Manual de Operacion H110FT (U005)

OPERATING MANUAL
FORTIS®
H80-120FT (U005)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4128512 1/19

Spacer
LIFT TRUCK MODEL SERIAL NUMBER

ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE SERIAL NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE GROUP NUMBER
DRIVE TIRE SIZE STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2019. All Rights Reserved.
HYSTER, , FORTIS, MONOTROL, and YARDMASTER are Registered Trademarks of Hyster-Yale Group, Inc. HSS, DURAMATCH, UNISOURCE, and
are Trademarks in the United States and certain other jurisdictions.
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: Various laws and regulations require the employer to train
lift truck operators. These laws and regulations include:
• Receive training in the proper operation of THIS lift truck.
• Occupational Safety and Health Act (USA)
• Understand any potential hazards that may exist in the
work place where the lift truck is intended to be used. • Canada Material Handling Regulations
• Understand the capabilities and limitations of the lift NOTE: A comprehensive operator training program is avail-
truck. able from Hyster Company. For further details, contact
your dealer for Hyster lift trucks.
• Become familiar with the construction of the lift truck and
see that it is maintained in good condition. This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
• Read and properly understand the warnings, instruc- nance of a basic lift truck. Optional equipment is sometimes
tions, and operating procedures in this manual. installed that can change some operating characteristics
In addition, a qualified person, experienced in lift truck described in this manual. Make sure the necessary instruc-
operation, must guide a new operator through several driv- tions are available and understood before operating the lift
ing and load handling operations before the new operator truck.
attempts to operate the lift truck alone.
©HYSTER COMPANY 2019 4128512 - ENGLISH-US 1

Foreword
Some of the components and systems described in this • Lift Truck/Pedestrian Accidents, Causes and Prevention.
Operating Manual will NOT be installed on your unit. If you Hyster Company (LIFTPED/B 12/2003).
have a question about any item described, contact your
NOTE: Hyster lift trucks are not intended for use on public
dealer for Hyster lift trucks.
roads.
Additional information that describes safe operation and
NOTE: The following symbols and words indicate safety
use of lift trucks is available from the following sources:
information in this manual:
• Employment safety and health standards or regulations
(Examples: "Occupational Safety and Health Standards WARNING
(USA)", "Canada Material Handling Regulations". Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
• Safety codes and standards (Example: Industrial Truck
Standards Development Foundation, ANSI/ITSDF
B56.1, Safety Standard for Low Lift and High Lift
CAUTION
Indicates a hazardous situation which, if not avoided,
Trucks).
could result in minor or moderate injury and property
• Publications from government safety agencies, govern- damage.
ment insurers, private insurers and private organizations
On the lift truck, the WARNING symbol and word are on
(Example: Accident Prevention Manual for Industrial
orange background. The CAUTION symbol and word
Operations, from the National Safety Council).
are on yellow background.
• Guide for Users of Industrial Lift Trucks (Hyster Part No.
852930) describes lift truck safety, good maintenance
practices, and training programs and is available from
your dealer for Hyster lift trucks.
2
Contents
Contents
Foreword ...................................................................... 1 PARKED REGENERATION REQUEST ..................... 69
TO OWNERS, USERS, AND OPERATORS: ............. 1 Regeneration Level 2 ................................................ 69
Warning ........................................................................ 7 WARNING LEVEL ...................................................... 71
Model Description ....................................................... 10 Regeneration Level 3 ................................................ 71
GENERAL ................................................................... 12 SERVICE LEVEL ........................................................ 71
OPERATOR PROTECTION EQUIPMENT ................. 13 Regeneration Level 4 ................................................ 71
NAMEPLATE .............................................................. 14 Operating Procedures ................................................ 72
SAFETY LABELS ....................................................... 15 GENERAL ................................................................... 72
DISPLAY SWITCH CLUSTER .................................... 20 Know Your Lift Truck ................................................ 72
Display Switch Cluster – Right-Side Display Inputs .. 20 Stability and Center of Gravity .................................. 74
Display Switch Cluster – Left-Side Display Inputs .... 27 Capacity (Weight and Load Center) ......................... 75
Display Switch Cluster – LCD Screen and Warning Impact Sensor ........................................................... 76
and Indicator Lights .............................................. 29 AIR CONDITIONER AND HEATER CONTROLS ....... 77
OPERATOR CONTROLS ........................................... 40 Heater Controls ......................................................... 77
DISPLAY, DIESEL PARTICULATE FILTER (DPF) .... 63 AC Controls .............................................................. 77
OPERATOR INTERFACE .......................................... 64 Air Circulation ........................................................... 77
CAN COMMUNICATION LOST .................................. 64 HEATER CONTROLS ................................................ 79
PASSIVE REGENERATION ONLY ............................ 65 Temperature Control ................................................. 79
Regeneration Level 0 ................................................ 65 Fan Speed Control .................................................... 79
AUTO/ACTIVE REGENERATION INHIBITED ........... 66 INSPECTION BEFORE OPERATION ........................ 81
AUTO/ACTIVE REGENERATION .............................. 66 Checks With the Engine Stopped ............................. 81
Regeneration Level 1 ................................................ 66 Operator Checklist .................................................... 82
Idle-up Auto/Active Regeneration ........................... 67 Mounting and Dismounting ....................................... 82
3
Contents
Lift Truck Interlocks ................................................... 83 Load Handling, Traveling .......................................... 112
Operator Passwords ................................................. 83 Load Handling, Emergency Load Lowering .............. 115
Starting Procedures .................................................. 84 HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ....... 118
Stop Procedures, Diesel Engine ............................... 86 ATTACHMENTS ......................................................... 119
Checks With the Engine Running ............................. 86 Disconnecting Attachment Hydraulic Quick-
Load Weighing Sensor ............................................. 87 Disconnect Hoses ................................................. 119
Set Load Weight to Zero ........................................... 88 Connecting Attachment Hydraulic Quick-Disconnect
Engine Shutdown ...................................................... 88 Hoses .................................................................... 121
Engine Modes (Generation 2 ECO-eLo) ................... 89 STOPPING ................................................................. 121
OPERATING TECHNIQUES ...................................... 90 PARKING .................................................................... 122
Basic Operating Procedures ..................................... 90 Maintenance ................................................................ 123
Driving and Direction Changes ................................. 96 GENERAL ................................................................... 123
General ................................................................... 98 Serial Number Data .................................................. 124
Normal Operations .................................................. 98 HOW TO MOVE A DISABLED LIFT TRUCK .............. 124
Standard Operator Presence System ..................... 99 How to Tow the Lift Truck ......................................... 124
Optional Operator Presence System ...................... 100 HOW TO PUT A LIFT TRUCK ON BLOCKS .............. 126
Powershift, Electronic Powershift 1 and 2 Speed How to Raise the Drive Tires .................................... 126
Transmission .................................................... 100 How to Raise the Steering Tires ............................... 126
DuraMatch and DuraMatch 2 .................................. 101 HOW TO CLEAN A LIFT TRUCK ............................... 127
Inching ...................................................................... 103 Maintenance Schedule ............................................... 128
Steering (Turning) ..................................................... 104 Maintenance Procedures Every 8 Hours or Daily .... 159
Load Handling, General ............................................ 105 HOW TO MAKE CHECKS WITH THE ENGINE
Load Handling, Lifting, Lowering, and Tilting ............ 106 STOPPED ................................................................. 159
Load Handling, How to Engage and Disengage a Tires and Wheels ...................................................... 159
Load ...................................................................... 109 Safety Labels ............................................................ 159
4
Contents
Mast, Carriage, Header Hoses, Lift Chains, and Forks, Adjustments ................................................. 190
Attachment ............................................................ 160 HOW TO MAKE CHECKS WITH THE ENGINE
Operator Restraint System ....................................... 161 RUNNING ................................................................. 190
Emergency Locking Retractor (ELR) ...................... 163 Indicator Lights, Horn, Fuses, and Relays ................ 191
Hood and Seat Latches ............................................ 163 Service Brakes .......................................................... 193
Engine Compartment ................................................ 164 Brake Oil Level ....................................................... 193
Paper Application ...................................................... 164 Operation, Check .................................................... 193
Fuel, Oil, and Coolant Leaks, Check ........................ 165 Parking Brake ........................................................... 194
Hydraulic Hoses ........................................................ 166 Engine Oil Pressure .................................................. 194
Coolant Hoses .......................................................... 166 Cooling System ......................................................... 195
Steering Column Gas Cylinder ................................. 166 Steering System ....................................................... 197
Transmission ............................................................ 167 Control Levers and Pedals ....................................... 197
Hydraulic System Oil ................................................ 167 Lift System Operation ............................................... 197
Engine Oil ................................................................. 169 HOW TO ADD FUEL TO THE LIFT TRUCK .............. 198
Air Filter .................................................................... 181 Liquefied Petroleum Gas (LPG) ................................ 198
Forks ......................................................................... 181 LPG Tank, Removal ............................................... 199
Forks, Remove ......................................................... 182 LPG Tank, Fill ......................................................... 202
Forks, Inspect ........................................................... 184 LPG Tank, Install .................................................... 203
Forks, Install ............................................................. 185 Gasoline Fuel ............................................................ 204
Forks, Adjust ............................................................. 186 Diesel Fuel ................................................................ 204
Integral Sideshift Carriage ........................................ 186 WHEELS AND TIRES ................................................. 204
Fork Positioner .......................................................... 187 General ..................................................................... 204
Forks, Remove ....................................................... 187 PNEUMATIC TIRE WITH TUBE, REPAIR ................. 204
Forks, Inspect ......................................................... 189 Remove Wheels From Lift Truck .............................. 204
Forks, Install ........................................................... 189 Remove Tire From Wheel ......................................... 205
5
Contents
Tire Removal, Two-Piece Wheel ............................ 207 Jump-Starting Using a Battery Charger .................... 224
Tire Removal, Three- and Four-Piece Wheels ....... 208 Jump-Starting Using Another Lift Truck .................... 224
Install Wheel in Tire .................................................. 209 OPERATING PROCEDURES FOR A NEW OR
Tire Installation Three- or Four-Piece Wheel .......... 210 REBUILT ENGINE .................................................... 224
Tire Installation Two-Piece Wheel .......................... 211 CHANGES TO THE OVERHEAD GUARD ................. 225
Add Air to Pneumatic Tires With Tube ...................... 211 HOW TO PUT INTERNAL COMBUSTION ENGINE
Install the Wheels ..................................................... 212 (ICE) TRUCKS IN STORAGE .................................. 225
PNEUMATIC TUBELESS TIRE, REPAIR .................. 213 Short-Term Storage .................................................. 226
Remove Tire From Lift Truck .................................... 213 Long-Term Storage ................................................... 226
Remove Tire From Wheel ......................................... 213 While the Lift Truck is in Storage .............................. 227
Install Tire on Wheel ................................................. 215 How to Put Batteries in Storage ................................ 227
Add Air to Pneumatic Tubeless Tire ......................... 218 Putting a Stored Lift Truck Back Into Service ........... 228
Install the Wheels ..................................................... 219 HOW TO MOVE A LIFT TRUCK ON A
SOLID RUBBER TIRES ON PNEUMATIC WHEELS, TRANSPORT ............................................................ 228
CHANGE .................................................................. 219 Loading ..................................................................... 229
Remove Tire From Wheel ......................................... 220 Unloading .................................................................. 230
Install Tire on Wheel ................................................. 221 PREPARATION FOR USE ......................................... 231
DUAL DRIVE WHEELS, INSTALL ............................. 223 Preparation After Transport ...................................... 231
JUMP-STARTING THE LIFT TRUCK ......................... 224
6
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
KNOW THE EQUIPMENT: • VERIFY truck is equipped with overhead guard and load
backrest adequate for the load.
• ALWAYS use 3 points of contact when getting on and off
the truck. LOOK WHERE YOU ARE GOING:
• KNOW operating, inspection, and maintenance instruc- • IF YOU CAN'T SEE, DON'T GO.
tions in this Operating Manual.
• TRAVEL in reverse if load blocks forward vision.
• DO NOT operate or repair truck unless trained and
• MAKE SURE tail swing area is clear.
authorized.
• SOUND horn at intersections or where vision is blocked.
• INSPECT truck before use.
• WATCH clearances, especially overhead.
• DO NOT operate if truck needs repair. Tag truck and
remove key. Repair truck before use. Always use Hyster KNOW YOUR LOADS:
Approved parts when making repairs. Replacement
• HANDLE only stable loads within specified weight and
parts must meet or exceed the specifications of the origi-
load center. See Nameplate on truck.
nal equipment manufacturer.
• DO NOT handle loose loads higher than load backrest.
• USE auxiliary equipment (attachments) for intended pur-
pose only. • SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
7
Warning
WARNING
USE COMMON SENSE: • WHEN PARKING, also shut off power, close LPG fuel
valve, block wheels on inclines.
• DO NOT use truck to lift people unless there is no other
practical option. Then, use only a securely attached spe- KNOW THE AREA:
cial work platform. Follow instructions in this Operating
• NEVER enter a trailer or railroad car unless its wheels
Manual.
are blocked.
• OBEY traffic rules. Yield right-of-way to pedestrians.
• CONFIRM floor strength.
• BE in complete control at all times.
• FILL fuel tank or charge battery only in designated area.
• ALLOW NO ONE under or near lift mechanism or load.
• TURN OFF engine when fueling.
• OPERATE truck only from operator's seat.
• AVOID sparks or open flame. Provide ventilation.
• KEEP arms, legs, and head inside operator's compart-
• DO NOT start if fuel is leaking.
ment.
• KEEP vent caps clear when charging battery.
• DO NOT move truck if anyone is between truck and sta-
tionary object. • DISCONNECT battery during servicing.
• BEFORE DISMOUNTING, neutralize travel control, • CHECK dockboard width, capacity, and security.
lower carriage, and set brake.
8
Warning
WARNING
PROTECT YOURSELF FASTEN YOUR SEAT BELT! • TRAVEL with carriage as low as possible and tilted
back.
• AVOID bumps, holes, and loose materials.
• SLOW DOWN before turning, especially without load.
• AVOID sudden starts or stops.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
• NEVER turn on or angle across an incline.
CAUSE THE LIFT TRUCK TO TIP.
• TRAVEL on inclines with load uphill or when unloaded
DO NOT JUMP off if the truck tips over. HOLD steering
with lift mechanism downhill.
wheel firmly. BRACE your feet. LEAN FORWARD and
• TILT mast slowly and smoothly. LIFT or LOWER with AWAY from point of impact.
upright vertical or tilted slightly back. Use minimum tilt
when stacking elevated loads.
9
Model Description
Model Description
Figure 1. Model View Showing Major Components
10
Model Description
Legend for Figure 1
1. COUNTERWEIGHT 9. MAST
2. OPERATING MANUAL (BEHIND SEAT) 10. LOAD BACKREST EXTENSION
3. OVERHEAD GUARD 11. CARRIAGE
4. SEAT 12. FORKS
5. SEAT BELT AND HIP RESTRAINT 13. DRIVE AXLE
6. DIESEL PARTICULATE FILTER DISPLAY 14. HOOD
7. STEERING WHEEL AND COLUMN 15. STEERING AXLE
8. PARKING BRAKE
11
Model Description
Model Description
General DuraMatch 2 transmission (see Table 6 and Figure 25)
and three types of controls:
This Operating Manual is for the following models of lift
trucks: • A pedal that controls both the forward and reverse oper-
ation of the transmission and the speed of the engine.
H80FT, H90FT, H100FT, H110FT, and H120FT (U005)
• A Direction Control Lever on the left side of the Display
These lift trucks are available with the following engines: Switch Cluster that controls the forward, neutral, and
• GM 4.3L engine with PSI fuel system which uses gaso- reverse operation of the transmission. A separate accel-
line or LPG fuel. erator pedal controls the engine speed.
• PSI 4.3L engine which uses gasoline or LPG fuel. • A Direction Control Switch next to the auxiliary horn but-
ton on the MLM Control armrest, controls both the for-
• Kubota 3.8L engine which uses LPG fuel. ward and reverse direction of the transmission. A
• Kubota 3.8L diesel engines. separate accelerator pedal controls the engine speed.
• Kubota 3.6L diesel engines. The lift trucks covered in this manual are equipped with
pneumatic tires or solid pneumatic shaped tires. See
• Kubota 3.8L 55kW diesel engines. Wheels and Tires in the Maintenance section for a
• Kubota 3.8L engine which uses gasoline or LPG fuel. description of these tires.
These lift truck models can be equipped with a Powershift 1 The lift trucks covered in this manual can be equipped with
Speed, Electronic Powershift (1 Speed), Powershift 2 either standard manual hydraulic levers or Electro-
Speed, Electronic Powershift (2 Speed), DuraMatch, or Hydraulic (E-Hydraulic) mini-levers. See Figure 8.
12
Model Description
If your lift truck is equipped with electronic hydraulics, it has The SEAT BELT AND HIP RESTRAINT provide additional
an emergency lowering valve. This emergency lowering means to help the operator keep the head and torso sub-
valve (see Figure 26) allows the operator or service techni- stantially within the confines of the lift truck frame and over-
cian to lower the lift truck's mast assembly if the electrical head guard if a tipover occurs. This restraint system is
signal to the main control valve is disrupted. See the Load intended to reduce the risk of the head and torso being
Handling, Emergency Load Lowering section in the trapped between the lift truck and the ground, but it cannot
Operating Procedures section. protect the operator against all possible injury in a tipover.
The hip restraint will help the operator resist side move-
Operator Protection Equipment ment. It is not a substitute for the seat belt. Always fasten
The LOAD BACKREST EXTENSION is installed to keep the seat belt.
loose parts of the load from falling back toward the opera- This lift truck is equipped with one of the three seat belt
tor. It must be high enough, with vertical openings small configurations.
enough, to prevent the parts of the load from falling back-
wards. If a load backrest extension that is different from the • Seat belt with no operation interlock.
one installed on your lift truck is required, contact your Hys- • Seat belt with operation interlock. Seat belt must be fas-
ter lift truck dealer. tened for lift truck to start or to travel.
The OVERHEAD GUARD is intended to offer reasonable • Seat belt with sequencing interlock. Operator must be in
protection to the operator from falling objects, but cannot the seat, then the seat belt fastened before lift truck will
protect against every possible impact. Therefore, it must operate. This seat belt is used with the Optional Opera-
not be considered a substitute for good judgment and care tor Presence System.
when handling loads. Do not remove the overhead guard.
NOTE: The seat belt can be either black or red.
13
Model Description
Nameplate The lift truck serial number code is on the Nameplate. The
serial number code is also stamped on the right-hand side
WARNING of the lift truck frame, under the floorplate.
DO NOT add to or modify the lift truck. Any modifica- When a lift truck is shipped incomplete from the factory, the
tion that affects the safe operation of the truck cannot Nameplate is covered by an INCOMPLETE label as shown
be undertaken without the written authorization of Hys- in Figure 2. If the equipment on the truck is changed, the
ter Company. Nameplate is covered by a NOTICE label as shown in Fig-
Any change to the lift truck, the tires, or its equipment ure 2. If your lift truck has either of these labels, do not
can change the lifting capacity. The lift truck must be operate the lift truck. Contact your dealer for Hyster lift
rated as equipped and the Nameplate must show the trucks to obtain a complete correct Nameplate.
new capacity rating.
The capacity is specified in kilograms (kg) and pounds (lb).
The capacity is the maximum load that the lift truck can
handle for the load condition shown on the Nameplate.
The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities with
the load height reduced or with optional load centers, may
also be shown on the Nameplate.
NOTE: The image in Figure 2 is a sample only. Reference
the actual nameplate installed on the truck for actual truck
specifications.
14
Model Description
Safety Labels
Safety labels are installed on the lift truck to give informa-
tion about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 3.
A. NAMEPLATE
B. NOTICE LABEL
C. INCOMPLETE LABEL
Figure 2. Nameplate and Labels
15
Model Description
Figure 3. Warning and Safety Labels (Sheet 1 of 3)
16
Model Description
17
Model Description
SEE THE PARTS MANUAL FOR THE PART NUMBER.
18
Model Description
Legend for Figure 3
A. LIFT TRUCKS EQUIPPED WITH DIESEL OR GASOLINE B. LIFT TRUCKS EQUIPPED WITH LPG ENGINE
ENGINES
1. FLAMMABLE LP-GAS 15. UNLEADED GASOLINE LABEL
2. TIPOVER WARNING 16. DIESEL FUEL LABEL
3. OVERHEAD GUARD LABEL 17. LIFT AND TILT LABEL (LOCATION NOT SHOWN)
4. OPERATION WARNING 18. ANTIFREEZE WARNING
5. NO RIDERS 19. LPG TANK WARNING
6. WARNING FOR PARKING BRAKE 20. LOCKING GAS SPRING
7. MAST WARNING 21. HOOD OPENING CAUTION
8. NAMEPLATE 22. BORON-FREE LABEL
9. DRIVE TRAIN PROTECTION CAUTION 23. ETHER WARNING (DIESEL ONLY)
10. NO ONE ON OR UNDER FORKS 24. UL LABEL
11. MAST WARNING 25. TRANSMISSION LABEL (EXAMPLE ONLY) (LOCATION NOT
12. OPTIONAL FIRE SAFETY RATING SHOWN)
13. FAN WARNING 26. STABILITY SYSTEM LABEL (ON BOTH SIDES OF LIFT TRUCK)
14. DIESEL FUEL LABEL 27. DIESEL PARTICULATE FILTER LABEL
28. HYDRAULIC FAN DRIVE OPTION FAN REVERSAL (LOCATION
NOT SHOWN)
19
Model Description
Display Switch Cluster Display Switch Cluster – Right-Side Display

Inputs
WARNING
If any of the instruments, levers, or pedals do not oper- The lift trucks covered in this manual can have several dif-
ate as described in the following tables, report the ferent options and configurations. Depending on the equip-
problem immediately. DO NOT operate the lift truck ment on the lift truck, warning and indicator lights on the
until the problem is corrected. right side of the Display Switch Cluster will vary and the
truck may not contain all the warning and indicator lights
shown in Figure 4, Figure 5, and Table 1.
20
Model Description
1. LEFT SIDE DISPLAY INPUTS
2. LCD SCREEN
3. RIGHT SIDE DISPLAY INPUTS
4. WARNING AND INDICATOR LIGHTS
Figure 4. Display Switch Cluster
21
Model Description
Figure 5. Display Switch Cluster - Right Side Display Inputs
22
Model Description
Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 5)
Item
Item Function
No.
1 Power ON/OFF If the lift truck is equipped with the keyless start option, lift truck system power is
turned ON by pressing this button. To turn the lift truck system power and engine OFF,
press the Power ON/OFF button again.
If lift truck has a key switch, the Power ON/OFF symbol is replaced with the Hourmeter
symbol.
2 Engine Start This button is used when the lift truck is equipped with the keyless start option. The
engine is started by pressing and holding this button. Lift truck power must be turned
ON (pressing Power ON/OFF button) before starting engine.
If the lift truck contains a key switch, the Engine Start graphic is covered and the func-
tion disabled.
3 1st Gear Locking This button engages and disengages the 1st Gear Locking function on trucks equip-
Button ped with the DuraMatch 2 or Techtronix (2 Speed) transmission.
23
Model Description
Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 5) (Continued)
Item
Item Function
No.
4 #1 Button If the lift truck is equipped with a DuraMatch 2 or Techtronix (2 Speed) transmission,
the 1st Gear Locking function and the #1 button will share space on the Display Switch
Cluster. When an operator or supervisor is in the main menu for entering and adminis-
tering passwords, the 1st Gear Locking function is disabled and the button is enabled
to enter the number 1 for password purposes. If the lift truck is not equipped with a
DuraMatch 2 or Techtronix (2 Speed) transmission, then this button functions only as
Password entry #1.
5 Front Work Lights This button controls the front work lights and the marker lights on lift trucks equipped
with this option.
6 #2 Button If the lift truck is equipped with front work lights, the #2 Button and the Front Work
Light button will share space on the Display Switch Cluster.
When an operator or supervisor are in the main menu for entering and administering
passwords, the Front Work Lights function is disabled and the button is enabled to
enter the number 2 for password purposes. If the lift truck is not equipped with Front
Work Lights, then this button functions only as Password entry #2.
7 Enter Button (STAR This button is used for menu entry, navigation, and data entry.
Key)
24
Model Description
Item
Item Function
No.
8 Rear Work Lights This button controls the rear work lights on lift trucks equipped with this option.
9 #3 Button If the lift truck is equipped with rear work lights, the #3 Button and the Rear Work Light
button will share space on the Display Switch Cluster.
When an operator or supervisor is in the main menu for entering and administering
passwords, the Rear Work Lights function is disabled and the button is enabled to
enter the number 3 for password purposes. If the lift truck is not equipped with rear
work lights, then this button functions only as Password entry #3.
10 Scroll Down This button is used for the following functions:
• Decreasing the value of a selected operating function
• Scrolling downward through a list of possible menu selections
11 #4 Button The Scroll Down and #4 Button share the same space on the Display Switch Cluster.
passwords, the Scroll Down function is disabled and the button is enabled to enter the
number 4 for password purposes.
25
Model Description
Item
Item Function
No.
12 Scroll Up This button is used for the following functions:
• Increasing the value of a selected operating function
• Scrolling upward through a list of possible menu selections
13 #5 Button The Scroll Up and #5 Button share the same space on the Display Switch Cluster.
passwords, the Scroll Up function is disabled and the button is enabled to enter the
number 5 for password purposes.
14 Hourmeter On trucks with key switch start, when truck is ON, engine hours will be displayed on
LCD screen on right side of second line. When truck is OFF, press hourmeter button to
display engine hours.
On trucks with keyless start option, when truck is ON, engine hours will be displayed
on LCD screen on right side of second line. When truck is OFF, engine hours can be
displayed when accessing menu to enter password. Password not required to view
engine hours.
Periodic Maintenance recommendations are based on these hours.
26
Model Description
Display Switch Cluster – Left-Side Display

Inputs
Lift truck models H80FT, H90FT, H100FT, H110FT, and
H120FT (U005) may be equipped with an optional
enclosed cab. If lift truck has this feature, the left side of the
Display Switch Cluster will contain icons and indicator lights
related to the front and back windshield wipers and wind-
shield washer fluid. See Figure 4, Figure 6, and Table 2.
Figure 6. Display Switch Cluster - Left Side Display

Inputs
27
Model Description
Table 2. Display Switch Cluster - Left Side Display Inputs (See Figure 6)
Item Item Function

No.
1 Windshield Push and hold button to release windshield washer fluid from washer reservoir.
Washer Release button to discontinue washer fluid from reservoir. Washer fluid and wind-
Fluid shield wipers are applied to both front and back windshields at the same time when
button is engaged.
2 Front Windshield Push this button once to turn on the front windshield wiper. Push button again to turn
Wiper front windshield wiper off.
3 Rear Windshield Push this button once to turn on the rear windshield wiper. Push button again to turn
Wiper rear windshield wiper off.
28
Model Description
Display Switch Cluster – LCD Screen and The time of day is displayed on the right side of the top line
Warning and Indicator Lights at all times during the selection of displayed text.
• HYD TEMP/FUNCTION REDUCED - shows when the
The LCD screen (see Figure 7) shows operator messages
hydraulic oil temperature is higher or lower than speci-
for the different functions. The LCD screen can display
fied limits. This is only active with trucks using E-hydraul-
messages on two lines with up to 20 characters per line.
ics.
Bar graphs are also shown on the display using solid block
characters of varying heights. Lift trucks equipped with wet brake oil overheat protection
will display the following messages on the LCD screen:
The following information is displayed on the LCD screen
when the truck is running: • BRAKE TEMP HIGH - shows when brake oil tempera-
ture reaches high level. It is recommended reducing
• Engine coolant temperature (standard)
brake usage, or allowing truck to cool down. 30 seconds
• Fuel level diesel and gasoline engines (standard) after this message, if temperature remains high, then the
second message will display
The engine coolant temperature is displayed on the top line
and the fuel level is shown on the bottom line. If load • TRAVEL SPEED REDUCED - shows when brake oil
weight and travel speed options are available, press the temperature reaches critical level. It is recommended
scroll down button to display the information for these fea- allowing truck to cool down. Speed will be limited to
tures. Press the scroll up button to return to the engine 4km/h (2.5mph) until oil temperature cools back to
coolant temperature and fuel level displays. If a fault acceptable level.
occurs, the fault number will be displayed on the top line.
29
Model Description
The warning lights and indicator symbols shown in Fig- see the appropriate symbol. When the warning lights and
ure 7 are on all lift truck models. Depending on the equip- indicators are off, the operator will see a black panel.
ment on the lift truck, the warning and indicator lights on Unless noted in Table 3, all programmed warning and indi-
the Display Switch Cluster will vary and not all the warning cator lights will light up for two seconds (Start Check) when
and indicator lights shown in Figure 7 will illuminate. When System Power is turned ON.
the warning lights and indicators are on, the operator will
30
Model Description
A. LCD SCREEN B. WARNING AND INDICATOR LIGHTS
Figure 7. Display Switch Cluster - LCD Screen and Warning and Indicator Lights
31
Model Description
Table 3. Instruments – Warning and Indicator Lights (See Figure 7)
Item No. Item Function

1 Indicator Light Left This green indicator will blink on and off when the left turn signal is selected. Not
Turn Signal on at Start Check.
2 Warning Light, This amber indicator is on when the system is in the ON state, and turns off as the
Engine RUN state is entered. This indicator will also illuminate when an engine related
Malfunction fault has occurred. Not on at Start Check.
Indicator
3 Warning Light, This amber light will illuminate when a fault that is not engine related occurs.
System
Malfunction
Indicator
4 Indicator Light Air If the lift truck is equipped with the premium monitoring package, the amber Air
Filter Restriction Filter Restriction light will illuminate when the air filter restriction switch senses a
restriction in the air filter. If there is a restriction in the air filter, visually inspect air
filter and remove restriction.
32
Model Description
Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (Continued)

5 Indicator Lights The green direction lights will illuminate when the operator selects the direction of
Direction and travel. When the transmission is put into NEUTRAL, the green N illuminates and
Transmission stays lit until transmission is not in NEUTRAL.
Lights
6 Warning Light,
CAUTION
Brake Oil Level
Do not continue to operate the lift truck if the light is on during operation.
Malfunction
Indicator The red brake fluid light will illuminate when the brake fluid level switch indicates a
low fluid condition.
7 Warning Light,
WARNING
Fasten Seat Belt
Always fasten the seat belt when operating the lift truck.
Malfunction
Indicator The red light is illuminated for 10 seconds after system power is turned ON. Not on
at Start Check.
33
Model Description

8 Warning Light,
WARNING
Parking Brake
Always apply the parking brake when leaving the lift truck.
Malfunction
Indicator The red parking brake light will illuminate any time the system power is ON and the
parking brake lever is moved into the applied position. The indicator light will flash
any time the Parking Brake Warning alarm is active. Not on at Start Check.
9 Warning Light, The red Alternator light will illuminate when the system is not in the OFF state and
Alternator the alternator is not in a charging state. This includes illuminating at System Power
Malfunction On until the normal operating minimum is reached. Not on at Start Check.
Indicator
10 Indicator Light This green indicator will blink on and off when the right turn signal is selected. Not
Right Turn Signal on at Start Check.
34
Model Description

11 Warning Light,
CAUTION
Transmission
Do not continue to operate the lift truck if the red light is ON.
Oil Temperature
Malfunction The red light will illuminate when the transmission oil temperature reaches the pre-
Indicator set warning level.
When light illuminates, and if truck is equipped with optional powertrain protection,
truck performance will decrease. Turn truck OFF and notify service person immedi-
ately for repair. If truck is not equipped with optional powertrain protection and light
is illuminated when engine is running, turn engine OFF immediately and have truck
repaired by service technician.
35
Model Description

12 Warning Light,
CAUTION
Engine Oil
Stop the engine immediately if the red light is ON while the engine is run-
Pressure
ning.
Malfunction
Indicator The red light will illuminate when the system is not in the OFF state and the oil
pressure sensor indicates an insufficient pressure. This includes illuminating at
System Power ON until the normal operating minimum is reached. Not on at Start
Check.
When light illuminates, lift truck will enter Engine Shutdown mode, if equipped with
optional powertrain protection. See Operating Procedures section for Engine
Shutdown optional powertrain protection and light is illuminated when engine is
running, turn engine OFF immediately and have truck repaired by service techni-
cian.
36
Model Description

13 Warning Light,
CAUTION
Engine Coolant
Temperature
Malfunction If this red light illuminates while the engine is running, it indicates the engine cool-
Indicator ant temperature is 110 °C (230 °F) for Kubota diesel engines.
Shutdown procedures. If truck is not equipped with optional powertrain protection
and light is illuminated when engine is running, turn engine OFF immediately and
have truck repaired by service technician.
37
Model Description

14 Warning Light,
CAUTION
Coolant Level
in Radiator
Malfunction If the lift truck is equipped with the premium monitoring package, this red warning
Indicator light will illuminate when the radiator coolant level switch indicates that the level of
coolant in the radiator is too low.
Shutdown procedures. If truck not equipped with optional powertrain protection
and light is illuminated when engine is running, turn engine OFF immediately and
check coolant level. If coolant level is satisfactory, have truck repaired by service
technician.
38
Model Description

15 Warning Light,
CAUTION
Fuel Level
Do not allow the lift truck to run out of LPG. Damage to the catalytic con-
Indicator
verter can result.
NOTE: For LPG trucks, see label on dash to identify how your truck is equipped.
This red indicator light will illuminate when the fuel level is low. For gasoline and
diesel trucks: The light first illuminates when there is 1/16th of fuel left in the tank.
For LPG truck with LPG pressure switch: The light illuminates when there is 30
seconds to 3 minutes of operation remaining.
For LPG trucks equipped with the Premium Low Fuel Sensor: The light illuminates
when there is 10 to 20 minutes of operation remaining. An audible alarm will sound
every 4 minutes when the red light is illuminated.
16 Indicator Light 1st This amber light will illuminate if the operator selects the 1st gear locking feature
Gear Locking on a DuraMatch 2 or Techtronix (2 Speed) transmission-equipped lift truck. The
(Multi-Speed light will flash until the lift truck and engine speed are low enough to permit a shift
Transmissions) to 1st gear and stay lit while 1st gear lock is active. Not on at Start Check.
39
Model Description

17 Indicator Light This amber indicator light will illuminate if the fuel-water separator sensor indicates
Water Separator that water must be drained. Not on at Start Check.
(Kubota 3.8L Die-
sel Only)
18 Indicator Light This amber indicator light will illuminate during the cold start delay period. Not on at
Cold Start (Diesel Start Check.
Only)
Operator Controls the problem immediately. DO NOT operate the vehicle

(See Figure 8 and Table 4) until the problem is corrected.
WARNING
If any of the controls, instruments, levers, or pedals do
not operate as described in the following tables, report
40
Model Description
SEE FIGURE 9 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS.

A. UNITS WITH MONOTROL® PEDAL B. UNITS WITH DIRECTION CONTROL LEVER
Figure 8. Operator Controls
41
Model Description
A. INCHING/BRAKE PEDAL D. INCHING/BRAKE PEDAL

B. MONOTROL PEDAL E. BRAKE PEDAL
C. ACCELERATOR PEDAL
Figure 9. Operator Compartment Pedal Configurations
42
Model Description
Table 4. Operator Controls (See Figure 8)
Item
Item Function
No.
1 Steering Wheel The steering wheel controls the position of the steer tires.
2 Inching/Brake Pedal By varying the position of the inching/brake pedal, the operator can move the lift
truck slowly while a high engine speed is used for lifting loads. Completely
depressing the pedal disengages the transmission and applies the service brakes.
The brake lights will be on when the brake pedal is depressed during normal oper-
ation. On units with a MONOTROL® pedal, the engine can be started when the
inching/brake pedal is fully depressed or when the parking brake is applied.
43
Model Description
Table 4. Operator Controls (See Figure 8) (Continued)
Item
Item Function
No.
3 Lever For Steering Column Tilt To move the steering column up, pull up on the tilt lever and the steering column
moves up. Release the lever when the steering column reaches the desired posi-
tion. To move the steering column down, grab the steering wheel and pull up on
the lever. Pull the steering column to the desired position.
4 Horn The horn button controls the operation of the horn.
44
Model Description
Item
Item Function
No.
5 Parking Brake Lever
WARNING
Correct adjustment is necessary to provide adequate braking. See the Main-
tenance section for adjustment procedures.
Always apply the parking brake when leaving the lift truck.
NOTE: There is a sensor in the seat that actuates an audible alarm. If the opera-
tor leaves the seat, with system power OFF, without applying the parking brake,
the alarm will sound for 10 seconds until the parking brake is applied or the opera-
tor sits back on the seat. If system power is ON or the engine is running, and the
operator leaves the seat, without applying the parking brake, the alarm will sound
continuously until parking brake is applied or the operator sits back on the seat.
45
Model Description
Item
Item Function
No.
5 Parking Brake Lever The lift truck is equipped with a lever to apply the parking brake. Pull the lever to
(Cont) apply the parking brake. Use your thumb to release the button on the lever when
the lever is moved to release the parking brake.
On units with a MONOTROL® pedal, applying the parking brake puts the trans-
mission in NEUTRAL. The parking brake must be fully applied for the grade or
surface conditions when operator leaves the lift truck. The lift truck can be started
with the park brake applied.
6 Inching/Brake By varying the position of the inching/brake pedal, the operator can move the lift
Pedal truck slowly while a high engine speed is used for lifting loads. Completely
depressing the pedal disengages the transmission and applies the service brakes.
The engine can be started when the inching/brake pedal is fully depressed and
Direction Control Lever is in neutral.
46
Model Description
Item
Item Function
No.
7 Brake Pedal This pedal, controlled by the operator's right foot, controls the application of the
service brakes.
8 Lift/Lower Control NOTE: Manual hydraulic control levers are standard on the trucks covered in this
Lever manual. Optional electronic hydraulic mini-levers are available for the hydraulic
functions. See Figure 8.
NOTE: To operate the mini-levers, the operator must be on the seat.
The lift/lower control lever can be either the first manual lever or first mini-lever to
the right of the operator's seat. Pull backward toward the operator to raise the car-
riage and forks. Push forward to lower the carriage and forks.
47
Model Description
Item
Item Function
No.
9 Tilt Control Lever NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual. Optional electronic hydraulic mini-levers are available for the hydraulic
The tilt control lever can be either the second manual lever or second mini-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.
48
Model Description
Item
Item Function
No.
9 Tilt Control Lever These trucks can be equipped with the Return to Set Tilt (RTST) option if truck
(Cont) has electronic hydraulic mini-levers. The RTST option automatically stops the tilt
function at a set point. To override the RTST option, momentarily push and
release the override button located directly behind the tilt mini-lever and push the
tilt mini-lever forward or pull backward.
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
be taken to operate the truck in accordance with load handling instructions as
described in Operating Techniques in the Operating Procedures section of this
Operating Manual.
49
Model Description
Item
Item Function
No.
10 Manual Control Lever for
WARNING
Auxiliary Hydraulic
A manual control lever with a detent must be installed when an attachment
Functions (3rd lever).
with a clamp is installed. See your dealer for Hyster lift trucks to get the cor-
See Figure 8.
rect control lever.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual. Optional electronic hydraulic mini-levers are available for the hydraulic
The third manual control lever is installed to the right of the manual tilt control
lever. This lever can have two methods of operation, depending on the attach-
ment.
50
Model Description
Item
Item Function
No.
10 Manual Control Lever for NOTE: If truck is equipped with only three levers and clamp attachment, the last
(Cont) Auxiliary Hydraulic (3rd) lever controls clamp functions.
Functions (3rd lever).
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.
51
Model Description
Item
Item Function
No.
10 Electronic Control Mini-Lever The third electronic control mini-lever is installed to the right of the electronic tilt
(Cont) for Auxiliary Hydraulic Func- control lever. This lever can have two methods of operation, depending on the
tions (3rd lever, Four Function attachment.
Control Valve).
NOTE: If truck is equipped with only three levers and clamp attachment, the last
(3rd) lever controls clamp functions.
NOTE: Third lever on four function control cannot have clamping. The last lever
(4th) controls clamp functions.
Trucks without Clamp Attachment: The lever is operated by moving it forward
and back. The lever is spring-loaded to return to the neutral position when
released.
52
Model Description
Item
Item Function
No.
11 Manual Control Lever for NOTE: Manual hydraulic control levers are standard on the trucks covered in this
Auxiliary Hydraulic manual. Optional electronic hydraulic mini-levers are available for the hydraulic
Functions (4th lever). functions. See Figure 8.
The fourth manual control lever is installed to the right of the third manual control
lever. This lever can have two methods of operation, depending on the attach-
ment.
NOTE: If truck is equipped with four levers and clamp attachment, the last (4th)
lever controls clamp functions.
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.
53
Model Description
Item
Item Function
No.
11 Electronic Control Mini-Lever The fourth electronic control lever is installed to the right of the third electronic
(Cont) for Auxiliary Hydraulic Func- control lever. This lever can have two methods of operation, depending on the
tions (4th lever, Four Function attachment.
Control Valve).
NOTE: If truck is equipped with four levers and clamp attachment, the last (4th)
lever controls clamp functions.
Trucks with Clamp Attachment: To engage the clamp, move the mini-lever
backward. To disengage the clamp, momentarily push and release the override
button located directly behind the mini-lever and push the mini-lever forward.
1. OVERRIDE BUTTON and back. The lever is spring-loaded to return to the neutral position when
released.
54
Model Description
Item
Item Function
No.
11 Electronic Control Mini-Lever NOTE: The lift trucks covered in this Operating Manual may be equipped with
(Cont) for Auxiliary Hydraulic Func- optional electronic hydraulic mini-levers that are available for the hydraulic func-
tions (4th lever, Five Function tions.
Control Valve).
NOTE: If truck is equipped with a four function control valve with solenoid and
clamp attachment, the last (4th) lever controls clamp functions.
The fifth function is controlled by using the fourth electronic control lever, which is
installed to the right of the third electronic control lever. If lift truck is equipped with
a clamp attachment, the last (4th) lever controls clamp functions. This lever can
have two methods of operation, depending on the attachment.
1. OVERRIDE BUTTON
55
Model Description
Item
Item Function
No.
11 Electronic Control Mini-Lever Trucks with Clamp Attachment: To engage the clamp, move the mini-lever
(Cont) for Auxiliary Hydraulic Func- backward. To disengage the clamp, momentarily push and release the override
tions (4th lever, Five Function button (green button) located directly behind the mini-lever and push the mini-
Control Valve). lever forward.
and back. The lever is spring loaded to return to the neutral position when
released.
1. OVERRIDE BUTTON
56
Model Description
Item
Item Function
No.
11 Electronic Control Mini-Lever On lift trucks equipped with a four function control valve and solenoid for fifth func-
(Cont) for Auxiliary Hydraulic Func- tion, the third lever controls both the third and fourth functions. To engage the
tions (3rd lever, Five Function fourth function, toggle in the yellow override button located directly behind the
Control Valve). third lever. To engage the third function, toggle out the override button. After
selecting desired function, operate the lever by moving it forward and backward.
The lever is spring loaded to return to the neutral position when released. To
engage the fifth function operator the 4th lever.
1. OVERRIDE BUTTON
57
Model Description
Item
Item Function
No.
12 Direc- NOTE: There is a sensor in the seat that actuates an audible buzzer. If the opera-
tion tor leaves the seat with the key switch ON and the lever is not in NEUTRAL, the
Con- buzzer will pulse ON and OFF for 10 seconds.
trol
The Direction Control Lever for the transmission is on the left side of the Display
Lever
Switch Cluster. The Direction Control Lever is used on lift trucks without a MONO-
TROL® pedal or MLM Direction Control Switch. The Direction Control Lever has
three positions that are indicated by three green lights on left side of Display
Switch Cluster (see Display Switch Cluster – LCD Screen and Warning and
Indicator Lights and Table 3): FORWARD, NEUTRAL (N), and REVERSE.
Move the lever to one of the direction positions for travel. The Direction Control
Lever must be in the NEUTRAL (N) position before the engine can be started.
The reverse lights will be on and, if equipped, reverse alarm will be activated
when the lever is placed in the REVERSE position.
58
Model Description
Item
Item Function
No.
13 Key Switch NOTE: There is no mechanical lockout that prevents the key switch from being
returned to the START position without first being returned to the OFF position.
However, the Vehicle System Manager (VSM) software prevents the starter motor
from being energized while the engine is running.
The key switch is located on the right side of the Display Switch Cluster. The key
switch has three positions:
No. 1 Position: OFF position. De-energizes all electric circuits except for the horn
and front and rear work lights.
No. 2 Position: ON position. Energizes all electric circuits except the starter circuit.
The key switch will be in this position during normal operation.
No. 3 Position: START position. Energizes the starter motor for starting the
engine. A spring returns the key to position No. 2 (ON position) when the key is
released.
14 MONOTROL® The MONOTROL® pedal controls the speed and direction of the lift truck. Pushing
Pedal on the right side of the pedal causes the lift truck to move in reverse. Pushing on
the left side of the pedal causes the lift truck to move in forward. The speed of the
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.
59
Model Description
Item
Item Function
No.
15 Accelerator Pedal This pedal controls the speed of the engine and is operated by the operator's right
foot. It is used on units that have a Direction Control Lever.
16 Direction The direction control switch for the transmission is next to the auxiliary horn button
Control on the armrest. The direction control switch is used on lift trucks without a MONO-
Switch TROL pedal.
17 Auxiliary Auxiliary horn button functions when the key or keyless ignition is in the ON posi-
Horn tion and up to 20 minutes after the key or keyless ignition is turned to the OFF
Button position.
60
Model Description
Item
Item Function
No.
18 Optional This option is available with e-hydraulics. The button reverses the fan direction to
Hydraulic blow debris out vented side panels
Fan
When pressed the fan direction changes, the max allowable speed runs for 20
Drive
seconds, then the fan ramps down, changes direction, and normal operation
Reversal
resumes.
Button
When the park brake handle is pulled, the hydraulic fan speed is limited to a max
speed of 1400 rpm (this permits normal conversation level for operator under high
cooling load periods).
Battery Dis- This switch is only on units with the GS, LPS, or DS fire safety rating. The opera-
connect tor can shut off all electrical power to the lift truck by pulling up on the T-handle
Switch (Not that is located between the steering wheel and the parking brake.
Shown In
Figure 8)
61
Model Description
Table 5. Auxiliary Control Levers
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/Counterclockwise 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
62
Model Description
Display, Diesel Particulate Filter (DPF)

Lift truck models in this manual may be equipped with the
Kubota 3.8L diesel engine. Lift trucks equipped with this
engine, will also be equipped with an operator's display for
the DPF mounted to the overhead guard in the upper right
corner. See Figure 10.
The DPF display will illuminate the appropriate icon(s)
according to regeneration level that the lift truck is operat-
ing at:
• Passive Regeneration Only (Regeneration Level 0)
• Active Regeneration Inhibited
• Auto/Active Regeneration (Regeneration Level 1)
1. DPF DISPLAY
• Parked Regeneration Request Level (Regeneration 2. LED INDICATOR
Level 2) 3. AUTO/ACTIVE REGENERATION INHIBIT ICON
4. PARKED REGENERATION AVAILABLE ICON
• Warning Request Level (Regeneration Level 3) 5. SOOT LEVEL METER
6. AUTO/ACTIVE REGENERATION INHIBIT ON/OFF BUTTON
• Service Request Level (Regeneration Level 4) 7. PARKED REGENERATION INITIATE BUTTON
Figure 10. DPF Display
63
Model Description
Operator Interface CAN Communication Lost
Figure 11. Refer to Operator Manual Icon Figure 12. CAN Communication Lost Icon
The Book Icon and software version will be displayed at The Wrench Icon is shown when the DPF display loses
startup for approximately 3 seconds. communication with ECU. See Figure 12.
The Book Icon will also be shown when operator attempts
to initiate a Parked Regeneration when truck is not in the
correct state (park brake on, transmission in neutral, etc...).
This icon will also be displayed for 30 seconds following an
interrupted Parked Regeneration while DPF cools off. See
Figure 11.
64
Model Description
Passive Regeneration Only

Regeneration Level 0
Figure 14. Partial Soot Level

Soot Meter bars will fill with increasing soot load in DPF.
This is an estimate based on multiple ECU parameters.
Figure 13. Empty Soot Meter See Figure 14.
NOTE: Empty Soot Meter will flash if no soot level data is Auto/Active Regeneration will begin when the Soot Meter
available from ECU. See Figure 13. displays 3 bars. If equipped with optional Idle-up feature,
engine idle speed will increase during Auto/Active Regen-
eration.
65
Model Description
Auto/Active Regeneration Inhibited feature, engine idle speed will increase during Auto/Active
Regeneration.
Auto/Active Regeneration
Regeneration Level 1
WARNING
During the Auto/Active Regeneration process, ensure
the lift truck operates in a location suitable for elevated
exhaust gas temperatures. Make sure the suitable loca-
tion is free of combustible materials, liquids, and gas-
ses. Failure to do so could cause serious injury to
operator and/or serious damage to property.
Figure 15. Auto/Active Regeneration

NOTE: Auto/Active Regeneration can be inhibited at any
time by the operator pressing the Auto/Active Regeneration
Inhibit ON/OFF button.
Soot meter shows 60% soot level in DPF. See Figure 15.
Auto/Active Regeneration will begin when the Soot Meter
displays 3 bars, and remain active at 2, 3, or 4 bars until
regeneration is complete. If equipped with optional Idle-up
66
Model Description
Following a successful Auto/Active Regeneration the unit
will return to Regeneration Level 0.
Idle-up Auto/Active Regeneration
Lift truck models with Kubota 3.8L diesel engine with DPF
may have an optional engine Idle-up feature that is active
during Auto/Active Regeneration. When the Soot Meter dis-
plays 3 bars, engine idle speed will increase the first time
the operator applies the accelerator pedal. For the duration
of the Auto/Active Regeneration process, minimum engine
speed will be 1200 rpm.
This feature improves the Auto/Active Regeneration clean-
Figure 16. High Temperature Icon ing process and will take 15-20 minutes to complete. Lift
truck operation can continue without any limitations, but
Auto/Active Regeneration will begin when engine load and avoid engine shut-down while truck is in Idle-up mode.
temperature meet appropriate conditions.
During Parked Regeneration, the High Temperature Icon
will be displayed. See Figure 16.
Lift truck operation can continue without any limitations or
loss of power during Auto/Active Regeneration. Higher
engine speeds will lead to a more successful Auto/Active
Regeneration.
Figure 17. Idle-up Active Range
67
Model Description
Engine Idle-up will start when the Soot Meter reaches 3 Once Auto/Active Regeneration is complete, engine idle
bars, and will remain active while 2, 3, or 4 bars are dis- speed returns to normal.
played. Optional Parked Regeneration is still possible at 3
or more Soot Meter bars, but should not be required once
Auto/Active Regeneration is complete.
68
Model Description
Parked Regeneration Request WARNING

Regeneration Level 2 Prior to initiating the Parked Regeneration process,
move the lift truck to a location suitable for elevated
After unsuccessful Auto/Active Regeneration, the ECU will exhaust gas temperatures. Make sure the suitable loca-
request a Parked Regeneration. DPF icon and LED are on tion is free of combustible materials, liquids, and gas-
to indicate Parked Regeneration is available. See Fig- ses. Failure to do so could cause serious injury to
ure 18. operator and/or serious damage to property.
To initiate the Parked Regeneration process, the operator
needs to push the Parked Regeneration Initiate Button after
all of the following conditions have been met. See Fig-
ure 18.
• Engine running
• Park Brake ON
• Transmission in Neutral
• Accelerator pedal NOT depressed
• Soot Meter displays 3, 4, or 5 bars
When Parked Regeneration is in process the High Temper-
Figure 18. Parked Regeneration Request ature Icon will be displayed. See Figure 16.
69
Model Description
Figure 19. DPF Display - 5 Bar Soot Meter Figure 20. Engine Warming Up Icon
Following a successful Parked Regeneration the unit will If Parked Regeneration process is initiated before lift truck
return to Regeneration Level 0. has warmed up properly, the Engine Warming Up Icon will
be displayed. See Figure 20.
70
Model Description
Warning Level Service Level

Regeneration Level 3 Regeneration Level 4
NOTE: Level 3 is the last opportunity for operator to initiate
CAUTION
the DPF regeneration process before a service technician
Regeneration Level 4 is the last opportunity for service
will be required.
technician to initiate Parked Regeneration process.
Regeneration Level 3 begins when Soot Meter display 5 Continued operation of lift truck without performing a
bars. See Figure 19. Parked Regeneration will result in permanent damage
to the Diesel Particulate Filter (DPF), resulting in costly
DPF Icon is on and LED is flashing to indicate Parked
repairs.
Regeneration is necessary. See Figure 18.
DPF Icon and LED both flash to indicate Parked Regenera-
Auto/Active Regeneration is no longer enabled by ECU.
tion must be completed by using PC Service Tool. See Fig-
DPF regeneration must be performed through Parked
ure 18.
Regeneration process.
At this regeneration level there is a 50% torque derate and
At this regeneration level there is a 50% torque derate and
1200 RPM limit on the engine.
1600 RPM limit on the engine.
MIL on dash is on and diagnostic trouble code (DTC) will
MIL on dash is on and diagnostic trouble code (DTC) will
be displayed. Successful Parked Regeneration will clear
be displayed. Successful Parked Regeneration will clear
active code and return unit to Regeneration Level 0.
active code and return unit to Regeneration Level 0.
71
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 (see 29
CFR 1910.1000 Table Z-1).
WARNING Follow the inspection and maintenance schedule and
Always make sure the parking brake is fully applied procedures in this manual. Do not alter exhaust, igni-
before leaving the lift truck. If the operator leaves the tion, or fuel systems.
lift truck without applying the parking brake, a seat
activated switch will shift the transmission to neutral, WARNING
and sound an alarm for 10 seconds. If the lift truck is FIRE HAZARD
left on a grade, without the parking brake fully applied, The hot engine surfaces and exhaust of internal com-
the lift truck will free-wheel down the grade, possibly bustion engine powered lift trucks can present fire haz-
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 can
monoxide is a colorless, odorless poison and can ignite these materials as well. Engine and exhaust sur-
cause unconsciousness or death without warning. face temperatures increase after engine shutoff, pre-
Long-term exposure to exhaust or chemicals in the senting increased fire hazard. Check the engine
exhaust can cause cancer, birth defects, and other compartment frequently in areas containing
reproductive harm. Avoid exposure to engine exhaust.
72
combustible dust, fibers, or paper and remove any for- The fork lift truck is designed to pickup, move, and tier
eign materials. Contact your local Hyster dealer for materials. The basic lift truck has a lift mechanism and
forklift modifications that may be appropriate in envi- forks on the front to engage the load. The lift mechanism
ronments with fire hazards. lifts the load so that it can be moved and stacked.
Operate the lift truck only in areas that have been In order to understand how the fork lift truck can pick up a
approved for lift truck operation. load, you must first know some basic things about the lift
truck.
• OSHA regulations prohibit the use of lift trucks in
areas containing hazardous concentrations of cer-
tain flammable gases or vapors.
• OSHA regulations require operating areas to be clas-
sified as hazardous or nonhazardous, and that the
lift trucks used in designated locations be of the
minimum type specified (see Guide For Users Of
Industrial Trucks, Appendix C and Table N-1).
The lift truck is based on the principle of two weights bal-
Only the designated types of approved lift trucks may
anced on opposite sides of a pivot (fulcrum). This is the
be used in areas classified as hazardous by the author-
same principle used for a see-saw. In order for this princi-
ity having jurisdiction. Areas classified as hazardous
ple to work for a lift truck, the load on the forks must be bal-
must be identified by signs to show the type of
anced by the weight of the lift truck. The location of the
approved lift truck required for operation in the area.
center of gravity of both the truck and the load is also a fac-
Modifications or poor maintenance can result in the lift
tor.
truck being unsuitable for operation in areas classified
as hazardous.
73
This basic principle is used for picking up a load. The ability The lift truck has moving parts and therefore has a CG that
of the lift truck to handle a load is discussed in terms of moves. The CG moves forward and back as the mast is til-
center of gravity and both forward and side stability. ted forward and back. The CG moves up and down as the
mast moves up and down.
Stability and Center of Gravity
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.
A. CG LOAD B. COMBINED CG C. CG TRUCK
The center of gravity, and therefore the stability of the loa-

ded lift truck, is affected by a number of factors such as
size, weight, shape, and position of the load; the height to
which the load is raised; the amount of forward and back-
A. CG LOAD B. CG TRUCK C. COMBINED CG ward tilt; tire pressure and the dynamic forces created
when the truck is moving. These dynamic forces are
The stability of the lift truck is determined by the location of
caused by things like acceleration, braking, turning, and
its CG, or if the truck is loaded, the combined CG.
74
operating on uneven surfaces or on an incline. These fac- Capacity (Weight and Load Center)
tors must be considered when traveling with an unloaded
truck, as well, because an unloaded truck will tip over to The capacity of the lift truck is shown on the Nameplate.
the side easier than a loaded truck with its load in the low- The capacity is listed in terms of weight and load center.
ered position. The weight is specified in kilograms and pounds. The load
center is specified in millimeters and inches. The capacity
In order for the lift truck to be stable (not tip over forward or is the maximum load that the lift truck can handle, with the
to the side), the CG must stay within the area of the lift mast vertical, for the load condition shown on the Name-
truck represented by a triangle drawn between the drive plate.
axle and the pivot of the steering axle.
A. DRIVE AXLE B. STEERING AXLE C. TRUCK WILL TIP OVER
If the CG moves forward of the drive axle, the lift truck will The load center of a load is determined by the location of
tip forward. If the CG moves outside of the line represented its center of gravity. The load center is measured from the
by the lines drawn between the drive wheels and the steer- front face of the forks, or the load face of an attachment, to
ing axle pivot, the lift truck will tip to that side.
75
the center of gravity of the load. Both the vertical and • An alarm will sound. The duration of the alarm is set by a
horizontal load centers are specified on the Nameplate. service technician or supervisor.
Loads should be transported while centered on the center- • The message "Impact Shutdown" will be displayed on
line of the lift truck. The operator must know whether or not the top line of the LCD screen (see Figure 7) and the
a load is within the maximum capacity of the lift truck message "Engine Shutdown in XX" will be displayed on
before the load is handled. the bottom line of the LCD screen. XX represents the
number of seconds before the engine shuts down and is
Impact Sensor factory set. If the delay is 0 seconds, the engine shuts
The lift trucks covered in this Operating Manual may be down immediately and the message is not displayed.
equipped with an optional impact sensor that can be ena- • After delay (XX, above) has elapsed, the engine will
bled or disabled by a service technician. The impact sensor immediately shutdown. The transmission and electro-
will sense when the lift truck has hit an object, and will hydraulic functions will also shutdown. If a load is in the
cause the lift truck to shutdown. There are two types of raised position and needs to be lowered, see Load Han-
impact that the Vehicle System Manager (VSM) recogni- dling, Emergency Load Lowering and Figure 26 in
zes: soft impact and hard impact. this section to lower the load.
The data parameters that determine whether an impact is a • The message "Impact Shutdown" will be displayed on
soft or hard one are entered into the lift truck's VSM by per- the top line of the LCD screen and the message "Super-
sonnel with a service password (see Operator Passwords visor Required" will be displayed on the bottom line of
in this section). the LCD screen.
If the impact sensor option is enabled and an impact has The lift truck can be turned on again, after delay has
been detected, the following actions will occur: elapsed, but the engine cannot be restarted until the Impact
Sensor is reset by a supervisor or service technician (see
Engine Shutdown in this section for procedures to start lift
76
truck after an engine shutdown). The messages "Impact control the temperature of the heater. Turn the knob to the
Shutdown" and "Supervisor Required" will continue to be left, toward wider part of red band to increase the tempera-
displayed on the LCD screen. Pressing the STAR (*) key ture. Turn the knob to the right, toward narrower part of red
will display the password entry menu. If the Impact Alarm band to decrease the temperature. The fan speed control
duration has been set to "Continuous" the alarm will con- knob controls the speed of the fan. There are three speeds
tinue to sound when lift truck power has been turn ON. available. Turn knob to the right to increase the fan speed
and to the left to decrease the fan speed.
To clear messages, turn off alarm, and reset truck to nor-
mal operation, an Impact Reset must be performed by AC Controls
either a service technician or supervisor. See User Inter-
face - Supervisor 2200 SRM 1130 or User Interface - Turn the AC switch ON by pushing on switch so that it is
Service Technician 2200 SRM 1131 for procedures. down toward the front of the truck. See Figure 21. Turn the
temperature control knob to control the temperature of the
Air Conditioner and Heater Controls AC. Turn the knob to the right to increase the temperature
and to the left to decrease the temperature. The fan speed
Lift truck models H80FT, H90FT, H100FT, H110FT, and
control knob controls the speed of the fan. There are three
H120FT (U005) may be equipped with an optional cab that
speeds available. Turn knob to the right to increase the fan
has an air conditioner (AC) and heater unit on the right
speed and to the left to decrease the fan speed.
door. See Figure 21. The information below describes how
to operate the controls for the optional cab AC/heater unit. Air Circulation
Heater Controls If the AC or heater are not being used, but fan is turned on
to blow air in from the outside, turn the temperature control
Make sure the AC switch is in the OFF position. The OFF
knob to the right to increase air circulation and to the left to
position is when the AC switch is down toward the opera-
decrease air circulation.
tor. See Figure 21. Turn the temperature control knob to
77
A. ON POSITION
B. OFF POSITION
1. AC SWITCH
2. TEMPERATURE CONTROL KNOB
3. FAN SPEED CONTROL KNOB
4. AC/HEATER UNIT
Figure 21. Air Conditioner/Heater Controls
78
Heater Controls right, toward narrower part of red band. See Figure 22. If
heater is not being used, but fan is turned on to blow air in
Lift truck models H80FT, H90FT, H100FT, H110FT, and from the outside, turn the temperature control knob to the
H120FT (U005) may be equipped with an optional cab that right, toward wider part of blue band to increase air circula-
has a heater unit underneath the right door cover. See Fig- tion and to the left, toward narrower part of blue band to
ure 22. The information below describes how to operate decrease air circulation.
the controls for the optional cab heater unit.
Fan Speed Control
Temperature Control
There are three speeds available. Turn knob to the right to
To increase the temperature, turn the temperature control increase the fan speed and to the left to decrease the fan
knob to the left, toward wider part of red band. To decrease speed. See Figure 22.
the temperature, turn the temperature control knob to the
79
1. TEMPERATURE CONTROL KNOB
2. FAN SPEED CONTROL KNOB
3. CONTROL PANEL
Figure 22. Heater Controls
80
Inspection Before Operation • Seat is correctly fastened to its mounts. Hood is correctly
latched.
WARNING • Condition of the engine compartment. Ensure all surfa-
Report damage or faulty operation immediately. Do not ces are free of oils, lubricants, fuel, and organic dusts or
operate a lift truck that needs repair. A lift truck will fibers (paper, wood, cotton, agricultural grass/grain, etc).
only do its job when it is in proper working order. If Remove all foreign materials.
repairs are required, install a tag in the operator's area
stating "DO NOT OPERATE" and remove the key from • Coolant level in the cooling system and condition of the
the key switch if truck is equipped with key switch drive belts.
option. • Condition of the radiator and screen. Clean if necessary.
• Fuel level.
Checks With the Engine Stopped • Oil level in the engine.
Inspect the lift truck before use and every eight hours or • Oil level in the hydraulic tank.
daily as described in the Maintenance section of this
Operating Manual. Inspect more frequently if used in • Leaks from the engine, transmission, hydraulic system,
severe operating conditions. and fuel system.
Before using the lift truck, make the following checks: • Loose or missing hardware.
• Condition of forks, carriage, chains, header hoses, mast, • Check transmission oil level.
attachment, and overhead guard.
• Condition of wheels and tires.
• Seat belt fastens correctly.
81
Operator Checklist there were any NO answered to checklist items, the truck
may or may not start. The lift truck can be set up to not start
If you lift truck is equipped with the optional operator check- (starter, engine outputs, transmission and hydraulic func-
list, it can be enabled or disabled by a supervisor or service tions disabled) if any item in the checklist is answered with
technician. a NO response. If lift truck is configured this way, the mes-
The operator checklist will appear on the LCD screen after sage "Truck Disabled" will appear on the first line of the
the lift truck has been powered ON and operator has LCD screen and the message "Checklist Failed" will appear
entered the correct password, if the password function is on the second line. The lift truck will stay disabled and mes-
activated. If password function is not activated, operator sages will continue to appear on the LCD screen until lift
checklist appears after lift truck is powered ON. truck has been reset by either a supervisor or service tech-
nician.
The operator checklist can store a maximum of 30 items.
Each item includes a text description of a system or com- If lift truck is configured to start after a NO response had
ponent the operator is to check. The operator is instructed been given to a checklist item, the failure will be logged into
to press button #1 for YES or button #2 for NO on the Dis- Checklist Log and operator will be allowed to start the lift
play Switch Cluster. See Figure 5. truck.
If any checklist item is answered with a NO response, the Mounting and Dismounting
checklist item will be repeated. If a NO response is given
again, the checklist item will be logged into the Checklist WARNING
Log as a FAIL. When the checklist fails due to a NO To avoid serious injury when entering or exiting the lift
answer, the display stops changing. No additional checklist truck, ALWAYS USE 3 POINTS OF CONTACT. Maintain
items are shown. contact simultaneously with two hands and one foot or
with two feet and one hand while climbing on or off the
Once the checklist has been completed and all items were
lift truck.
answered with YES, the operator can start the lift truck. If
82
Place feet carefully. Always face the lift truck when climbing bled. The LCD screen on the display panel will provide a
on or off. Use added care when surfaces are slippery. Keep non-service fault message "Hydraulic Interlock Engaged."
hands free of any obstacles such as food, beverages, or To reactivate hydraulics, the operator must return to the
tools. seat and press the brake pedal. Once the needed actions
are completed, the hydraulic function will be enabled and
Lift Truck Interlocks the operator can continue to load and unload material.
Certain operator actions, if not performed correctly while Operator Passwords
operating the lift truck, will cause traction and the hydraulic
functions to become disabled. The lift trucks covered in this manual have an optional
password feature.
DRIVE INTERLOCKS: Traction is enabled when the opera-
tor is in the seat (occupancy sensor), seat belt should be The Operator Passwords are a series of five numbers.
fastened, a direction of travel is selected, engine is running, Each of the five number digits can be the numbers 1
and the parking brake is released. If any of the above through 5. If enabled, the password number series must be
actions are not performed while operating the lift truck, trac- entered into the memory by a technician and assigned to
tion will be disabled. To reactivate traction, the operator an operator. Remember the password. A technician can
must return to the seat and press the brake pedal. Once use a personal computer (PC), connected to the vehicle, to
the needed actions are completed, traction will be enabled check as well as assign the passwords.
and the operator can continue to load and unload material.
There are four password types used on these trucks:
HYDRAULIC INTERLOCKS: The hydraulic functions are
• Operator: Allows operator to operate lift truck.
enabled when the operator is in the seat (occupancy sen-
sor), seat belt should be fastened, and the engine is run- • Lockout Reset: Lockout will occur when an operator
ning. If any of the above actions are not performed while incorrectly enters their password a specified number of
operating the lift truck, the hydraulic functions will be disa- times. After lockout occurs the following message will
83
appear in the display, "Password Lockout" "Supervisor The number of attempts is adjustable and set by a supervi-
Required." The supervisor will enter the Lockout Reset sor or service technician.
password to unlock the system.
If the truck is locked out, the message PASSWORD LOCK-
• Supervisor: Has all rights assigned to Operator and OUT, SUPERVISOR REQUIRED is displayed. A Lockout
Lockout Reset passwords. Can add, edit, and delete Reset, Supervisor, or Service password is needed to
Operator or Supervisor passwords and view all truck unlock the lift truck. System power can be turned OFF,
diagnostic information. Allows access to truck service while in lockout mode by turning key switch to OFF or
parameters within preset limits. pressing the Power ON/OFF button. To reset a system
lockout that occurs while attempting to enter a password
• Service: Has all rights assigned to Operator, Lockout
within the on-board menu, after a correct operator pass-
Reset, and Supervisor passwords. Can add, edit, and
word has been entered, recycle the system power. For all
delete Operator, Supervisor, and Service passwords and
other lockout conditions, cycling the truck power will not
view all truck diagnostic information. Allows access to
reset the lockout.
truck service parameters within preset limits.
If the optional password feature is enabled and after the Starting Procedures
key is moved to the ON position, or the Power ON/OFF but- Do not start or operate the lift truck,
ton is pressed, the LCD screen will show the message including any of its functions or attach-
PASSWORD ENTRY. Use the numbered push buttons ments, from any place other than the des-
(see Figure 5 and Table 1) to enter the five digit password ignated operator's position.
and then press the STAR (*) button to enter the password
and access main menu. If the password is entered incor- If equipped, be sure cab door is secured
rectly, and truck is not locked out, the message PASS- in either the opened or closed position
WORD INVALID and DISABLED IN ###, with ### being before starting lift truck operation.
the number of attempts remaining before lockout occurs.
84
If lift truck is equipped with the optional operator presence 5. If equipped, put the direction control lever for the trans-
system, the following sequence must be followed for mission in the NEUTRAL (N) position.
engine to start:
6. Turn the key to the ON position or depress and release
• Operator must be in seat the Power ON/OFF button. If lift truck is equipped with a
diesel engine and if the engine is cold, the cold start indica-
• Set belt must be fastened
tor light will illuminate and the cold start circuit will be ener-
• Make sure park brake is applied gized.
7. If the truck is equipped with Operator Password feature,
WARNING
enter correct password.
LPG is very flammable. An odor of LPG fuel can indi-
cate a leak in the fuel system. DO NOT start the engine 8. If lift truck is equipped with a diesel engine and the cold
until the fuel leak is repaired and the atmosphere is start indicator light is illuminated wait for the light to go out.
free of LPG.
9. Turn the key to the START position or press and hold
NOTE: Your lift truck is equipped with either: the Engine Start button to engage the starter. A countdown
timer will appear on the LCD screen and limit the cranking
• 3-position key switch ON-OFF-START
time.
• Power ON/OFF button and Engine Start button
10. When the engine starts, check to see that the oil pres-
1. If lift truck uses LPG fuel, open the fuel valve on the LPG sure lamp and charge lamp are off. If the lamps are still on,
tank. immediately stop the engine, and determine the cause
before restarting.
2. Make sure lift truck hood is closed.
11. Warm up the engine at medium speed without load.
3. Sit in operator's seat and fasten seat belt.
4. Make sure the parking brake is applied.
85
If engine fails to start before the cranking countdown timer
reaches zero, the starter will shut down for a cooling off Checks With the Engine Running
period. A countdown timer will appear on the LCD screen
showing the time remaining before another start can be
tried.
WARNING
FASTEN SEAT BELT
To attempt another start procedure, repeat Step 6 through If Lift Truck Tips Over
Step 11.
• Do Not Jump – Stay On Truck
Stop Procedures, Diesel Engine • Hold Firmly To Steering Wheel – Brace
On lift trucks equipped with a diesel engine, allow the Feet – Lean Forward And Away From
engine to idle for 5 minutes before shutting it off after full Impact
load operation. Failure to do so may result in turbo charger The seat belt is installed to help the opera-
damage. tor stay on the truck if the lift truck tips
over. IT CAN ONLY HELP IF IT IS FAS-
TENED.
The operator must be aware that the lift truck
can tip over. There is a great risk that the oper-
ator or someone else can be killed or injured if
trapped or hit by the truck as it tips over. The
risk of injury can be reduced if the operator stays on the
truck. If the truck tips over, do not jump off!
THE SEAT BELT AND HIP RESTRAINT bracket provides a
means to help the operator keep the head and torso
86
substantially within the confines of the truck frame and • Check the operation of the steering system.
overhead guard if a tipover occurs. This protection system
• Check the oil level in the transmission when the oil is at
is intended to reduce the risk of the head and torso being
operating temperature 50 °C (120 °F). Turn the truck off
trapped between the truck and the ground, but it can not
and wait one minute. Then check the transmission oil
protect the operator against all possible injury in a tipover.
level.
Make sure that the area around the lift truck is clear before
starting the engine or making any operational checks. Be Load Weighing Sensor
careful when making the checks. If the lift truck is stationary If your lift truck is equipped with the optional load weight
during a check, apply the parking brake and make sure the sensor, it can display the weight of the load in either
direction control is in NEUTRAL. Proceed carefully. pounds or kilograms on the LCD screen (see Figure 7).
Check the operation of the following functions as described The unit of measure is preset by a service technician and
in the Maintenance section: can be changed by a service technician.
• Check the operation of the horn, gauges, and indicator The operator can access the load weight function by press-
lights. ing the up or down arrow keys on the Display Switch Clus-
ter (see Figure 5), until the word "Weight" appears on the
• Operate the LIFT, TILT, and auxiliary functions to check LCD screen. See Figure 7.
for correct operation of the mast, carriage, and attach-
ments. To most accurately weigh a load, follow these instructions:
• Check the operation of the MONOTROL® pedal or the 1. With a load on the forks, position the mast in a vertical
optional direction control lever and accelerator pedal. position.
• Check the operation of the service brakes and parking 2. Lift the load 0.6 m (2 ft) off the ground, but if freelift cylin-
brake. der is present, not more than maximum freelift.
87
3. Lower the load 51 mm (2 in.). Stop lowering, wait 1 sec- Certain faults or sensor measurements can cause the truck
ond, and read the load weight. This will be the most accu- to go into Engine Shutdown mode. The following actions
rate weight. Waiting longer to read the load weight will occur when truck is in this mode:
reduce accuracy.
• The fault number is displayed on the top line of the LCD
Set Load Weight to Zero screen and a 30-second countdown timer is shown on
the bottom line.
The service technician or supervisor can set the load
weight to zero, when the no-load weight displayed on the • An alarm will sound during the 30-second countdown
LCD screen (see Figure 7) is not within ±2% of truck and continue for 10 seconds afterwards.
capacity. See User Interface - Supervisor 2200 SRM • The Engine Malfunction icon illuminates (see Figure 7
1130 or User Interface - Service Technician 2200 SRM and Table 3).
1131 for procedures.
At the end of the 30-second countdown, all power to the lift
Engine Shutdown truck is turned off. After shutdown has occurred, recycle
power to ON, load can then be lowered without starting the
NOTE: The information in this section pertains to lift trucks engine.
with the powertrain protection option. On trucks without
powertrain protection, the fault number is displayed on the CAUTION
LCD screen and the Engine Malfunction icon will illuminate,
If lift truck experiences an engine shutdown, call a
but engine will not shutdown or truck performance will not
service technician immediately. Continued operation of
be decreased. DO NOT continue to run lift truck. Turn
lift truck after engine shutdown can cause damage to
engine OFF and notify service technician immediately
the lift truck and its components.
for repair.
To restart the lift truck, turn the key switch OFF and ON
again to cycle the system power. If lift truck is equipped
88
with the Power ON/OFF button, press Power ON/OFF but- Take the lift truck to a service technician immediately for
ton twice to cycle the system power and then press the repair if it experiences a decrease in performance.
Engine Start button. If the Engine Start button is pressed
before the Power ON/OFF button, the starter will not oper- Engine Modes (Generation 2 ECO-eLo)
ate. See Starting Procedures in this section, if starter NOTE: Two engine modes are available for lift trucks
becomes disabled. equipped with Kubota 3.8L LPG engine. For lift truck mod-
When the lift truck has been restarted, it will run for 30 sec- els H80-120FT (U005) equipped with a Kubota 3.8L LPG
onds before shutting down again. Cycle the truck power engine and Powershift 1 Speed, Electronic Powershift (1
again to run the lift truck for another 30 seconds. This proc- Speed), Powershift 2 Speed, Electronic Powershift (2
ess provides enough power for the lift truck to move under Speed), DuraMatch (1 Speed), Techtronix (1 Speed), Dura-
its own power so that it can be moved to a safe location. Match 2 (2 Speed), or Techntronix (2 Speed) transmission
the initial setting is Mode 1.
Some faults or sensor measurements will not always cause
the engine to shutdown, but will cause the speed of the lift • ECO-eLo provides lower available engine torque to opti-
truck to be restricted, or will either disable or restrict the mize fuel economy.
truck's hydraulic functions. • Normal (Mode 1) provides normal engine torque to
When this occurs, the following actions take place: maximum productivity.
• The fault number is displayed on the top line of the LCD

screen and a description of truck performance being
decreased is shown on bottom line.
• The Engine Malfunction icon illuminates (see Figure 7
and Table 3).
• An alarm will sound for 10 seconds.
89
Operating Techniques
WARNING
Before operating the lift truck,
FASTEN YOUR SEAT BELT.
There are a number of operations,
if not performed carefully, that
can cause the lift truck to tip. If you have not read the
WARNING page in the front of this Operating Manual,
Figure 23. do so NOW. As you study the following information
Engine modes are set in the DSC. When one of the modes about how to properly operate a lift truck, remember
is selected, the VSM sends a message requesting the the WARNINGS.
engine ECU to establish a set engine torque output.
Basic Operating Procedures
One personnel with a service or supervisor password can
change the engine mode. See User Interface, Supervisor Many people make the mistake of thinking that operating a
2200 SRM 1130 or User Interface, Service Technician lift truck is the same as driving an automobile. This is not
2200 SRM 1131 for procedures to change engine mode. true. A lift truck is a special machine designed to do a much
different job than an automobile. Because of the close
areas in which a lift truck operates and its other operating
characteristics (like rear wheel steering and tail swing),
every operator must receive additional training, even if they
have a license to drive an automobile.
90
The following discussion lists basic procedures applicable If a lift truck is used to elevate a
to lift truck operation. worker, a safety platform must
be attached to the forks and car-
1. AUTHORIZED AND TRAINED
riage. The platform must be spe-
OPERATOR ONLY. This means
cially built to meet or exceed the
the operator must be trained (see
requirements of ANSI/ITSDF
29 CFR 1910.178 section I) to
B56.1. It must have a solid floor
drive the lift truck and it means that
with a surface to prevent the feet
the operator must thoroughly
of the worker from slipping, hand
understand the procedures for lift
rail, toe board, and a screen or
truck operation. It also means that a qualified person expe-
shield at least 2 m (7 ft) high between the people on the
rienced in lift truck operation must guide the operator
platform and the lift mechanism.
through several driving and load handling operations before
the operator attempts to operate the lift truck alone. A basic The combined weight of the platform, load, and person-
education in proper driving and load handling techniques is nel is not to exceed one-half of the capacity as indica-
absolutely necessary to prepare the new operator for ted on the nameplate of the truck on which the platform
proper defensive driving and to expect the unexpected. is used.
Before anyone is allowed in the platform, lift and lower
WARNING
the mast slowly with the platform in place to make sure
This lift truck is designed for handling materials. A lift
the mast functions properly. Apply the parking brake.
truck is not designed to lift people. Do not use a lift
Do not travel with people in the platform. The operator
truck to lift people unless it has been determined that
must remain at the controls. Watch for overhead
there is no other practical option (scaffolds, elevated
obstructions.
work platforms, aerial baskets, etc.) to perform the nee-
ded work.
91
2. NO RIDERS. A lift truck is built for only NOTE: It is important to adjust the weight setting for each
one person – the operator. It is danger- operator.
ous for anyone to ride on the forks or any-
NOTE: The seat is designed for a maximum weight of
where else on the lift truck.
135 kg (298 lb)
• The target is for the "ride indicator" to fall between the
arrows when the operator sits upright in the seat with the
feet positioned on the pedals. This ensures that the
3. ADJUST SEAT - INTERNAL SUSPENSION. operator is set at the midpoint of the 40 mm (1.57 in.)
Seat Position Adjustment (Swivel Seat) suspension.
• The seat swivels 10.5 degrees to the right to allow the • The weight adjustment knob can be turned left or right to
operator a more ergonomic position when driving in increase or decrease the weight resistance. As the
reverse. weight adjustment knob is turned the "stiffness" of the
suspension can be felt to increase or decrease depend-
• The seat swivels 5 degrees to the left to allow an easier ing on which way the weight adjustment knob is turned.
exit of the truck.
4. ADJUST SEAT - FULL SUSPENSION.
• The neutral position is shown in Figure 24.
• Fore and aft adjustment – it is recommended that the
Seat Adjustment for Operator Weight seat be adjusted so that the thigh is horizontal to the
ground so that the best ergonomic position is achieved.
CAUTION See Figure 24.
A major cause for high Whole Body Vibration is caused
by the operator not adjusting the seat to his/her weight.
92
Seat Position Adjustment (Swivel Seat) NOTE: The seat is designed for a maximum weight of
135 kg (298 lb)
• The seat swivels 12 degrees to the right to allow the
operator a more ergonomic position when driving in • The target is for the "ride indicator" to fall between the
reverse. arrows when the operator sits upright in the seat with the
feet positioned on the pedals. This ensures that the
• The seat swivels 5 degrees to the left to allow an easier
operator is set at the midpoint of the 80 mm (3.5 in.) sus-
exit of the truck.
pension.
• The neutral position is shown in Figure 24.
• The handle can be turned as shown to increase or
Seat Adjustment for Operator Weight decrease the weight resistance, pull handle out before
turning. As the handle is turned the "stiffness" of the sus-
CAUTION pension can be felt to increase or decrease depending
A major cause for high Whole Body Vibration is caused on which way the handle is turned.
by the operator not adjusting the seat to his/her weight.
NOTE: It is important to adjust the weight setting for each
operator.
93
Figure 24. Seat Adjustment - Full Suspension
94
Legend for Figure 24
A. STANDARD, NON-SWIVEL SEAT B. FULL SUSPENSION SWIVEL SEAT
1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
95
5. Do not drive a lift truck into an elevator unless authorized the power. It is advisable that all other personnel leave the
to do so. Approach the elevator slowly. After the elevator is elevator before the lift truck enters or leaves.
properly leveled, the lift truck must be centered so that the
6. Drive carefully, observe traffic rules, and be in
elevator is balanced.
full control of the lift truck at all times. Be com-
pletely familiar with all the driving and load handling
techniques contained in this Operating Manual.
Driving and Direction Changes
KNOW YOUR TRANSMISSION OPTION. The lift truck
models covered in this manual can be equipped with a
Powershift 1 Speed, Electronic Powershift (1 Speed), Pow-
ershift 2 Speed, Electronic Powershift (2 Speed), or Dura-
Match transmission. Read the following section carefully.
See Table 6 and Figure 25 for the features and operational
When the lift truck is in the proper position in the elevator,
differences in these transmission types.
set the brakes, put the controls in NEUTRAL and shut off
96
Table 6. Transmissions
Powershift Powershift
(1 Speed) or (2 Speed) or
DuraMatch
Operational Electronic Electronic DuraMatch 2
(1 Speed)
Feature Powershift Powershift Transmission
Transmission
(1 Speed) (2 Speed)
Transmission Transmission
Electronic Inching Yes Yes Yes Yes
Electronic Control of Yes Yes Yes Yes
Direction Changes
Auto Deceleration – – Yes Yes
Controlled Power Reversal – – Yes Yes
Roll Reduction Feature – – Yes Yes
Roll Back Feature – – Yes Yes
Reduced Drive Tire – – Yes Yes
Slippage
97
General
The lift truck can have either a MONOTROL® pedal, a
Direction Control Lever, or a Direction Control Switch to
control the transmission. The selected direction of travel is
shown on the display switch cluster. See Figure 7. If the lift
truck has a MONOTROL® pedal, push on the left side of
the pedal to go FORWARD, or the right side of the pedal to
go in REVERSE. If the lift truck has a Direction Control
Switch, rock the switch toward the palm rest to go FOR-
WARD and toward the base to go in REVERSE. If the lift
truck has a direction control lever, move the lever toward
the front of the lift truck to go FORWARD and toward the
rear of the lift truck to go in REVERSE.
Normal Operations
In normal operating conditions, either at start or while driv-
1. POWERSHIFT 1 SPEED TRANSMISSION ing, the lift truck can only be maintained at a stopped posi-
2. POWERSHIFT 2 SPEED TRANSMISSION
tion by applying the service brake or parking brake.
3. DURAMATCH TRANSMISSION
4. DURAMATCH 2 TRANSMISSION When moving away from a stop:
5. ELECTRONIC POWERSHIFT
6. ELECTRONIC POWERSHIFT 1. Select direction while maintaining braking.
7. DURAMATCH
8. DURAMATCH 2. Depress the accelerator or MONOTROL® pedal.
Figure 25. Transmission Label 3. Release the brakes (parking and/or service brake)
98
Depress the accelerator or MONOTROL® pedal to ensure slight delay in the seat switch to allow the operator to repo-
the lift truck will move in the selected direction when the sition himself without disengaging the transmission. When
brakes are released. the seat switch disengages the transmission (neutral posi-
tion), the operator must depress the service brake pedal to
Due to variable load and grade conditions, this procedure
re-engage the traction (travel mode).
minimizes the possibility of the lift truck traveling in a direc-
tion opposite to the one selected. A switch in the operator's seat will automatically shift the
transmission to neutral within 1-2 seconds when the opera-
Standard Operator Presence System
tor leaves the seat of the lift truck with the engine running
and without applying the parking brake.
WARNING
Always make sure the parking brake is fully applied If the lift truck is equipped with a Direction Control Lever
before leaving the lift truck. If the operator leaves the and the operator leaves the seat without engaging the
lift truck without applying the parking brake, a seat parking brake, the N indicator light on the Display Switch
activated switch will shift the transmission to neutral, Cluster will illuminate regardless of the position of the
and sound an alarm for 10 seconds. If the lift truck is Direction Control Lever. When the operator returns to the
left on a grade, without the parking brake fully applied, seat, to resume travel, the Direction Control Lever must be
the lift truck will freewheel down the grade, possibly moved to the N position, then to the desired direction of
causing injury or property damage. travel.
The lift trucks covered in this Operating Manual are equip- If the lift truck is equipped with a MONOTROL® pedal or
ped with an Operator Presence System (OPS). The OPS MLM Direction Control Switch and the operator leaves the
feature has an electrical switch in the seat which senses seat without engaging the parking brake, the N indicator
the presence of the operator. This allows the transmission light on the Display Switch Cluster will illuminate regardless
in internal combustion engine trucks to be engaged only of the position of the MONOTROL® pedal. When the oper-
when the operator is in the seat. The OPS is designed with ator returns to the seat, the indicator light will change from
99
N to the direction of travel that the MONOTROL® pedal or The seat switch will automatically disable hydraulics within
MLM Direction Control Switch was last in when the opera- 1-2 seconds when the operator leaves the seat of the lift
tor left the lift truck. The operator can resume travel by truck. When the seat switch disables the hydraulic func-
depressing the MONOTROL® pedal or MLM Direction tions, the operator must sit in the seat and depress the
Control Switch. service brake pedal to re-engage hydraulic functions.
Optional Operator Presence System Powershift, Electronic Powershift 1 and 2 Speed
Transmission
WARNING
ALWAYS make sure the parking brake is fully applied WARNING
before leaving the lift truck. If the operator leaves the DO NOT select the travel direction if the accelerator is
lift truck without applying the parking brake, a seat depressed. The lift truck will move rapidly and can
activated switch will cut off traction and hydraulic cause damage or injury.
power to the lift truck.
Lift trucks produced after March, 2009 are equipped with
an Operator Presence System (OPS). The OPS feature
uses an electrical switch in the seat which senses the pres-
ence of the operator, and interlocks to prevent the use of
hydraulic functions. This allows the mast hydraulic control
functions to be engaged only when the operator is in the
seat. The OPS is designed with a delay in activating the
A. MONOTROL PEDAL
interlock to allow the operator time to reposition himself B. ACCELERATOR PEDAL
without disabling the hydraulic controls. C. DIRECTION CONTROL LEVER
D. MLM DIRECTION CONTROL SWITCH
100
due to rapid direction reversals and unstable loads.
CAUTION
The factory settings for the Controlled Power Reversal
The drive train can be damaged if the lift truck is travel-
Feature can be changed by a Hyster Service Techni-
ing too fast when the controls are changed to the
cian when required to meet special application require-
opposite direction of travel.
ments.
The operator can change the direction of travel at slow
The DuraMatch and DuraMatch 2 transmissions allow the
travel speeds (less than a walking speed), but the mast
operator to change travel direction at any travel speed with-
must not be in a raised position. If the lift truck is moving
out damaging the transmission. The operator should
rapidly, slow to a walking speed before changing the direc-
always consider the load that is being carried, and keep the
tion of travel.
carriage lowered, when making a controlled power reversal
DuraMatch and DuraMatch 2 or using transmission braking. The operator is responsible
for control of the truck and the stability of the load.
The DuraMatch and DuraMatch 2 transmissions are equip-
ped with Controlled Power Reversal, Auto-Deceleration, When a direction change is selected, the lift truck's Vehicle
Roll Reduction, Roll Back, and Reduced Drive Tire Slip- Management System (VSM) automatically reduces engine
page features. See Table 6 and Figure 25. speed to idle and activates transmission braking. The oper-
ator controls the level of transmission braking, or decelera-
Operators should be trained and become familiar with
tion, with the use of the accelerator or MONOTROL®
these operating features before transporting loads.
pedal. Depressing the accelerator or MONOTROL® pedal
Controlled Power Reversal increases the amount of transmission braking before the lift
truck begins to move in the opposite direction. Releasing
WARNING the accelerator or MONOTROL® pedal after selecting a
The factory settings are set for most load handling direction change, reduces the amount of transmission brak-
applications, but may require adjustment for special ing. Application of the service brakes allows the operator to
applications to avoid load damage or personal injury bring the lift truck to a complete stop at any time. Once the
101
truck stops and travel direction changes, the normal control always consider the load that is being carried, and keep the
of the accelerator or MONOTROL® pedal returns. carriage lowered, when using transmission braking.
The operator should always consider the load that is being Roll Reduction Feature
carried, and keep the carriage lowered, when making a
controlled power reversal or using transmission braking. WARNING
The lift truck is only considered at a controlled stop
Auto-Deceleration Feature
when the truck is not rolling and the service or parking
brake is applied. The operator cannot rely on transmis-
WARNING
sion braking alone to bring the lift truck to a full con-
The factory settings are set for most load handling
trolled top. Failure to use the service or parking brakes
applications, but may require adjustment for special
could result in damage to the lift truck and/or injury to
applications to avoid load damage or personal injury
personnel.
due to rapid direction reversals and unstable loads.
The factory settings for the Auto-Deceleration Feature Provides limited transmission braking to stop the lift truck
can be changed by a Hyster Service Technician when from rolling on level ground or to limit vehicle speeds to
required to meet special application requirements. less than slow walking speed on minor grades. This feature
will attempt to stop the lift truck when the transmission is in
Provides transmission braking, or deceleration, when the
either FORWARD or REVERSE, and both the accelerator
accelerator or pedal is released at vehicle travel speeds
or pedal and inching/brake pedals are released. The trans-
greater than operator walking speed. The amount of decel-
mission cannot stop the lift truck in all conditions. It is the
eration is controlled by the accelerator or pedal position.
operator's responsibility to use the service or parking brake
Releasing the accelerator or pedal causes a greater
to stop and hold the lift truck from moving.
amount of transmission braking. Depression of the acceler-
ator or pedal increases acceleration. The operator should
102
Roll Back Feature Inching is the movement of a lift truck that allows a slow
travel speed while keeping the engine speed high for fast
If the operator uses the brakes to bring the lift truck, regard-
operation of the lift mechanism.
less of direction selected, to a stop on a grade; then relea-
ses the brake, the Roll Back feature limits and controls the The inching/brake pedal is used to control the inching oper-
speed at which the truck rolls backward or forward. This ation. When the inching/brake pedal is initially applied, the
feature is effective on grades up to 10% and limits the clutch in the transmission is partially disengaged and the
speed to 7.6 cm (3 in.) per second. (The lift truck may roll movement of the truck is slow. When the inching/brake
faster than 7.6 cm (3 in.) per second until the Roll Back fea- pedal is fully applied, the transmission is completely disen-
ture slows it down.) gaged and the brakes are applied. Use the accelerator
pedal or MONOTROL® pedal to keep the engine speed
Reduced Drive Tire Slippage
high while inching.
Electronically controls engine power and clutch pack
engagement during acceleration and reduces the possibility
of drive tire wheel spin.
For fine positioning, the use of the inching/brake pedal is
recommended.
Inching
WARNING A. FAST B. SLOW

Inching requires coordinated movement of the inching/
brake pedal and the accelerator or the MONOTROL®
pedal. New operators must practice this procedure
before attempting to handle loads.
103
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 must
actually tip over easier when empty, than when loaded with be aware of tail swing and always check to make sure the
the load lowered. Mast tilt, off-center loads, and uneven tail swing area is clear before turning. Failure to observe
104
the tail swing area when making a turn can lead to injury or Load Handling, General
death.
1. The capacity is the maximum
Do not turn on an incline. To reduce load that the lift truck can handle for
the possibility of a tipover, a lift truck the load condition shown on the
must not be driven across an incline. Nameplate. The operator must
When possible, keep both hands on know whether or not a load is within
the steering wheel. During most the maximum capacity of the lift
loading or unloading operations, the truck before the load is handled.
operator steers with the left hand. However, factors such as weak floors or uneven terrain,
The right hand is used to operate loads with a high center of gravity, unevenly distributed
the lift, tilt, and attachment controls. loads, or tire condition can mean that the safe working 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.
When turning the lift truck from a wide aisle into a narrow
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.
105
If the weight of the load is not centered between the forks,
WARNING
the load can fall from the forks when you turn a corner or
Do not handle a load if
hit a bump. An off-center load will increase the possibility of
any loose part of it is
the truck tipping over to the side. Make sure the pins that
above the load backrest
keep the forks in position are engaged so that the forks
or any part of the load is
cannot move.
likely to fail.
4. Check the condition of the driving surface. Make sure the
2. Handle only stable loads.
floor will support the weight of the lift truck and the load.
A load can have unstable
items that can easily shift Load Handling, Lifting, Lowering, and Tilting
and fall on someone.
NOTE: The lift trucks covered in this manual can be equip-
ped with either standard manual hydraulic levers or Electro-
WARNING Hydraulic (E-Hydraulic) mini-levers (see Figure 8 and
If the fork/locking pin is not Table 4).
fully engaged, the fork could
become unintentionally disen- The LIFT and TILT functions are controlled by separate
gaged. levers. See Figure 8 in the Model Description section for
the correct operation.
3. Position each fork the same
distance from the center of the The speed of the hydraulic functions is controlled by the
carriage. This action will help position of the control levers. The farther the hand lever is
center the load on the carriage. moved from the NEUTRAL position, the faster the speed of
Set the forks as far apart as possible for maximum support the hydraulic function.
of the load. Center the weight of the load between the
forks.
106
Do not lift or hit anything that can fall on the operator or a The operator must exercise care while working near such
bystander. Remember, a lift truck equipped with a over- objects. Whether the lift truck is loaded or empty, do not
head guard and load backrest extension provides reasona- travel with the load or carriage in a raised position.
ble protection to the operator from falling objects, but can
not protect against every possible impact. WARNING
Keep yourself and all others clear of the lift mecha-

nism. Never allow anyone under or on the forks.
WARNING
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 NEVER put hands, arms, head, or legs through the
could become dislodged and fall. mast or near the carriage or lift chains. This warning
107
applies not only to the operator but also a helper. A forward, braking when traveling forward, or accelerat-
helper must not be near the load or lift mechanism ing in reverse.
while the operator is attempting to handle a load. The
If the lift mechanism is raised to pick up or deposit a load,
lift mechanism has moving parts with close clearances
keep the tilt angle in either direction to a minimum. Back-
that can cause serious injury.
ward and forward tilt are helpful, but they affect side and
Lift and lower with the mast vertical or tilted slightly back- forward stability. Do not tilt in either direction more than
ward from vertical. Tilt elevated loads forward only when necessary when handling a load that is raised. The lift truck
directly over the unloading place. 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.
WARNING
The lift truck can tip over forward when the load is
raised. Forward tipping is even more likely when tilting
108
Load Handling, How to Engage and Make sure that the load is centered between the forks.
Disengage a Load Make sure that the forks do not extend past the load so that
loads or equipment that are behind the load being lifted are
1. Avoid fast starts. not damaged. Lift the load a small distance from the floor to
Sudden movement make sure the lift truck has the capacity to lift the load.
can cause the lift
truck to tip. People
can be hurt or killed
and material can be
damaged.
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
the load. Lift the load from the surface. Move backward a
few inches, then lower the load onto the surface and inch
forward to engage the load against the carriage. Tilt the
mast backward just far enough to lift the load from the sur-
face.
2. Move forward slowly until the forks are in position under
the load. The forks must support at least two-thirds (2/3) of
the length of the load.
109
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.
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 WARNING
permit smooth removal of the forks. Carefully move the lift Move carefully and smoothly when the load is raised
truck backward to remove the forks from under the load. 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
110
Move forward slowly. When the load is in position, lower

IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE the load on to the stack or the rack. Lower the forks just
OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO enough to remove them from under the load. Do not lower
STEERING WHEEL, BRACE YOUR FEET, AND LEAN the forks so that they will drag on the surface under the
FORWARD AND AWAY FROM THE POINT OF IMPACT. load. Tilt the mast forward just enough to permit smooth
removal of the forks from under the load. Carefully move
the lift truck backward to remove the forks from under the
load. Lower the forks when traveling.
NOTE: Not every load can be lifted using only the forks of a
lift truck. Some loads will require a special attachment.
6. When lifting round objects, use a block behind the
object. Tilt the mast forward so that the forks can slide
111
along the floor under the object to be lifted. Tilt the mast
fully backward to help keep the load on the forks.
2. Travel with the lift mechanism raised only enough to

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
Load Handling, Traveling (travel) position. Therefore, a lift truck without a load is
more likely to tip sideways, especially in a turn, than a lift
1. When traveling with the load lowered, keep the load truck with a load carried in the lowered position.
against the carriage and the mast tilted fully backward. This
action will help keep the load on the forks and provide good WARNING
forward and side stability. 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.
112
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 When operating an unloaded lift truck on a grade in
travel in a direction where visibility is obstructed, a lookout excess of 5%, keep the counterweight upgrade.
helper is required. Never drive when visibility is obstructed.
5. Watch out for pedestrians at all times.
Do not drive up to anyone standing in
front of an object. Use extra care at
cross-aisles, doorways, and other loca-
tions where pedestrians can step into
the path of travel of the lift truck.
Slow down when approaching blind
intersections or turns and sound the
horn. The horn is to warn pedestrians that there is a vehicle
4. When traveling up or down grades in excess of 5% with in the area and to be alert to possible danger.
a heavily loaded lift truck, keep the load upgrade to main-
tain control.
113
6. Anytime the lift truck is moving 8. Watch clearances, especially forks, mast, overhead
keep arms, legs, etc., inside the guard, and tail swing. A lift truck is designed to perform a
operator's compartment. Arms and wide variety of functions within limited space.
legs outside the machine can be
injured when passing obstructions.
7. Avoid bumps, holes, mud, slick
spots, and loose materials that
may cause the lift truck to swerve
or tip. If unavoida-
ble, slow down.
The operator must be aware that the forks can sometimes
Different models of extend beyond the front of the load. If the forks extend
lift trucks are beyond the load, the operator can hit an object or lift
designed to operate another load. Serious accidents can be caused by mast
under different con- and overhead guards hitting pipes and beams near the ceil-
ditions. Solid rubber ing.
tire models are
designed to operate
on relatively smooth,
firm surfaces. Lift
trucks with pneumatic tires can adapt to more uneven
ground. Always make sure you pick the smoothest route for
your lift truck.
114
run off the edge of the travel surface onto soft ground, the
lift truck can tip over.
12. Under all travel conditions,
operate the lift truck at a speed
that will permit it to be brought to a
stop in a safe manner.
Load Handling, Emergency
Load Lowering
9. Do not indulge in stunt driving or horseplay.
WARNING
10. Do not pass another lift truck traveling in the same On trucks equipped with an
direction at intersections, blind spots, or at other dangerous electronic hydraulic control valve, when the electronic
locations. signal to the mini-levers is disrupted, the mast assem-
bly can ONLY be lowered with the emergency load low-
ering valve, located on the main hydraulic valve (see
Figure 26). When using the emergency load lowering
valve to lower a load, serious injury can result if any-
one is near the load or under the load.
WARNING
11. Stay away from the edge of the road. Keep the wheels When power is interrupted on trucks equipped with a
of the lift truck on the roadway. If the wheels are allowed to manual hydraulic control valve and emergency load
lowering valve, the following procedure must be used
115
to lower a load. When lowering a load using this proce- truck is equipped with an LPG tank, swing the LPG tank to
dure, serious injury can result if anyone is near or the side before opening the hood.
under the load.
2. Remove floor mat and floor plate.
WARNING 3. Turn the emergency load lowering valve two complete
Always lower the mast assembly when leaving the lift turns to the left. See Figure 26.
truck unattended.
4. When load has been lowered, close the emergency load
NOTE: The emergency load lowering valve is to be used lowering valve.
ONLY if the electrical signal to the main control valve has
5. Install floor plate and floor mat.
been disrupted and there is a load lifted.
6. If truck is equipped with an LPG tank, swing LPG tank
To use the emergency load lowering valve, follow these
back into position on the truck. Close the hood and adjust
steps:
the seat and steering column.
1. Move seat all the way forward and raise the steering col-
umn to its highest position and open lift truck hood. If lift
116
1. EMERGENCY LOAD LOWERING VALVE 3. COWL WELDMENT

2. MAIN CONTROL VALVE 4. KICK PANEL
Figure 26. Emergency Load Lowering Valve
117
Highway Trucks, Rail Cars, and Docks • DO NOT use a lift truck to open or close the door on a
rail car unless the lift truck has an attachment that is
WARNING specifically designed for opening and closing rail car
Maintain a safe distance from the doors and the operator is trained in its use.
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
STEERING WHEEL, BRACE YOUR FEET, AND LEAN • Check to make sure that the brakes on the highway
FORWARD AND AWAY FROM THE POINT OF IMPACT. truck are set and that wheel blocks have been placed on
Before operating in a highway truck or rail car, observe the both sides of the rear wheels (unless a dock locking
following: mechanism is engaged). Fixed jacks may be necessary
to support the front and rear of a highway truck trailer to
• DO NOT use a lift truck to move a rail car. prevent it from moving or tipping during loading or
unloading.
118
• Make sure that the rail car brakes are set and the wheels
are blocked while loading or unloading. Do this check so
that the rail car will not move due to the movement of the
lift truck in and out of the rail car.
• Check the condition of the driving surface. Make sure
the floor will support the weight of the lift truck and the
load.
• Make sure the dock board is secured, in good condition,
and of the proper capacity.
If an attachment is installed on the lift truck, make sure the
• When entering a rail car, the operator can enter at an operating instructions are available and understood before
angle (if the dock plate or bridge is wide enough). This operating the attachment. For the operation of attachment
will reduce the turning required after entering. control levers, see Figure 8, Figure 9, and Table 4.
• Never leave a parked truck on a dock plate. Attachments must be removed or installed by trained per-
Attachments sonnel only.
NOTE: Make sure the Nameplate is correct if an attach- Disconnecting Attachment Hydraulic Quick-
ment has been installed. Disconnect Hoses
NOTE: Step 1 through Step 4 is to be used for lift trucks
equipped with electro-hydraulics.
1. Turn the key switch or keyless switch to the OFF posi-
tion.
119
2. Disconnect the negative terminal of the battery.
NOTE: If the Quick-Disconnect hose connectors cannot be
disconnected, repeat Step 3 and Step 4. If the hoses still
cannot be disconnected, notify service personnel.
3. Press the plunger button located on the top of the pres-
sure relief valve, and listen for the flow of hydraulic fluid
through the valve when the button is pressed. See Fig-
ure 27.
Figure 27. Quick-Disconnect Procedure
120
Legend for Figure 27 3. Turn the key switch or keyless switch to the ON position
1. PRESSURE RELIEF VALVE
and start the engine.
2. PLUNGER BUTTON
4. Move the manual hydraulic levers forward and back-
4. Disconnect the Quick-Disconnect hose connectors. ward, and check the hydraulic system for leaks.
NOTE: Step 5 through Step 8 is to be used for lift trucks NOTE: Step 5 through Step 8 is to be used for lift trucks
equipped with manual hydraulics. equipped with electro-hydraulics.
5. Turn the key switch or keyless switch to the OFF posi- 5. Connect the Quick-Disconnect hose connectors.
tion. 6. Connect the negative terminal of the battery.
6. Disconnect the negative terminal of the battery. 7. Turn the key switch or keyless switch to the ON position
7. Move the manual hydraulic levers forward and backward and start the engine.
to relieve the system hydraulic pressure. 8. Move the mini-levers forward and backward, and check
8. Disconnect the Quick-Disconnect hose connectors. the hydraulic system for leaks.
Connecting Attachment Hydraulic Quick- Stopping

Disconnect Hoses
NOTE: Step 1 through Step 4 is to be used for lift trucks
equipped with manual hydraulics.
1. Connect the Quick-Disconnect hose connectors.
2. Connect the negative terminal of the battery.
121
Stop the lift truck as gradually as possible. Hard braking tion. Failure to do so may result in turbo charger dam-
and wheel sliding can cause the forklift to tip or the load to age.
fall off of the forks and damage the load or hurt someone.
4. Turn the key to the OFF position to stop the engine.
Parking 5. If the lift truck must be left on an incline, put blocks on
The operator must never leave a lift truck in a condition so the down hill side of the wheels so that the lift truck can not
that it can cause damage and injury. When parking the lift move.
truck, do the following operations: 6. Check engine compartment, if operating in areas con-
1. Stop the lift truck and apply the parking brake. Applying taining combustible material, and remove foreign debris.
the parking brake puts the transmission in NEUTRAL when See FIRE HAZARD WARNING at the beginning of this
the lift truck has a pedal or MLM Direction Control Switch. section.
2. Fully lower the forks or carriage. Tilt mast forward until 7. If the lift truck is equipped with an LPG fuel system and
the tips of the forks touch the ground. the lift truck is not in active use, close the fuel valve at the
tank. If the lift truck is going to be left over night or longer,
3. If equipped, move the Direction Control Lever to the the truck must be parked outside or the LPG tank must be
NEUTRAL position. removed and stored outside.
CAUTION Do not park the lift truck so that it limits access to fire
For Kubota diesel engines only - Allow engine to idle aisles, stairways, and fire equipment.
for 5 minutes before shutting it off after full load opera-
122
Maintenance
Maintenance
General The Maintenance Schedule has time intervals for inspec-
tion, lubrication, and maintenance for your lift truck. The
WARNING service intervals are provided in both operating hours
Do not make modifications to the lift truck that affect recorded on the lift truck hour meter, and in calendar time.
the safe operation of the lift truck. Don't add parts or Use the 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. If • Poor ground conditions.
truck is equipped with a key switch, remove the key. • Intensive usage at high performance levels or 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.
123
Maintenance
Some users have service personnel and equipment to do the lift truck difficult to steer. Poor traction can cause
the inspection, lubrication, and maintenance shown in the the disabled lift truck or towing vehicle to slide. A
Maintenance Schedule. Service Manuals are available slope will also make the lift truck more difficult to stop.
from your dealer for Hyster lift trucks to help users who do
Never lift and move a disabled lift truck unless the dis-
their own maintenance.
abled lift truck MUST be moved and cannot be towed. A
Serial Number Data lift truck used to move a disabled lift truck MUST have
a capacity rating equal to or greater than the weight of
The serial number for the lift truck is on the Nameplate. It is the disabled lift truck. The capacity of the lift truck
also on the right side of the frame, under the floor plate. used to move a disabled lift truck must have a load
center equal to half the width of the disabled lift truck.
How to Move a Disabled Lift Truck
See the Nameplate of the disabled lift truck for the
approximate total weight. The forks must extend the
WARNING full width of the disabled lift truck. Put the weight cen-
Use extra caution when towing a lift truck if any of the ter of the disabled lift truck on load center of the forks.
following conditions exist: Be careful to not damage the under side of the lift
1. Brakes do not operate correctly. truck.
2. Steering does not operate correctly. How to Tow the Lift Truck
3. Tires are damaged. 1. The towed lift truck must have an operator.
4. Traction conditions are bad. 2. Tow the lift truck slowly.
5. The lift truck must be towed on a slope. 3. Using a lift truck or a lifting device that can be attached
If the engine cannot run, there is no power available for to the mast (I.E. come-a-long), raise the carriage and forks
the hydraulic steering system. This condition can make approximately 30 cm (12 in.) from surface. Install a chain
124
Maintenance
around a mast crossmember and the carriage, to prevent
carriage and mast channels from moving.
4. If another lift truck is used to tow the disabled lift truck,
that lift truck must have an equal or larger capacity than the
disabled lift truck. Install approximately 1/2 of a capacity
load on the forks of the lift truck that is being used to tow
the disabled lift truck. This 1/2 capacity load will increase
the traction of the lift truck. Keep the load as low as possi-
ble.
5. If lift trucks are equipped with a tow pin in the counter-
weight (standard counterweight), use a towing link made of
steel that fastens to the tow pins in the counterweights of
both lift trucks. See Figure 28. Slowly and carefully remove
the slack out of the towing link.
1. TOWING LINK 2. TOW PIN
Figure 28. Counterweight Types
125
Maintenance
How to Put a Lift Truck on Blocks How to Raise the Drive Tires
(See Figure 29)
WARNING 1. Put blocks on each side (front and back) of the steering
The lift truck must be put on blocks for some types of tires to prevent movement of the lift truck.
maintenance and repair. The removal of the following
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, 3. Tilt the mast fully forward until the drive tires are raised
put additional blocks in the following positions to from the surface.
maintain stability:
4. Put additional blocks under the frame behind the drive
1. Before removing the mast and drive axle, put tires.
blocks under the counterweight so that the lift
truck cannot fall backward. 5. If the hydraulic system will not operate, use a hydraulic
jack under the side of the frame near the front. Make sure
2. Before removing the counterweight, put blocks that the jack has a capacity equal to at least half the weight
under the mast assembly so that the lift truck can- of the lift truck. See the Nameplate.
not fall forward.
The surface must be solid, even, and level when the lift
How to Raise the Steering Tires
(See Figure 29)
truck is put on blocks. Make sure that any blocks used
to support the lift truck are solid, one piece units. 1. Apply the parking brake. Put blocks on both sides (front
and back) of the drive tires to prevent movement of the lift
NOTE: Some lift trucks have lifting eyes. These lifting eyes
truck.
can be used to raise the lift truck so that blocks can be
installed.
126
Maintenance
2. Use a hydraulic jack to raise the steering tires. Make NOT directly spray any electrical components, espe-
sure that the jack has a capacity of at least 2/3 of the total cially connectors, switches, electro-hydraulic controls,
weight of the lift truck as shown on the Nameplate. battery area, and dash display during the cleaning
process.
3. Put the jack under the steering axle or frame to raise the
lift truck. Put blocks under the frame to support the lift truck. Portions of your lift truck may be washed with a non-heated
pressure washer. Steam cleaning is not recommended in
How to Clean a Lift Truck most instances, as condensation may form in electrical
components causing damage or erratic behavior. For
CAUTION cleaning guidelines and components to avoid, see the Peri-
Your lift truck may be damaged if water or cleaning odic Maintenance section of the Service Manual for your
agents come in contact with electrical components. DO lift truck.
127
Maintenance Schedule
1. DRIVE TIRES 2. STEERING TIRES
Figure 29. Put a Lift Truck on Blocks
128
Figure 30. Maintenance and Lubrication Points, 4.3L LPG Trucks (Dana Wet Brake Drive Axle Shown)
129
Figure 31. Maintenance and Lubrication Points, 4.3L LPG Trucks (NMHG Wet Brake Drive Axle Shown)
130
Figure 32. Maintenance and Lubrication Points, 4.3L Gas Trucks (NMHG Wet Brake Drive Axle Shown)
131
Figure 33. Maintenance and Lubrication Points, Kubota 3.8L Diesel Trucks (NMHG Wet Brake Drive Axle Shown)
132
Figure 34. Maintenance and Lubrication Points, Kubota 3.6L Diesel Trucks (NMHG Wet Brake Drive Axle Shown)
133
Figure 35. Maintenance and Lubrication Points, Kubota 3.8L LPG Trucks (NMHG Wet Brake Drive Axle shown)
134
Figure 36. Maintenance and Lubrication Points, Kubota 3.8L 55kW Diesel Trucks (NMHG Wet Brake Drive Axle
shown)
135
Figure 37. Maintenance and Lubrication Points, Kubota 3.8L Bi-Fuel Trucks (NMHG Wet Brake Drive Axle shown)
136
(See Figure 30, Figure 31, Figure 32, Figure 33, Fig-
ure 34, Figure 35, Figure 36, and Figure 37)
Item 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item Specification
No. 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr Quantity
25 TIRES AND WHEELS X Check See Nameplate.
Condition.
SAFETY LABELS X Replace as See Parts Manual.
Necessary.
27, MAST, CARRIAGE, X Check See Parts Manual.
28, 29 HEADER HOSES, Condition
LIFT CHAINS, AND and
ATTACHMENT Lubrication.
SEAT BELT, HIP X Check
RESTRAINTS, AND Condition
SEAT RAILS and Operation.
HOOD AND SEAT X Check
LATCHES Condition
and Operation.
X = Check C = Change L = Lubricate CIL = Check Indicator Light during operation
137
Item Specification
ENGINE X Remove
COMPARTMENT Combustible
Materials.
See NOTE 5.
PAPER APPLICATION X Check
Engine Compartment; Condition.
Truck Components; Clean as
Exhaust Wraps; Required.
Radiator; Replace as
Radiator Screen, if Required.
equipped; Belly Pan, if See NOTE 8.
equipped
CHECK FOR LEAKS - X Check for
FUEL, OIL, WATER Leaks.
See NOTE 1.
HYDRAULIC HOSES X Check See Parts Manual.
Condition.
13 COOLANT HOSES X Check See Parts Manual.
Condition.
16 FUEL TANK CIL 15.1 to 20.4 kg LPG - HD 5, HD 10
LPG (33.5 to
45.0 lb)
Full
138
Item Specification
16 FUEL TANK (Short Wheel CIL 79 liter 86 Octane Minimum
Base) 4.3L (20.8 gal)
Gasoline
16 FUEL TANK (Long Wheel CIL 100.3 liter 86 Octane Minimum
Base) 4.3L (26.5 gal)
Gasoline
16 FUEL TANK (Short Wheel CIL 79 liter See Table 7
Base) (20.8 gal)
Kubota 3.6L Diesel
Engine
16 FUEL TANK (Long Wheel CIL 100.3 liter See Table 7
Base) (26.5 gal)
Kubota 3.6L Diesel
Engine
16 FUEL TANK (Short Wheel CIL 79 liter See Table 7
Base) (20.8 gal)
See NOTE 19.
Kubota 3.8L Diesel
Engines
16 FUEL TANK (Long Wheel CIL 100.3 liter See Table 7
Base) (26.5 gal)
See NOTE 19.
Kubota 3.8L Diesel
Engines
139
Item Specification
16 FUEL TANK (Gasoline) CIL 79 liter 86 Octane Minimum
(Short Wheel Base) (20.8 gal)
Kubota 3.8L Bi-Fuel
Engines
16 FUEL TANK (Gasoline) CIL 100.3 liter 86 Octane Minimum
(Long Wheel Base) (26.5 gal)
Kubota 3.8L Bi-Fuel
Engines
HORN, LIGHTS, X Check
ALARMS, FUSES, Operation.
AND RELAYS
1 SERVICE BRAKES X Check
Operation.
23 PARKING BRAKE X Check
Operation.
STEERING CONTROLS X Check
AND STEERING Operation
COLUMN GAS and Condition.
CYLINDER
22 TRANSMISSION X Check for John Deere
Leaks. JDM J20C
Check Opera- See NOTE 18.
tion.
140
Item Specification
22 TRANSMISSION X Perform Auto- See Calibration Proce-
matic Clutch dures 8000 SRM 1134.
Calibration.
3 HYDRAULIC OIL SHORT X X C 62.0 liter ISO VG 46 Hydraulic Oil
WHEEL BASE (65.5 qt) −15 °C (5 °F) and Above
See NOTE 2, See NOTE 18.
NOTE 3, and
NOTE 17.
3 HYDRAULIC OIL LONG X X C 78 liter ISO VG 46 Hydraulic Oil
WHEEL BASE (82.4 qt) −15 °C (5 °F) and Above
See NOTE 2, See NOTE 18.
NOTE 3, and
NOTE 17.
6 HYDRAULIC OIL FILTER C 1 Filter See Parts Manual.
See NOTE 17.
10 HYDRAULIC TANK X C Inspect and See Parts Manual.
BREATHER Replace as
Required.
See NOTE 5.
8 BATTERY AND CABLE X Clean.
TERMINALS
141
Item Specification
9 ENGINE OIL X C 4.7 liter (5.0 qt) –7 °C (20 °F) and Below
4.3L Engine CIL See NOTE 4 SAE 5W-20
and NOTE 5. 16 °C (60 °F) and Below
SAE 5W-30
–18 °C (0 °F) and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
19 ENGINE OIL FILTER C 1 Filter See Parts Manual.
4.3L Engine See NOTE 4
and NOTE 5.
9 ENGINE Oil X C 13.2 liter See Table 7
Kubota 3.8L Diesel CIL (13.9 qt)
Engine See NOTE 4
and NOTE 5.
Kubota 3.8L Diesel See NOTE 4
Engine and NOTE 5.
9 ENGINE Oil X C 13.2 liter See Table 7
Kubota 3.6L Diesel CIL (13.9 qt)
Engine See NOTE 4
and NOTE 5.
142
Item Specification
Kubota 3.6L Diesel See NOTE 4
Engine and NOTE 5.
9 ENGINE Oil X C 12.2 liter SAE 10W-30
Kubota 3.8L LPG/Bi- CIL (12.9 qt) API SL
Fuel Engine See NOTE 4 ILSAC GF3
and NOTE 5. MINIMUM
Kubota 3.8L LPG/Bi- See NOTE 4
Fuel Engine and NOTE 5.
18 AIR FILTER CIL C 1 Filter See Parts Manual.
(WITH PREMIUM MONI- See NOTE 5,
TORING) NOTE 6, and
NOTE 12.
18 AIR FILTER X C 1 Filter See Parts Manual.
See NOTE 5,
NOTE 6, and
NOTE 12.
ENGINE OIL PRESSURE CIL Check 4.3L Engine - 207 to
Oil Pressure. 380 kPa (30 to 55 psi)
Kubota Diesel Engine
50 kPa (7 psi) Minimum
Kubota LPG Engine
50 km/h (7 psi) Minimum
143
Item Specification
15 DRIVE BELT X Check for
4.3L Engine Wear and
Damage.
No Adjustment
Needed.
See NOTE 5.
Kubota Diesel Engine Wear and
Damage.
Adjust as
Needed.
See NOTE 5.
Kubota LPG/Bi-Fuel Wear and
Engine Damage.
Adjust as Nee-
ded.
See NOTE 5.
33 LPG CONVERTER X Drain Tar.
Kubota 3.8L SI LPG See NOTE 5.
Engine
INTAKE VALVES X Clean Carbon Use Sea Foam Spray
Kubota 3.8L, PSI and Buildup
(Hyster P/N 4032507)
GM 4.3L LPG Engines
144
Item Specification
ENGINE IDLE SPEED X See NOTE 5. 750 ±25 RPM
4.3L Engine
(Gas/LPG)
ENGINE GOVERNED X See NOTE 5. 2400 ±25 RPM
SPEED
4.3L (Gas/LPG)
ENGINE IDLE SPEED X Coolant 800 ±25 RPM
Hot Engine Temperature
Kubota 3.8L Diesel Greater Than
15 °C (59 °F)
ENGINE GOVERNED X 2200 ±25 RPM
SPEED (No Load)
Kubota 3.8L Diesel
ENGINE IDLE SPEED X Coolant 850 ±50 RPM
Hot Engine Temperature
Kubota 3.6L Diesel Greater Than
15 °C (59 °F)
SPEED (No Load)
Kubota 3.6L Diesel
145
Item Specification
ENGINE IDLE SPEED X 800 ±50 RPM
Hot Engine
Kubota 3.8L LPG/Bi-
Fuel
SPEED (No Load)
Kubota 3.8L LPG/Bi-
Fuel
39 CRANKCASE C See NOTE 14.
BREATHER ELEMENT
Kubota 3.8L Diesel/Bi-
Fuel
4 VALVE ADJUSTMENT Not Adjustable.
4.3L Engine
4 VALVE ADJUSTMENT X Adjust as Intake (Cold)
Kubota Diesel Engine Required.
0.23 to 0.27 mm
(0.009 to 0.011 in.)
Exhaust (Cold)
0.23 to 0.27 mm
(0.009 to 0.011 in.)
146
Item Specification
4 VALVE ADJUSTMENT X Adjust as Intake (Cold)
Kubota LPG and Bi- Required.
0.18 to 0.22 mm
Fuel Engines
(0.0071 to 0.0086 in.)
Exhaust (Cold)
0.18 to 0.22 mm
(0.0071 to 0.0086 in.)
17 FUEL FILTER C 1 Filter See Parts Manual.
LPG (4.3L)
LPG/Bi-Fuel (Kubota)
Gasoline (4.3L)
Gasoline (Kubota Bi-
Fuel)
17 FUEL WATER CIL C 1 Filter See Parts Manual.
SEPARATOR FILTER Drain Water
Kubota 3.8L Diesel from Filter as
Engine Required.
147
Item Specification
17 FUEL WATER X C 1 Filter See Parts Manual.
SEPARATOR FILTER Drain Water
Kubota 3.6L Diesel from Filter as
Engine Required.
36 IN-LINE FUEL STRAINER C 1 Filter See Parts Manual.
Kubota Diesel Engine
20 FUEL INJECTORS X Check and
Kubota Diesel Engine Replace if
Required.
4 Injectors
20 FUEL INJECTORS X Check and
Kubota Bi-Fuel Engine Replace if
Required.
4 Injectors
5 SPARK PLUGS C Check Plug See NOTE 9.
4.3L Engines Wires.
6 Plugs
5 SPARK PLUGS, STAND- C 4 Plugs See Parts Manual.
ARD
Kubota 3.8L LPG /Bi-
Fuel Engines
148
Item Specification
5 SPARK PLUGS, LONG- C 4 Plugs See Parts Manual.
LIFE
Kubota 3.8L LPG /Bi-
Fuel Engines
12,14 COOLING SYSTEM X C 15.1 liter See NOTE 13.
4.3L Engine CIL (15.9 qt)
12,14 COOLING SYSTEM X C 11.0 liter See NOTE 13.
Kubota Diesel Engine CIL (11.6 qt)
12,14 COOLING SYSTEM X C 11.0 liter
Kubota LPG/Bi-Fuel CIL (11.6 qt)
Engine
CLEAN DEBRIS FROM X See NOTE 5.
RADIATOR CORE
7 TRANSMISSION OIL X C 20 liter (21 qt) John Deere
JDM J20C
See NOTE 18.
21 TRANSMISSION OIL C 1 Filter See Parts Manual.
FILTER AND 1 Breather
BREATHER See NOTE 4.
26 FORKS X X X Check
Condition.
149
Item Specification
26 FORK LATCHES L Lubricate as Multipurpose Grease
Necessary. See NOTE 7.
LIFT SYSTEM, OPERATE X Check
Operation.
27 MAST L Lubricate as Multipurpose Grease
Sliding Surfaces and Required. See NOTE 7.
Load Roller Surfaces See NOTE 10
and NOTE 11.
27 HEADER HOSES X Check
Condition.
28 LIFT CHAINS X Check Engine Oil
Condition. SAE 30W
Lubricate as
Required.
See NOTE 11.
28 LIFT CHAINS L L,X Check for Engine Oil
Wear. SAE 30W
Lube as
Required.
MAST L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
150
Item Specification
MAST X L X Lube as Multipurpose Grease
Integral Sideshift Required. See NOTE 7.
Carriage Sliding 8 Fittings 2.0 mm (0.08 in.) minimum
Surfaces 4 Bearing thickness.
Strips. Check
Bearing Strips
for Wear.
MAST L Lubricate as Multipurpose Grease.
Integral Sideshift Required. See NOTE 7.
Carriage See NOTE 5.
Fork Positioner
TILT CYLINDER ENDS L 4 Fittings Multipurpose Grease
See NOTE 7.
BRAKE MASTER L SAE 10W-30
CYLINDER ROD API SM
END PIN ILSAC GF4
SAE J2362
MANUAL HYDRAULIC L SAE 10W-30
HAND LEVERS API SM
ILSAC GF4
SAE J2362
24 BRAKE OIL CIL X C 0.35 liter Dexron III from Sealed
Master Cylinder (0.74 pt) Container
151
Item Specification
11 STEERING AXLE L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 7.
11 STEERING AXLE L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 7.
34 WHEEL BEARINGS L Check Grease. Use Multipurpose Grease.
Steer Wheel See NOTE 7.
2 PEDALS, LEVERS, SEAT L Lubricate as Use Silicone Spray
RAILS, CABLES, Necessary. Hyster Part No. 328388.
HINGES, LINKAGES,
HOOD LATCH
23 PARKING BRAKE X X Adjust as nec- Must Hold a Full Capacity
ADJUSTMENT essary. Load on 15% Grade.
23 PARKING BRAKE L Lubricate as Use Silicone Spray
Necessary. Hyster Part No. 328388.
30 TRANSMISSION AND X C 31.3 liter John Deere
PLANETARY CARRIER (32.9 qt) JDM J20C
HOUSING OIL See NOTE 18.
Dana Drive Axle
38 CENTER SECTION OIL X C 2.0 liter SAE 80W-90
Dana Drive Axle (2.1 qt)
152
Item Specification
7 TRANSMISSION OIL X C 20.0 liter John Deere
NMHG Drive Axle (21.0 qt) JDM J20C
See NOTE 18.
30 WET BRAKE DRIVE X C 10.3 liter John Deere
AXLE OIL (10.9 qt) JDM J20C
NMHG Drive Axle See NOTE 16.
37 PARKING BRAKE LEV- X Check and Normal operating environ-
ERS Lubricate as ment:
(DANA WET BRAKE) Necessary Spray Lubricant
Hyster P/N 4066494
Heavy-duty or contamina-
ted environment:
Multipurpose Grease
See NOTE 7
INSPECT ENGINE X
ELECTRICAL SYSTEM,
CONNECTORS
INSPECT ENGINE X
VACUUM AND
FUEL LINES
AND FITTINGS
153
Item Specification
INSPECT LOCK-OFF X
FOR LEAKS AND
ENSURE LOCK-OFF
CLOSING
CHECK AIR INDUCTION X
SYSTEM FOR LEAKS
CHECK MANIFOLD FOR X
VACUUM LEAKS
CHECK THROTTLE X
SHAFT FOR STICKING
CHECK INJECTORS X
AND RAIL FOR LEAKS
32 INSPECT EXHAUST X
MANIFOLD AND
PIPING FOR LEAKS
INSPECT CATALYST X
INLET AND OUTLET
31 IGNITION SYSTEM: C Replace.
DISTRIBUTOR CAP,
ROTOR,
AND SPARK
PLUG WIRES
154
Item Specification
INSPECT MUFFLER X Replace as
INLET AND OUTLET Required.
MAST AND CARRIAGE X Inspect. Dye Penetrant Test:
WITH PAPER ROLL See Specifica- Inspect after an impact
CLAMP tion. likely to cause damage.
Also, in large diameter
paper-roll production appli-
cations, inspect at first
4000 hours with subse-
quent inspection at 2000-
hour intervals. At your
request your Hyster dealer
will advise you of the
appropriate service inter-
vals based on an applica-
tion survey.
35 DIESEL PARTICULATE X Service See NOTE 15.
FILTER (DPF)
155
Item Specification
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 the first 100 hours of operation. Change transmission oil filter after the first 500 hours of operation.
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 serv-
ice intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Vehicles used in paper application require regular inspection and cleaning to minimize risk of fire. This should be done at least once every 8
hours or more frequently depending upon operating environment. Use compressed air and steam clean as necessary.
NOTE 9: See Capacities and Specifications 8000 SRM 1903.
NOTE 10: Lubricate mast every 3 months if unit has less than 1000 hours.
NOTE 11: Lubricate if dry or at first sign of visible surface rust.
NOTE 12: 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.
156
Item Specification
NOTE 13: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water.
NOTE 14: Change every 1500 hours. Use hour interval only.
NOTE 15: Service Diesel Particulate Filter (DPF) every 3000 hours. See Hyster dealer. User hourly interval only.
NOTE 16: Quantity shown for factory or rebuild. Service will be 9.3 liter (9.8 qt).
NOTE 17: 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 18: If lift truck is used in Paper application use ONLY JDM J20C type fluid for both the transmission and hydraulic system.
NOTE 19: See Capacities and Specifications for diesel fuel cleanliness requirements before filling lift truck tank with diesel fuel.
157
Table 7. Diesel Fuel and Lube Chart
Engine Oil Specification by Diesel Fuel Type

Diesel Fuel Type
WWFC Diesel WWFC Diesel WWFC Diesel
Category 1 Category 2 Category 4
500ppm<Sulfur 15ppm<Sulfur ASTM D975 No. 2 D S15 Sul- Engine Oil Viscosity based on ambient
Engine <5000ppm <500ppm fur<15ppm temperature
3.6L T3 API CF API CF or better API CF or better −15 °C (5 °F) and above 15W-40
3.8L w/ DPF NA NA API CJ-4 −25 °C (−13 °F) and above 10W30
Below −25 °C (−13 °F) 5W-30
158
Maintenance
Maintenance Procedures Every 8 Hours or Daily

How to Make Checks With the Engine Safety Labels
Stopped
WARNING
WARNING Safety labels are installed on the lift truck to provide
Do not operate a lift truck that needs repairs. Report information about operation and possible hazards. It is
the need for repairs immediately. If repair is necessary, important that all safety labels are installed on the lift
put a DO NOT OPERATE tag in the operator's area. If truck and can be read.
lift truck is equipped with a key switch, remove the key. Check that all safety labels are installed in the correct loca-
Put the lift truck on a level surface. Lower the carriage and tion on the lift truck. See the Parts Manual, the Model
forks, stop the engine, and apply the parking brake. Open Description section in this Operating Manual, or the
the hood and check for leaks and conditions that are not Frame section of the Service Manual 100 SRM 1891 for
normal. Clean any oil or fuel spills. Ensure all surfaces are the correct location of the safety labels. See the Parts
free of oils, lubricants, fuel and organic dust or fibers Manual for the part numbers of the safety labels.
(paper, wood, cotton, agricultural grass/grain, etc.).
Tires and Wheels
Check the tires for damage (see Figure 38). Check the
tread and remove any objects that will cause damage.
Check for bent or damaged rims. Check for loose or miss-
ing hardware. Remove any wire, strapping, or other mate-
rial that is wrapped around the axle.
159
Maintenance
parts of the mast are completely lowered and the
engine is STOPPED.
DO NOT operate fork lift without lateral fork stops in
place. Forks may disengage from fork carriage.
1. Inspect the welds on the mast, cylinders, and carriage
for cracks. Make sure that the capscrews and nuts are
tight.
2. Inspect the carriage to be sure fork stops are in place.
Fork stops prevent forks from laterally disengaging from the
carriage.
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER
OBJECTS FROM THE TREAD) 3. Inspect the channels for wear in the areas where the roll-
2. MAKE SMOOTH EDGES
3. CHECK THE TIRE PRESSURE ers travel. Inspect the rollers for wear or damage.
Figure 38. Check the Tires 4. Inspect the load backrest extension for cracks and dam-
age.
Mast, Carriage, Header Hoses, Lift Chains,
5. If the lift truck is equipped with a sideshift carriage or
and Attachment attachment, inspect the parts for cracks and wear. Make
sure the parts that fasten the sideshift carriage or attach-
WARNING ment to the carriage are in good condition.
Lower the lift mechanism completely. Never allow any
person under a raised carriage. Do not put any part of 6. Visually inspect hoses/fittings for hydraulic leaks; hose
your body in or through the lift mechanism unless all cover for cuts, cracks, or exposed reinforcement; defective/
broken clamping devices or sheaves; and proper tracking
160
Maintenance
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 39.
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
chains must be done by authorized personnel.
1. WORN PIN 5. LOOSE LEAVES
Operator Restraint System 2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. CORROSION
The seat belt, hip restraint, seat, hood, and hood latches 4. HOLE WEAR
are all part of the operator restraint system (see Figure 40).
Each item must be checked to make sure it is fastened cor- Figure 39. Lift Chain Check
rectly, functions correctly, and is in good condition.
161
Maintenance
NON-SWIVEL SEAT SHOWN.
1. LATCH STRIKER
2. HOOD LATCH
3. FORWARD/BACKWARD
ADJUSTMENT
4. HOOD
5. OPERATOR WEIGHT
ADJUSTMENT
6. SEAT RAIL
7. ARMREST
8. SEAT BELT
9. SEAT
10. HIP RESTRAINT
11. HOOD HINGE
Figure 40. Hood and Seat Check
162
Maintenance
Emergency Locking Retractor (ELR) 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 hood closed and in the locked position, pull the
ing without activating the locking mechanism. If the truck seat belt with a sudden jerk. Make sure the seat belt will
tips over, travels off a dock, or comes to a sudden stop, the not pull from the retractor assembly. If the seat belt can
locking mechanism will be activated and hold the operator's be pulled from the retractor when it is pulled with a sud-
lower torso in the seat. See Figure 40. den jerk, replace the seat belt assembly.
A seat belt that is damaged, worn, or does not operate • With the hood 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 hood in the
belt must be in good condition. Replace the seat belt if it is open position, replace the seat belt assembly.
damaged or worn.
Hood 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 40). The seat rails must be correctly
• With the hood closed and in the locked position, pull the fastened to the hood and the hood fastened to the hinges
seat belt slowly from the retractor assembly. Make sure on the frame. Try to lift the hood to make sure it is fastened
the seat belt pulls out and retracts smoothly. If the seat correctly and will not move.
belt does not pull out of the retractor assembly the inter-
nal latch may be locked. Pull firmly on the seat belt and Adjust hood, hood latch, and latch striker when any of the
hold for a moment to remove slack from the belt in the parts of the operator restraint system are installed or
retractor. Release the seat belt. Seat belt will retract and replaced. See the Periodic Maintenance or Frame sec-
the internal latch will unlock. If the seat belt cannot be tions of the Service Manual.
163
Maintenance
Engine Compartment actually increase the engine temperature because of no

heat transfer through the radiator.
Check for the presence of any combustible material such
as paper, leaves etc. Remove any combustible materials. With engine OFF and lift truck components cooled, check
and clean the radiator and if equipped, radiator screen.
Paper Application Check engine manifold, exhaust pipes, muffler, and cata-
lytic converter for paper scraps. Clean as required. Check
Vehicles used in paper applications require regular inspec- and clean the engine compartment components, transmis-
tion and cleaning to minimize the risk of fire. This should be sion, fan shroud, belly pan, if equipped, and inside frame
done at least once every 8 hours or more frequently ledges to avoid paper, dust, and oil accumulation. Check
depending upon operating environment. The paper applica- axle and cowl openings for paper buildup and bailing wire.
tion will help limit the contact of paper or tissue scraps to Remove any debris.
hot surfaces under the hood, but frequent maintenance is
required. WARNING
Compressed air can move particles so that they cause
WARNING injury to the user or to other personnel. Make sure that
Engine and exhaust system components are hot to the the path of the compressed air is away from all person-
touch. Be sure lift truck components are cool before nel. Wear protective goggles or a face shield to prevent
starting inspection and cleaning, or personal injury injury to the eyes.
may occur.
Ensure the truck engine cools properly by allowing it to idle CAUTION
for several minutes. Shutting the truck down while hot will Air pressure, nozzle, or extension tube may cause
not allow the engine to cool quickly due to the loss of cool- damage to exhaust wraps and radiator fins. Assure that
ant circulation. The heat trapped under the hood may air pressure, nozzle, or extension tube does not dam-
age exhaust wraps or radiator fins.
164
Maintenance
Paper removal can generally be accomplished using a wraps if they have been removed for some other service
compressed air line and nozzle. An extension may be help- operation.
ful to access hard to reach places. Remove floor plates and
side covers for better access to engine compartment. Open Fuel, Oil, and Coolant Leaks, Check
or remove belly pan, if equipped. Clean components with
compressed air. Take care to maintain the integrity of the WARNING
exhaust wraps when cleaning with compressed air and use All fuels are very flammable and can burn or cause an
caution to not force debris into openings. explosion. Do not use an open flame to check the fuel
level or to check for leaks in the fuel system. If there is
WARNING a leak in the fuel system, extra care must be used dur-
Be careful when cleaning with steam. Steam can cause ing the repair. Do not operate the lift truck until a leak
serious burns. Wear protective clothing, gloves, and is repaired.
eye protection. Never expose your skin to steam. Make a visual check for leaks on and under the lift truck. If
If compressed air did not adequately remove debris, steam possible, find and report the leak to maintenance for repair.
clean to remove any persistent accumulation of material or Leaks often indicate a need for repair of damaged or worn
oil. Protect electrical components from moisture when components. Leaks in the LPG fuel system are usually not
steam cleaning. Do not spray exhaust wraps directly with visible unless ice is present. There is however, usually a
high pressure steam. Allow lift truck to air dry before return- strong odor. Fuel leaks MUST be repaired IMMEDIATELY.
ing to work in a contaminated environment. Paper dust and Check the fuel system for leaks and the condition of parts.
scraps will adhere to wet surfaces. When fuel is added to the lift truck, see the section, How to
Check the condition of exhaust wraps for wear, proper fit, Add Fuel to the Lift Truck.
contamination with oil or antifreeze, gaps in coverage, and
failed fasteners. Replace as necessary. Do not reuse
165
Maintenance
Also check the condition of the radiator or heater hoses
that are not leaking. Soft or cracked hoses need to be
replaced before a major leak occurs.
Hydraulic Hoses
Check the condition of the hydraulic hoses for serviceability
by inspecting for cracks or other obvious damage. Check to
insure that the hydraulic hoses are not leaking. If any hose
is leaking, report it to maintenance for repair.
Coolant Hoses
Check the condition of the coolant hoses for serviceability
by inspecting for cracks or other obvious damage. Check to
insure that the coolant hoses are not leaking. If any hose is
leaking, report it to maintenance for repair.
Steering Column Gas Cylinder
Make sure the gas cylinder for the steering column oper-
ates correctly. The cylinder must NOT allow the column to 1. TILT LEVER 2. GAS CYLINDER
move unless the tilt lever is released. See Figure 41.
Figure 41. Steering Column Gas Cylinder and Tilt Lever
166
Maintenance
Transmission Never operate the hydraulic pump without oil in the

hydraulic system. The operation of the hydraulic pump
Check the transmission for leaks and damage or loose without oil will damage the pump.
components. Heavy-duty or high-temperature operations
can require more frequent checks. After the engine has stopped, wait one minute before
checking the oil level. Keep oil at the correct level as indi-
Hydraulic System Oil cated on the dipstick (see Figure 42). Use the correct oil as
shown in the Maintenance Schedule.
WARNING Check the hydraulic system for leaks and damaged or
At operating temperature the hydraulic oil is HOT. Do loose components. Heavy-duty or high-temperature opera-
not permit the hot oil to touch the skin and cause a tions can require more frequent checks.
burn.
CAUTION
Do not permit dirt to enter the hydraulic system when
the oil level is checked or the filter is changed.
167
Maintenance
1. HYDRAULIC OIL DIPSTICK
2. TRANSMISSION OIL DIPSTICK
Figure 42. Transmission and Hydraulic Oil Checks
168
Maintenance
Engine Oil There is an indicator light for the engine oil pressure on the
Display Switch Cluster. During normal operation, the red
WARNING indicator light will illuminate when the key switch is turned
At operating temperature, the engine oil is HOT. Do not to ON, if the truck is equipped with a key switch, or when
permit the hot oil to touch the skin and cause a burn. the power ON/OFF button is pressed. If the truck is equip-
ped with a keyless option, and will stay illuminated until cor-
CAUTION rect oil pressure is obtained, at which time the light will go
Do not permit dirt to enter the engine when the oil level off.
is checked or the filter is changed. If the light continues to stay on when engine is running, the
Never operate the engine without oil. The operation of engine oil pressure is low. Stop the engine and check the
the engine without oil will damage the engine. oil level. See Figure 43, Figure 44, Figure 45, Figure 46,
Figure 47, Figure 48, Figure 49, and Figure 50. Do not
After the engine has stopped, wait one minute before restart the engine until the low pressure condition has been
checking the oil level. See Figure 43, Figure 44, Fig- corrected.
ure 45, Figure 46, Figure 47, Figure 48, Figure 49, and
Figure 50. Keep the oil at the correct level as indicated on
the dipstick. Use the correct oil as shown in the Mainte-
nance Schedule.
169
Maintenance
1. DIPSTICK ENGINE OIL
2. BATTERY
3. AUXILIARY COOLANT RESERVOIR
4. RADIATOR CAP
5. ENGINE OIL FILL
6. DRIVE BELT
7. AIR FILTER
8. ENGINE OIL FILTER
9. SPARK PLUGS
10. ENGINE LABEL
11. LPG CONVERTER
Figure 43. Engine Maintenance Points GM 4.3L LPG Engines
170
Maintenance
1. LPG CONVERTER
3. SPARK PLUGS
4. BATTERY
6. RADIATOR CAP
7. DRIVE BELT
8. AIR FILTER
9. ENGINE MANUFACTURER ID
10. DIPSTICK ENGINE OIL
11. ENGINE OIL FILL
Figure 44. Engine Maintenance Points PSI 4.3L LPG Engines
171
Maintenance
1. AIR FILTER
2. DIPSTICK
3. ENGINE LABEL
4. ENGINE OIL FILL
6. SPARK PLUG
7. BATTERY
8. AUXILIARY COOLANT
RESERVOIR
9. RADIATOR CAP
10. DRIVE BELT
11. FUEL FILTER
Figure 45. Engine Maintenance Points GM 4.3L Gas Engines
172
Maintenance
Figure 46. Maintenance Points Kubota 3.8L Diesel Engine
173
Maintenance
A. TOP VIEW B. LEFT SIDE VIEW
1. BATTERY 7. FUEL INJECTION PUMP
2. AUXILIARY COOLANT RESERVOIR 8. ENGINE OIL CAP
3. RADIATOR CAP 9. IN-LINE FUEL STRAINER
4. CRANKCASE BREATHER 10. ENGINE OIL DIPSTICK
5. AIR FILTER 11. FUEL INJECTOR
6. WATER SEPARATOR 12. DRIVE BELT
174
Maintenance
Figure 47. Maintenance Points Kubota 3.6L Diesel Engine
175
Maintenance
1. BATTERY 7. ENGINE OIL CAP
2. AUXILIARY COOLANT RESERVOIR 8. IN-LINE FUEL STRAINER
3. RADIATOR CAP 9. ENGINE OIL DIPSTICK
4. WATER SEPARATOR 10. FUEL INJECTOR
5. AIR FILTER 11. DRIVE BELT
6. FUEL INJECTION PUMP
176
Maintenance
1. BATTERY
3. DIPSTICK
4. RADIATOR CAP
5. DRIVE BELT
6. ENGINE OIL FILL
7. LPG CONVERTER
8. AIR FILTER
10. SPARK PLUGS
Figure 48. Maintenance Points Kubota 3.8L LPG Engine
177
Maintenance
Figure 49. Maintenance Points Kubota 3.8L 55kW Diesel Engine
178
Maintenance
1. BATTERY 7. FUEL INJECTION PUMP
2. AUXILIARY COOLANT RESERVOIR 8. ENGINE OIL CAP
3. RADIATOR CAP 9. IN-LINE FUEL STRAINER
4. CRANKCASE BREATHER 10. ENGINE OIL DIPSTICK
5. AIR FILTER 11. FUEL INJECTOR
6. WATER SEPARATOR 12. DRIVE BELT
179
Maintenance
Figure 50. Maintenance Points Kubota 3.8L Bi-Fuel Engine
180
Maintenance
1. BATTERY 7. LPG CONVERTER
2. AUXILIARY COOLANT RESERVOIR 8. AIR FILTER
3. ENGINE OIL DIPSTICK 9. FUEL FILTER, GASOLINE
4. RADIATOR CAP 10. SPARK PLUGS
5. DRIVE BELT 11. FUEL INJECTOR
6. ENGINE OIL CAP
Air Filter Forks

The air filter canister should not be opened until an air filter NOTE: The information in this section covers removing and
element replacement is required. An air filter element installing forks on lift trucks equipped with a standard car-
replacement is required when one of the following occurs: riage or integral sideshift carriage. If lift truck is equipped
with an optional fork positioner attachment, go to Fork
• the optional air flow restriction indicator light on the dash
Positioner section for procedures to remove and install the
illuminates.
forks.
• the optional manual air flow indicator button pops up.
NOTE: Forks must be removed or installed by trained per-
• the specified number of hours has passed since the last sonnel only.
filter element replacement.
The identification of a fork describes how the fork is con-
Do not operate the lift truck until the air filter element has nected to the carriage. These lift trucks have hook forks.
been replaced.
181
Maintenance
Forks, Remove
WARNING
Do not try to move a fork without a lifting device. Each
hook fork for these lift trucks can weigh 45 to 115 kg
(99 to 253 lb).
NOTE: Forks are to be replaced only in sets and not indi-
vidually.
A fork can be removed from the carriage for replacement of
the fork or other maintenance. Slide a hook fork to the fork
removal notch on the carriage. See Figure 51 and Fig-
ure 52. Lower the fork onto blocks so that the bottom hook
of the fork moves through the fork removal notch. See Fig-
ure 52. Lower the carriage further so that the top hook of
the fork is disengaged from the top carriage bar. Move the
carriage away from the fork, or use a lifting device to move
the fork away from the carriage. 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
Figure 51. Remove a Hook Fork
182
Maintenance
Fork Tip Alignment

Length of Forks 3% Dimension
1067 mm (42 in) 32 mm (1.26 in)
1207 mm (47.5 in) 36 mm (1.42 in)
1219 mm (48 in) 39 mm (1.54 in)
1372 mm (54 in) 41 mm (1.61 in)
1524 mm (60 in) 46 mm (1.81 in)
1829 mm (72 in) 55 mm (2.17 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 52. Forks Check
183
Maintenance
Forks, Inspect c. If fork enters opening, it is mandatory to replace it.

DANGER OF BREAKING. Furthermore, a 10% reduc-
1. Inspect the forks for cracks and wear. Check that the tion in fork blade thickness results in 20% reduction in
fork tips are aligned as shown in Figure 52. Check that the operating capacity.
bottom of the fork is not worn (Item 4 in Figure 52).
2. Replace any damaged or broken parts that are used to
keep the forks locked in position. See Figure 54.
3. Inspect fork wear. Ensure heel wear is not more than
10% of original thickness. If fork wear is more than 10%,
fork must be replaced or rerated. Perform fork wear inspec-
tion using a BOL256N1 caliper ruler Hyster P/N 4092984
as follows. See Figure 53.
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.
b. Position caliper at end of heel internal radius (item 4,
Figure 52) with opening corresponding to measured
thickness of fork shank in Step a above. (e.g. for N 1.75
use N 1.75 opening). This is typically the section of fork
where wear is greatest. Note that opening distance has
been reduced by 10% from nominal thickness.
184
Maintenance
Forks, Install
Move the fork and carriage so that the top hook on the fork
can engage the upper carriage bar. Raise the carriage to
move the lower hook through the fork removal notch. Slide
the fork on the carriage so that both upper and lower hooks
engage the carriage. Engage the lock pin with a notch in
the upper carriage bar. See Figure 54.
1. FORK 5. WEDGE
2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN ASSEMBLY
Figure 53. Fork Wear Check 4. WASHER
Figure 54. Fork Lock Pin Assembly
185
Maintenance
Forks, Adjust
NOTE: During the adjustment of the forks, the heel of the
forks should not be touching the ground.
The forks are connected to the carriage by hooks and lock
pins. See Figure 51 and Figure 54. The lock pins are
installed through the top fork hooks and fit into slots in the
top carriage bar. If pin does not remain engaged in carriage
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.
1. CAPSCREWS 7. CYLINDER ROD
Integral Sideshift Carriage 2. LOWER HOOK 8. SNAP RING
3. APRON 9. ROD SCRAPER
Check for cracks, wear, and damage. If damaged, see the 4. LOWER BEARING STRIPS 10. ROD BUSHINGS
5. UPPER BEARING STRIPS 11. SEAL
section Mast Repairs 2- and 3-Stage Mast 4000 SRM 6. GREASE FITTINGS 12. FIXED FRAME
1250 for repair procedures. If necessary, lubricate sliding
surfaces at grease fittings with multipurpose grease shown Figure 55. Integral Sideshift Carriage
in the Maintenance Schedule. See Figure 55.
186
Maintenance
Fork Positioner b. Remove two screws and one block from bottom of
each support. See Figure 56.
This section describes how to remove and install forks to lift
trucks equipped with a fork positioner attachment. For more c. Remove two socket head capscrews from surface of
information on how to service and repair the fork positioner forks. See Figure 56.
attachment, see the manufacturer's maintenance manual d. Remove fork securing pin from bottom of fork support.
for instructions. See Figure 56.
Forks, Remove e. Use lifting device to remove fork from fork support.
WARNING 2. For lift trucks equipped with 150 mm (6.0 in.) wide forks:
DO NOT try to move a fork without a lifting device. a. Remove two headless screws and two nuts from sides
Each hook fork for these lift trucks can weigh 45 to of fork support. See Figure 56.
115 kg (99 to 253 lb).
b. Remove two screws and one block from bottom of
NOTE: Forks must be removed or installed by trained per- each support. See Figure 56.
sonnel only.
c. Remove fork securing pin from bottom of fork support.
NOTE: Forks are to be replaced only in sets and not indi- See Figure 56.
vidually.
d. Use lifting device to remove fork from fork support.
1. For lift trucks equipped with 120 to 125 mm (4.7 to
4.9 in.) wide forks:
a. Remove two headless screws and two nuts from sides
of fork support. See Figure 56.
187
Maintenance
Figure 56. Fork Positioner, Remove/Install Forks
188
Maintenance
A. FORK POSITIONER WITH 120 TO 125 MM (4.7 TO 4.9 IN.) B. FORK POSITIONER WITH 150 MM (6.0 IN.) WIDE FORKS
WIDE FORKS
1. SOCKET HEAD CAPSCREW 6. PIN
2. FORK SUPPORT 7. FORKS
3. HEADLESS SCREWS AND NUTS 8. BOTTOM HOOK
4. BLOCK 9. TOP HOOK
5. SCREWS
Forks, Inspect 1. For lift trucks equipped with 120 to 125 mm (4.7 to
4.9 in.) wide forks:
1. See section Forks, Inspect above for inspection proce-
dures. a. Using a lifting device, plate top and bottom hooks on
fork onto top and bottom hooks of fork support. Push
Forks, Install
fork outwards to ensure hooks are secured in fork sup-
port. See Figure 56.
WARNING
DO NOT try to move a fork without a lifting device. b. Secure fork to fork support using two socket head
Each hook fork for these lift trucks can weigh 45 to capscrews. See Figure 56. Tighten socket head cap-
115 kg (99 to 253 lb). screws to 357 N•m (263 lbf ft).
NOTE: Forks must be removed or installed by trained per- c. Install fork securing pin into bottom of fork support.
sonnel only. See Figure 56.
NOTE: Forks are to be replaced only in sets and not indi- d. Install two headless screws and two nuts to side of
vidually. fork support. Tighten nuts to 210 N•m (155 lbf ft). See
Figure 56.
189
Maintenance
e. Install block onto securing pin on bottom of fork sup- How to Make Checks With the Engine
port using two screws. See Figure 56. Running
2. For lift trucks equipped with 150 mm (6.0 in.) wide forks:
WARNING
a. Using a lifting device, plate top and bottom hooks on
DO NOT operate a lift truck that needs repairs. Report
fork onto top and bottom hooks of fork support. Push
the need for repair immediately. If repair is necessary,
fork outwards to ensure hooks are secured in fork sup-
put a DO NOT OPERATE tag in the operator's area. If
port. See Figure 56.
lift truck is equipped with a key switch, remove the key.
b. Install fork securing pin into bottom of fork support.
See Figure 56. WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed to
c. Install two headless screws and two nuts to side of
help the operator stay on the truck if the lift truck tips
fork support. Tighten nuts to 210 N•m (155 lbf ft). See
over. IT CAN ONLY HELP IF IT IS FASTENED.
Figure 56.
Make sure that the area around the lift truck is clear before
d. Install block onto securing pin on bottom of fork sup-
starting the engine or making any checks of the operation.
port using two screws. See Figure 56.
Be careful when making the checks. If the lift truck is sta-
Forks, Adjustments tionary during a check, apply the parking brake and put the
transmission in NEUTRAL. Make the checks carefully.
For information on how to adjust the forks, see the manu-
facturer's maintenance manual.
190
Maintenance
Indicator Lights, Horn, Fuses, and Relays the key switch to the START position, if truck is equipped
with a key switch, or press the engine start button, if truck
If lift truck is equipped with a key switch, turn key to ON is equipped with this button. If any of the indicator lights do
position. If lift truck is equipped with a Power ON/OFF but- not operate correctly, check the fuses. The fuses are loca-
ton, press button to turn system power on. Check all indicated in the Power Distribution Module (PDM) which is under
tor lights for correct operation as described in Table 3. the hood next to the battery on the right side. See Fig-
Check the operation of the horn. Start the engine by turning ure 57.
191
Maintenance
NOTE: HOOD REMOVED FOR CLARITY.
1. BATTERY
2. POWER DISTRIBUTION MODULE (PDM)
3. RESISTOR (68 OHM)
4. START RELAY
5. STARTER (30 AMP FUSE)
6. IGNITION 3 RELAY
7. BACKUP RELAY
8. BACKUP (20 AMP)
9. IGNITION (30 AMP)
10. SPARE FUEL PUMP (20 AMP)
11. SPARE FUEL PUMP RELAY
12. BATTERY (25 AMP)
13. FRONT WORK LIGHT (20 AMP)
14. FRONT/REAR WORK LIGHT RELAYS
16. REAR WORK LIGHT (20 AMP)
17. IGNITION 1 (20 AMP)
18. IGNITION RELAY
Figure 57. Fuses and Relays
192
Maintenance
Service Brakes There is an indicator light on the Display Switch Cluster for
the brake oil. The red light is ON when the key switch is in
Brake Oil Level the START position or the Power ON/OFF button is
pressed, and must go OFF when the engine is running. If
WARNING the light is ON when the engine is running, the brake fluid
Small amounts of water in the brake system can cause level in the reservoir is too low.
reduced braking performance if the water reaches the
wheel cylinder (dry brakes) or brake cylinder (wet Operation, Check
brakes) area(s). Do not allow water entry. Ensure that Check the operation of the service brakes. Push on the
the sealed reservoir lid is properly replaced. inching/brake pedal. The service brakes must be applied
The brake system has a boosted master cylinder. Brak- before the inching/brake pedal reaches the floor plate. The
ing will be more difficult if the engine is not running. pedal must stop firmly and must not move slowly down
after the brakes are applied. The service brakes must apply
Loss of oil from the brake oil reservoir indicates a leak. equally to both drive wheels. The service brakes must not
Repair the brake system before using the lift truck. pull the lift truck to either side of the direction of travel when
Replace the brake oil in the system if there is dirt or they are applied. The service brakes are automatically
water in the system. adjusted when the brakes are applied and the lift truck
DO NOT use "DOT" fluid, only use Dexron III oil from changes direction. Full application of the inching/brake
sealed container to prevent possible damage to the pedal applies the service brakes and puts the transmission
brake system. in NEUTRAL.
Failure to observe the above warnings could result in Lift trucks with a pedal or MLM Direction Control
death or serious injury. Switch: When the inching/brake pedal is fully applied, a
switch in the starting circuit is closed so that the engine can
be started.
193
Maintenance
Parking Brake Engine Oil Pressure

There is an indicator icon on the display panel for the park- NOTE: Lift trucks equipped with 4.3L LPG or gasoline
ing brake. This icon is illuminated as described in the engine will enter shutdown mode after a warning buzzer
Model Description section of this manual. There is a sen- sounds and a 30-second countdown if engine oil pressure
sor in the seat that actuates an audible alarm. If the opera- is less than 34.5 kPa (5 psi) on lift trucks with powertrain
tor leaves the seat, with system power OFF, without protection system. Lift trucks equipped with Kubota diesel
applying the parking brake, the alarm will sound for 10 sec- engine will enter the shutdown mode when the engine oil
onds until the parking brake is applied or the operator sits pressure is less than 50 kPa (7 psi) on lift trucks with pow-
back on the seat. If system power is ON or the engine is ertrain protection system. Lift trucks equipped with Kubota
running and the operator leaves the seat without applying LPG or Bi-Fuel engine eill enter the shutdown mode when
the parking brake, the alarm will sound continuously until the enging oil pressure is less than 49 kPa (7 psi) on lift
parking brake is applied or the operator sits back on the trucks with powertrain protection system. See the Engine
seat. Shutdown procedures in the Operating Procedures sec-
tion in this manual.
Make sure the service brakes operate correctly before
checking the operation of the parking brake. Check the There is an indicator light for the engine oil pressure on the
operation of the parking brake. The parking brake, when in Display Switch Cluster for the engine oil pressure. During
good condition and correctly adjusted, will hold a lift truck normal operation, the red indicator light will illuminate when
with a full capacity load on 15% grade [a slope that increa- the key switch is turned to ON, if the truck is equipped with
ses 1.5 meters in 10 meters (1.5 feet in 10 feet)]. If parking a key switch, or when the power ON/OFF button is
brake requires adjustment, notify service personnel. pressed, will stay illuminated until correct minimum oil pres-
sure is obtained, at which time the light will go off.
If the light continues to stay on when the engine is running,
the engine oil pressure is low. Stop the engine and check
194
Maintenance
the oil level. Do not restart the engine until the low pressure There is an indicator light on the Display Switch Cluster for
condition has been corrected. the coolant temperature. The red light is ON when the key
switch is in the START position or the Power ON/OFF but-
Cooling System ton is pressed, and must go OFF when the engine is run-
ning. If the light is ON when the engine is running, the
WARNING coolant and engine are too hot. Stop the engine and check
DO NOT remove the radiator cap from the radiator the coolant level in the coolant recovery reservoir.
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system. If Make sure the coolant level is between the ADD and FULL
the system is hot, the steam and boiling coolant can marks on the auxiliary coolant reservoir (See Figure 58).
cause burns. The coolant will expand as it is heated and the level in the
auxiliary coolant reservoir will increase.
NOTE: The engine will enter shutdown mode after a warn-
ing buzzer sounds and a 30-second countdown if coolant CAUTION
temperature reaches 118 °C (245 °F) or above for 4.3L lift Additives may damage the cooling system. Before
trucks with powertrain protection system. Lift trucks equip- using additives, contact your local Hyster dealer.
ped with a Kubota diesel engine will enter the shutdown
mode when the coolant temperature reaches 114 °C If coolant is added, use the correct mixture of water and
(238 °F) or above on lift trucks with powertrain protection ethylene glycol shown in the Maintenance Schedule.
system. Lift trucks equipped with Kubota LPG or Bi-Fuel
engine eill enter the shutdown mode when the coolant tem- WARNING
perature reaches 114 °C (238 °F) on lift trucks with power- Compressed air can move particles so that they cause
train protection system. See the Engine Shutdown injury to the user or to other personnel. Make sure that
procedures in the Operating Procedures section in this the path of the compressed air is away from all person-
manual. nel. Wear protective goggles or a face shield to prevent
injury to the eyes.
195
Maintenance
Turn lift truck engine OFF and 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-
lem is corrected.

2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
Figure 58. Auxiliary Coolant Reservoir
196
Maintenance
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 cannot 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 4. Check
that the pedals operate correctly as described in Table 4. 1. Turn lift truck engine OFF and check for leaks in the
hydraulic system. Check the condition of the hydraulic
Lift System Operation hoses and tubes.
WARNING NOTE: Some parts of the mast move at different speeds

during raising and lowering.
When working on or near the mast, see Safety Proce-
dures When Working Near the Mast in the Periodic 2. Slowly raise and lower the mast several times without a
Maintenance 8000 SRM 1902. load. Raise the mast to its full height at least once. The
mast components must raise and lower smoothly in the cor-
Lower the lift mechanism completely. Never allow any
rect sequence. Hose must track properly during operation.
person under a raised carriage. Do not put any part of
your body in or through the lift mechanism unless all
197
Maintenance
3. The inner weldments and the carriage must lower com- All fuels for internal combustion engines are very flam-
pletely. mable.
4. Raise the mast 1 m (3 ft) with a capacity load. The inner Fill the fuel tank only in a designated area with good
weldments and the carriage must raise smoothly. Lower ventilation. Have a fire extinguisher available.
the mast. All moving components must lower smoothly.
Never fill the fuel tank near an open flame or near
5. Lower the load to approximately 0.3 m (1 ft). Tilt the equipment that can create sparks. Never check fuel
mast forward and backward. The mast must tilt smoothly level or check for leaks with an open flame.
and both tilt cylinders must stop evenly.
Breathing fuel vapor may cause nausea, unconscious-
6. Check that the controls for the attachment operate the ness, or death. Long-term exposure to gasoline vapors
functions of the attachment. See the symbols by each of may cause liver or kidney damage and cancer. Avoid
the controls. Make sure all of the hydraulic lines are con- breathing vapor.
nected correctly and do not leak.
Liquefied Petroleum Gas (LPG)
How to Add Fuel to the Lift Truck
WARNING
WARNING Close the fuel valve on the tank when the lift truck is
Use only unleaded gasoline. not in active use. Do not park the lift truck near heat or
ignition sources.
Stop the engine. Turn the key switch to OFF, if truck is
equipped with a key switch; or press the Power For complete instructions on the storage of LPG fuels
ON/OFF button. The operator must be off the lift truck and the refueling of LPG tanks, refer to NFPA 58 & 505.
while fuel is added.
LPG is extremely flammable. When checking or filling
No smoking. an LPG tank: No smoking. Stop engine.
198
Maintenance
Frost on the surface of the tank, the valves, or the fit- Removable LPG tanks must be removed from the fork
tings and the odor of LPG fuel indicates a leak. Inspect lift before filling. If the lift truck is equipped with a non-
the LPG system and repair a leak immediately. An LPG removable LPG tank, make sure all components
fuel leak creates an explosion and fire hazard. Do not (engine, transmission, muffler, catalytic muffler) have
attempt to start the engine if there is a leak in the LPG surface temperatures that have cooled to below 427 °C
fuel system. (800 °F).
Only trained and authorized personnel are permitted to LPG Tank, Removal
operate filling equipment.
NOTE: The LPG tank bracket used on lift trucks covered in
Use only the LPG tank indicated on the label on the this manual to mount the LPG tank onto the counterweight
tank bracket. Do not use an LPG tank that is damaged. comes in two styles. One style of bracket swings out to the
A damaged LPG tank must be removed from service. side of the truck and the other swings out to the side and
drops down (EZXchange bracket). See Figure 59.
WARNING
1. Removable LPG tanks can be replaced indoors only if
LPG tanks are heavy. The weight of an LPG tank can
the lift truck is a minimum of 8 m (26 ft) from any open
exceed the maximum recommended weight for safe lift-
flame, motor vehicles, electrical equipment, or ignition
ing by an individual. Get assistance when lifting or low-
source. Move lift truck to an area where LPG tanks are
ering an LPG tank. Use correct lifting procedures.
changed.
LPG can cause an explosion. Do not cause sparks or
2. Turn the shutoff valve clockwise until the valve is com-
permit flammable material near the LPG system. LPG
pletely closed.
fuel systems can be disconnected indoors only if the
lift truck is at least 8 m (26 ft) from any open flame, 3. Run the engine until it stops, then turn the key switch to
motor vehicles, electrical equipments, or ignition the OFF position if truck is equipped with key switch, or
source.
199
Maintenance
press the Power ON/OFF button if truck is equipped with the tank down to the side of the truck for ease of removal.
keyless start option. See Figure 59.
4. Disconnect the quick-disconnect fitting on the LPG tank. 6. Push in the bracket release pin, grab the bracket handle,
See Figure 59. and swing the tank and bracket out to the side of the lift
truck.
5. Push and hold bracket release lever up, grab the bracket
handle, and swing the tank and bracket out tot he side of 7. Unlatch the tank strap and remove the LPG tank from
the lift truck. If your truck is equipped with a swing out and the bracket.
drop down LPG tank bracket (EZXchange bracket), drop
200
Maintenance
Figure 59. LPG Tank and Bracket
201
Maintenance
A. SWING OUT BRACKET B. (EZXCHANGE TANK BRACKET)
1. LPG TANK 7. STOP PIN
2. TANK STRAP 8. BRACKET HANDLE
3. QUICK DISCONNECT FITTING 9. BRACKET PIVOT
4. HYDROSTATIC RELIEF VALVE 10. GAS SPRING (EZXCHANGE BRACKET)
5. MANIFOLD BLOCK 11. BRACKET RELEASE PIN
6. ALIGNMENT PIN 12. LPG TANK BRACKET STRIKER BOLT
LPG Tank, Fill 2. Open the liquid outlet valve and bypass return valve on
the storage tank.
WARNING
3. Start the pump.
Read and follow all the refueling precautions and
instructions under Liquefied Petroleum Gas (LPG). 4. Connect the supply hose to the quick disconnect fitting
Removable LPG tanks must be removed from the fork on the LPG tank (see Figure 59) If the LPG tank has an
lift before filling. auxiliary fill fitting, connect the supply hose to this fitting.
Make sure the correct adapter is used to connect the sup-
NOTE: The following instructions are general procedures.
ply hose to the auxiliary fill fitting.
There is a variation in equipment for filling LPG tanks. The
local authorities that have jurisdiction have specific rules 5. Open the vent valve on the liquid level indicator.
and regulations for filling LPG tanks. Make sure these rules
6. Open the fuel valve on the LPG tank.
and regulations are available and understood.
7. Open the valve on the end of the supply hose.
1. Check the gauge on tank to make sure it needs filling.
During the fill operation, the LPG tank must be in a position 8. Watch for a discharge from the vent valve on the liquid
so that the liquid level indicator will always be in the vapor level indicator. When a cloud of visible vapor appears, the
space above the liquid level. LPG tank is full. Do not fill the LPG tank to more than the
202
Maintenance
maximum level indicated by the liquid level indicator. Imme- tank. If the pin is damaged, repair it before installing the
diately close the valve at the end of the supply hose. tank. Secure the tank strap around the tank and close the
strap.
9. Close the vent valve on the LPG tank.
2. Pull the stop pin and swing the LPG tank bracket into the
10. Close the fuel valve on the LPG tank.
resting position on the counterweight. Be sure that the
11. Disconnect the hose supply. bracket locks into position.
12. Stop the pump. 3. Connect the quick-disconnect fitting on the LPG tank.
See Figure 59.
13. Close the liquid outlet and the bypass return valve on
the storage tank. 4. Turn the fuel valve counterclockwise to open the fuel
valve.
LPG Tank, Install
5. Inspect the fuel system for leaks when the fuel valve is
NOTE: The LPG bracket must be in the swing out position
open. There are four methods used to inspect the fuel sys-
to install the LPG tank. If your lift truck has the swing out
tem for leaks:
and drop down bracket (EZXchange bracket), position the
bracket in the drop down position. See Figure 59. a. Sound - Listen for sound of LPG escaping from a tank
fitting or hose connection.
WARNING
b. Smell - LPG has a very distinctive odor. If you smell
When closing the LPG tank strap, do not wrap your fin-
LPG, DO NOT start the engine.
gers around the strap handle. The strap can close
quickly and with enough force to cause injury to the c. Soapy Water - This method is used in conjunction
fingers and hand. with Step b above. If the odor of LPG is present but
escaping fuel cannot be heard, apply soapy water to the
1. Place the LPG tank into the bracket. Be sure alignment
fittings and observe for bubbles.
pin on tank bracket is properly aligned with the hole in the
203
Maintenance
d. Frost - If the amount of LPG escaping is sufficient, 1. Remove the fuel cap. Make sure the fuel tank is filled
frost may appear on the fittings. with the correct fuel for the type of engine in the lift truck.
See Table 7. Clean the fuel cap.
Gasoline Fuel
2. Replace the fuel cap.
WARNING Wheels and Tires
When fuel is added, keep the funnel or fuel nozzle in
contact with the metal of the fuel tank to reduce the General
possibility of static electric sparks. Clean any spilled
fuel. The lift trucks covered in this Operating Manual have
pneumatic tires or solid rubber tires that look like pneumatic
1. Remove the fuel cap. Make sure the fuel tank is filled tires. These variations in tires also cause a variation in the
with the correct fuel for the type of engine in the lift truck. types of wheels and the disassembly and assembly proce-
Clean the fuel cap. dures.
2. Replace the fuel cap. Pneumatic Tire With Tube, Repair
Diesel Fuel
Remove Wheels From Lift Truck
WARNING
When fuel is added, keep the funnel or fuel nozzle in
WARNING
A solid rubber tire that is the same shape as a pneu-
contact with the metal of the fuel tank to reduce the
matic tire can be installed on a three-piece or four-
possibility of static electric sparks. Clean any spilled
piece wheel for a pneumatic tire. DO NOT make
fuel.
changes in the parts of the rim if this type of solid rub-
ber tire is installed instead of a pneumatic tire.
204
Maintenance
Changes to the parts of the rim can cause a failure of
CAUTION
the wheel and cause an accident.
Not all makes of radial tires have sufficient side wall
The type of tire and the tire pressure (pneumatic tires) strength for successful use on forklift trucks. This can
are shown on the Nameplate. Make sure the Nameplate affect stability and ride quality. Check with your dealer
is correct for the type of tires on the lift truck. If the whether a specific radial tire is approved for use on
truck is equipped with bias-ply tires, the ply rating lis- Hyster trucks.
ted on the Nameplate is the minimum ply rating that
1. Put the lift truck on blocks as described in How to Put a
must be installed. Tires with ply rating greater than or
Lift Truck on Blocks at the beginning of this section.
equal to the Nameplate listed ply rating may be accept-
able. Check with your dealer whether a specific bias- 2. Remove the air from the tire. Remove the valve core to
ply tire is approved for use on Hyster trucks. make sure that all of the air is out of the inner tube. Push a
wire through the valve stem to make sure that the valve
WARNING stem does not have a restriction.
Wheels must be changed and tires repaired by trained
3. Remove the wheel nuts and remove the wheel and tire
personnel only.
from the lift truck. Lift truck tires and wheels are heavy.
Deflate tire completely before removing the wheel from
the lift truck. If dual wheels are used, deflate both tires. Remove Tire From Wheel
Air pressure in the tires can cause the tire and rim When disassembling wheels, see Figure 60. There are
parts to explode causing serious injury or death. several types of wheels used on this series of lift trucks.
Always wear safety glasses. See Tire Removal, Two-Piece Wheel and Tire Removal,
Three- and Four-Piece Wheels.
Never loosen the nuts that hold the inner and outer
wheel halves together when there is air pressure in the
tire.
205
Maintenance
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 60. Types of Pneumatic Wheels
206
Maintenance
Tire Removal, Two-Piece Wheel
WARNING
Make sure all of the air pressure is removed from the
tire before a wheel is disassembled. Always use a tire
inflator with a clip-on chuck when deflating the tire
pressure. The tire inflator must be equipped with a
pressure gauge and a hose of at least 3 m (9.8 ft)
length. Air pressure in the tires can cause the tire and
rim parts to explode causing serious injury or death.
Keep tire 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 2. Loosen the tire bead from the wheel rim.
the wheel rims together.
3. Remove the wheel rims from
tire. Remove the inner tube and
flap.
207
Maintenance
Tire Removal, Three- and Four-Piece Wheels 2. Put the tire 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
tire before a wheel is disassembled. Always use a tire seat, remove it.
length. Air pressure in the tires can cause the tire and 3. Loosen the bead from the other
rim parts to explode causing serious injury or death. side of the wheel rim. Remove the
valve stem from the wheel.
Keep tire tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
an injury.
1. Loosen the tire bead from
the side flange.
208
Maintenance
4. Remove the wheel rim from the • DO NOT mix types of tires, type of tire tread, or
tire. wheel assemblies of different manufacturers on any
one lift truck.
Do not use a steel hammer on the wheel. Use a rubber,
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 clear-
ance at the ends of the side ring will be approximately
Install Wheel in Tire 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 tire 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 tire. Used tubes and flaps
can cause tire failure.
• Clean and inspect all parts of the wheel before
installing the tire. WARNING
• DO NOT use any damaged or repaired wheel parts. Do not lubricate the tire bead with antifreeze or petro-
leum-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 tire
• DO NOT mix parts between different types or manu- bead and tube.
facturers of wheels.
4. Install a new tire flap.
209
Maintenance
WARNING
rim parts to explode causing serious injury or death.
Do not lubricate the tire bead with antifreeze or petro-
leum-based liquid. Vapors from these liquids can Keep tire tools in firm contact with the wheel parts. If
cause an explosion during inflation or use. the tool slips, it can move with enough force to cause
an injury.
5. Make sure the rim is the correct size for the tire. Lubri-
cate the part of the wheel that contacts the bead and flap. 1. Install the inner tube and the rubber flap
in the tire.
6. Install the three-piece or four-piece wheel in the tire as
shown in Tire Installation Three- or Four-Piece Wheel.
CAUTION
Do not use pneumatic-shaped, solid tires on two-piece
bolt together drive wheels. Spinning may occur.
7. Install the two-piece wheel in the tire as shown in Tire
Installation Two-Piece Wheel. 2. Install the wheel rim in the
tire. Make sure the stem of the
Tire Installation Three- or Four-Piece Wheel inner tube is aligned with the
slot in the rim.
WARNING
tire before a wheel is disassembled. Always use a tire
210
Maintenance
3. Turn over the rim and tire. Put 1. Install the inner tube and the
blocks under the rim so that the rubber flap in the tire. Install both
rim is 8 to 10 cm (3 to 4 in.) above halves of the wheel rim in the tire.
the floor. Install the flange seat (if Make sure the stem of the inner
used) and the lock ring. tube is aligned with the slot in the
rim.
2. Tighten the nuts that hold the

4. Put the lock ring in the correct
rim halves together to 175 N•m
position on the rim. Add air pres-
(130 lbf ft). Add air pressure to
sure to the tire as described in
the tire as described in Add Air
Add Air to Pneumatic Tires
to Pneumatic Tires With
With Tube.
Tube.
Add Air to Pneumatic Tires With Tube

Tire Installation Two-Piece Wheel
WARNING
CAUTION Add air pressure to the tires only in a safety cage. See
Do not use pneumatic-shaped, solid tires on two-piece Figure 61. Inspect the safety cage for damage before
bolt together drive wheels. Spinning may occur. use. When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make sure
211
Maintenance
there is enough hose to permit the operation to stand
away from the safety cage when air pressure is added
to the tire.
WARNING
Do not sit or stand by the safety cage. Do not use a
hammer to try and correct the position of the side
flange or lock ring when the tire has air pressure
greater than 20 kPa (3 psi) of air pressure to the tire.
1. Put the tire in a safety cage. See Figure 61.
2. Add 20 kPa (3 psi) of air pressure to the tire.
3. Check that all wheel parts are correctly installed. Hit the
lock ring lightly to make sure that it is in the seat.
4. If installation is correct, add air pressure to the tire to the Figure 61. Add Air to Tires With Tube
specified pressure. See Nameplate.
Install the Wheels
5. Check that all wheel parts are correctly installed. If instal-
lation is not correct, remove all of the air pressure from the Install the wheel on the hub. Tighten the nuts in a cross
tire. Remove the valve core to make sure all of the air pres- pattern to 610 to 680 N•m (450 to 502 lbf ft) torque. If the
sure has been removed and then make adjustments. The wheels are the two-piece rims, make sure the nuts that fas-
clearance at the ends of the lock ring will be approximately ten the rim halves together are toward the hub when they
13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air are installed.
pressure.
212
Maintenance
Pneumatic Tubeless Tire, Repair The main component of the TBS is a special rubber ring
that fits inside the tire between the tire beads to ensure the
Remove Tire From Lift Truck airtightness of the existing wheel and the tubeless tire
assembly. See Figure 60.
WARNING 1. Put the lift truck on blocks as described in How to Put a
Wheels must be changed and tires repaired by trained Lift Truck on Blocks at the beginning of this section.
personnel only.
2. Remove the valve cap and core to remove all air from
Deflate tire completely before removing the wheel from the tire.
the lift truck. If dual wheels are used, deflate both tires.
Always use a tire inflator with a clip-on chuck when 3. Remove the wheel nuts and remove the wheel and tire
deflating the tire pressure. The tire inflator must be from the lift truck. Lift truck tires and wheels are heavy.
equipped with a pressure gauge and a hose of at least
3 m (9.8 ft) length. Air pressure in the tires can cause
Remove Tire From Wheel
the tire and rim parts to explode causing serious injury
or death. WARNING
Always wear safety glasses. tire before a wheel is disassembled. Always use a tire
Never loosen the nuts that hold the inner and outer inflator with a clip-on chuck when deflating the tire
wheels halves together when there is air pressure in pressure. The tire inflator must be equipped with a
the tire. pressure gauge and a hose of at least 3 m (9.8 ft)
The Tubeless Bead Seal (TBS) enables tubeless tires to be rim parts to explode causing serious injury or death.
used on wheel rims that were designed to be used with a
tube.
213
Maintenance
Keep tire tools in firm contact with the wheel parts. If 2. Put wheel and tire assem-
the tool slips, it can move with enough force to cause bly on the press. Position the
an injury. feet of the press on the loose
flange. Push press down on
NOTE: There are several types of wheels used on these lift
loose flange to expose the
trucks. When disassembling wheels, see Figure 60.
locking ring.
1. If wheel rim is a three- or
four-piece rim, turn the valve
1/4 turn and remove valve
from wheel.
3. Remove the loose flange

locking ring and the advance
band (four-piece wheel only)
using a tire tool.
214
Maintenance
4. Remove the press and • Clean and inspect all parts of the wheel before
remove the loose flange lock- installing the tire.
ing ring and the advance
• DO NOT use any damaged or repaired wheel parts.
band (four-piece wheel only)
from the tire and wheel • Make sure that all parts of the wheel are the correct
assembly. parts for that wheel assembly.
• DO NOT mix parts between different types or manu-
facturers of wheels.
• DO NOT mix types of tires, type of tire tread, or
wheel assemblies of different manufacturers on any
one lift truck.
5. Push the TBS toward the
WARNING
inside of the tire to remove it.
Install Tire on Wheel lead, plastic, or brass hammer to put parts together.
WARNING WARNING
Damage to the tire and Do not lubricate the tire bead with antifreeze or petro-
wheel assembly and injury leum-based liquid. Vapors from these liquids can
or death can occur if you cause an explosion during inflation or use.
do not do the following pro-
cedures:
215
Maintenance
1. Clean interior and exte- 2. Apply lubricant to the nee-
rior bead area of the tire. dle valve and the valve hole
Lubricate tire beads and that will be used (see NOTE
the inside of the tire, up to in Step 1), by inserting and
the tire shoulders. Apply removing the lubricated valve
lubricant to entire under- several times. If a three- or
side of the TBS. four-piece wheel is being
used, remove the valve. If a
two-piece wheel is being
used, leave valve in valve
hole.
NOTE: If the wheel rim width is less than six inches, the If the TBS has two valve holes, lubricate the plastic plug
TBS will contain one valve hole to accommodate the nee- and insert into valve hole that will not be used.
dle valve. If the wheel rim width is greater than six inches,
the TBS will have two holes for the needle valve. 3. Place the TBS inside the
One hole is centrally located and the other is offset, to tire, making sure that the
ensure the correct positioning of the valve in the valve slot. wings of the TBS are not fol-
The valve hole that is not used should be sealed with a ded over. Make a mark on the
small plastic plug. tire to note the position of the
valve hole in the TBS.
216
Maintenance
4. Apply lubricant to the rim. If a four-piece wheel is being 5. Place the wheel and tire
used, lubricate the advance band. Slide the tire and TBS assembly on a flat surface.
onto the wheel. Turn the valve a 1/4 turn to
lock the collar under the
Line up the valve hole in the
edges of the rim valve slot.
TBS with the valve slot in the
wheel. Lubricate and insert
the valve into the valve hole.
Make sure it is fully inserted.
6. Raise the tire and position

the base and threaded stem
of the press through the hole
in the center of the wheel.
Insert in wheel assembly, the
following parts:
217
Maintenance
• Advance band (four-piece wheel only) 8. Insert tire tool into the lock-
ing ring groove, and a vise
• Loose flange
grip on other end. Remove
• Locking ring vise grip. Release the press
and check that all component
7. Position the advance band. Ensure that it does not go in
parts are correctly positioned.
too far and damage the valve. Position the arms of the
Replace the valve core.
press onto the loose flange.
Push down on press to
depress the tire beads until
the locking ring groove is fully
exposed.
9. Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to
ensure all components are correctly sealed. Remove the
press from wheel and tire assembly.
Add Air to Pneumatic Tubeless Tire
WARNING
Add air pressure to the tires only in a safety cage. See
Figure 62. 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
218
Maintenance
safety cage when air pressure is added to the tire. Do Install the Wheels
not sit or stand by the safety cage.
Install the wheel on the hub. Tighten the nuts in a cross
Add air to tire to the recommended pressure that is shown pattern to 610 to 680 N•m (450 to 502 lbf ft). If the wheels
on the Nameplate. Install valve cap to ensure air stays in are the two-piece rims, make sure the nuts that fasten the
the tire. rim halves together are toward the hub when they are
installed.
Solid Rubber Tires on Pneumatic Wheels,
Change
WARNING
personnel only.
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 tire
from the lift truck. Lift truck tires and wheels are heavy.
Figure 62. Add Air to Tubeless Tire
219
Maintenance
Remove Tire From Wheel 1. Put the wheel rim on the

bed of the press. Put the
WARNING cage in position on the tire.
Keep tire tools in firm contact with the wheel. If the tool Use the press to push the
slips, it can move with enough force to cause serious tire away from the side
injury. flange.
NOTE: When disassembling wheels, see Figure 60. There

are several types of wheels used on these series of lift
trucks.
WARNING
personnel only. 2. Put the tire tool into the
slot between the lock ring
Always wear safety glasses. and the wheel rim. Remove
the lock ring and side flange.
220
Maintenance
3. Turn the tire over. Put a Install Tire on Wheel
support under the wheel rim.
Make sure the wheel rim is at WARNING
least 150 to 200 mm (6 to Damage to tire and wheel assembly and injury or death
8 in.) from the bed of the can occur if you do not do the following procedures:
press.
• Clean and inspect all parts of the wheel before
installing the tire.
• 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.
4. Put the cage in position on • DO NOT mix parts between different types or manu-
the tire. Use the press to facturers of wheels.
push the tire from the wheel
rim. • DO NOT mix type of tires, type of tire tread, or wheel
assemblies of different manufacturers on any one lift
truck.
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 clear-
ance at the ends of the side ring will be approximately
221
Maintenance
13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the 2. Put the wheel rim on the
clearance is wrong, the wrong part has been used. bed of the press. Put the tire
over the wheel rim. Put the
NOTE: When disassembling wheels, see Figure 60. There
cage in position on the tire.
are several types of wheels used on these series of lift
Use the press to install the
trucks.
tire on the wheel rim.
CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.
1. Lubricate the wheel rim
and the inner surface of the
tire with tire lubricant or 3. Remove the cage and put
soap. the flange seat (if used), the
side ring, and the lock ring in
position on the wheel rim.
Install the cage on the tire.
Use the press to push the
tire onto the wheel rim so
that the side flange and lock
ring can be installed.
222
Maintenance
4. While the cage is holding 3. Install the outer wheel on the spacer. Tighten the nuts to
the tire on the wheel rim, 610 to 680 N•m (450 to 502 lbf ft). If the wheels are the
install the lock ring. Use a two-piece rims, make sure the nuts that fasten the rim
tire tool to make sure the halves together are toward the brake drum when they are
lock ring is in the correct installed.
position.
Dual Drive Wheels, Install

NOTE: Some lift trucks can have dual drive wheels. The
following procedures describe the steps to install the dual
sets of wheels.
1. See Figure 63. Install the inner wheel on the hub.
Tighten the nuts to 610 to 680 N•m (450 to 502 lbf ft). If
two-piece wheels are installed, make sure the nuts that fas-
ten the rim halves together are toward the brake drum
when they are installed.
1. INNER WHEEL
2. Install the spacer to the axle shaft. Tighten the nuts to 2. ADAPTER ASSEMBLY
98 N•m (72 lbf ft). 3. OUTER WHEEL
4. EXTENSION, AIR VALVE
Figure 63. Dual Drive Wheels Installation
223
Maintenance
Jump-Starting the Lift Truck 1. Always connect positive jumper cable to positive terminal
of discharged battery and negative jumper cable to nega-
Jump-Starting Using a Battery Charger tive terminal.
If the battery becomes discharged and requires a booster 2. Always connect jumper cable, that is the ground cable,
battery to start the engine, follow these procedures care- last.
fully when connecting the jumper cables: 3. Always connect jumper cables to discharge lift truck bat-
1. Disconnect the negative battery terminal of the lift truck tery before connecting them to the fully charged lift truck
being started. battery.
2. Always connect positive jumper cable to positive terminal Operating Procedures for a New or Rebuilt
of discharged battery and negative jumper cable to nega- Engine
tive terminal.
A new or rebuilt engine must be operated under special
3. Always connect jumper cable, that is the ground cables, conditions during the first 50 hours. These special condi-
last. tions prevent damage to the engine until the new parts can
4. Always connect jumper cables to discharged battery wear and adjust to fit each other.
before connecting them to booster battery. 1. Make sure the fluid levels of oil and coolant are correct.
Jump-Starting Using Another Lift Truck 2. Start and run the engine at approximately one-half throt-
tle for 30 minutes for the first operation. Check the gauges
WARNING and indicators for the correct operation during this first
To prevent possible arcing between the two lift trucks, operating period. Check for leaks.
make sure that the lift trucks are not touching.
3. If the work conditions are slow and the loads are less
than 50% of the truck capacity, a simulated work condition
224
Maintenance
must be used during the first four hours of operation. Oper- How to Put Internal Combustion Engine (ICE)
ate the lift truck with a minimum load of 75% capacity. Trucks in Storage
Operate the engine through cycles from idle to full throttle
and back to idle. Avoid long periods of high engine speeds It is important to store your lift truck properly to protect it.
with a light load during the first 50 hours of operation. High The main areas of concern are engines, hydraulic compo-
engine speeds with a light load can cause damage to the nents, and truck batteries. The length of storage time and
cylinders in the engine. the storage location determines what procedures you
should follow.
Changes to the Overhead Guard
Before placing any lift truck in storage, you must choose an
WARNING area that is clean, dry, and free from airborne contami-
Do not operate the lift truck without the overhead nates. For safety and increased usable floor area, remove
guard correctly fastened to the lift truck. the forks and tag them with the lift truck serial number. For
best protection, operate your internal combustion engine lift
Do not make changes to the overhead guard by weld- truck for a short period each month.
ing. Changes that are made by welding, or by drilling
holes that are too big in the wrong location, can reduce The following storage procedures are for conditions and
the strength of the overhead guard. temperatures above 0 °C (32 °F). Adjust these procedures
for local conditions and any changes in conditions during
See your dealer for Hyster lift trucks BEFORE perform- storage. The preparations necessary for storage are also
ing any changes to the overhead guard. determined from the following conditions:
• Short-term storage is from one to six months. Long-term
storage is over six months.
225
Maintenance
• Storage Location. A lift truck stored indoors will not 5. Install blocks, front and rear, at the drive wheels. If the lift
require as much external protection as a lift truck stored truck must be left on an incline, put blocks on the downhill
outdoors. 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 tire pressure, if applicable. Make sure the tires
tank. Make sure the coolant mixture will protect cooling sys- have the correct pressure (see the Nameplate.)
tem 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.
226
Maintenance
2. Wrap or cover all exterior lights, radiator grill, and air Each month all hydraulic cylinders must be cycled several
vents with a moisture barrier cover. Use tape to hold the times to keep the seals active and to coat the interior walls
covers in place. with oil. Actuate each cylinder, in both directions, until it
reaches the stops.
3. Remove the battery or batteries from the lift truck. Store
the battery or batteries in an approved space. Be sure to Return lift truck to its storage state for another month.
follow local regulations. Batteries that are stored for long
periods can become damaged. Either keep batteries in How to Put Batteries in Storage
service or follow the battery storage procedures below. Batteries are to be placed on a wooden pallet and stored in
4. Spray exterior surfaces and frame with preservative a dry, moderately cool area.
coating. Lead acid batteries will slowly "self-discharge" over a
While the Lift Truck is in Storage period of time due to their chemical makeup. If the self-dis-
charge is left uncontrolled, excessive sulphation can occur
Each month make a visual inspection for leaks or signs of which is difficult to reduce and can damage the anodes. A
deterioration. Take corrective action immediately. Check discharged battery with a specific gravity of 1.000 will
the fluid level in engine, radiator, hydraulic tank, and brake freeze at −7.8 °C (18 °F) A fully-charged battery with a spe-
master cylinder. cific gravity of 1.280 will freeze at −66 °C (−87 °F).
NOTE: Do not shut down an engine before it reaches oper- This "self-discharge" is due to a chemical reaction; there-
ating temperature. fore, that chemical reaction can be accelerated by heat
resulting in more rapid "self-discharge." The rate of dis-
Each month set the park brake, start engine, and run until
charge can amount to an average of about 0.001 point drop
normal operating temperature is reached. This will coat the
in specific gravity per day.
internal engine components with a film of oil and rid the
engine of built-up condensation.
227
Maintenance
The following procedure can be followed when placing a NOTE: If the lift truck has been stored longer than one
battery in storage or when not in operation for more than 30 year, all lubricants and fluids must be drained and
days. replaced. See the Periodic Maintenance section of your
service manual for the procedures.
1. Give an equalizing charge prior to placing new batteries
in storage. Used batteries are to be fully charged, then 3. Clean the battery cables and terminals. Check the bat-
allowed to balance for approximately three more hours. tery voltage. If the voltage is not correct, charge battery.
Connect battery cables to battery.
2. Neutralize and clean the battery. Clean with a solution of
100 grams (3.5 oz) of sodium bicarbonate (baking soda) 4. When a lift truck is to be put into service after storage, it
per 1 liter (0.25 gal) of water. must be given the 250-hour inspection shown in the Rec-
ommended Schedule of Maintenance.
3. Store in a cool, dry location.
4. Check each cell in the battery at least once every 30 How to Move a Lift Truck on a Transport
days and boost charge when specific gravity falls below
1.240 Hg. WARNING
Stay a safe distance from the edge of docks, ramps,
5. Protect batteries from ambient contamination. platforms, and other similar working surfaces. Watch
If a greasy film forms on the top of a battery, this is acid the “tail swing.” Remember when traveling in the for-
and must be neutralized with the solution described above. ward direction and the steering wheel is turned to
move the lift truck away from the edge of the dock, the
Putting a Stored Lift Truck Back Into Service rear will swing toward the edge. This can cause the lift
truck to fall off the dock.
1. Remove all tape, covers, and preservation materials.
2. Check the lift truck for damage and missing components.
Repair damage and/or replace missing components.
228
Maintenance
truck by attaching a lifting device to any other part of the lift
WARNING
truck for the purposes of loading or unloading.
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO NOT
JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, Loading
BRACE YOUR FEET, AND LEAN FORWARD AND
AWAY FROM THE POINT OF IMPACT. WARNING
Before the lift truck is moved on a The straps or chains used to fasten the lift truck to the
transport, check the selected route to transport must be directly connected to the lift truck
make sure there is enough clearance frame or to a component (drive axle, tow pin) that is
for the lift truck as loaded on the solidly attached to the frame. Do not fasten a strap or
transport vehicle. Bridges, over- chain to the mast or any attachment to hold the lift
passes, powerlines, and natural bar- truck on the transport.
riers can prevent clearance.
Removal of the mast can be neces- CAUTION
sary. Make sure that any straps or chains used to fasten the
lift truck to the transport do not contact any tubes,
If a trailer is the method of transpor- hoses, hydraulic cylinders, or other parts of the truck
tation, use blocks in front and back that are easily damaged.
of the trailer tires to prevent move-
ment of the trailer when the lift truck is loaded and unloa- If components and attachments must be removed for trans-
ded. If a loading ramp is used, make sure that the ramp is port of the lift truck, see the Service Manual for removal
the correct design and capacity. procedures.
If the lift truck is equipped with lifting eyes, use a crane to The operator must never leave a lift truck in a condition so
load and unload the lift truck from the transport. If the truck that it can cause damage and injury. When the lift truck is
is not equipped with approved lifting eyes, do not lift the loaded on the transport, do the following operations:
229
Maintenance
1. Apply the parking brake. If the lift truck is equipped with an LPG fuel system and is
not in active use, close the fuel valve at the tank. If the lift
2. If the mast is mounted on the lift truck, fully lower the
truck is going to be left overnight or longer, the truck must
forks or carriage. Tilt the mast FORWARD until the tips of
be parked outside or the LPG tank must be removed and
the forks touch the surface.
stored outside.
3. Put the direction control lever for the transmission in
If the lift truck is transported in severe weather or any other
NEUTRAL (N). If the lift truck has a manual transmission,
condition that can damage the lift truck, cover the lift truck.
leave the gears of the transmission engaged. DO NOT
Make sure the protective cover is designed for the applica-
leave a manual transmission in NEUTRAL (N).
tion and is securely fastened.
4. Turn the key switch to OFF to stop the engine, if truck is
equipped with a key switch, or press the Power ON/OFF Unloading
button, if truck is equipped with a keyless option. Check If components normally attached to the lift truck were
that all switches and accessories are turned OFF. removed for transport, see the Service Manual for installa-
5. Put blocks in front and back of the lift truck tires to pre- tion procedures.
vent any movement of the lift truck. Make sure the blocks 1. If used, remove any protective cover.
are attached to the load surface.
2. Make sure the parking brake is applied.
6. Tie the lift truck to the transport vehicle using straps or
chains. The straps or chains must be directly connected to 3. Disconnect the straps or chains.
the lift truck frame or to a component such as the drive 4. Remove the wheel blocks.
axle, tow pin in the counterweight, or the two center grill
bars in the counterweight for lift trucks equipped with a lea- 5. Check that all switches and accessories are turned OFF.
ded counterweight without a tow pin (see Figure 28). 6. Unload the lift truck.
230
Maintenance
Preparation for Use 2. Inspect the lift truck for damage and missing compo-
nents.
After being transported or stored, the lift truck must be pre-
pared for use for proper operation. All problems must be 3. Follow the steps in the section Engine Shutdown.
corrected before use of the lift truck, see the Service Man-
ual for procedures.
Preparation After Transport
1. Complete the unloading procedures.
231
NOTES
232
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OPERATING MANUAL
FORTIS®
H80-120FT (U005)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4128512 1/19

Manual de Operacion H110FT (U005)

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OPERATING MANUAL

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4128512 1/19

LIFT TRUCK MODEL SERIAL NUMBER

TRANSMISSION TYPE SERIAL NUMBER

MAST LIFT HEIGHT GROUP NUMBER

CARRIAGE TYPE GROUP NUMBER

DRIVE TIRE SIZE STEERING TIRE SIZE

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2019. All Rights Reserved.

©HYSTER COMPANY 2019 4128512 - ENGLISH-US 1

Figure 1. Model View Showing Major Components

Figure 2. Nameplate and Labels

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

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

SEE THE PARTS MANUAL FOR THE PART NUMBER.

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

Display Switch Cluster Display Switch Cluster – Right-Side Display

Figure 4. Display Switch Cluster

Figure 5. Display Switch Cluster - Right Side Display Inputs

Display Switch Cluster – Left-Side Display

Figure 6. Display Switch Cluster - Left Side Display

Item Item Function

A. LCD SCREEN B. WARNING AND INDICATOR LIGHTS

Table 3. Instruments – Warning and Indicator Lights (See Figure 7)

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Item No. Item Function

Operator Controls the problem immediately. DO NOT operate the vehicle

SEE FIGURE 9 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS.

Figure 8. Operator Controls

A. INCHING/BRAKE PEDAL D. INCHING/BRAKE PEDAL

Figure 9. Operator Compartment Pedal Configurations

4 Horn The horn button controls the operation of the horn.

Display, Diesel Particulate Filter (DPF)

Figure 10. DPF Display

Operator Interface CAN Communication Lost

Passive Regeneration Only

Figure 14. Partial Soot Level

Figure 15. Auto/Active Regeneration

Parked Regeneration Request WARNING

Warning Level Service Level

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

The center of gravity, and therefore the stability of the loa-

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

Figure 21. Air Conditioner/Heater Controls

Figure 22. Heater Controls

• The fault number is displayed on the top line of the LCD

Figure 24. Seat Adjustment - Full Suspension

WARNING A. FAST B. SLOW

Keep yourself and all others clear of the lift mecha-

A lift truck without an overhead guard provides no such

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

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