyre. side ring, and the lock ring in position on the wheel rim.
Use the press to install the tyre on the wheel rim. Install the cage on the tyre. Use the press to push the tyre
onto the wheel rim so that the side flange and lock ring can
be installed.

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Always wear safety glasses.
1. Put the lift truck on blocks as described in How to Put a
Lift Truck on Blocks at the beginning of this section.
2. Remove the wheel nuts and remove the wheel and tyre
from the lift truck. Lift truck tyres and wheels are heavy.
NOTE: See Figure 35 when you disassemble the wheels.
There are several types of wheels used on these series of
lift trucks.
4. While the cage is holding the tyre on the wheel rim,
install the lock ring. Use a tyre tool to make sure the lock
ring is in the correct position.
Snap-On Tyre, Change

WARNING
Wheels must be changed and tyres repaired by trained
personnel only.

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Figure 35. Tyres and Rim Configurations

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Remove Tyre, Solid Tyre From Wheel 1. Put a support under the wheel rim. Make sure the wheel
rim is at least 150 to 200 mm (6 to 8 in.) from the bed of the
WARNING press.
Keep tyre tools in firm contact with the wheel. If the
tool slips, it can move with enough force to cause seri-
ous injury.

2. Put the cage in position on the tyre. Use the press to

push the tyre from the wheel rim.

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Install Snap-On-Tyre, Solid Tyre on Wheel 1. Lubricate the wheel rim

and the inner surface of the
NOTE: When wheels are disassembled, see Figure 35. tyre with tyre lubricant.
There are several types of wheels used on this series of lift
trucks.

WARNING
Failure to follow these procedures will cause damage
to the tyre and wheel assembly and can cause injury.
• Clean and inspect all parts of the wheel before
installing the tyre.
• 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 manu-
facturers of wheels.
• DO NOT mix type of tyres, type of tyre tread, or
wheel assemblies of different manufacturers on any
one lift truck.

CAUTION
Too much lubricant can cause the tyre to slide and
move around the wheel rim.

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2. Put the wheel rim on the bed of the press. Put the tyre and back to idle. Avoid long periods of high engine speeds
over the wheel rim. Put the cage in position on the tyre. with a light load during the first 50 hours of operation. High
Use the press to install the tyre on the wheel rim. engine speeds with a light load can cause damage to the
cylinders in the engine.
Operating Procedures for a New or Rebuilt
Engine Jump-Starting the Lift Truck
A new or rebuilt engine must be operated under special Jump-Starting Using a Battery Charger
conditions during the first 50 hours. These special condi-
tions prevent damage to the engine until the new parts can If the battery becomes discharged and requires a booster
wear and adjust to fit each other. battery to start the engine, follow these procedures care-
fully when connecting the jump lead:
1. Make sure the fluid levels of oil and coolant are correct.
1. Disconnect the negative battery terminal of the lift truck
2. Start and run the engine at approximately one-half throt- being started.
tle for 30 minutes for the first operation. Check the gauges
and indicators for the correct operation during this first 2. Always connect positive jump lead to positive terminal of
operating period. Check for leaks. discharged battery and negative jump lead to negative ter-
minal.
3. If the work conditions are slow and the loads are less
than 50% of the truck capacity, a simulated work condition 3. Always connect jump lead, that is the earth cables, last.
must be used during the first four hours of operation. Oper- 4. Always connect jump lead to discharged battery before
ate the lift truck with a minimum load of 75% capacity. connecting them to booster battery.
Operate the engine through cycles from idle to full throttle

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Jump-Starting Using Another Lift Truck See your dealer for Hyster lift trucks BEFORE perform-
ing any changes to the overhead guard.
WARNING How to Put Internal Combustion Engine (ICE)
To prevent possible arcing between the two lift trucks,
make sure that the lift trucks are not touching.
Trucks in Storage
1. Always connect positive jump lead to positive terminal of It is important to store your lift truck properly to protect it.
discharged battery and negativejump lead to negative ter- The main areas of concern are engines, hydraulic compo-
minal. nents, and truck batteries. The length of storage time and
the storage location determines what procedures you
2. Always connect jump lead, that is the ground cable, last. should follow.
3. Always connect jump lead to discharge lift truck battery Before placing any lift truck in storage, you must choose an
before connecting them to the fully charged lift truck bat- area that is clean, dry, and free from airborne contami-
tery. nates. For safety and increased usable floor area, remove
the forks and tag them with the lift truck serial number. For
Changes to the Overhead Guard
best protection, operate your internal combustion engine lift
truck for a short period each month.
WARNING
Do not operate the lift truck without the overhead The following storage procedures are for conditions and
guard correctly fastened to the lift truck. temperatures above 0 °C (32 °F). Adjust these procedures
for local conditions and any changes in conditions during
Do not make changes to the overhead guard by weld- storage. The preparations necessary for storage are also
ing. Changes that are made by welding, or by drilling determined from the following conditions:
holes that are too big in the wrong location, can reduce
the strength of the overhead guard. • Short-term storage is from one to six months. Long-term
storage is over six months.

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• Storage Location. A lift truck stored indoors will not 5. Install blocks, front and rear, at the drive wheels. If the
require as much external protection as a lift truck stored lift truck must be left on an incline, put blocks on the down-
outdoors. hill side of all wheels so that the lift truck cannot move. DO
NOT USE THE PARKING BRAKE.
Short-Term Storage
6. Disconnect the battery cables from the battery. Apply a
Perform the following steps to prepare your lift truck for protective coating to the cable connectors and battery ter-
storage from one to six months: minals to prevent corrosion.
1. Check lubricant and fluid levels. Completely fill the fuel 7. Check the tyre pressure, if applicable. Make sure the
tank. Make sure the coolant mixture will protect cooling tyres have the correct pressure (see the Nameplate.)
system and engine to lowest temperature expected during
storage. Make sure all caps and dipsticks are installed cor- 8. Clean the lift truck and engine compartment to prevent
rectly. corrosion.

2. Fully lower the mast. If lift truck is equipped with forks, tilt 9. If the lift truck is not stored indoors, put a cover over the
mast FORWARD until the tips of the forks touch the floor. lift truck to prevent damage from the weather. In wet condi-
Apply a thin coat of fresh, high grade SAE 30 or 40 weight tions, a cover will not prevent corrosion to the lift truck.
engine oil to the exposed cylinder rods. If the forks are Long-Term Storage
removed, tilt mast BACKWARD until cylinders are com-
pletely retracted. This protects the cylinder rods. Do the following steps to prepare the lift truck for storage
for 6 months or longer:
3. Check that all switches and accessories are in the OFF
position. 1. Complete all short-term storage procedures.
4. Activate each control lever to relieve hydraulic pressure. 2. Wrap or cover all exterior lights, radiator grill, and air
vents with a moisture barrier cover. Use tape to hold the
covers in place.

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3. Remove the battery or batteries from the lift truck. Store Return lift truck to its storage state for another month.
the battery or batteries in an approved space. Be sure to
follow local regulations. Batteries that are stored for long How to Put Batteries in Storage
periods can become damaged. Either keep batteries in Batteries are to be placed on a wooden pallet and stored in
service or follow the battery storage procedures below. a dry, moderately cool area.
4. Spray exterior surfaces and frame with preservative Lead acid batteries will slowly "self-discharge" over a
coating. period of time due to their chemical makeup. If the self-dis-
While the Lift Truck is in Storage charge is left uncontrolled, excessive sulphation can occur
which is difficult to reduce and can damage the anodes. A
Each month make a visual inspection for leaks or signs of discharged battery with a specific gravity of 1.000 will
deterioration. Take corrective action immediately. Check freeze at −7.8 °C (18 °F) A fully-charged battery with a spe-
the fluid level in engine, radiator, hydraulic tank, and brake cific gravity of 1.280 will freeze at −66 °C (−87 °F).
master cylinder.
This "self-discharge" is due to a chemical reaction; there-
NOTE: Do not shut down an engine before it reaches oper- fore, that chemical reaction can be accelerated by heat
ating temperature. resulting in more rapid "self-discharge." The rate of dis-
charge can amount to an average of about 0.001 point
Each month set the park brake, start engine, and run until
drop in specific gravity per day.
normal operating temperature is reached. This will coat the
internal engine components with a film of oil and rid the The following procedure can be followed when placing a
engine of built-up condensation. battery in storage or when not in operation for more than
30 days.
Each month all hydraulic cylinders must be cycled several
times to keep the seals active and to coat the interior walls 1. Give an equalizing charge prior to placing new batteries
with oil. Actuate each cylinder, in both directions, until it in storage. Used batteries are to be fully charged, then
reaches the stops. allowed to balance for approximately three more hours.

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2. Neutralize and clean the battery. Clean with a solution of 3. Clean the battery cables and terminals. Check the bat-
100 grams (3.5 oz) of sodium bicarbonate (baking soda) tery voltage. If the voltage is not correct, charge battery.
per 1 liter (0.25 gal) of water. Connect battery cables to battery.
3. Store in a cool, dry location. 4. When a lift truck is to be put into service after storage, it
must be given the 500-hour inspection shown in the Peri-
4. Check each cell in the battery at least once every 30
odic Maintenance service manual.
days and boost charge when specific gravity falls below
1.240 Hg. How to Move a Lift Truck on a Transport
5. Protect batteries from ambient contamination.
WARNING
If a greasy film forms on the top of a battery, this is acid Stay a safe distance from the
and must be neutralized with the solution described above. edge of docks, ramps, platforms,
Putting a Stored Lift Truck Back Into Service and other similar working surfa-
ces. Watch the “tail swing.”
1. Remove all tape, covers, and preservation materials. Remember when traveling in the
forward direction and the steering
2. Check the lift truck for damage and missing components.
wheel is turned to move the lift
Repair damage and/or replace missing components.
truck away from the edge of the
NOTE: If the lift truck has been stored longer than one dock, the rear will swing toward
year, all lubricants and fluids must be drained and the edge. This can cause the lift
replaced. See the Periodic Maintenance section of your truck to fall off the dock.
service manual for the procedures.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO NOT
JUMP OFF! HOLD FIRMLY TO STEERING WHEEL,

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BRACE YOUR FEET, AND LEAN FORWARD AND solidly attached to the frame. Do not fasten a strap or
AWAY FROM THE POINT OF IMPACT. chain to the mast or any attachment to hold the lift
truck on the transport.
Before the lift truck is moved on a transport, check the
selected route to make sure there is enough clearance for
CAUTION
the lift truck as loaded on the transport vehicle. Bridges,
Make sure that any straps or chains used to fasten the
overpasses, powerlines, and natural barriers can prevent
lift truck to the transport do not contact any tubes,
clearance. Removal of the mast can be necessary.
hoses, hydraulic cylinders, or other parts of the truck
If a trailer is the method of transportation, use blocks in that are easily damaged.
front and back of the trailer tyres to prevent movement of
If components and attachments must be removed for trans-
the trailer when the lift truck is loaded and unloaded. If a
port of the lift truck, see the Service Manual for removal
loading ramp is used, make sure that the ramp is the cor-
procedures.
rect design and capacity.
The operator must never leave a lift truck in a condition so
If the lift truck is equipped with lifting eyes, use a crane to
that it can cause damage and injury. When the lift truck is
load and unload the lift truck from the transport. If the truck
loaded on the transport, do the following operations:
is not equipped with approved lifting eyes, do not lift the
truck by attaching a lifting device to any other part of the lift 1. Apply the parking brake.
truck for the purposes of loading or unloading.
2. If the mast is mounted on the lift truck, fully lower the
Loading forks or carriage. Tilt the mast FORWARD until the tips of
the forks touch the surface.
WARNING 3. Put the direction control lever for the transmission in
The straps or chains used to fasten the lift truck to the NEUTRAL and leave the gears of the transmission
transport must be directly connected to the lift truck engaged. DO NOT leave the transmission in NEUTRAL.
frame or to a component (drive axle, tow pin) that is

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4. Turn the key switch to OFF to stop the engine and check 3. Disconnect the straps or chains.
that all switches and accessories are turned OFF.
4. Remove the wheel blocks.
5. Put blocks in front and back of the lift truck tyres to pre-
5. Check that all switches and accessories are turned OFF.
vent any movement of the lift truck. Make sure the blocks
are attached to the load surface. 6. Unload the lift truck.
If the lift truck is not in active use, close the fuel valve at the Preparation for Use
LPG tank. If the lift truck is going to be left overnight or lon-
ger, the truck must be parked outside or the LPG tank must After being transported or stored, the lift truck must be pre-
be removed and stored outside. pared for use for proper operation. All problems must be
corrected before use of the lift truck, see the Service Man-
If the lift truck is transported in severe weather or any other ual Periodic Maintenance 8000 SRM 2000 for proce-
condition that can damage the lift truck, cover the lift truck. dures.
Make sure the protective cover is designed for the applica-
tion and is securely fastened. Preparation After Transport
Unloading 1. Complete the unloading procedures.

If components normally attached to the lift truck were 2. Inspect the lift truck for damage and missing compo-
removed for transport, see the Service Manual for installa- nents.
tion procedures. 3. Follow the steps in the section How to Make Checks
1. If used, remove any protective cover. With the Engine Stopped.

2. Make sure the parking brake is applied.

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Maintenance Register
Protect your investment in materials handling equipment! This Maintenance Register is used to record the time of
Keep a high-residual value in your Hyster lift truck! Do the each periodic inspection and maintenance. The dealer's
maintenance according to the Maintenance Schedule in stamp or authorized signature confirms that maintenance
this Operating Manual. and inspection was done at regular intervals by authorized
personnel.
Your dealer for Hyster lift trucks has the equipment and
trained service personnel to do a complete program of
inspection, lubrication, and maintenance.

1. 2. 3. 4.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
5. 6. 7. 8.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
9. 10. 11. 12.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
13. 14. 15. 16.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________

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Maintenance
17. 18. 19. 20.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
21. 22. 23. 24.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
25. 26. 27. 28.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
29. 30. 31. 32.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
33. 34. 35. 36.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
37. 38. 39. 40.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
41. 42. 43. 44.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________

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NOTES

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 OPERATING MANUAL

H2.0-3.0XT (A380)
www.duma-rent.com

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4150903 12/17