Operating Manual: H6.0FT, H7.0FT (L006)

www.duma-rent.
com
OPERATING MANUAL
FORTENS
H6.0FT, H7.0FT (L006)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4139132 9/18

www.duma-rent.com
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 2018. All Rights Reserved.
HYSTER, , FORTENS, and MONOTROL are Registered Trademarks of Hyster-Yale Group, Inc. DURAMATCH, UNISOURCE, and are Trademarks
in the United States and certain other jurisdictions.
www.duma-rent.com
Foreword
Foreword
To OWNERS, USERS, and OPERATORS: NOTE: A comprehensive operator training program is
available from Hyster Company. For further details, con-
The safe and efficient operation of a lift truck requires tact your dealer for Hyster lift trucks.
skill and alertness on the part of the operator. To develop
the skill required, the operator must: This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
• Receive training in the proper operation of THIS lift nance of a basic fork lift truck. Optional equipment is
truck. sometimes installed that can change some operating char-
• Understand the capabilities and limitations of the lift acteristics described in this manual. Make sure the neces-
truck. sary instructions are available and understood before
operating the lift truck.
• Become familiar with the construction of the lift truck and
see that it is maintained in good condition. Some of the components and systems described in this
Operating Manual will NOT be installed on your unit. If
• Read and properly understand the warnings, instruc- you have a question about any item described, contact
tions, and operating procedures in this manual. your dealer for Hyster lift trucks.
In addition, a qualified person, experienced in lift truck The following additional information is provided as speci-
operation, must guide a new operator through several driv- fied in Machinery Directive 98/37 EEC and/or 2006/42/EC:
ing and load handling operations before the new operator
attempts to operate the lift truck alone. • Dimensional Details: Certain information is shown on
the lift truck Nameplate. For additional dimensional
It is the responsibility of the employer to make sure that the details on this or any other specific truck, consult your
operator can see, hear, and has the physical and mental dealer.
ability to operate the equipment safely.
©HYSTER COMPANY 2018 4139132 - ENGLISH-UK 1

www.duma-rent.com
Foreword
• Noise Levels. Note: The directive legally requires this
information. The values have been calculated from the
Whole-body vibration:
acoustic power levels for lifting and driving only and are
only used for comparable value for different trucks. — Measured whole body vibration at the operator position,
Higher or lower noise emissions can exist during opera- based on standard production truck with full-suspension
tion of the truck, for example due to type of operation, seat is listed below.
environmental influences, and additional noise source
— Declared whole-body vibration emission value is in
outside of the truck.
accordance with EN 12096.
In accordance with standards EN 12053 and EN ISO
• Measured vibration emission value aW,Z = 0.6 m/s2
4871, the equivalent sound pressure level (Lpaz) at the
operator position is in the range of: • Uncertainty, K = 0.2 m/s2
— GM 4.3L — 79.0 - 80.0 db(A)
— Values determined according to EN 13059.
— PSI 4.3L — 79.0 — 80.0 db (A)
Hand-arm vibration:
— Kubota 3.8L Diesel — 79.0 db(A)
— Hand-arm vibration emission value = <2.5 m/s2
— Kubota 3.6L Diesel — 80.0 db(A)
• Hazardous Atmosphere: Before any truck within the
• Human Vibration (Whole-Body and Hand-Arm Vibra- European Community can be operated in a Potentially
tion). Note: The whole-body vibration level is measured Explosive Atmosphere, it is necessary that the truck is
according to standard EN 13059 which contains specific suitably converted for the application. Conversions
test criteria (load, speed, roadway surface, etc.) Work- should only be carried out by a Hyster approved sup-
site vibration levels may vary depending on actual oper- plier. Confirmation of the conversion can be made by
ating and surface conditions. referring to the truck Declaration of Conformity which will
confirm compliance with European Directive 94/9/ce. If
2
www.duma-rent.com
Foreword
you are in doubt, please contact your Hyster dealer for NOTE: The following symbols and words indicate safety
assistance. information in this manual:
• Manufacturer: Hyster Europe, Centennial House, Build-
WARNING
ing 4.5, Frimley Business Park, Frimley, Surry GU16
Indicates a hazardous situation which, if not avoided,
7SG, United Kingdom
could result in death or serious injury.
• The EC Conformity: Each lift truckships with a unique
EC Declaration of Conformity certificate. See the end of CAUTION
this section for a sample EC Declaration of Conformity Indicates a hazardous situation which, if not avoided,
certificate which complies with Machinery Directive could result in minor or moderate injury and property
2006/42/EC. damage.
CAUTION On the lift truck, the WARNING symbol is on an orange

background. The CAUTION symbol is on a yellow
Disposal of lubricants and fluids must meet local envi-
background.
ronmental regulations.
NOTE: Hyster lift trucks are not intended for use on public
roads.
3
www.duma-rent.com
Foreword
Atmospheric Conditions
This range of lift trucks is designed to work in the following atmospheric conditions:
Standard Construction
Average ambient temperature for continuous duty: +30°C
Maximum ambient temperature, short term with potentially reduced performance: +49°C
Lowest ambient temperature for trucks intended for continuous use in normal indoor conditions: +5°C
Lowest ambient temperature for trucks intended for short term use in normal outdoor conditions: −20°C
Altitude: Up to 2000m
From 30% to 95%
Relative humidity:
(non-condensing)
4
www.duma-rent.com
Foreword
NOTE: For lift trucks operating under continuous heavy- business, the user may arrange for a modification or altera-
duty, extreme high temperature or high humidity conditions, tion to a powered industrial truck, provided, however, that
special equipment may be required. Contact your local the user shall:
Hyster dealer.
1. Arrange for the modification or alteration to be
Lifting designed, tested, and implemented by an engineer(s)
expert in industry trucks and their safety;
When transporting the truck, should lifting be
required, please use the points indicated on the 2. Maintain a permanent record of the design, test(s),
truck by the hook symbols. Traction batteries and implementation of the modification or alteration;
should be removed and lifted separately by the 3. Approve and make appropriate changes to the
lifting eyes on the battery box. capacity plate(s), decals, tags and instruction hand-
book;
Truck Modification
4. Affix a permanent and readily visible label to the truck
Unauthorized truck modification is not permitted. To obtain stating the manner in which the truck has been modi-
authorization contact your Hyster dealer. fied or altered together with the date of modification or
Only in the event that the truck manufacturer is no longer in alteration, and the name and address of the organiza-
business and there is no successor in the interest of the tion that accomplished the tasks.
5
6
Foreword
EC DECLARATION OF CONFORMITY
WE HYSTER EUROPE
CENTENNIAL HOUSE
BUILDING 4.5
FRIMLEY BUSINESS PARK
FRIMLEY, SURRY GU16 7SG
UNITED KINGDOM
DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE
CATEGORY: FORKLIFT IC ENGINE POWERED
TYPE
SERIAL NUMBER(S)
YEAR OF CONSTRUCTION
IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC. COMPLIANCE WITH

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

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

NETHERLANDS.
NAME
POSITION PLANT MANAGER
(BLOCK LETTERS)
SIGNATURE
DATE
www.duma-rent.com
Contents
Contents
Foreword ..................................................................... 1 Parked Regeneration Request ................................. 48
TO OWNERS, USERS, AND OPERATORS: ............. 1 Regeneration Level 2 ............................................. 48
ATMOSPHERIC CONDITIONS .................................. 4 Warning Level .......................................................... 50
LIFTING ...................................................................... 5 Regeneration Level 3 ............................................. 50
TRUCK MODIFICATION ............................................ 5 Service Level ............................................................ 50
Warning ....................................................................... 11 Regeneration Level 4 ............................................. 50
Model Description ...................................................... 14 DIESEL EXHAUST FLUID (DEF) ............................... 51
GENERAL .................................................................. 16 Normal DEF .............................................................. 51
OPERATOR PROTECTION EQUIPMENT ................ 17 Low DEF ................................................................... 52
NAMEPLATE .............................................................. 18 Empty DEF ............................................................... 53
SAFETY LABELS ....................................................... 19 Bad DEF Quality ....................................................... 54
DISPLAY SWITCH CLUSTER ................................... 25 OPERATOR CONTROLS .......................................... 54
Display Switch Cluster – Right-Side Display Inputs . 25 AUXILIARY CONTROL LEVERS ............................... 74
Display Switch Cluster – LCD Screen and Warning Operating Procedures ................................................ 75
and Indicator Lights .............................................. 32 GENERAL .................................................................. 75
DISPLAY, DIESEL PARTICULATE FILTER (DPF) .... 42 Know Your Lift Truck ................................................ 75
Operator Interface .................................................... 43 Stability and Center of Gravity .................................. 77
CAN Communication Lost ........................................ 44 Capacity (Weight and Load Center) ......................... 78
Passive Regeneration Only ...................................... 44 Impact Sensor .......................................................... 79
Regeneration Level 0 ............................................. 44 INSPECTION BEFORE OPERATION ........................ 80
Auto/Active Regeneration ......................................... 45 Checks With the Engine Stopped ............................. 80
Auto/Active Regeneration ......................................... 46 Operator Checklist .................................................... 81
Regeneration Level 1 ............................................. 46 Mounting and Dismounting ....................................... 82
Idle-up Auto/Active Regeneration ........................... 47 Lift Truck Interlocks .................................................. 82
7
www.duma-rent.com
Contents
Operator Passwords ................................................. 82 Load Handling, Emergency Load Lowering ............. 114
Starting Procedures .................................................. 84 HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ...... 116
Stop Procedures, Diesel Engine .............................. 85 ATTACHMENTS ......................................................... 117
Checks With the Engine Running ............................. 85 Disconnecting Attachment Hydraulic Quick-
Load Weighing Sensor ............................................. 86 Disconnect Hoses ................................................ 117
Set Load Weight to Zero .......................................... 87 Connecting Attachment Hydraulic Quick-Disconnect
Engine Shutdown ..................................................... 87 Hoses ................................................................... 118
OPERATING TECHNIQUES ...................................... 89 STOPPING ................................................................. 119
Basic Operating Procedures .................................... 89 PARKING ................................................................... 119
Driving and Direction Changes ................................. 94 Maintenance ................................................................ 121
General ................................................................... 96 GENERAL .................................................................. 121
Normal Operations ................................................. 96 Serial Number Data .................................................. 122
Standard Operator Presence System .................... 97 HOW TO MOVE A DISABLED LIFT TRUCK ............. 122
Optional Operator Presence System ...................... 98 How to Tow the Lift Truck ......................................... 122
Powershift 2 Speed Transmission or Powershift HOW TO PUT A LIFT TRUCK ON BLOCKS ............. 124
Transmission .................................................... 98 How to Raise the Drive Tires .................................... 124
DuraMatch, DuraMatch Plus, and Duramatch AH How to Raise the Steering Tires ............................... 124
Transmissions .................................................. 99 HOW TO CLEAN A LIFT TRUCK ............................... 126
Inching ...................................................................... 101 Maintenance Schedule ............................................... 126
Steering (Turning) .................................................... 102 Maintenance Procedures Every 8 Hours or Daily .... 152
Load Handling, General ........................................... 104 HOW TO MAKE CHECKS WITH THE ENGINE
Load Handling, Lifting, Lowering, and Tilting ........... 105 STOPPED ................................................................ 152
Load Handling, How to Engage and Disengage a Tires and Wheels ..................................................... 152
Load ..................................................................... 107 Safety Labels ............................................................ 153
Load Handling, Traveling ......................................... 110
8
www.duma-rent.com
Contents
Mast, Carriage, Header Hoses, Lift Chains, and Brake Oil Level ....................................................... 180
Attachment ........................................................... 153 Operation, Check ................................................... 181
Operator Restraint System ....................................... 154 Parking Brake ........................................................... 181
Emergency Locking Retractor (ELR) ...................... 155 Engine Oil Pressure ................................................. 181
Seat Plate and Seat Rails ........................................ 156 Cooling System ........................................................ 182
Engine Compartment ............................................... 156 Steering System ....................................................... 184
Paper Application ..................................................... 156 Control Levers and Pedals ....................................... 184
Fuel, Oil, and Coolant Leaks, Check ........................ 158 Lift System Operation ............................................... 184
Hydraulic Hoses ....................................................... 158 Air Filter .................................................................... 185
Coolant Hoses .......................................................... 158 Fuel/Water Separator Filter, Kubota Diesel Engine . 186
Steering Column Gas Cylinder ................................. 158 HOW TO ADD FUEL TO THE LIFT TRUCK .............. 186
Transmission ............................................................ 159 Liquefied Petroleum Gas (LPG) ............................... 187
Hydraulic System Oil ................................................ 159 LPG Tank, Removal ............................................... 188
Engine Oil ................................................................. 160 LPG Tank, Fill ......................................................... 190
Air Filter .................................................................... 171 LPG Tank, Install .................................................... 190
Forks ........................................................................ 171 Diesel Fuel ............................................................... 191
Forks, Remove ......................................................... 171 Diesel Exhaust Fluid (DEF) ...................................... 191
Forks, Inspect ........................................................... 174 Refilling DEF Tank ................................................. 191
Forks, Install ............................................................. 175 Storage of DEF ....................................................... 192
Forks, Adjust ............................................................ 175 WHEELS AND TIRES ................................................ 192
Hang On Sideshift Carriage ..................................... 176 General ..................................................................... 192
HOW TO MAKE CHECKS WITH THE ENGINE PNEUMATIC TIRE WITH TUBE, REPAIR ................. 193
RUNNING ................................................................. 178 Remove Wheels From Lift Truck .............................. 193
Indicator Lights, Horn, Fuses, and Relays ............... 178 Remove Tire From Wheel ........................................ 194
Service Brakes ......................................................... 180 Tire Removal, Two-Piece Wheel ............................ 196
9
www.duma-rent.com
Contents
Tire Removal, Three- and Four-Piece Wheels ....... 197 JUMP-STARTING THE LIFT TRUCK ........................ 216
Install Wheel in Tire .................................................. 198 Jump-Starting Using a Battery Charger ................... 216
Tire Installation Three- or Four-Piece Wheel ......... 199 Jump-Starting Using Another Lift Truck ................... 217
Tire Installation Two-Piece Wheel .......................... 200 OPERATING PROCEDURES FOR A NEW OR
Add Air to Pneumatic Tires With Tube ..................... 200 REBUILT ENGINE ................................................... 217
Install the Wheels ..................................................... 201 CHANGES TO THE OVERHEAD GUARD ................ 218
PNEUMATIC TUBELESS TIRE, REPAIR .................. 202 HOW TO PUT INTERNAL COMBUSTION ENGINE
Remove Tire From Lift Truck .................................... 202 (ICE) TRUCKS IN STORAGE .................................. 218
Remove Tire From Wheel ........................................ 202 Short-Term Storage .................................................. 218
Install Tire on Wheel ................................................. 204 Long-Term Storage .................................................. 219
Add Air to Pneumatic Tubeless Tire ......................... 207 While the Lift Truck is in Storage .............................. 220
Install the Wheels ..................................................... 208 How to Put Batteries in Storage ............................... 220
SOLID RUBBER TIRES ON PNEUMATIC WHEELS, Putting a Stored Lift Truck Back Into Service ........... 221
CHANGE .................................................................. 208 HOW TO MOVE A LIFT TRUCK ON A
Remove Tire From Wheel ........................................ 208 TRANSPORT ........................................................... 221
Install Tire on Wheel ................................................. 210 Loading ..................................................................... 221
DUAL DRIVE WHEELS, INSTALL ............................. 212 Unloading ................................................................. 223
SNAP-ON-TIRE, CHANGE ........................................ 213 PREPARATION FOR USE ......................................... 223
Remove Snap-On-Tire, Solid Tire From Wheel ....... 215 Preparation After Transport ...................................... 223
Install Snap-On-Tire, Solid Tire on Wheel ................ 215 Maintenance Register ................................................ 224
10
www.duma-rent.com
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

• ALWAYS use 3 points of contact when getting on and • IF YOU CAN'T SEE, DON'T GO.
off the truck.
• TRAVEL in reverse if load blocks forward vision.
• KNOW operating, inspection, and maintenance instruc-
• MAKE SURE tail swing area is clear.
tions in this Operating Manual.
• SOUND horn at intersections or where vision is blocked.
• DO NOT operate or repair truck unless trained and
authorized. • WATCH clearances, especially overhead.
• INSPECT truck before use. KNOW YOUR LOADS:
• DO NOT operate if truck needs repair. Tag truck and • HANDLE only stable loads within specified weight and
remove key. Repair truck before use. Always use Hys- load center. See Nameplate on truck.
ter Approved parts when making repairs. Replacement
• DO NOT handle loose loads higher than load backrest.
parts must meet or exceed the specifications of the origi-
nal equipment manufacturer. • SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
• USE auxiliary equipment (attachments) for intended pur-
pose only.
• VERIFY truck is equipped with overhead guard and load
backrest adequate for the load.
11
www.duma-rent.com
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.
12
www.duma-rent.com
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.
13
www.duma-rent.com
Model Description
Model Description
Figure 1. Model View Showing Major Components
14
www.duma-rent.com
Model Description
Legend for Figure 1
1. COUNTERWEIGHT 8. LOAD BACKREST EXTENSION
2. OVERHEAD GUARD 9. CARRIAGE
3. SEAT 10. FORKS
4. SEAT BELT AND HIP RESTRAINT 11. DRIVE WHEELS
5. STEERING WHEEL AND COLUMN 12. HOOD
6. PARKING BRAKE 13. STEER WHEELS
7. MAST 14. OPERATING MANUAL (BEHIND SEAT)
15
www.duma-rent.com
Model Description
Model Description
General • A direction control lever on the left side of the Display
Switch Cluster that controls the forward, neutral, and
This Operating Manual is for the following models of lift reverse operation of the transmission. A separate accel-
trucks: erator pedal controls the engine speed.
H6.0FT, H7.0FT (L006) • A directional control switch integrated into the armrest
These lift trucks are available with the following engines: on units equipped with E-Hydraulics. Controls both for-
ward and reverse operation of the transmission. A sepa-
• 4.3L LPG engine rate accelerator pedal control engine speed.
• Kubota 3.8L diesel engine The lift trucks covered in this manual are equipped with
• Kubota 3.6L diesel engine pneumatic tires or solid rubber tires that look like pneu-
matic tires. See Wheels and Tires in the Maintenance
• Kubota 3.8L 55kW diesel engine Section for a description of these tires.
These lift truck models can be equipped with either a Pow- The lift trucks covered in this manual can be equipped with
ershift 2 Speed Transmission, a DuraMatch Transmission either standard manual hydraulic levers or Electro-
(3-speed), a DuraMatch Plus Transmission (3-speed), a Hydraulic (E-Hydraulic) mini-levers. See Figure 22.
Powershift Transmission, a DuraMatch Transmission, or a
DuraMatch AH Transmission and three types of controls: Trucks equipped with E-Hydraulics are equipped with a
main control valve which incorporates an emergency lower-
• A MONOTROL® pedal that controls both the forward ing valve (see Figure 27). This valve allows the operator or
and reverse operation of the transmission and the speed service technician to lower the lift truck's mast assembly if
of the engine the electrical signal to the main control valve is disrupted.
16
www.duma-rent.com
Model Description
See the Load Handling, Emergency Load Lowering Operator Protection Equipment
section in the Operating Procedures section.
The LOAD BACKREST EXTENSION is installed to keep
CAUTION loose parts of the load from falling back toward the opera-
If the lift truck is equipped with a 3-stage mast, in cir- tor. It must be high enough, with vertical openings small
cumstances where overhead clearance is restricted, be enough, to prevent the parts of the load from falling back-
sure inner mast/carriage does not extend before full wards. If a load backrest extension that is different from the
free lift of the mast is reached. one installed on your lift truck is required, contact your
Hyster lift truck dealer.
NOTE: Cold hydraulic oil and high oil flow rates may cause
the inner mast to extend above the outer mast before full The OVERHEAD GUARD is intended to offer reasonable
free lift is reached. The hydraulic oil must be hot if the lift protection to the operator from falling objects, but cannot
truck is to be operated where overhead clearance is restric- protect against every possible impact. Therefore, it must
ted. not be considered a substitute for good judgment and care
when handling loads. Do not remove the overhead guard.
To assure hydraulic oil is hot, operate mast at full lift speed
and observe for movement of the inner mast before full free NOTE: The seat belt can be either black or red.
lift is reached. If any inner mast movement occurs, fully The SEAT BELT AND HIP RESTRAINT provide additional
lower carriage, place the transmission into neutral, set the means to help the operator keep the head and torso sub-
park brake, and then hold the tilt mini-lever fully open at stantially within the confines of the lift truck frame and over-
engine governed speed for approximately 3 minutes. head guard if a tipover occurs. This restraint system is
Repeat above procedure until no movement of the inner intended to reduce the risk of the head and torso being
mast is observed, then proceed with lift truck operation. trapped between the lift truck and the ground, but it cannot
protect the operator against all possible injury in a tipover.
The lift trucks covered in this manual may be equipped with
either a 2-stage limited freelift or a 3-stage full freelift mast.
17
www.duma-rent.com
Model Description
The hip restraint will help the operator resist side move- rated as equipped and the Nameplate must show the
ment. It is not a substitute for the seat belt. Always fasten new capacity rating.
the seat belt.
The capacity is specified in kilograms (kg) and pounds (lb).
This lift truck is equipped with one of the three seat belt The capacity is the maximum load that the lift truck can
configurations. handle for the load condition shown on the Nameplate.
• Seat belt with no operation interlock. The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities with
• Seat belt with operation interlock. Seat belt must be fas-
the load height reduced or with optional load centers, may
tened for lift truck to start or to travel.
also be shown on the Nameplate.
• Seat belt with sequencing interlock. Operator must be in
NOTE: The image in Figure 2 is a sample only. Reference
the seat, then the seat belt fastened before lift truck will
the actual nameplate installed on the truck for actual truck
operate. This seat belt is used with the Optional Opera-
specifications.
tor Presence System.
The lift truck serial number code is on the Nameplate. The
Nameplate serial number code is also stamped on the right-hand side
of the lift truck frame, under the floorplate.
WARNING
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-
ure 2. If your lift truck has either of these labels, do not
Any change to the lift truck, the tires, or its equipment operate the lift truck. Contact your dealer for Hyster lift
can change the lifting capacity. The lift truck must be trucks to obtain a complete and correct Nameplate.
18
www.duma-rent.com
Model Description
Safety Labels
Safety labels are installed on the lift truck to provide infor-
mation about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 3.
A. NAMEPLATE (CE C. INCOMPLETE LABEL

NAMEPLATE SHOWN)
B. NOTICE LABEL
Figure 2. Nameplate and Labels
19
www.duma-rent.com
Model Description
Figure 3. Warning and Safety Labels (Sheet 1 of 5)
20
www.duma-rent.com
Model Description
21
www.duma-rent.com
Model Description
22
www.duma-rent.com
Model Description
23
www.duma-rent.com
Model Description
24
www.duma-rent.com
Model Description
Legend for Figure 3
1. MAST WARNING 12. ANTIFREEZE WARNING
2. OPERATION WARNING 13. FLAMMABLE LP GAS WARNING
3. ETHER WARNING (DIESEL) 14. LPG TANK LABEL
4. DIESEL FUEL LABEL 15. AIR FILTER CAUTION
5. TIPOVER WARNING 16. PARK BRAKE WARNING
6. DIESEL EMISSIONS DISPLAY LABEL 17. EMERGENCY BATTERY DISCONNECT
7. NO RIDERS 18. NAMEPLATE
8. MAST WARNING 19. DRIVE TRAIN PROTECTION CAUTION
9. NO ONE ON OR UNDER FORKS 20. TRANSMISSION LABEL (EXAMPLE ONLY)
10. FAN WARNING 21. BRAKE FLUID WARNING
11. BORON-FREE LABEL 22. RADIAL TIRE WARNING
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. Injury to personnel can occur if ment on the lift truck, warning and indicator lights on the
the instruments, levers, or pedals do not operate as right side of the Display Switch Cluster will vary and the
described in the following tables. DO NOT operate the truck may not contain all the warning and indicator lights
lift truck until the problem is corrected. shown in Figure 5 and Table 1.
NOTE: On the lift truck models covered in this manual, the

left side (see Figure 4) of the Display Switch Cluster does
not perform any functions.
25
www.duma-rent.com
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
26
www.duma-rent.com
Model Description
Figure 5. Display Switch Cluster - Right Side Display Inputs
27
www.duma-rent.com
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 Hourme-
ter 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.
Button
4 #1 Button When an operator or supervisor is in the main menu for entering and administering
passwords, the 1st Gear Locking function is disabled and the button is enabled to
enter the number 1 for password purposes.
5 Front Work Lights This button controls the front work lights and the marker lights on lift trucks equipped
with this option.
28
www.duma-rent.com
Model Description
Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 5) (Continued)
Item
Item Function
No.
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 is 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)
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.
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.
29
www.duma-rent.com
Model Description
Item
Item Function
No.
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.
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.
30
www.duma-rent.com
Model Description
Item
Item Function
No.
14 Hourmeter NOTE: Lift trucks equipped with key switch start will have the hourmeter symbol in the
Display Switch Cluster. Trucks equipped with keyless start option will have the power
ON/OFF symbol on the Display Switch Cluster in place of hourmeter symbol. See Fig-
ure 5.
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.
31
www.duma-rent.com
Model Description
Display Switch Cluster – LCD Screen and tures. Press the scroll up button to return to the engine
Warning and Indicator Lights coolant temperature and fuel level displays. If a fault
occurs, the fault number will be displayed on the top line.
The LCD screen (see Figure 6) shows operator messages The time of day is displayed on the right side of the top line
for the different functions. The LCD screen can display at all times during the selection of displayed text.
messages on two lines with up to 20 characters per line.
The warning lights and indicator symbols shown in Fig-
Bar graphs are also shown on the display using solid block
ure 6 are on all lift truck models. Depending on the equip-
characters of varying heights.
ment on the lift truck, the warning and indicator lights on
The following information is displayed on the LCD screen the Display Switch Cluster will vary and not all the warning
when the truck is running: and indicator lights shown in Figure 6 will illuminate. When
the warning lights and indicators are on, the operator will
• Engine coolant temperature (standard)
see the appropriate symbol. When the warning lights and
• Fuel level (standard on diesel trucks) indicators are off, the operator will see a black panel.
Unless noted in Table 2, all programmed warning and indi-
The engine coolant temperature is displayed on the top line
cator lights will light up for two seconds (Start Check) when
and the fuel level is shown on the bottom line. If load
System Power is turned ON.
weight and travel speed options are available, press the
scroll down button to display the information for these fea-
32
www.duma-rent.com
Model Description
A. LCD SCREEN B. WARNING AND INDICATOR LIGHTS
Figure 6. Display Switch Cluster - LCD Screen and Warning and Indicator Lights
33
www.duma-rent.com
Model Description
Table 2. Display Switch Cluster – Warning and Indicator Lights (See Figure 6)
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
Engine Mal- the RUN state is entered. This indicator will also illuminate when an engine rela-
function ted fault has occurred. Not on at Start Check.
Indictor
3 Warning Light, This amber light will illuminate when a fault that is not engine related occurs.
System Mal-
function Indica-
tor
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.
34
www.duma-rent.com
Model Description
Table 2. Display Switch Cluster – Warning and Indicator Lights (See Figure 6) (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 Fluid Level
DO NOT continue to operate the lift truck if the light is on during operation.
Malfunction Indica-
tor 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. Injury to personnel
Malfunction Indi-
may occur if seat belt is not fastened.
cator
The red light is illuminated for 10 seconds after system power is turned ON. Not
on at Start Check.
35
www.duma-rent.com
Model Description

8 Warning Light,
WARNING
Parking Brake Mal-
Always apply the parking brake when leaving the lift truck. Failure to apply
function Indicator
parking brake may result in injury to personnel.
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 Malfunc- the alternator is not in a charging state. This includes illuminating at System
tion Indicator Power On until the normal operating minimum is reached. Not on at Start Check.
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.
36
www.duma-rent.com
Model Description

11 Warning Light,
CAUTION
Transmission Oil
Do not continue to operate the lift truck if the red light is ON. Damage to lift
Temperature
truck and transmission may occur.
Malfunction Indi-
cator The red light will illuminate when the transmission oil temperature reaches the
preset warning level.
When light illuminates, and if truck is equipped with optional powertrain protec-
tion, truck performance will decrease. Turn truck OFF and notify service person
immediately 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.
37
www.duma-rent.com
Model Description

12 Warning Light,
CAUTION
Engine Oil
Stop the engine immediately if the red light is ON while the engine is run-
Pressure Mal-
ning. Damage to lift truck and engine may occur.
function 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 procedures. If truck is not equipped with optional powertrain
protection and light is illuminated when engine is running, turn engine OFF imme-
diately and have truck repaired by service technician.
38
www.duma-rent.com
Model Description

13 Warning Light,
CAUTION
Engine Coolant
Do not continue to operate the lift truck if the light is on during operation.
Temperature
Operation of lift truck with warning light ON may result in damage to engine.
Malfunction Indi-
cator If this red light illuminates while the engine is running, it indicates the engine cool-
ant temperature has reached 118 °C (245 °F) or above for 4.3L engines. For
Kubota engines, the temperature is 115 °C (240 °F).
Engine Shutdown procedures. If truck is not equipped with optional powertrain
protection and light is illuminated when engine is running, turn engine OFF imme-
diately and have truck repaired by service technician.
39
www.duma-rent.com
Model Description

14 Warning Light,
CAUTION
Coolant Level
Do not continue to operate the lift truck if the light is on during operation.
in Radiator
Operation of lift truck with warning light ON may result in damage to engine.
Malfunction
Indicator If the lift truck is equipped with the premium monitoring package, this red warning
light will illuminate when the radiator coolant level switch indicates that the level of
coolant in the radiator is too low.
Engine Shutdown procedures. If truck not equipped with optional powertrain pro-
tection and light is illuminated when engine is running, turn engine OFF immedi-
ately and check coolant level. If coolant level is satisfactory, have truck repaired
by service technician.
40
www.duma-rent.com
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 diesel trucks: The light first illuminates when there is 1/16th of fuel left in the
tank.
For LPG trucks with LPG pressure switch: The light illuminates when there is 30
seconds to 3 minutes of operation remaining.
For LPG trucks 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 The light will flash until the lift truck and engine speed are low enough to permit a
shift to 1st gear and stay illuminated while 1st gear lock is active. Not on at Start
Check.
41
www.duma-rent.com
Model Description

17 Indicator Light This amber indicator light will illuminate if the fuel-water separator sensor indi-
Water Separator cates that water must be drained. Not on at Start Check.
(Kubota 3.8L Die-
sel Only)
18 Indicator Light Cold This amber indicator light will illuminate during the cold start delay period. Not on
Start (Diesel Only) at Start Check.
Display, Diesel Particulate Filter (DPF) • Auto/Active Regeneration (Regeneration Level 1)
Lift truck models in this manual may be equipped with the • Parked Regeneration Request Level (Regeneration
Kubota 3.8L diesel engine. Lift truck equipped with this Level 2)
engine, will also be equipped with an operator's display, for • Warning Request Level (Regeneration Level 3)
the DPF, mounted to the overhead guard in the upper right
corner. See Figure 7. • Service Request Level (Regeneration Level 4)
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
42
www.duma-rent.com
Model Description
Operator Interface
1. DPF DISPLAY Figure 8. Refer to Operator Manual Icon

2. LED INDICATOR
3. AUTO/ACTIVE REGENERATION INHIBIT ICON The Book Icon and DPF software version display at startup
4. PARKED REGENERATION AVAILABLE ICON for approximately 3 seconds.
5. SOOT LEVEL METER
6. AUTO/ACTIVE REGENERATION INHIBIT ON/OFF BUTTON The Book Icon will also be shown when operator attempts
7. PARKED REGENERATION INITIATE BUTTON
to initiate a Parked Regeneration when truck is not in the
8. DEF ICON
9. DEF PERCENTAGE correct state (park brake on, transmission in neutral, etc...).
This icon will also be displayed for 30 seconds following an
Figure 7. DPF Display interrupted Parked Regeneration while DPF cools off. See
Figure 8.
43
www.duma-rent.com
Model Description
CAN Communication Lost Passive Regeneration Only

Regeneration Level 0
Figure 9. CAN Communication Lost Icon

The Wrench Icon is shown when the DPF display looses Figure 10. Empty Soot Meter
communication with ECU. See Figure 9.
NOTE: Empty Soot Meter will flash if no soot level data is
available from ECU. See Figure 10.
44
www.duma-rent.com
Model Description
Auto/Active Regeneration
Figure 11. Partial Soot Level

Soot Meter bars will fill with increasing soot load in DPF. Figure 12. Auto/Active Regeneration
This is an estimate based on multiple ECU parameters.
See Figure 11. NOTE: Auto/Active Regeneration can be inhibited at any
time by the operator pressing the Auto/Active Regeneration
Auto/Active Regeneration will begin when the Soot Meter Inhibit ON/OFF button.
displays 3 bars. If equipped with optional Idle-up feature,
engine idle speed will increase during Auto/Active Regen- Soot meter shows partial soot load. See Figure 12.
eration. 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
45
www.duma-rent.com
Model Description
feature, engine idle speed with 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 13. High Temperature Icon
Auto/Active Regeneration will begin when engine load and
temperature meet appropriate conditions.
During Parked Regeneration, the High Temperature Icon
will be displayed. See Figure 13.
Lift truck operation can continue without any limitation or
loss of power during Auto/Active Regeneration. Higher
engine speeds will lead to a more successful Auto/Active
Regeneration.
46
www.duma-rent.com
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. Optional Idle-up feature
is standard with DuraMatch transmission, not available with
Powershift transmission. When the Soot Meter displays 3 Figure 14. Idle-up Active Range
bars, engine idle speed will increase the first time the oper- Engine Idle-up will start when the Soot Meter reaches 3
ator applies the accelerator pedal. For the duration of the bars and will remain active while 2, 3, or 4 bars are dis-
Auto/Active Regeneration process, minimum engine speed played. See Figure 14. Optional Parked Regeneration is
will be 1200 rpm. still possible at 3 or more Soot Meter bars, but should not
This feature improves the Auto/Active Regeneration clean- be required once Auto/Active Regeneration is complete.
ing process and will take at least 20 minutes to complete. Once Auto/Active Regeneration is complete, engine idle
Lift truck operation can continue without any limitations, but speed returns to normal.
avoid engine shut-down while truck is in Idle-up mode.
47
www.duma-rent.com
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 15. 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
Figure 15.
• 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 15. Parked Regeneration Request ature Icon will be displayed. See Figure 13.
48
www.duma-rent.com
Model Description
Figure 16. DPF Display - 5 Bar Soot Meter Figure 17. 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 17.
49
www.duma-rent.com
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 displays 5 Continued operation of lift truck without performing a
bars. See Figure 16 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 15.
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 15.
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.
50
www.duma-rent.com
Model Description
Diesel Exhaust Fluid (DEF) g. Derate is none.
NOTE: The status of the DEF tank is indicated on the DPF

Display. DPF functionality is unchanged.
Normal DEF
1. At >10% the following is applicable, see Figure 18:
a. DEF quality is Good.
b. DEF level >10%.
c. DEF Icon is ON.
d. DEF Level % is ON.
e. DPF Regen is available. Figure 18. DEF Normal
f. No DTC is shown.
51
www.duma-rent.com
Model Description
Low DEF
1. At <10% the following is applicable, see Figure 19:
b. DEF level <10%.
c. DEF Icon is FLASHING.
e. DPF Regen is available.
f. No DTC is shown.
g. Derate is none.
Figure 19. DEF Low
52
www.duma-rent.com
Model Description
Empty DEF
1. At 0% the following is applicable, see Figure 20:
b. DEF level 0%.
c. DEF Icon is FLASHING.
d. DEF Level % is FLASHING.
e. DPF Regen is unavailable.
f. DTC on dash shown.
g. Engine speed and torque derate.
Figure 20. DEF Empty
2. Fill DEF tank with at least 4 liter (1 gal) to reset DTC and
resume normal operation. See Refilling DEF Tank for fill
procedures.
53
www.duma-rent.com
Model Description
Bad DEF Quality

1. If DEF quality is bad the following is applicable, see Fig-
ure 21:
a. DEF quality is Bad.
b. DEF level Any Level.
c. DEF Icon is ON with Slash.
e. DPF Regen is unavailable.
f. DTC for auto clear shown.
Figure 21. DEF Quality ICON
g. Derate is Level 2.
Operator Controls
(See Table 3 and Figure 22)
WARNING
If any of the controls, instruments, levers, or pedals do
not operate as described in the following tables, report
the problem immediately. Injury to personnel can
occur if the instruments, levers, or pedals do not oper-
ate as described in the following tables. DO NOT oper-
ate the vehicle until the problem is corrected.
54
www.duma-rent.com
Model Description
A. UNITS WITH MONOTROL® PEDAL AND E-HYDRAULICS

B. UNITS WITH DIRECTIONAL CONTROL LEVER AND MANUAL HYDRAULICS
Figure 22. Operator Controls
55
www.duma-rent.com
Model Description
A. INCHING/BRAKE PEDAL D. INCHING/BRAKE PEDAL

B. MONOTROL® PEDAL E. BRAKE PEDAL
C. ACCELERATOR PEDAL
Figure 23. Operator Compartment Pedal Configurations
56
www.duma-rent.com
Model Description
Table 3. Operator Controls (See Figure 22)
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 nor-
mal operation. 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.
57
www.duma-rent.com
Model Description
Table 3. Operator Controls (See Figure 22) (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.
58
www.duma-rent.com
Model Description
Item
Item Function
No.
5 Parking Brake Lever
WARNING
Correct adjustment is necessary to provide adequate braking. Injury to per-
sonnel can occur if parking brake is not adjusted correctly. See the Mainte-
nance section for adjustment procedures.
Always apply the parking brake when leaving the lift truck.
CAUTION
Damage to lift truck and equipment can occur if parking brake is not applied
when operator leaves 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 oper-
ator 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.
59
www.duma-rent.com
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 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.
60
www.duma-rent.com
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.
61
www.duma-rent.com
Model Description
Item
Item Function
No.
8 Lift/Lower Control
CAUTION
Lever
If the lift truck is equipped with a 3-stage mast, in circumstances where
overhead clearance is restricted, be sure inner mast/carriage does not
extend before full free lift of the mast is reached.
NOTE: Cold hydraulic oil and high oil flow rates may cause the inner mast to
extend above the outer mast before full free lift is reached. The hydraulic oil must
be hot if the lift truck is to be operated where overhead clearance is restricted.
To assure hydraulic oil is hot, operate mast at full lift speed and observe for
movement of the inner mast before full free lift is reached. If any inner mast
movement occurs, fully lower carriage, place the transmission into neutral, set the
park brake, and then hold the tilt mini-lever fully open at engine governed speed
for approximately 3 minutes.
Repeat above procedure until no movement of the inner mast is observed, then
proceed with lift truck operation.
62
www.duma-rent.com
Model Description
Item
Item Function
No.
8 Lift/Lower Control NOTE: Manual hydraulic control levers are standard on the trucks covered in this
(cont) Lever manual (see Figure 22). Electronic hydraulic mini-levers (see Figure 22) are
available as an optional control feature for the hydraulic functions.
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 the lever backward toward the operator to
raise the carriage and forks. Push the lever forward to lower the carriage and
forks.
63
www.duma-rent.com
Model Description
Item
Item Function
No.
9 Tilt Control Lever NOTE: Manual hydraulic control levers are standard on the trucks covered in this
manual (see Figure 22). Electronic hydraulic mini-levers (see Figure 22) are
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.
These trucks can be equipped with the Return to Set Tilt (RTST) option if truck
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.
64
www.duma-rent.com
Model Description
Item
Item Function
No.
9 Tilt Control Lever When tilt set point delay feature is used in setup hydraulics, a timer can be set so
(cont) the override button is not used. The operator keeps the tilt mini-lever actuated for
the programmed amount of time (0.1 to 3.0 seconds). The RTST will be overrid-
den, and tilt will continue.
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.
65
www.duma-rent.com
Model Description
Item
Item Function
No.
10 Manual Control Lever for Auxili- NOTE: A manual control lever with a detent must be installed when an attach-
ary Hydraulic Functions (3rd ment with a clamp is installed. See your dealer for Hyster lift trucks to get the cor-
lever). See Figure 22. rect control lever.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
NOTE: If truck is equipped with only three levers and clamp attachment, the last
(3rd) lever controls clamp functions.
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.
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.
66
www.duma-rent.com
Model Description
Item
Item Function
No.
10 Electronic Control Mini-Lever NOTE: The lift trucks covered in this Operating Manual may be equipped with
for Auxiliary Hydraulic Func- optional electronic hydraulic mini-levers that are available for the hydraulic func-
tions (3rd lever). See Fig- tions.
ure 22.
NOTE: If truck is equipped with only three levers and clamp attachment, the last
(3rd) lever controls clamp functions.
The third electronic control mini-lever is installed to the right of the electronic tilt
control lever. This lever can have two methods of operation, depending on the
attachment.
Trucks with Clamp Attachment: To engage the clamp, move the mini-lever
1. OVERRIDE BUTTON backward. To disengage the clamp, momentarily push and release the override
button located directly behind the mini-lever and push the mini-lever forward.
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.
67
www.duma-rent.com
Model Description
Item
Item Function
No.
11 Manual Control Lever for Auxili- NOTE: A manual control lever with a detent must be installed when an attach-
ary Hydraulic Functions (4th ment with a clamp is installed. See your dealer for Hyster lift trucks to get the cor-
lever). See Figure 22. rect control lever.
NOTE: Manual hydraulic control levers are standard on the trucks covered in this
NOTE: If truck is equipped with four levers and clamp attachment, the last (4th)
lever controls clamp functions.
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.
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.
68
www.duma-rent.com
Model Description
Item
Item Function
No.
11 Electronic Control Mini-Lever NOTE: The lift trucks covered in this Operating Manual may be equipped with
for Auxiliary Hydraulic Func- optional electronic hydraulic mini-levers that are available for the hydraulic func-
tions (4th lever). See Figure 22. tions.
NOTE: If truck is equipped with four levers and clamp attachment, the last (4th)
lever controls clamp functions.
The fourth electronic control lever is installed to the right of the third electronic
control lever. This lever can have two methods of operation, depending on the
attachment.
1. OVERRIDE BUTTON 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.
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.
69
www.duma-rent.com
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 MON-
OTROL® pedal. The Direction Control Lever has three positions that are indica-
ted by three green lights on left side of Display Switch Cluster (see Figure 6 and
Table 2): FORWARD, NEUTRAL (N), and REVERSE. Move the lever to one of
the direction positions for travel. The Direction Control Lever must be in the NEU-
TRAL (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.
If lift truck is equipped with a MONOTROL® pedal, the lever on the left side of the
Display Switch Cluster functions as the turn signal lever. Push the lever up to sig-
nal a right turn. Pull the lever down to signal a left turn.
70
www.duma-rent.com
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 cir-
cuit. 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. Push-
Pedal ing 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.
71
www.duma-rent.com
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 Turn Signal If lift truck is not equipped with a MONOTROL® pedal, the turn signal lever is on
Lever the right side of the Display Switch Cluster. Push the lever up to signal a left turn.
Pull the lever down to signal a right turn.
17 Direction The direction control switch for the transmission is next to the auxiliary horn but-
Control ton on the armrest. The direction control switch is used on lift trucks without a
Switch MONOTROL® pedal.
72
www.duma-rent.com
Model Description
Item
Item Function
No.
18 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.
73
www.duma-rent.com
Model Description
Auxiliary Control Levers

Table 4. 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
74
www.duma-rent.com
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. Injury to
personnel can result if engine exhaust gases are not
WARNING adequately ventilated.
Always make sure the parking brake is fully applied Follow the inspection and maintenance schedule and
before leaving the lift truck. If the operator leaves the procedures in this manual. Do not alter exhaust, igni-
lift truck without applying the parking brake, a seat tion, or fuel systems.
activated switch will shift the transmission to neutral,
and sound an alarm for 10 seconds. If the lift truck is WARNING
left on a grade, without the parking brake fully applied, FIRE HAZARD
the lift truck will freewheel down the grade, possibly The hot engine surfaces and exhaust of internal com-
causing injury or property damage. bustion engine powered lift trucks can present fire haz-
ards when operating in areas containing flammable
WARNING gases, vapors, liquids, dusts, fibers, or paper debris.
EXHAUST GASES Engine and exhaust component surface temperatures
Exhaust from internal combustion engines contains can exceed the ignition temperatures of common sol-
carbon monoxide and other harmful chemicals. Carbon vents, fuels, oil, paper, and other organic materials
monoxide is a colorless, odorless poison and can (wood, wheat, cotton, etc.). Exhaust emitted sparks
cause unconsciousness or death without warning. can ignite these materials as well. Engine and exhaust
Long-term exposure to exhaust or chemicals in the surface temperatures increase after engine shutoff,
exhaust can cause cancer, birth defects, and other presenting increased fire hazard. Check the engine
reproductive harm. Avoid exposure to engine exhaust. compartment frequently in areas containing
75
www.duma-rent.com
combustible dust, fibers, or paper and remove any for-
eign materials. Contact your local Hyster dealer for
forklift modifications that may be appropriate in envi-
ronments with fire hazards.
Operate the lift truck only in areas that have been
approved for lift truck operation.
Only the designated types of approved lift trucks may
The lift truck is based on the principle of two weights bal-
be used in areas classified as hazardous by the author-
anced on opposite sides of a pivot (fulcrum). This is the
ity having jurisdiction. Areas classified as hazardous
same principle used for a seesaw. In order for this principle
must be identified by signs to show the type of
to work for a lift truck, the load on the forks must be bal-
approved lift truck required for operation in the area.
anced by the weight of the lift truck. The location of the
Modifications or poor maintenance can result in the lift
center of gravity of both the truck and the load is also a fac-
truck being unsuitable for operation in areas classified
tor.
as hazardous.
This basic principle is used for picking up a load. The ability
The fork lift truck is designed to pickup, move, and stack
of the lift truck to handle a load is discussed in terms of
materials. The basic lift truck has a lift mechanism and
center of gravity and both forward and side stability.
forks on the front to engage the load. The lift mechanism
lifts the load so that it can be moved and stacked.
In order to understand how the fork lift truck can pick up a
load, you must first know some basic things about the lift
truck.
76
www.duma-rent.com
Stability and Center of Gravity ted forward and back. The CG moves up and down as the
mast moves up and down.
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
A. CG LOAD B. CG TRUCK C. COMBINED CG
size, weight, shape, and position of the load; the height to
which the load is raised; the amount of forward and back-
The stability of the lift truck is determined by the location of ward tilt; tire pressure and the dynamic forces created
its CG, or if the truck is loaded, the combined CG. when the truck is moving. These dynamic forces are
caused by things like acceleration, braking, turning, and
The lift truck has moving parts and therefore has a CG that
operating on uneven surfaces or on an incline. These fac-
moves. The CG moves forward and back as the mast is til-
tors must be considered when traveling with an unloaded
77
www.duma-rent.com
truck, as well, because an unloaded truck will tip over to Capacity (Weight and Load Center)
the side easier than a loaded truck with its load in the low-
ered position. The capacity of the lift truck is shown on the Nameplate.
The capacity is listed in terms of weight and load center.
In order for the lift truck to be stable (not tip over forward or The weight is specified in kilograms and pounds. The load
to the side), the CG must stay within the area of the lift center is specified in millimeters and inches. The capacity
truck represented by a triangle drawn between the drive is the maximum load that the lift truck can handle, with the
axle and the pivot of the steering axle. mast vertical, for the load condition shown on the Name-
plate.
A. DRIVE AXLE B. STEERING AXLE C. TRUCK WILL TIP OVER
If the CG moves forward of the drive axle, the lift truck will
tip forward. If the CG moves outside of the line represented The load center of a load is determined by the location of
by the lines drawn between the drive wheels and the steer- its center of gravity. The load center is measured from the
ing axle pivot, the lift truck will tip to that side. front face of the forks, or the load face of an attachment, to
78
www.duma-rent.com
the center of gravity of the load. Both the vertical and hori- • The message "Impact Shutdown" will be displayed on
zontal load centers are specified on the Nameplate. the top line of the LCD screen (see Figure 6) and the
message "Engine Shutdown in XX" will be displayed on
Loads should be transported while centered on the center-
the bottom line of the LCD screen. XX represents the
line of the lift truck. The operator must know whether or not
number of seconds before the engine shuts down and is
a load is within the maximum capacity of the lift truck
factory set. If the delay is 0 seconds, the engine shuts
before the load is handled.
down immediately and the message is not displayed.
Impact Sensor • After delay (XX, above) has elapsed, the engine will
The lift trucks covered in this Operating Manual may be immediately shutdown. The transmission and electro-
equipped with an optional impact sensor that can be ena- hydraulic functions will also shutdown. If a load is in the
bled or disabled by a service technician or a supervisor. raised position and needs to be lowered, see Load Han-
The impact sensor will sense when the lift truck has hit an dling, Emergency Load Lowering and Figure 27 in
object, and will cause the lift truck to shutdown. There are this section to lower the load.
two types of impact that the Vehicle System Manager • The message "Impact Shutdown" will be displayed on
(VSM) recognizes: soft impact and hard impact. the top line of the LCD screen and the message "Super-
The data parameters that determine whether an impact is a visor Required" will be displayed on the bottom line of
soft or hard one are entered into the lift truck's VSM by per- the LCD screen.
sonnel with a service or supervisor password (see Opera- The lift truck can be turned on again, after delay has
tor Passwords in this section). elapsed, but the engine cannot be restarted until the
If the impact sensor option is enabled and an impact has Impact Sensor is reset by a supervisor or service techni-
been detected, the following actions will occur: cian (see Engine Shutdown in this section) for procedures
to start lift truck after an engine shutdown). The messages
• An alarm will sound. The duration of the alarm is set by "Impact Shutdown" and "Supervisor Required" will continue
a service technician or a supervisor.
79
www.duma-rent.com
to be displayed on the LCD screen. Pressing the STAR (*)
key will display the password entry menu. If the Impact Checks With the Engine Stopped
Alarm duration has been set to "Continuous," the alarm will
continue to sound when lift truck power has been turned Inspect the lift truck before use and every eight hours or
ON. daily as described in the Maintenance section of this
Operating Manual. Inspect more frequently if used in
To clear messages, turn off alarm, and reset truck to nor-
severe operating conditions.
mal operation, an Impact Reset must be performed by
either a service technician or supervisor. See Hyster Serv- Before using the lift truck, make the following checks:
ice Manuals User Interface, Supervisor 2200 SRM 1130
• Condition of forks, carriage, chains, header hoses, mast,
or User Interface, Service 2200 SRM 1131 for proce-
attachment, and overhead guard.
dures.
• Condition of wheels and tires.
Inspection Before Operation
• Seat belt fastens correctly.
WARNING • Seat is correctly fastened to its mounts. Hood is cor-
Report damage or faulty operation immediately. Do not rectly latched.
operate a lift truck that needs repair. A lift truck will
only do its job when it is in proper working order. • Condition of the engine compartment. Ensure all surfa-
Injury to personnel can result if lift truck is operated ces are free of oils, lubricants, fuel, and organic dusts or
when not in proper working order. If repairs are fibers (paper, wood, cotton, agricultural grass/grain,
required, install a tag in the operator's area stating "DO etc.). Remove all foreign materials.
NOT OPERATE" and remove the key from the key • Coolant level in the cooling system and condition of the
switch if truck is equipped with key switch option. drive belts.
• Condition of the radiator and screen. Clean if necessary.
80
www.duma-rent.com
• Fuel level. to press button #1 for YES or button #2 for NO on the Dis-
play Switch Cluster. See Figure 5.
• Oil level in the engine.
If any checklist item is answered with a NO response, the
• Oil level in the hydraulic tank.
checklist item will be repeated. If a NO response is given
• Leaks from the engine, transmission, hydraulic system, again, the checklist item will be logged into the Checklist
and fuel system. Log as a FAIL. When the checklist fails due to a NO
answer, the display stops changing. No additional checklist
• Loose or missing hardware.
items are shown.
• Check transmission oil level.
Once the checklist has been completed and all items were
Operator Checklist answered with YES, the operator can start the lift truck. If
there were any NO answers to checklist items, the truck
If your lift truck is equipped with the optional operator may or may not start. The lift truck can be set up to not
checklist, it can be enabled or disabled by a supervisor or start (starter, engine outputs, transmission and hydraulic
service technician. functions disabled) if any item in the checklist is answered
The operator checklist will appear on the LCD screen after with a NO response. If lift truck is configured this way, the
the lift truck has been powered ON and operator has message "Truck Disabled" will appear on the first line of
entered the correct password, if the password function is the LCD screen and the message "Checklist Failed" will
activated. If password function is not activated, operator appear on the second line. The lift truck will stay disabled
checklist appears after lift truck is powered ON. and messages will continue to appear on the LCD screen
until lift truck has been reset by either a supervisor or serv-
The operator checklist can store a maximum of 30 items. ice technician.
Each item includes a text description of a system or com-
ponent the operator is to check. The operator is instructed If lift truck is configured to start after a NO response had
been given to a checklist item, the failure will be logged into
81
www.duma-rent.com
Checklist Log and operator will be allowed to start the lift actions are not performed while operating the lift truck,
truck. traction will be disabled. To reactivate traction, the operator
must return to the seat and press the brake pedal. Once
Mounting and Dismounting the needed actions are completed, traction will be enabled
and the operator can continue to load and unload material.
WARNING
To avoid serious injury when entering or exiting the lift HYDRAULIC INTERLOCKS: The hydraulic functions are
truck, ALWAYS USE 3 POINTS OF CONTACT. Maintain enabled when the operator is in the seat (occupancy sen-
contact simultaneously with two hands and one foot or sor), seat belt should be fastened, and the engine is run-
with two feet and one hand while climbing on or off the ning. If any of the above actions are not performed while
lift truck. operating the lift truck, the hydraulic functions will be disa-
bled. The LCD screen on the display panel will provide a
Place feet carefully. Always face the lift truck when climb- non-service fault message "Hydraulic Interlock Engaged."
ing on or off. Use added care when surfaces are slippery. To reactivate hydraulics, the operator must return to the
Keep hands free of any obstacles such as food, beverages, seat and press the brake pedal. Once the needed actions
or tools. are completed, the hydraulic function will be enabled and
the operator can continue to load and unload material.
Lift Truck Interlocks
Certain operator actions, if not performed correctly while
Operator Passwords
operating the lift truck, will cause traction and the hydraulic The lift trucks covered in this manual have an optional
functions to become disabled. password feature.
DRIVE INTERLOCKS: Traction is enabled when the oper- The Operator Passwords are a series of five numbers.
ator is in the seat (occupancy sensor), seat belt should be Each of the five number digits can be the numbers 1
fastened, a direction of travel is selected, engine is running, through 5. If enabled, the password number series must be
and the parking brake is released. If any of the above entered into the memory by a technician or a supervisor
82
www.duma-rent.com
and assigned to an operator. Remember the password. A If the optional password feature is enabled and after the
technician can use a personal computer (PC), connected to key is moved to the ON position, or the Power ON/OFF
the vehicle, to check as well as assign the passwords. button is pressed, the LCD screen will show the message
PASSWORD ENTRY. Use the numbered push buttons
There are four password types used on these trucks:
(see Figure 5 and Table 1) to enter the five digit password
• Operator: Allows operator to operate lift truck. and then press the STAR (*) button to enter the password
and access main menu. If the password is entered incor-
• Lockout Reset: Lockout will occur when an operator
rectly, and truck is not locked out, the message PASS-
incorrectly enters their password a specified number of
WORD INVALID and DISABLED IN ###, with ### being
times. After lockout occurs the following message will
the number of attempts remaining before lockout occurs.
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: Same rights as the Service Level pass-
OUT, SUPERVISOR REQUIRED is displayed. A Lockout
word, except Supervisor Level password cannot add,
Reset, Supervisor, or Service password is needed to
change, or delete Service Level passwords.
unlock the lift truck. System power can be turned OFF,
• Service: Has all rights assigned to Operator, Lockout while in lockout mode by turning key switch to OFF or
Reset, and Supervisor passwords. Can add, edit, and pressing the Power ON/OFF button. To reset a system
delete Operator, Supervisor, and Service passwords lockout that occurs while attempting to enter a password
and view all truck diagnostic information. Allows access within the on-board menu, after a correct operator pass-
to truck service parameters within preset limits. On word has been entered, recycle the system power. For all
trucks with hood switch option, allows starting truck with other lockout conditions, cycling the truck power will not
hood open. reset the lockout.
83
www.duma-rent.com
Starting Procedures 1. If the lift truck uses LPG fuel, open the fuel valve on the
LPG tank.
Do not start or operate the lift truck,
including any of its functions or attach- 2. Make sure lift truck hood is closed.
ments, from any place other than the des- 3. Sit in operator's seat and fasten seat belt
ignated operator's position.
4. Make sure the parking brake is applied.
If lift truck is equipped with the optional
operator presence system, the following 5. If equipped, put the direction control lever for the trans-
sequence must be followed for engine to mission in the NEUTRAL (N) position.
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 engine is cold, the cold start indicator
• Set belt must be fastened light will illuminate and the cold start circuit will be ener-
• Make sure park brake is applied gized.
If equipped, be sure cab door is secured in either the 7. If the truck is equipped with Operator Password feature,
opened or closed position before starting lift truck opera- enter correct password.
tion. 8. If the truck is equipped with a diesel engine and the cold
start indicator light is illuminate wait for the light to go out.
WARNING
LPG is very flammable and can cause serious injury to 9. Turn the key to the START position or press and hold
personnel if ignited. An odor of LPG fuel can indicate a the Engine Start button to engage the starter. A countdown
leak in the fuel system. DO NOT start the engine until timer will appear on the LCD screen and limit the cranking
the fuel leak is repaired and the atmosphere is free of time.
LPG.
84
www.duma-rent.com
10. When the engine starts, check to see that the oil pres-
sure lamp and charge lamp are off. If the lamps are still on, Checks With the Engine Running
immediately stop the engine, and determine the cause
before restarting.
11. Warm up the engine at medium speed without load.
If engine fails to start before the cranking countdown timer
reaches zero, the starter will shut down for a cooling off
period. A countdown timer will appear on the LCD screen
showing the time remaining before another start can be
tried.
To attempt another start procedures, repeat Step 6 through
Step 11.
Stop Procedures, Diesel Engine
On lift trucks equipped with a diesel engine, allow the
engine to idle for 5 minutes before shutting it off after full
load operation. Failure to do so may result in turbo charger
damage.
WARNING
FASTEN SEAT BELT
If Lift Truck Tips Over
• Do Not Jump – Stay On Truck
85
www.duma-rent.com
• Hold Firmly To Steering Wheel – Brace Feet – Lean Check the operation of the following functions as described
Forward And Away From Impact in the Maintenance section:
The seat belt is installed to help the operator stay on • Check the operation of the horn and indicator lights.
the truck if the lift truck tips over. IT CAN ONLY HELP
• Operate the LIFT, TILT, and auxiliary functions to check
IF IT IS FASTENED.
for correct operation of the mast, carriage, and attach-
The operator must be aware that the lift truck can tip over. ments.
There is a great risk that the operator or someone else can
• Check the operation of the MONOTROL® pedal or the
be killed or injured if trapped or hit by the truck as it tips
optional direction control lever and accelerator pedal.
over. The risk of injury can be reduced if the operator stays
on the truck. If the truck tips over, do not jump off! • Check the operation of the service brakes and parking
brake.
THE SEAT BELT AND HIP RESTRAINT bracket provides
a means to help the operator keep the head and torso sub- • Check the operation of the steering system.
stantially within the confines of the truck frame and over-
• Check the oil level in the transmission when the oil is at
head guard if a tipover occurs. This protection system is
operating temperature 50 °C (120 °F). Turn the truck off
intended to reduce the risk of the head and torso being
and wait one minute. Then check the transmission oil
trapped between the truck and the ground, but it can not
level.
protect the operator against all possible injury in a tipover.
Make sure that the area around the lift truck is clear before Load Weighing Sensor
starting the engine or making any operational checks. Be If your lift truck is equipped with the optional load weight
careful when making the checks. If the lift truck is station- sensor, it can display the weight of the load in either
ary during a check, apply the parking brake and make sure pounds or kilograms on the LCD screen (see Figure 6).
the direction control is in NEUTRAL. Proceed carefully. The unit of measure is preset by a service technician or a
86
www.duma-rent.com
supervisor and can be changed by a service technician or 1130 or User Interface - Service Technician 2200 SRM
supervisor. 1131 for procedures.
The operator can access the load weight function by press- Engine Shutdown
ing the up or down arrow keys on the Display Switch Clus-
ter (see Table 1), until the word "Weight" appears on the NOTE: The information in this section pertains to lift trucks
LCD screen. See Figure 6. with the powertrain protection option. On trucks without
powertrain protection, the fault number is displayed on the
To most accurately weigh a load, follow these instructions: LCD screen and the Engine Malfunction icon will illuminate,
1. With a load on the forks, position the mast in a vertical but engine will not shutdown or truck performance will not
position. be decreased. DO NOT continue to run lift truck. Turn
engine OFF and notify service technician immediately
2. Lift the load 0.6 m (2 ft) off the ground, but if free-lift cyl- for repair.
inder is present, not more than maximum free lift.
Certain faults or sensor measurements can cause the truck
3. Lower the load 51 mm (2 in.). Stop lowering, wait 1 sec- to go into Engine Shutdown mode. The following actions
ond, and read the load weight. This will be the most accu- occur when truck is in this mode:
rate weight. Waiting longer to read the load weight will
reduce accuracy. • The fault number is displayed on the top line of the LCD
screen and a 30-second countdown timer is shown on
Set Load Weight to Zero the bottom line.
The service technician or supervisor can set the load • An alarm will sound during the 30-second countdown
weight to zero, when the no-load weight displayed on the and continue for 10 seconds afterwards.
LCD screen (see Figure 6) is not within ±2% of truck
• The Engine Malfunction icon illuminates. If engine shut-
capacity. See User Interface - Supervisor 2200 SRM
down was caused by low coolant level, low engine oil
pressure, high coolant temperature, or high transmission
87
www.duma-rent.com
oil temperature, the appropriate icon will also be illumi- ess provides enough power for the lift truck to move under
nated. See Figure 6 and Table 1. its own power so that it can be moved to a safe location.
At the end of the 30-second countdown, all power to the lift Some faults or sensor measurements will not always cause
truck is turned off. After shutdown has occurred, recycle the engine to shutdown, but will cause the speed of the lift
power to ON, load can then be lowered without starting the truck to be restricted, or will either disable or restrict the
engine. truck's hydraulic functions.
When this occurs, the following actions take place:
CAUTION
If lift truck experiences an engine shutdown, call a • The fault number is displayed on the top line of the LCD
service technician immediately. Continued operation of screen and a description of truck performance being
lift truck after engine shutdown can cause damage to decreased is shown on bottom line.
the lift truck and its components.
• The Engine Malfunction icon illuminates (see Figure 6
To restart the lift truck, turn the key switch OFF and ON and Table 2).
again to cycle the system power. If lift truck is equipped
• An alarm will sound for 10 seconds.
with the Power ON/OFF button, press Power ON/OFF but-
ton twice to cycle the system power and then press the Take the lift truck to a service technician immediately for
Engine Start button. If the Engine Start button is pressed repair if it experiences a decrease in performance.
before the Power ON/OFF button, the starter will not oper-
ate. See Starting Procedures in this section, if starter
becomes disabled.
When the lift truck has been restarted, it will run for 30 sec-
onds before shutting down again. Cycle the truck power
again to run the lift truck for another 30 seconds. This proc-
88
www.duma-rent.com
Operating Techniques Basic Operating Procedures

Many people make the mistake of thinking that operating a
WARNING
lift truck is the same as driving an automobile. This is not
Before operating the lift truck,
true. A lift truck is a special machine designed to do a
FASTEN YOUR SEAT BELT.
much different job than an automobile. Because of the
Failure to fasten seat belt may close areas in which a lift truck operates and its other oper-
result in injury to personnel. ating characteristics (like rear wheel steering and tail
swing), every operator must receive additional training,
There are a number of operations, if not performed
even if they have a license to drive an automobile.
carefully, that can cause the lift truck to tip. If you have
not read the WARNING page in the front of this Operat- The following discussion lists basic procedures applicable
ing Manual, do so NOW. As you study the following to lift truck operation.
information about how to properly operate a lift truck,
1. AUTHORIZED AND TRAINED
remember the WARNINGS.
OPERATOR ONLY. This means
NOTE: Lift trucks covered in this manual are equipped with the operator must be trained to
the Emergency Locking Retractor (ELR) style seat belt. drive the lift truck and it means that
When the ELR seat belt is properly buckled across the the operator must thoroughly
operator, the belt will permit slight operator repositioning understand the procedures for lift
without activating the locking mechanism. If the truck tips, truck operation. It also means that
travels off a dock, or comes to a sudden stop, the locking a qualified person experienced in lift truck operation must
mechanism will be activated and hold the operator's lower guide the operator through several driving and load han-
torso in the seat. dling operations before the operator attempts to operate
the lift truck alone. A basic education in proper driving and
load handling techniques is absolutely necessary to
89
www.duma-rent.com
prepare the new operator for proper defensive driving and Before anyone is allowed in the platform, lift and lower
to expect the unexpected. the mast slowly with the platform in place to make sure
the mast functions properly. Apply the parking brake.
WARNING Do not travel with people in the platform. The operator
This lift truck is designed for handling materials. A lift must remain at the controls. Watch for overhead
truck is not designed to lift people. Do not use a lift obstructions.
truck to lift people unless it has been determined that
2. NO RIDERS. A lift truck is built for only
there is no other practical option (scaffolds, elevated
one person – the operator. It is danger-
work platforms, aerial baskets, etc.) to perform the
ous for anyone to ride on the forks or any-
needed work.
where else on the lift truck.
If a lift truck is used to elevate a
3. ADJUST SEAT - INTERNAL SUSPEN-
worker, a safety platform must be
SION.
attached to the forks and carriage.
The platform must have a solid Seat Position Adjustment (Swivel Seat)
floor with a surface to prevent the
• The seat swivels 10.5 degrees to the right to allow the
feet of the worker from slipping,
operator a more ergonomic position when driving in
hand rail, toe board, and a screen
reverse.
or shield at least 2 m (7 ft) high
between the people on the platform and the lift mecha- • The seat swivels 5 degrees to the left to allow an easier
nism. exit of the truck.
The combined weight of the platform, load, and per- • The neutral position is shown in Figure 24.
sonnel is not to exceed one-half of the capacity as indi-
cated on the nameplate of the truck on which the
platform is used.
90
www.duma-rent.com
Seat Adjustment for Operator Weight • The measured vibration levels measured to EN13059
are noted in the front of this manual in the Foreword
CAUTION section.
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
NOTE: It is important to adjust the weight setting for each
operator.
NOTE: The seat is designed for a maximum weight of
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
operator is set at the midpoint of the 40 mm (1.57 in.)
suspension.
• The weight adjustment knob can be turned left or right to
increase or decrease the weight resistance. As the
weight adjustment knob is turned the "stiffness" of the
suspension can be felt to increase or decrease depend-
ing on which way the weight adjustment knob is turned.
Figure 24. Seat Adjustment - Internal Suspension
91
www.duma-rent.com
Legend for Figure 24 NOTE: It is important to adjust the weight setting for each
1. SEAT BELT 5. BACKREST ANGLE
operator.
2. WEIGHT ADJUSTMENT ADJUSTMENT LEVER
NOTE: The seat is designed for a maximum weight of
KNOB 6. ARMREST
3. RIDE POSITION 7. SWIVEL LATCH RELEASE 135 kg (298 lb)
INDICATOR LEVER
4. FORWARD/BACKWARD
• The target is for the "ride indicator" to fall between the
ADJUSTMENT LEVER arrows when the operator sits upright in the seat with the
feet positioned on the pedals. This ensures that the
4. ADJUST SEAT - FULL SUSPENSION. operator is set at the midpoint of the 80 mm (3.5 in.)
suspension.
Seat Position Adjustment (Swivel Seat)
• The handle can be turned as shown to increase or
• The seat swivels 12 degrees to the right to allow the decrease the weight resistance, pull handle out before
operator a more ergonomic position when driving in turning. As the handle is turned the "stiffness" of the
reverse. 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 handle is turned.
exit of the truck. • The measured vibration levels measured to EN13059
• The neutral position is shown in Figure 25. are noted in the front of this manual in the Foreword
section.
Seat Adjustment for Operator Weight
CAUTION
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight.
92
www.duma-rent.com
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
Figure 25. Seat Adjustment - Full Suspension
93
www.duma-rent.com
5. Do not drive a lift truck into an elevator unless authorized 6. Drive carefully, observe traffic rules, and be in
to do so. Approach the elevator slowly. After the elevator is full control of the lift truck at all times. Be com-
properly leveled, the lift truck must be centered so that the pletely familiar with all the driving and load han-
elevator is balanced. dling 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 either
a Powershift 2 Speed Transmission, DuraMatch Transmis-
sion (3-speed), a DuraMatch Plus Transmission (3-speed),
Powershift Transmission, DuraMatch Transmission, or
DuraMatch AH Transmission. Read the following sections
carefully. See Table 5 and Figure 26 for the features and
When the lift truck is in the proper position in the elevator, operational differences in these transmission types.
set the brakes, put the controls in NEUTRAL and shut off
the power. It is advisable that all other personnel leave the
elevator before the lift truck enters or leaves.
94
www.duma-rent.com
Table 5. Transmissions
Powershift 2 Speed DuraMatch Plus (3-Speed)
Operational Feature DuraMatch (3-Speed)
or Powershift or DuraMatch AH
Electronic Inching No Yes Yes
Auto Deceleration No Yes Yes
Electronic Control of Direction Changes Yes Yes Yes
Controlled Power Reversal No Yes Yes
Roll Back Feature No Yes Yes
Roll Reduction Feature No Yes Yes
Reduced Drive Tire Slippage No Yes Yes
Throttle Up No No Yes
95
www.duma-rent.com
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 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-
ing, the lift truck can only be maintained at a stopped posi-
tion by applying the service brake or parking brake.
When moving away from a stop:
1. Select direction while maintaining braking.
1. POWERSHIFT 2 SPEED TRANSMISSION LABEL
2. DURAMATCH TRANSMISSION LABEL 2. Depress the accelerator or MONOTROL® pedal.
3. DURAMATCH PLUS TRANSMISSION LABEL
4. POWERSHIFT LABEL 3. Release the brakes (parking and/or service brake)
5. DURAMATCH LABEL
6. DURAMATCH AH LABEL Depress the accelerator or MONOTROL® pedal to ensure
the lift truck will move in the selected direction when the
Figure 26. Transmission Labels brakes are released.
General Due to variable load and grade conditions, this procedure
The lift truck can have either a MONOTROL® pedal or a minimizes the possibility of the lift truck traveling in a direc-
Direction Control Lever to control the transmission. The tion opposite to the one selected.
selected direction of travel is shown on the display switch
cluster. See Figure 6. If the lift truck has a MONOTROL®
96
www.duma-rent.com
Standard Operator Presence System tor leaves the seat of the lift truck with the engine running
and without applying the parking brake.
WARNING
If the lift truck is equipped with a Direction Control Lever
Always make sure the parking brake is fully applied
and the operator leaves the seat without engaging the
before leaving the lift truck. If the operator leaves the
parking brake, the N indicator light on the Display Switch
lift truck without applying the parking brake, a seat
Cluster will illuminate regardless of the position of the
activated switch will shift the transmission to neutral,
Direction Control Lever. When the operator returns to the
and sound an alarm for 10 seconds. If the lift truck is
seat, to resume travel, the Direction Control Lever must be
left on a grade, without the parking brake fully applied,
moved to the N position, then to the desired direction of
the lift truck will freewheel down the grade, possibly
travel.
causing injury or property damage.
If the lift truck is equipped with a MONOTROL® pedal and
The lift trucks covered in this Operating Manual are equip-
the operator leaves the seat without engaging the parking
ped with an Operator Presence System (OPS). The OPS
brake, the N indicator light on the Display Switch Cluster
feature has an electrical switch in the seat which senses
will illuminate regardless of the position of the MONO-
the presence of the operator. This allows the transmission
TROL® pedal. When the operator returns to the seat, the
in internal combustion engine trucks to be engaged only
indicator light will change from N to the direction of travel
when the operator is in the seat. The OPS is designed with
that the MONOTROL® pedal was last in when the operator
slight delay in the seat switch to allow the operator to repo-
left the lift truck. The operator can resume travel by
sition himself without disengaging the transmission. When
depressing the MONOTROL® pedal.
the seat switch disengages the transmission (neutral posi-
tion), the operator must depress the service brake pedal to
re-engage the traction (travel mode).
A switch in the operator's seat will automatically shift the
transmission to neutral within 1-2 seconds when the opera-
97
www.duma-rent.com
Optional Operator Presence System Powershift 2 Speed Transmission or Powershift
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 INDICATOR LIGHTS
The seat switch will automatically disable hydraulics within

1-2 seconds when the operator leaves the seat of the lift CAUTION
truck. When the seat switch disables the hydraulic func- The drive train can be damaged if the lift truck is travel-
tions, the operator must sit in the seat and depress the ing too fast when the controls are changed to the
service brake pedal to re-engage hydraulic functions. opposite direction of travel.
The operator can change the direction of travel at slow
travel speeds (less than a walking speed), but the mast
98
www.duma-rent.com
must not be in a raised position. If the lift truck is moving The factory settings for the Controlled Power Reversal
rapidly, slow to a walking speed before changing the direc- feature can be changed by a Hyster Service Technician
tion of travel. when required to meet special application require-
ments.
DuraMatch, DuraMatch Plus, and Duramatch AH
Transmissions The DuraMatch and DuraMatch Plus transmissions allow
the operator to change direction at any travel speed without
The DuraMatch, DuraMatch Plus, and Duramatch AH
damaging the transmission. The operator shoud always
Transmissions are equipped with Controlled Power Rever-
consider the load that is being carried, and keep the car-
sal, Auto Deceleration, Roll Reduction, Roll Back, and
riage lowered, when making a controlled power reversal or
Reduced Drive Tire Slippage features. See Table 5. Oper-
using transmission braking. The operator is responsible for
ators should be trained and become familiar with these
control of the truck and the stability of the load.
operating features before transporting loads.
When a direction change is selected, the lift truck's Vehicle
The DuraMatch Plus and Duramatch AH (three speeds for-
Management System (VSM) automatically reduces engine
ward, two speeds reverse) transmission contain the same
speed to idle and activates transmission braking. The oper-
features a the DuraMatch transmissions, and also two
ator controls the level of transmission braking, or decelera-
more features: Auto-Speed Hydraulics and Throttle
tion, with the use of the accelerator or MONOTROL®
Response Management. See Table 5.
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
due to rapid direction reversals and unstable loads. truck stops and travel direction changes, the normal control
99
www.duma-rent.com
of the accelerator or MONOTROL® pedal returns. The Roll Reduction Feature
operator should always consider the load that is being car-
ried, and keep the carriage lowered, when making a con- WARNING
trolled power reversal or using transmission braking. The lift truck is only considered at a controlled stop
when the truck is not rolling and the service or parking
Auto-Deceleration Feature
brake is applied. The operator cannot rely on transmis-
sion braking alone to bring the lift truck to a full con-
WARNING
trolled stop. Failure to use the service or parking
The factory settings are set for most load handling
brakes could result in damage to the lift truck and/or
applications, but may require adjustment for special
injury to personnel.
applications to avoid load damage or personal injury
due to rapid direction reversals and unstable loads. Provides limited transmission braking to stop the lift truck
The factory settings for the Auto-Deceleration feature from rolling on level ground or to limit vehicle speeds to
can be changed by a Hyster Service Technician when less than slow walking speed on minor grades. This feature
required to meet special application requirements. will attempt to stop the lift truck when the transmission is in
either FORWARD or REVERSE, and both the accelerator
Provides transmission braking, or deceleration, when the
or MONOTROL® pedal and inching/brake pedals are
accelerator or MONOTROL® pedal is released at vehicle
released. The transmission cannot stop the lift truck in all
travel speeds greater than walking speed. The amount of
conditions. It is the operator's responsibility to use the serv-
deceleration is controlled by the accelerator or MONO-
ice or parking brake to stop and hold the lift truck from
TROL® pedal position. Releasing the accelerator or MON-
moving.
OTROL® pedal causes a greater amount of transmission
braking. Depression of the accelerator or MONOTROL® Roll Back Feature
pedal increases acceleration. The operator should always
If the operator uses the brakes to bring the lift truck,
consider the load that is being carried, and keep the car-
regardless of direction selected, to a stop on a grade; then
riage lowered, when using transmission braking.
100
www.duma-rent.com
releases the brake, the Roll Back feature limits and con- Inching
trols the speed at which the truck rolls backward or for-
ward. This feature is effective on grades up to 10% and WARNING
limits the speed to 7.6 cm (3 in.) per second. (The lift truck Inching requires coordinated movement of the inching/
may roll faster than 7.6 cm (3 in.) per second until the Roll brake pedal and the accelerator or the MONOTROL®
Back feature slows it down.) pedal. New operators must practice this procedure
Reduced Drive Tire Slippage before attempting to handle loads.
Electronically controls engine power and clutch pack If inching is not done correctly, damage to material and
engagement during acceleration and reduces the possibil- lift truck and injury to personnel can occur.
ity of drive tire wheel spin. Inching is the movement of a lift truck that allows a slow
Auto-Speed Hydraulic Feature travel speed while keeping the engine speed high for fast
operation of the lift mechanism.
When lift truck hydraulic functions are activated, lift truck
will electronically increase engine speed to meet the The inching/brake pedal is used to control the inching oper-
increase in hydraulic flow. At the same time, lift truck speed ation. When the inching/brake pedal is initially applied, the
with stay the same and be independent from hydraulic clutch in the transmission is partially disengaged and the
functions. movement of the truck is slow. When the inching/brake
pedal is fully applied, the transmission is completely disen-
Throttle Response Management gaged and the brakes are applied. Use the accelerator
Electronically controls the drive torque by limiting engine pedal or MONOTROL® pedal to keep the engine speed
speed to prevent tire slippage and over torque in the trans- high while inching.
mission.
101
www.duma-rent.com
FEET, AND LEAN FORWARD AND AWAY FROM THE
POINT OF IMPACT.
If the above steps are not followed during a lift truck
tipover, injury to personnel can occur.
Most operators can understand the need to be careful
when handling loads. But some operators do not realize
that a tipover can occur with an empty lift truck because
A. FAST B. SLOW similar dynamic forces are present. In fact, the lift truck will
actually tip over easier when empty, than when loaded with
Steering (Turning) the load lowered. Mast tilt, off-center loads, and uneven
ground will aggravate these conditions and cause the fork-
WARNING lift to become unstable.
TRAVEL SLOWLY WHEN TURN-
ING. Lift trucks can tip over even WARNING
at very slow speeds. The combi- Failure to observe the tail swing area when making a
nation of speed and the sharp- turn can injure or kill someone.
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
102
www.duma-rent.com
Do not turn on an incline. To reduce
the possibility of a tipover, a lift truck
must not be driven across an
incline.
When possible, keep both hands on
the steering wheel. During most
loading or unloading operations, the
operator steers with the left hand.
A. TAIL SWING The right hand is used to operate the lift, tilt, and attach-
ment controls.
Because lift trucks are designed to work in a relatively
small space, they can turn sharper than some other vehi-
cles. Most lift trucks are steered by the rear wheels and the
rear of the lift truck can move to the side very fast during a
turn. This movement is called "tail swing". An operator
must be aware of tail swing and always check to make sure
the tail swing area is clear before turning. Failure to
observe the tail swing area when making a turn can lead to
injury or death. 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.
103
www.duma-rent.com
Load Handling, General WARNING

1. The capacity is the maximum Do not handle a load if
load that the lift truck can handle for any loose part of it is
the load condition shown on the above the load backrest
Nameplate. The operator must or any part of the load is
know whether or not a load is within likely to fail. Injury to per-
the maximum capacity of the lift sonnel and damage to lift
truck before the load is handled. truck and materials may
occur.
However, factors such as weak floors or uneven terrain,
loads with a high center of gravity, unevenly distributed 2. Handle only stable
loads, or tire condition can mean that the safe working load loads. A load can have
is less than the capacity shown on the Nameplate. When unstable items that can
such conditions exist, the operator must reduce the load so easily shift and fall on someone.
the lift truck will remain stable. 3. Position each fork the same
distance from the center of the
carriage. This action will help
center the load on the carriage.
Set the forks as far apart as
possible for maximum support of
the load. Center the weight of
the load between the forks.
If the weight of the load is not
centered between the forks, the
104
www.duma-rent.com
load can fall from the forks when you turn a corner or hit a sonable protection to the operator from falling objects, but
bump. An off-center load will increase the possibility of the can not protect against every possible impact.
truck tipping over to the side. Make sure the pins that keep
the forks in position are engaged so that the forks cannot
move.
4. Check the condition of the driving surface. Make sure
the floor will support the weight of the lift truck and the load.
Load Handling, Lifting, Lowering, and Tilting
NOTE: The lift trucks covered in this manual are equipped
with Electro-Hydraulic (E-Hydraulic) mini-levers (see Fig-
ure 22 and Table 3).
The LIFT and TILT functions are controlled by separate
levers. See Operator Controls step in the Model
Description section for the correct operation.
The speed of the hydraulic functions is controlled by the
position of the mini-levers. The farther the mini-lever is A lift truck without an overhead guard provides no such
moved from the NEUTRAL position, the faster the speed of protection and other personnel have no overhead protec-
the hydraulic function. tion. Avoid hitting objects such as stacked material that
could become dislodged and fall.
Do not lift or hit anything that can fall on the operator or a
bystander. Remember, a lift truck equipped with a Hyster The operator must exercise care while working near such
overhead guard and load backrest extension provides rea- objects. Whether the lift truck is loaded or empty, do not
travel with the load or carriage in a raised position.
105
www.duma-rent.com
lift mechanism has moving parts with close clearances
WARNING
that can cause serious injury.
Lift and lower with the mast vertical or tilted slightly back-
ward from vertical. Tilt elevated loads forward only when
directly over the unloading place.
Keep yourself and all others clear of the lift mecha-

nism. Never allow anyone under or on the forks.
WARNING
WARNING
NEVER put hands, arms, head, or legs through the The lift truck can tip over forward when the load is
mast or near the carriage or lift chains. This warning raised and cause serious injury to personnel and dam-
applies not only to the operator but also a helper. A age equipment and material.
helper must not be near the load or lift mechanism
while the operator is attempting to handle a load. The NOTE: Forward tipping is even more likely when tilting for-
ward, braking when traveling forward, or accelerating in
reverse.
106
www.duma-rent.com
If the lift mechanism is raised to pick up or deposit a load, Load Handling, How to Engage and
keep the tilt angle in either direction to a minimum. Back- Disengage a Load
ward and forward tilt are helpful, but they affect side and
forward stability. Do not tilt in either direction more than 1. Avoid fast starts.
necessary when handling a load that is raised. The lift truck Sudden movement
can tip forward if the mast is tilted forward with a load in the can cause the lift
raised position. truck to tip. People
can be hurt or killed
WARNING and material can be
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! damaged.
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR
Approach the load carefully. Make sure that the truck is
FEET, AND LEAN FORWARD AND AWAY FROM POINT
perpendicular to the load. Raise the forks to the proper
OF IMPACT.
height for engaging the load.
If the above steps are not followed during a lift truck
tipover, injury to personnel can occur.
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.
107
www.duma-rent.com
Make sure that the load is centered between the forks.
Make sure that the forks do not extend past the load so
that loads or equipment that are behind the load being lif-
ted are not damaged. Lift the load a small distance from
the floor to make sure the lift truck has the capacity to lift
the load.
3. When a load is put on the floor, tilt the mast forward to a
vertical position and lower the load. Tilt the mast forward to
permit smooth removal of the forks. Carefully move the lift
truck backward to remove the forks from under 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. 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
108
www.duma-rent.com
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.
WARNING
Move carefully and smoothly when the load is raised
over a stack. When the load is elevated the center of
gravity of the lift truck and the load is much higher.
The lift truck can tip over when the load is raised and
cause serious injury to personnel and damage to the WARNING
lift truck and materials. IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE
OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO
5. To put the load on a stack, align the lift truck with the
STEERING WHEEL, BRACE YOUR FEET, AND LEAN
stack. Raise the load higher than the point where it will be
FORWARD AND AWAY FROM THE POINT OF IMPACT.
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 If the above steps are not followed during a lift truck
operation uses added energy. Be careful not to damage or tipover, injury to personnel can occur.
move adjacent loads.
109
www.duma-rent.com
along the floor under the object to be lifted. Tilt the mast
fully backward to help keep the load on the forks.
Move forward slowly. When the load is in position, lower

the load on to the stack or the rack. Lower the forks just
enough to remove them from under the load. Do not lower
the forks so that they will drag on the surface under the
load. Tilt the mast forward just enough to permit smooth Load Handling, Traveling
removal of the forks from under the load. Carefully move
the lift truck backward to remove the forks from under the 1. When traveling with the load lowered, keep the load
load. Lower the forks when traveling. against the carriage and the mast tilted fully backward. This
action will help keep the load on the forks and provide good
NOTE: Not every load can be lifted using only the forks of forward and side stability.
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
110
www.duma-rent.com
Always look in the direction of travel to avoid damage
to something or injury to someone.
3. For better visibility with large loads, travel with the load
trailing, but always keep a proper lookout in the direction of
travel. Normally, direction of travel is determined by the
best visibility available to the operator. If the lift truck must
travel in a direction where visibility is obstructed, a lookout
2. Travel with the lift mechanism raised only enough to
helper is required. Never drive when visibility is obstructed.
clear the ground or obstacles.
When the mast, carriage, or load is in a raised position, the
stability of the lift truck is reduced. This is also critical when
the lift truck is not carrying a load. The ability of the lift truck
to resist side tipping can be less on a lift truck without a
load than it is on a lift truck with a load in the lowered
(travel) position. Therefore, a lift truck without a load is
more likely to tip sideways, especially in a turn, than a lift
truck with a load carried in the lowered position.
4. When traveling up or down grades in excess of 5% with
WARNING a heavily loaded lift truck, keep the load upgrade to main-
tain control.
Some lift trucks have mirrors for viewing along the
side to observe the tail swing area. These mirrors are
an aid to the driver, but are NOT driving mirrors and
must NOT be used as such when operating in reverse.
111
www.duma-rent.com
6. Anytime the lift truck is moving
keep arms, legs, etc., inside the
operator's compartment. Arms and
legs outside the machine can be
injured when passing obstructions.
When operating an unloaded lift truck on a grade in 7. Avoid bumps, holes, mud, slick
excess of 5%, keep the counterweight upgrade. spots, and loose materials that
may cause the lift truck to swerve
5. Watch out for pedestrians at all times.
or tip. If unavoida-
Do not drive up to anyone standing in
ble, slow down.
front of an object. Use extra care at
cross-aisles, doorways, and other loca- Different models of
tions where pedestrians can step into lift trucks are
the path of travel of the lift truck. designed to operate
under different con-
Slow down when approaching blind
ditions. Solid rubber
intersections or turns and sound the
tire models are
horn. The horn is to warn pedestrians that there is a vehicle
designed to operate
in the area and to be alert to possible danger.
on relatively
smooth, firm surfa-
ces. Lift trucks with pneumatic tires can adapt to more
uneven ground. Always make sure you pick the smoothest
route for your lift truck.
112
www.duma-rent.com
8. Watch clearances, especially forks, mast, overhead
guard, and tail swing. A lift truck is designed to perform a
wide variety of functions within limited space.
10. Do not pass another lift truck traveling in the same

direction at intersections, blind spots, or at other dangerous
locations.
The operator must be aware that the forks can sometimes 11. Stay away from the edge of the road. Keep the wheels
extend beyond the front of the load. If the forks extend of the lift truck on the roadway. If the wheels are allowed to
beyond the load, the operator can hit an object or lift run off the edge of the travel surface onto soft ground, the
another load. Serious accidents can be caused by mast lift truck can tip over.
and overhead guards hitting pipes and beams near the 12. Under all travel conditions,
ceiling. operate the lift truck at a speed
that will permit it to be brought to a
stop in a safe manner.
9. Do not indulge in stunt driving or horseplay.
113
www.duma-rent.com
Load Handling, Emergency Load Lowering NOTE: The emergency load lowering valve is to be used
ONLY if the electrical signal to the main control valve has
WARNING been disrupted and there is a load lifted.
When the electronic signal to the mini-levers is disrup- To use the emergency load lowering valve, follow these
ted, the mast assembly can ONLY be lowered with the steps:
emergency load lowering valve, located on the main
hydraulic valve (see Figure 27). When using the emer- 1. Remove floor mat and floor plate.
gency load lowering valve to lower a load, serious 2. Turn the emergency load lowering valve two complete
injury can result if anyone is near the load or under the turns to the left. See Figure 27.
load.
3. When load has been lowered, close the emergency load
WARNING lowering valve.
Always lower the mast assembly when leaving the lift 4. Install floor plate and floor mat.
truck unattended.
114
www.duma-rent.com
1. EMERGENCY LOAD LOWERING VALVE
2. MAIN CONTROL VALVE
3. COWL WELDMENT
4. KICK PANEL
Figure 27. Emergency Load Lowering Valve
115
www.duma-rent.com
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
If the above steps are not followed during a lift truck both sides of the rear wheels (unless a dock locking
tipover, injury to personnel can occur. mechanism is engaged). Fixed jacks may be necessary
to support the front and rear of a highway truck trailer to
Before operating in a highway truck or rail car, observe the prevent it from moving or tipping during loading or
following: unloading.
• DO NOT use a lift truck to move a rail car.
116
www.duma-rent.com
• Make sure that the rail car brakes are set and the
If an attachment is installed on the lift truck, make sure the
wheels are blocked while loading or unloading. Do this
operating instructions are available and understood before
check so that the rail car will not move due to the move-
operating the attachment. For the operation of attachment
ment of the lift truck in and out of the rail car.
control levers, see Table 3, Figure 22, and Figure 28.
• Check the condition of the driving surface. Make sure
Attachments must be removed or installed by trained per-
the floor will support the weight of the lift truck and the
sonnel only.
load.
• Make sure the dock board is secured, in good condition, Disconnecting Attachment Hydraulic Quick-
and of the proper capacity. Disconnect Hoses
• When entering a rail car, the operator can enter at an NOTE: Step 1 through Step 4 is to be used for lift trucks
angle (if the dock plate or bridge is wide enough). This equipped with electro-hydraulics.
will reduce the turning required after entering.
1. Turn the key switch or keyless switch to the OFF posi-
• Never leave a parked truck on a dock plate. tion.
Attachments 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-
NOTE: Make sure the Nameplate is correct if an attach- ure 28.
ment has been installed.
117
www.duma-rent.com
NOTE: Step 5 through Step 7 is to be used for lift trucks
equipped with manual hydraulics.
5. Turn the key switch or keyless switch to the OFF posi-
tion.
6. Disconnect the negative terminal of the battery.
7. Move the manual hydraulic levers forward and backward
to relieve the system hydraulic pressure.
8. Disconnect the Quick-Disconnect hose connectors.
Connecting Attachment Hydraulic Quick-
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.
3. Turn the key switch or keyless switch to the ON position
1. PLUNGER BUTTON and start the engine.
2. PRESSURE RELIEF VALVE
4. Move the manual hydraulic levers forward and back-
Figure 28. Quick-Disconnect Procedure ward, and check the hydraulic system for leaks.
4. Disconnect the Quick-Disconnect hose connectors.
118
www.duma-rent.com
NOTE: Step 5 through Step 8 is to be used for lift trucks Parking
equipped with electro-hydraulics.
The operator must never leave a lift truck in a condition so
5. Connect the Quick-Disconnect hose connectors. that it can cause damage and injury. When parking the lift
6. Connect the negative terminal of the battery. truck, do the following operations:
7. Turn the key switch or keyless switch to the ON position 1. Stop the lift truck and apply the parking brake. Applying
and start the engine. the parking brake puts the transmission in NEUTRAL when
the lift truck has a MONOTROL® pedal.
8. Move the mini-levers forward and backward, and check
the hydraulic system for leaks. 2. Fully lower the forks or carriage. Tilt mast forward until
the tips of the forks touch the ground.
Stopping
3. If equipped, move the Direction Control Lever to the
NEUTRAL position.
CAUTION
For Kubota diesel engines only - allow engine to idle
for 5 minutes before shutting it OFF after full load
operation. Failure to do so may result in turbo charger
damage.
Stop the lift truck as gradually as possible. Hard braking 4. Turn the key to the OFF position to stop the engine.
and wheel sliding can cause the forklift to tip or the load to
fall off of the forks and damage the load or hurt someone. 5. If the lift truck must be left on an incline, put blocks on
the down hill side of the wheels so that the lift truck can not
move.
119
www.duma-rent.com
6. Check engine compartment, if operating in areas con- tank. If the lift truck is going to be left over night or longer,
taining combustible material, and remove foreign debris. the truck must be parked outside or the LPG tank must be
See FIRE HAZARD WARNING at the beginning of this removed and stored outside.
section.
Do not park the lift truck so that it limits access to fire
7. If the lift truck is equipped with an LPG fuel system and aisles, stairways, and fire equipment.
the lift truck is not in active use, close the fuel valve at the
120
www.duma-rent.com
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 and cause injury to personnel. • 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.
121
www.duma-rent.com
Maintenance
Some users have service personnel and equipment to do make the lift truck difficult to steer. Poor traction can
the inspection, lubrication, and maintenance shown in the cause the disabled lift truck or towing vehicle to slide.
Maintenance Schedule. Service Manuals are available A slope will also make the lift truck more difficult to
from your dealer for Hyster lift trucks to help users who do stop.
their own maintenance.
Never lift and move a disabled lift truck unless the dis-
Serial Number Data abled lift truck MUST be moved and cannot be towed.
A lift truck used to move a disabled lift truck MUST
The serial number for the lift truck is on the Nameplate. It is have a capacity rating equal to or greater than the
also on the right side of the frame, under the floor plate. weight of the disabled lift truck. The capacity of the lift
truck used to move a disabled lift truck must have a
How to Move a Disabled Lift Truck
load center equal to half the width of the disabled lift
truck. See the Nameplate of the disabled lift truck for
WARNING the approximate total weight. The forks must extend
Use extra caution when towing a lift truck if any of the the full width of the disabled lift truck. Put the weight
following conditions exist: center of the disabled lift truck on load center of the
1. Brakes do not operate correctly. forks. Be careful to not damage the under side of the
lift truck.
2. Steering does not operate correctly.
3. Tires are damaged.
How to Tow the Lift Truck
4. Traction conditions are bad. CAUTION
5. The lift truck must be towed on a slope. To prevent damage to the transmission during towing,
lift drive wheels off of ground or disconnect the drive-
If the engine cannot run, there is no power available for shaft.
the hydraulic steering system. This condition can
122
www.duma-rent.com
Maintenance
CAUTION
DO NOT try to start the engine by pushing or towing
the lift truck. Damage to the transmission can occur if
engine is started by pushing or towing lift truck.
1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. Using a lift truck or a lifting device that can be attached
to the mast (I.E. come-a-long), raise the carriage and forks
approximately 30 cm (12 in.) from surface. Install a chain
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 1. STEEL TOW LINK
the traction of the lift truck. Keep the load as low as possi- 2. TOW PIN
ble. Figure 29. Towing Lift Truck
5. Use a towing link made of steel that fastens to the tow
pins in the counterweights of both lift trucks. Slowly and
carefully remove the slack out of the towing pin. See Fig-
ure 29.
123
www.duma-rent.com
Maintenance
How to Put a Lift Truck on Blocks How to Raise the Drive Tires
(See Figure 30)
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 30)
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.
124
www.duma-rent.com
Maintenance
2. Use a hydraulic jack to raise the steering tires. Make 3. Put the jack under the steering axle or frame to raise the
sure that the jack has a capacity of at least 2/3 of the total lift truck. Put blocks under the frame to support the lift
weight of the lift truck as shown on the Nameplate. truck.
1. DRIVE TIRES 2. STEERING TIRES
Figure 30. Put a Lift Truck on Blocks
125
www.duma-rent.com
Maintenance Schedule
How to Clean a Lift Truck battery area, and dash display during the cleaning
process.
CAUTION Portions of your lift truck may be washed with a non-heated
Your lift truck may be damaged if water or cleaning pressure washer. Steam cleaning is not recommended in
agents come in contact with electrical components. DO most instances, as condensation may form in electrical
NOT directly spray any electrical components, espe- components causing damage or erratic behavior. For
cially connectors, switches, electro-hydraulic controls, cleaning guidelines and components to avoid, see the Peri-
odic Maintenance section of the Service Manual for your
lift truck.
126
www.duma-rent.com
Figure 31. Maintenance and Lubrication Points, 4.3L LPG Trucks
127
www.duma-rent.com
Figure 32. Maintenance and Lubrication Points, Kubota 3.8L T4 Final Diesel Trucks
128
www.duma-rent.com
Figure 33. Maintenance and Lubrication Points, Kubota 3.6L Diesel Trucks
129
www.duma-rent.com
Figure 34. Maintenance and Lubrication Points, Kubota 3.8L 55kW Diesel Trucks
130
www.duma-rent.com
(See Figure 31, Figure 32, Figure 33, and Figure 34)
8 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure or
Item No. Item Specification
1 Day 1 Yr 1 Yr 1 Yr 2 Yr Quantity
32 TIRES AND WHEELS X Check See Nameplate.
Condition.
SAFETY LABELS X Replace as Neces- See Parts Manual.
sary.
13, 14, MAST, CARRIAGE, X Check See Parts Manual.
15, 22 HEADER HOSES, Condition
LIFT CHAINS, AND and
ATTACHMENT Lubrication.
SEAT BELT, HIP X Check
RESTRAINTS, AND Condition
SEAT RAILS and
Operation.
ENGINE COMPARTMENT X Remove
Combustible
Materials.
See NOTE 5.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
131
www.duma-rent.com
PAPER APPLICATION X Check
Engine Compartment; Condition.
Truck Components; Clean as Required
Exhaust Wraps; Replace as
Radiator; Required.
Radiator Screen, See NOTE 8.
if equipped;
Belly Pan, if equipped
CHECK FOR LEAKS - X Check for Leaks.
FUEL, OIL, WATER See NOTE 1.
HYDRAULIC HOSES X Check See Parts Manual.
Condition.
33 COOLANT HOSES X Check See Parts Manual.
Condition.
34 FUEL TANK - LPG CIL Dual Tanks LPG - HD 5 or HD 10
4.3L 67 liter (17.7 gal)
or
87 liter (23 gal)
Single Tank
43.5 liter (11.5 gal)
34 FUEL TANK CIL 79 liter (20.8 gal) See Table 6
Kubota 3.8L Diesel
See NOTE 21
Engines
132
www.duma-rent.com
34 FUEL TANK CIL 79 liter (20.8 gal) See Table 6
Kubota 3.6L Diesel
Engines
HORN, LIGHTS, ALARMS, X Check
FUSES, AND RELAYS Operation.
35 SERVICE BRAKES X Check
Operation.
36 PARKING BRAKE X Check
Operation.
STEERING CONTROLS X Check
AND STEERING COLUMN Operation
GAS CYLINDER and
Condition.
5 TRANSMISSION X Check for Leaks
and Operation.
6 TRANSMISSION OIL X Check Oil Level. John Deere
BREATHER/DIPSTICK JDM J20C
See NOTE 19.
6 TRANSMISSION OIL X Check Breather. See Parts Manual.
BREATHER/DIPSTICK 1 Breather.
37 TRANSMISSION OIL C 24 liter (25.4 qt) John Deere
JDM J20C
See NOTE 19.
133
www.duma-rent.com
29 TRANSMISSION OIL C 1 Filter See Parts Manual.
FILTER See NOTE 4.
5 TRANSMISSION X Perform Automatic See Calibration
Clutch Procedures
Calibration. 8000 SRM 1134 for
Calibration Procedures.
7 HYDRAULIC OIL X X C 71.5 liter (75.8 qt) ISO VG 46 Hydraulic Oil
See NOTE 2, −15 °C (5 °F) and Above
NOTE 3, and See NOTE 19.
NOTE 16.
23 HYDRAULIC OIL FILTER C 1 Filter See Parts Manual.
See NOTE 16.
8 HYDRAULIC TANK X C Inspect and See Parts Manual.
BREATHER Replace as
Required.
See NOTE 5.
9 BATTERY AND CABLE X Clean.
TERMINALS
134
www.duma-rent.com
1 ENGINE OIL X C 4.7 liter (5.0 qt) –7 °C (20 °F) and Below SAE
4.3L LPG Engine CIL Every 6 mo See NOTE 4 and 5W-20
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
2 ENGINE OIL FILTER C 1 Filter See Parts Manual.
4.3L Engine Every 6 mo See NOTE 4 and
NOTE 5.
1 ENGINE OIL X C 13.2 liter (13.9 qt) See Table 6
Kubota Diesel Engine CIL See NOTE 4 and
NOTE 5.
Kubota 3.8L Diesel See NOTE 4 and
Engine NOTE 5.
Kubota 3.6L Diesel See NOTE 4 and
Engine NOTE 5.
135
www.duma-rent.com
24 AIR FILTER X C 1 Filter See Parts Manual.
CIL See NOTE 5,
NOTE 6, and
NOTE 11.
ENGINE OIL PRESSURE CIL Check Oil Pres- Kubota Diesel Engine at Idle
Kubota Diesel Engine sure. Speed
50 kPa (7 psi)
3 DRIVE BELT X Check for Wear
4.3L Engine and Damage.
No Adjustment
Needed.
See NOTE 5.
3 DRIVE BELT X Check for Wear
Kubota Diesel Engine and Damage.
Adjust as
Needed.
See NOTE 5.
4 LPG CONVERTER Drain Tar.
4.3L LPG Engine See NOTE 5.
INTAKE VALVES C Clean Carbon Use Sea Foam Spray.
4.3L LPG Engine Buildup
(Hyster P/N 4032507)
136
www.duma-rent.com
ENGINE IDLE SPEED 750 ±25 RPM
4.3L Engine
(LPG)
ENGINE GOVERNED 2400 ±25 RPM
SPEED
4.3L (LPG)
(No Load)
ENGINE IDLE SPEED X Coolant 800 ±50 RPM
Hot Engine Temperature
Kubota Diesel Greater Than
15 °C (59 °F)
ENGINE GOVERNED X 2200 ±25 RPM
SPEED (No Load)
Kubota 3.8L Diesel
ENGINE GOVERNED X 2580 ±50 RPM
SPEED (No Load)
Kubota 3.6L Diesel
OXYGEN SENSOR X Replace as Neces-
4.3L Engine CIL sary.
25 VALVE ADJUSTMENT Not
4.3L Engine Adjustable.
137
www.duma-rent.com
25 VALVE ADJUSTMENT X Adjust as Required. Intake
Kubota Engine 0.23 to 0.27 mm (0.009 to
0.011 in.)
Exhaust
0.23 to 0.27 mm (0.009 to
0.011 in.)
19 LPG FUEL FILTER C 1 Filter See Parts Manual.
4.3L Engine
10 FUEL WATER CIL C 1 Filter See Parts Manual.
SEPARATOR FILTER Drain Water from
Kubota Diesel Engine Filter as Required.
11 IN-LINE FUEL STRAINER C 1 Filter See Parts Manual.
Kubota Diesel Engine
26 CRANKCASE BREATHER C 1 Filter See Parts Manual.
FILTER See NOTE 20.
Kubota 3.8L Engine
OIL BREATHER X Check Condition.
Kubota 3.6L Engine
20 FUEL INJECTORS X Check and Replace
4.3L LPG Engine if Required.
6 Injectors
138
www.duma-rent.com
20 FUEL INJECTORS X Check and Replace
Kubota Diesel Engines if Required.
4 Injectors
27 SPARK PLUGS C Change Spark 1.5 mm (0.059 in.)
4.3L Engines Plugs. AC41-993
6 Plugs
28 COOLING SYSTEM X C 15.1 liter (15.9 qt) See NOTE 12.
4.3L Engine CIL
28 COOLING SYSTEM X C 11 liter (11.6 qt) See NOTE 13.
Kubota Engine CIL
CLEAN DEBRIS FROM X See NOTE 5.
RADIATOR CORE
12 FORKS X X X Check
Condition.
12 FORK LATCHES L Lubricate as Nec- Multipurpose Grease
essary. See NOTE 7.
LIFT SYSTEM, OPERATE X Check
Operation.
13 MAST L Lubricate as Multipurpose Grease
Sliding Surfaces and Required. See NOTE 7.
Load Roller Surfaces See NOTE 9.
139
www.duma-rent.com
14 HEADER HOSES X Check
Condition.
15 LIFT CHAINS X Check Engine Oil
Condition. SAE 30W
Lubricate if neces-
sary.
See NOTE 10.
15 LIFT CHAINS L L,X Check for Wear. Engine Oil
Lube as Required. SAE 30W
MAST L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
22 MAST X L X Lube as Required. Multipurpose Grease
Hang On Sideshift 4 Fittings See NOTE 7 and NOTE 15.
Carriage Sliding for Upper 2.5 mm (0.10 in.) Minimum
Surfaces (Upper Bearings and Thickness.
and Lower Bearings) 3 Lower
Bearing
Strips.
Check Lower Bear-
ing Strips for Wear.
140
www.duma-rent.com
Mast X X X Check/Adjust 1 mm (0.04 in.) minimum -
for Required Play 2 mm (0.08 in.) maximum
Bolzoni
Hang On Sideshift X X X Check 280 N•m (207 lbf ft)
Lower Hooks Torque
8 Sockethead
Screws
Mast X X X Check 50 N•m (37 lbf ft)
Torque
Bolzoni
4 Sockethead
Hang On Sideshift
Screws
Side Rollers
X X X Check See Parts Manual
Operation
Check for
Damage
Replace as
Necessary
141
www.duma-rent.com
Mast L L L Lube as Multipurpose Grease
Required See NOTE 7
Bolzoni
2 Fittings
Hang On Sideshift
Upper Slide Blocks X Check 1.5 mm (0.05 in.)
Thickness See Parts Manual
Replace as
Necessary
C Replace See Parts Manual
Slide Blocks
MAST X L X Lube as Required. Multipurpose Grease
Fork Positioner 2 Fittings See NOTE 7 and NOTE 15.
MAST X L X Lube as Required. Multipurpose Grease
Fork Positioner Cylinder 2 Anchors See NOTE 7 and NOTE 15.
Rod Anchors
MAST X Check See NOTE 15.
Fork Positioner and Torque.
Lower Hook Capscrews 8 Capscrews
MAST L Lube as Required. See NOTE 15.
Fork Carrier
TILT CYLINDER ENDS L 4 Fittings Multipurpose Grease
See NOTE 7.
142
www.duma-rent.com
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
16 BRAKE OIL CIL X C 0.35 liter (0.74 pt) Dexron III from
Master Cylinder Sealed Container
BRAKE SYSTEM X Check Pre-charge Pressure
ACCUMULATOR Pre-charge 4 ±0.35 bar (58 ±5 psi)
Pressure.
17 STEERING AXLE L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 7.
17 STEERING AXLE L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 7.
38 WHEEL BEARINGS L Check Grease. Multipurpose Grease
Steer Wheel See NOTE 7.
21 PEDALS, LEVERS, SEAT L Lubricate as Nec- Use Silicone Spray
RAILS, CABLES, HINGES, essary. Hyster Part No. 328388.
LINKAGES
143
www.duma-rent.com
35 PARKING BRAKE X Adjust as neces- Must Hold a Full Capacity
ADJUSTMENT sary. Load on a 15% Grade.
35 PARKING BRAKE L Lubricate as Nec- Use Silicone Spray
essary. Hyster Part No. 328388.
18 DIFFERENTIAL AND C Change Oil. Left/Right Chamber
DRIVE AXLE OIL (WET Left/Right John Deere
BRAKE) Chambers JDM J20C
15.6 liter (16.5 qt) Center Chamber
Center Chamber SAE J2360 Gear Oil.
4.6 liter (4.9 qt)
18 DIFFERENTIAL AND X X Check for Leaks.
DRIVE AXLE OIL (WET Check Level.
BRAKE)
39 PARKING BRAKE LEVERS X Check and Lubri- Normal operating environ-
(WET BRAKE) cate as Necessary ment:
Spray Lubricant
Hyster P/N 4066494
Heavy-duty or contaminated
environment:
Multipurpose Grease
See NOTE 7.
INSPECT ENGINE X
ELECTRICAL SYSTEM,
CONNECTORS
144
www.duma-rent.com
INSPECT ENGINE X
VACUUM AND
FUEL LINES
AND FITTINGS
INSPECT LOCK-OFF FOR X
LEAKS AND ENSURE
LOCK-OFF CLOSING
TEST LPG X
REGULATOR
PRESSURE
CHECK AIR INDUCTION X
SYSTEM FOR LEAKS
CHECK MANIFOLD FOR X
VACUUM LEAKS
CHECK THROTTLE X
SHAFT FOR STICKING
CHECK INJECTORS AND X
RAILS FOR LEAKS
INSPECT EXHAUST X
MANIFOLD AND
PIPING FOR LEAKS
INSPECT CATALYST X
INLET AND OUTLET
145
www.duma-rent.com
30 IGNITION SYSTEM: C Replace.
DISTRIBUTOR CAP,
ROTOR,
AND SPARK PLUG
WIRES
INSPECT MUFFLER INLET X Replace as
AND OUTLET Required.
31 Diesel Particulate Filter X Service. See NOTE 14.
(DPF)
Kubota Engine
40 Diesel Exhaust Fluid (DEF) C Service Filter.
Filter See
Kubota Engine NOTE 12.
40 Diesel Exhaust Fluid (DEF) X Check Levels. 32.5% Urea
Filter AUS 32
Kubota Engine ISO 22241
Tank Capacity
20 liter (21.1 qt)
Usable Fluid
15 liter (15.9 qt)
Diesel Exhaust Fluid (DEF) X Replace as See Parts Manual.
Injector tip See NOTE Required.
17.
146
www.duma-rent.com
Diesel Exhaust Fluid (DEF) C Replace. See Parts Manual.
Pump Filter See
NOTE 12.
Diesel Exhaust Fluid (DEF) C Replace. See Parts Manual.
Tank Filter See
NOTE 18.
147
www.duma-rent.com
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving contaminated environments
such as high levels of airborne debris (dust and waste paper); chemical or abrasive compounds; poor ground conditions; intensive usage at high perform-
ance levels; or other abnormal conditions will require more frequent servicing. At your request, your Hyster dealer will advise you of the appropriate
service intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: 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: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 10: Lubricate if dry or at first sign of visible surface rust.
NOTE 11: Do not open the air filter canister except to change the air filter element. See the Periodic Maintenance Manual for your lift truck for the correct
procedure to change air filter element.
148
www.duma-rent.com
NOTE 12: Replace after 3000 hours. Use hour interval only.
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: Service Diesel Particulate Filter (DPF) every 3000 hours. See Hyster dealer. Use hour interval only.
NOTE 15: For lift trucks equipped with Sideshift Carriage (with or without Fork Positioner) see section Maintenance Procedures Every 500 Hours or 1
Year, Mast Lubrication, of Periodic Maintenance 8000 SRM 1957.
NOTE 16: 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 17: Check at 1500 hours. Use hour interval only.
NOTE 18: Replace filter at 8000 hours. Use hour interval only.
NOTE 19: If lift truck is used in Paper application use ONLY JDM J20C type fluid for both the transmission and hydraulic system.
NOTE 20: Replace filter at 1500 hours. Use hour interval only.
NOTE 21: See Capacities and Specifications 8000SRM1958 for diesel fuel cleanliness requirements before filling lift truck tank with diesel fuel.
149
www.duma-rent.com
Table 6. 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 Engine Oil Viscosity based on ambient
Engine <5000ppm <500ppm Sulfur<15ppm temperature
3.6L T3 API CF API CF or better API CF or better −15 °C (5 °F) and above 15W-40
−25 °C (−13 °F) and above 10W30
Below −25 °C (−13 °F) 5W-30
3.8L T4 w/ DPF NA NA API CJ-4
and SCR
3.8L T4 w/ DOC NA NA API CJ-4
150
www.duma-rent.com
Store DEF at a temperature between 10 to 40 °C (50 to
104 °F). Higher temperatures within this range reduce shelf
life as shown in Table 7.
Table 7. DEF Storage
Storage temperature Shelf life

10 to 20 °C (50 to 68 °F) 24 months
20 to 30 °C (68 to 86 °F) 18 months
35 °C (95 °F) 12 months
40 °C (104 °F) 3 months
151
www.duma-rent.com
Maintenance
Maintenance Procedures Every 8 Hours or Daily

How to Make Checks With the Engine ing hardware. Remove any wire, strapping, or other mate-
Stopped rial that is wrapped around the axle.
WARNING
Do not operate a lift truck that needs repairs. Report
the need for repairs immediately. If repair is necessary,
put a DO NOT OPERATE tag in the operator's area. If
lift truck is equipped with a key switch, remove the
key. Operating a lift truck that needs repair may dam-
age lift truck and cause injury to personnel.
Put the lift truck on a level surface. Lower the carriage and
forks, stop the engine, and apply the parking brake. Open
both hood door assemblies and check for leaks and condi- 1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER
tions that are not normal. Clean any oil or fuel spills. OBJECTS FROM THE TREAD)
Ensure all surfaces are free of oils, lubricants, fuel and 2. CHECK EDGES FOR WEAR
organic dust or fibers (paper, wood, cotton, agricultural 3. CHECK TIRE PRESSURE
grass/grain, etc.). Figure 35. Check the Tires
Tires and Wheels
Check the tires for damage (see Figure 35). Check the
tread and remove any objects that will cause damage.
Check for bent or damaged rims. Check for loose or miss-
152
www.duma-rent.com
Maintenance
Safety Labels 1. Inspect the welds on the mast, cylinders, and carriage
for cracks. Make sure that the capscrews and nuts are
WARNING tight.
Safety labels are installed on the lift truck to give infor- 2. Inspect the channels for wear in the areas where the roll-
mation about operation and possible hazards. It is ers travel. Inspect the rollers for wear or damage.
important that all safety labels are installed on the lift
truck and can be read to avoid damage to lift truck and 3. Inspect the load backrest extension for cracks and dam-
injury to personnel. age.
Check that all safety labels are installed in the correct loca- 4. If the lift truck is equipped with a sideshift carriage or
tion on the lift truck. See the Parts Manual, the Model attachment, inspect the parts for cracks and wear. Make
Description section in this Operating Manual, or the sure the parts that fasten the sideshift carriage or attach-
Frame section of the Service Manual 100 SRM 1948 for ment to the carriage are in good condition.
the correct location of the safety labels. See the Parts 5. Visually inspect hoses/fittings for hydraulic leaks; hose
Manual for the part numbers of the safety labels. cover for cuts, cracks, or exposed reinforcement; defective/
broken clamping devices or sheaves; and proper tracking
Mast, Carriage, Header Hoses, Lift Chains,
during operation. Adjust/repair/replace hose/components
and Attachment as necessary.
WARNING 6. Check that the lift chains are correctly lubricated. Use
Lower the lift mechanism completely. Never allow any SAE 30W engine oil to lubricate the lift chains.
person under a raised carriage. Do not put any part of 7. Inspect the lift chains for cracks or broken links and worn
your body in or through the lift mechanism unless all or turned pins. Lift chains must be replaced as a set. See
parts of the mast are completely lowered and the Figure 36.
engine is STOPPED.
153
www.duma-rent.com
Maintenance
8. Inspect the chain anchors and pins for cracks and dam-
age.
9. 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.
Operator Restraint System
The seat belt, hip restraint, seat, seat plate, and seat rails
are all part of the operator restraint system (see Fig-
ure 37). Each item must be checked to make sure it is fas-
tened correctly, functions correctly, and is in good
condition.
1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
Figure 36. Lift Chain Check
154
www.duma-rent.com
Maintenance
Legend for Figure 37
1. FLANGE NUT 5. SEAT BELT
2. SEAT PLATE 6. HIP RESTRAINT
3. FORWARD/BACKWARD 7. OPERATOR WEIGHT
ADJUSTMENT ADJUSTMENT
4. SEAT RAIL 8. SEAT
Emergency Locking Retractor (ELR)

When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposition-
ing without activating the locking mechanism. If the truck
tips over, travels off a dock, or comes to a sudden stop, the
locking mechanism will be activated and hold the opera-
tor's lower torso in the seat. See Figure 37.
A seat belt that is damaged, worn, or does not operate
properly will not provide protection when it is needed. The
end of the belt must fasten correctly in the latch. The seat
NON-SWIVEL SEAT SHOWN. belt must be in good condition. Replace the seat belt if it is
Figure 37. Seat, Seat Rail, Seat Plate, and Seat Belt damaged or worn.
Check NOTE: The following seat belt operation checks must be
performed three times before replacing the seat belt
assembly.
155
www.duma-rent.com
Maintenance
• With the hood closed and in the locked position, pull the the seat plate and the seat plate must be secured to the
seat belt slowly from the retractor assembly. Make sure frame.
the seat belt pulls out and retracts smoothly. If the seat
belt does not pull out of the retractor assembly the inter- Engine Compartment
nal latch may be locked. Pull firmly on the seat belt and Check for the presence of any combustible material such
hold for a moment to remove slack from the belt in the as paper, leaves etc. Remove any combustible materials.
retractor. Release the seat belt. Seat belt will retract and
the internal latch will unlock. If the seat belt cannot be Paper Application
pulled from the retractor assembly or the belt will not
retract, replace the seat belt assembly. Vehicles used in paper applications require regular inspec-
tion and cleaning to minimize the risk of fire. This should be
• With the hood closed and in the locked position, pull the done at least once every 8 hours or more frequently
seat belt with a sudden jerk. Make sure the seat belt will depending upon operating environment. The paper appli-
not pull from the retractor assembly. If the seat belt can cation will help limit the contact of paper or tissue scraps to
be pulled from the retractor when it is pulled with a sud- hot surfaces under the hood doors, but frequent mainte-
den jerk, replace the seat belt assembly. nance is required.
• With the hood in the open position, make sure the seat
belt will not pull from the retractor assembly. If the seat
WARNING
belt can be pulled from the retractor, with the hood in the Engine and exhaust system components are hot to the
open position, replace the seat belt assembly. touch. Be sure lift truck components are cool before
starting inspection and cleaning, or personal injury
Seat Plate and Seat Rails may occur.
Make sure the seat rails are not loose. The seat rails must Ensure the truck engine cools properly by allowing it to idle
lock tightly in position, but move freely when unlocked (see for several minutes. Shutting the truck down while hot will
Figure 37 ). The seat rails must be correctly fastened to not allow the engine to cool quickly due to the loss of
156
www.duma-rent.com
Maintenance
coolant circulation. The heat trapped under the hood doors that air pressure, nozzle, or extension tube does not
may actually increase the engine temperature because of damage exhaust wraps or radiator fins.
no heat transfer through the radiator.
Paper removal can generally be accomplished using a
With engine OFF and lift truck components cooled, check compressed air line and nozzle. An extension may be help-
and clean the radiator and if equipped, radiator screen. ful to access hard to reach places. Remove floor plates and
Check engine manifold, exhaust pipes, muffler, and cata- both hood doors for access to the engine compartment.
lytic converter for paper scraps. Clean as required. Check Open or remove belly pan, if equipped. Clean components
and clean the engine compartment components, transmis- with compressed air. Take care to maintain the integrity of
sion, fan shroud, belly pan, if equipped, and inside frame the exhaust wraps when cleaning with compressed air and
ledges to avoid paper, dust, and oil accumulation. Check use caution to not force debris into openings.
axle and cowl openings for paper buildup and bailing wire.
Remove any debris. WARNING
Be careful when cleaning with steam. Steam can cause
WARNING serious burns. Wear protective clothing, gloves, and
Compressed air can move particles so that they cause eye protection. Never expose your skin to steam.
injury to the user or to other personnel. Make sure that
If compressed air did not adequately remove debris, steam
the path of the compressed air is away from all person-
clean to remove any persistent accumulation of material or
nel. Wear protective goggles or a face shield to prevent
oil. Protect electrical components from moisture when
injury to the eyes.
steam cleaning. Do not spray exhaust wraps directly with
high pressure steam. Allow lift truck to air dry before return-
CAUTION
ing to work in a contaminated environment. Paper dust and
Air pressure, nozzle, or extension tube may cause
scraps will adhere to wet surfaces.
damage to exhaust wraps and radiator fins. Assure
157
www.duma-rent.com
Maintenance
Check the condition of exhaust wraps for wear, proper fit, Also check the condition of the radiator or heater hoses
contamination with oil or antifreeze, gaps in coverage, and that are not leaking. Soft or cracked hoses need to be
failed fasteners. Replace as necessary. Do not reuse replaced before a major leak occurs.
wraps if they have been removed for some other service
operation. Hydraulic Hoses
Fuel, Oil, and Coolant Leaks, Check 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
WARNING
is leaking, report it to maintenance for repair.
All fuels are very flammable and can burn or cause an
explosion. Do not use an open flame to check the fuel Coolant Hoses
level or to check for leaks in the fuel system. If there is
a leak in the fuel system, extra care must be used dur- Check the condition of the coolant hoses for serviceability
ing the repair. Do not operate the lift truck until a leak by inspecting for cracks or other obvious damage. Check to
is repaired. insure that the coolant hoses are not leaking. If any hose is
leaking, report it to maintenance for repair.
Make a visual check for leaks on and under the lift truck. If
possible, find and report the leak to maintenance for repair. Steering Column Gas Cylinder
Leaks often indicate a need for repair of damaged or worn
Make sure the gas cylinder for the steering column oper-
components. Leaks in the LPG fuel system are usually not
ates correctly. The cylinder must NOT allow the column to
visible unless ice is present. There is however, usually a
move unless the tilt lever is released. See Figure 38.
strong odor. Fuel leaks MUST be repaired IMMEDIATELY.
Check the fuel system for leaks and the condition of parts.
When fuel is added to the lift truck, see the section, How to
Add Fuel to the Lift Truck.
158
www.duma-rent.com
Maintenance
Transmission
NOTE: The transmission oil dipstick and transmission oil
breather are one unit. See Figure 39.
Check the transmission for leaks and damage or loose
components. Heavy-duty or high-temperature operations
can require more frequent checks. See Figure 39.
Hydraulic System Oil
WARNING
At operating temperature the hydraulic oil is HOT. Do
not permit the hot oil to touch the skin and cause a
burn.
CAUTION
Do not permit dirt to enter the hydraulic system when
the oil level is checked or the filter is changed.
1. TILT LEVER 2. GAS CYLINDER Never operate the hydraulic pump without oil in the
hydraulic system. The operation of the hydraulic pump
Figure 38. Steering Column Gas Cylinder and Tilt Lever without oil will damage the pump.
159
www.duma-rent.com
Maintenance
After the engine has stopped, wait one minute before Never operate the engine without oil. The operation of
checking the oil level. Keep oil at the correct level as indi- the engine without oil will damage the engine.
cated on the dipstick (see Figure 39). Use the correct oil
After the engine has stopped, wait one minute before
as shown in the Maintenance Schedule.
checking the oil level. See Figure 40, Figure 41, Fig-
Check the hydraulic system for leaks and damaged or ure 42, Figure 43, and Figure 44. Keep the oil at the cor-
loose components. Heavy-duty or high-temperature opera- rect level as indicated on the dipstick. Use the correct oil as
tions can require more frequent checks. shown in the Maintenance Schedule.
Engine Oil
WARNING
At operating temperature, the engine oil is HOT. Do not
permit the hot oil to touch the skin and cause a burn.
CAUTION
Do not permit dirt to enter the engine when the oil level
is checked or the filter is changed.
160
www.duma-rent.com
Maintenance
1. TRANSMISSION OIL
DIPSTICK/BREATHER
2. TRANSMISSION OIL
FILTER
3. HYDRAULIC TANK
BREATHER
4. HYDRAULIC OIL
FILTER
5. HYDRAULIC OIL
DIPSTICK
6. HYDRAULIC TANK
7. HYDRAULIC OIL
DRAIN PLUG
8. TRANSMISSION OIL
DRAIN PLUG
Figure 39. Transmission and Hydraulic Oil Checks
161
www.duma-rent.com
Maintenance
Figure 40. Engine Maintenance Points - GM 4.3L With PSI Fuel System Installed
162
www.duma-rent.com
Maintenance
1. BATTERY 8. DRIVE BELT
2. POWER DISTRIBUTION MODULE (PDM) 9. RADIATOR CAP
3. LPG FUEL FILTER ASSEMBLY 10. AUXILIARY COOLANT RESERVOIR
4. ENGINE OIL FILL 11. AIR FILTER PRECLEANER
5. ENGINE OIL DIPSTICK 12. LPG CONVERTER
6. AIR FILTER 13. COOLANT HOSES
7. SPARK PLUGS 14. ENGINE LABEL
163
www.duma-rent.com
Maintenance
Figure 41. Engine Maintenance Points - PSI 4.3L
164
www.duma-rent.com
Maintenance
1. BATTERY 8. AIR FILTER PRE-CLEANER
2. POWER DISTRIBUTION MODULE (PDM) 9. AIR FILTER
3. SPARK PLUGS 10. ENGINE MANUFACTURER ID
4. LPG CONVERTER 11. ENGINE OIL DIPSTICK
5. COOLANT HOSES 12. LPG FUEL FILTER ASSEMBLY
6. AUXILIARY COOLANT RESERVOIR 13. ENGINE OIL FILL
7. RADIATOR CAP
165
www.duma-rent.com
Maintenance
Figure 42. Engine Maintenance Points - Kubota 3.8L T4 Final Diesel
166
www.duma-rent.com
Maintenance
A. TOP VIEW B. LEFT-SIDE VIEW
1. BATTERY 7. RADIATOR CAP
2. POWER DISTRIBUTION MODULE (PDM) 8. FUEL INJECTION PUMP
3. ENGINE OIL CAP 9. AIR FILTER
4. ENGINE OIL DIPSTICK 10. CRANKCASE BREATHER
5. DRIVE BELT 11. WATER SEPARATOR
6. AUXILIARY COOLANT RESERVOIR 12. IN-LINE FUEL STRAINER
167
www.duma-rent.com
Maintenance
Figure 43. Engine Maintenance Points - Kubota 3.6L Diesel
168
www.duma-rent.com
Maintenance
A. TOP VIEW B. LEFT-SIDE VIEW
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
169
www.duma-rent.com
Maintenance
Figure 44. Engine Maintenance Points - Kubota 3.8L 55kW Diesel
170
www.duma-rent.com
Maintenance
1. BATTERY 8. DRIVE BELT
2. PDM 9. AIR FILTER
3. FUEL INJECTOR 10. CRANKCASE BREATHER
4. ENGINE OIL DIPSTICK 11. WATER SEPARATOR
5. ENGINE OIL CAP 12. FUEL PUMP
6. AUXILIARY COOLANT RESERVOIR 13. IN-LINE STRAINER
7. RADIATOR CAP
Air Filter Forks

The air filter canister should not be opened until an air filter NOTE: Forks must be removed or installed by trained per-
element replacement is required. An air filter element sonnel only.
replacement is required when one of the following occurs:
The identification of a fork describes how the fork is con-
• the optional air flow restriction indicator light on the dash nected to the carriage. These lift trucks have hook forks.
illuminates
Forks, Remove
• the optional manual air flow indicator button pops up
• the specified number of hours has passed since the last WARNING
filter element replacement Do not try to move a fork without a lifting device. Each
hook fork for these lift trucks can weigh 66 to 183 kg
Do not operate the lift truck until the air filter element has (145 to 402 lb). Removing a fork without a lifting device
been replaced. can result in serious injury to personnel.
NOTE: Forks are to be replaced only in sets and not indi-
vidually.
171
www.duma-rent.com
Maintenance
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 45 and Fig-
ure 46. Lower the fork onto blocks so that the bottom hook
of the fork moves through the fork removal notch. See Fig-
ure 46. 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
2. HOOK FORK
3. BLOCKS
Figure 45. Remove a Hook Fork
172
www.duma-rent.com
Maintenance
Fork Tip Alignment

Length of Forks 3% Dimension
1200 mm (47 in.) 36 mm (1.42 in.)
1300 mm (51 in.) 39 mm (1.53 in.)
1500 mm (59 in.) 45 mm (1.77 in.)
1800 mm (71 in.) 54 mm (2.13 in.)
2400 mm (94 in.) 72 mm (2.83 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 46. Forks Check
173
www.duma-rent.com
Maintenance
Forks, Inspect tion in fork blade thickness results in 20% reduction in

operating capacity.
1. Inspect the forks for cracks and wear. Check that the
fork tips are aligned as shown in Figure 46. Check that the
bottom of the fork is not worn (Item 4 in Figure 46).
2. Replace any damaged or broken parts that are used to
keep the forks locked in position. See Figure 48.
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 47.
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 46) 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.
c. If fork enters opening, it is mandatory to replace it.
DANGER OF BREAKING. Furthermore, a 10% reduc- Figure 47. Fork Wear Check
174
www.duma-rent.com
Maintenance
Forks, Install Forks, Adjust

Move the fork and carriage so that the top hook on the fork NOTE: During the adjustment of the forks, the heel of the
can engage the upper carriage bar. Raise the carriage to forks should not be touching the ground.
move the lower hook through the fork removal notch. Slide
The forks are connected to the carriage by hooks and lock
the fork on the carriage so that both upper and lower hooks
pins. See Figure 45 and Figure 48. The lock pins are
engage the carriage. Engage the lock pin with a notch in
installed through the top fork hooks and fit into slots in the
the upper carriage bar. See Figure 48.
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. FORK 5. WEDGE
2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN ASSEMBLY
4. WASHER
Figure 48. Fork Lock Pin Assembly
175
www.duma-rent.com
Maintenance
Hang On Sideshift Carriage If the lift truck is equipped with a fork positioner, lubricate
fork positioner carrier at grease fittings and the fork cylinder
Check for cracks, wear, and damage. If damaged, see the rod anchors with multipurpose grease shown in the Main-
section Mast Repairs 2- and 3-Stage Mast 4000 SRM tenance Schedule. See Figure 49.
1956 for repair procedures. If necessary, lubricate sliding
surfaces (upper bearings) at grease fittings and lower bear-
ing strips with multipurpose grease shown in the Mainte-
nance Schedule. See Figure 49.
176
www.duma-rent.com
Maintenance
1. BACKREST
2. FORK CARRIER RETAINER CAPSCREWS
3. CYLINDER ANCHOR BAR CAPSCREWS
4. CYLINDERS AND HOSES
5. FORKS
6. LOWER HOOKS
7. MOUNTING FLANGE CAPSCREWS
8. BACKREST CAPSCREWS
Figure 49. Hang On Sideshift Carriage With Fork Positioner
177
www.duma-rent.com
Maintenance
How to Make Checks With the Engine Be careful when making the checks. If the lift truck is sta-
Running tionary during a check, apply the parking brake and put the
transmission in NEUTRAL. Make the checks carefully.
WARNING Indicator Lights, Horn, Fuses, and Relays
DO NOT operate a lift truck that needs repairs. Report
the need for repair immediately. If repair is necessary, If lift truck is equipped with a key switch, turn key to ON
put a DO NOT OPERATE tag in the operator's area. If position. If lift truck is equipped with a Power ON/OFF but-
lift truck is equipped with a key switch, remove the ton, press button to turn system power on. Check all indica-
key. If a lift truck requiring repair is operated, damage tor lights for correct operation as described in Table 2.
to lift truck and injury to personnel can occur. Check the operation of the horn. Start the engine by turning
the key switch to the START position, if truck is equipped
WARNING with a key switch, or press the engine start button, if truck
FASTEN YOUR SEAT BELT! The seat belt is installed is equipped with this button. If any of the indicator lights do
to help the operator stay on the truck if the lift truck not operate correctly, check the fuses. The fuses are loca-
tips over. IT CAN ONLY HELP IF IT IS FASTENED. ted in the Power Distribution Module (PDM) which is loca-
ted under the floor plates mounted on the right side of the
Make sure that the area around the lift truck is clear before lift truck frame. See Figure 50.
starting the engine or making any checks of the operation.
178
www.duma-rent.com
Maintenance
Figure 50. PDM Showing Fuses and Relays
179
www.duma-rent.com
Maintenance
NOTE: FLOOR PLATES REMOVED FOR CLARITY.
1. BATTERY 11. SPARE FUEL PUMP RELAY
2. POWER DISTRIBUTION MODULE (PDM) 12. BATTERY (20 AMP)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20 AMP)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30 AMP FUSE) 15. BATTERY (25 AMP)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20 AMP)
7. BACKUP RELAY 17. IGNITION 1 (20 AMP)
8. BACKUP (20 AMP) 18. IGNITION RELAY
9. IGNITION (30 AMP) 19. BATTERY (25 AMP)
10. SPARE FUEL PUMP (20 AMP) 20. SEMICONDUCTOR TRANSZORB
Service Brakes Replace the brake oil in the system if there is dirt or
water in the system.
Brake Oil Level
DO NOT use "DOT" fluid, only use Dexron III oil from
WARNING sealed container to prevent possible damage to the
Small amounts of water in the brake system can cause brake system.
reduced braking performance if the water reaches the Failure to observe the above warnings could result in
wheel cylinder area. Do not allow water entry. Ensure death or serious injury.
that the sealed reservoir lid is properly replaced.
There is an indicator light on the Display Switch Cluster for
The brake system has a boosted master cylinder. Brak- the brake oil. The red light is ON when the key switch is in
ing will be more difficult if the engine is not running. the START position or the Power ON/OFF button is
Loss of oil from the brake oil reservoir indicates a leak. pressed, and must go OFF when the engine is running. If
Repair the brake system before using the lift truck.
180
www.duma-rent.com
Maintenance
the light is ON when the engine is running, the brake fluid sor in the seat that actuates an audible alarm. If the opera-
level in the reservoir is too low. tor leaves the seat, with system power OFF, without
applying the parking brake, the alarm will sound for 10 sec-
Operation, Check
onds until the parking brake is applied or the operator sits
Check the operation of the service brakes. Push on the back on the seat. If system power is ON or the engine is
inching/brake pedal. The service brakes must be applied running, and the operator leaves the seat, without applying
before the inching/brake pedal reaches the floor plate. The the parking brake, the alarm will sound continuously until
pedal must stop firmly and must not move slowly down parking brake is applied or the operator sits back on the
after the brakes are applied. The service brakes must apply seat.
equally to both drive wheels. The service brakes must not
Make sure the service brakes operate correctly before
pull the lift truck to either side of the direction of travel when
checking the operating of the parking brake. Check the
they are applied. The service brakes are automatically
operation of the parking brake. The parking brake, when in
adjusted when the lift truck is moving and the brakes are
good condition and correctly adjusted, will hold a lift truck
firmly applied. Full application of the inching/brake pedal
with a full capacity load on a 15% grade [a slope that
applies the service brakes and puts the transmission in
increases 1.5 meters in 10 meters (1.5 feet increase in 10
NEUTRAL.
feet)]. If parking brake requires adjustment, notify service
Lift trucks with a MONOTROL® pedal: when the inching/ personnel.
brake pedal is fully applied, a switch in the starting circuit is
closed so that the engine can be started. Engine Oil Pressure
Parking Brake NOTE: The 4.3L engine will enter shutdown mode after a
warning buzzer sounds and a 30-second countdown if
There is an indicator icon on the display panel for the park- engine oil pressure is less than 34.5 kPa (5 psi) on lift
ing brake. This icon is illuminated as described in the trucks with powertrain protection system. Lift trucks equip-
Model Description section of this manual. There is a sen- ped with a Kubota diesel engine will enter shutdown mode
181
www.duma-rent.com
Maintenance
when the engine oil pressure is less than 49 kPa (7 psi) on the system is hot, the steam and boiling coolant can
lift trucks with powertrain protection system. See Engine cause burns.
Shutdown procedures in the Operating Procedures sec-
NOTE: The engine will enter shutdown mode after a warn-
tion in this manual.
ing buzzer sounds and a 30-second countdown, if coolant
There is an indicator light for the engine oil pressure on the temperature reaches 118 °C (245 °F) or above, for GM or
Display Switch Cluster. During normal operation, the red PSI 4.3L on lift trucks with powertrain protection system.
indicator light will illuminate when the key switch is turned Lift trucks equipped with a Kubota diesel engine will enter
to ON, if the truck is equipped with a key switch, or when the shutdown mode when the coolant temperature reaches
the power ON/OFF button is pressed, and will stay illumi- 115 °C (240 °F) or above on lift trucks with powertrain pro-
nated until correct minimum oil pressure is obtained, at tection system. See Engine Shutdown procedures in the
which time the light will go off. Operating Procedures section in this manual.
If the light continues to stay on when the engine is running, There is an indicator light on the Display Switch Cluster for
the engine oil pressure is low. Stop the engine and check the coolant temperature. The red light is ON when the key
the oil level. See Figure 40, Figure 41, Figure 42, Fig- switch is in the START position or the Power ON/OFF but-
ure 43, or Figure 44. Do not restart the engine until the low ton is pressed, and must go OFF when the engine is run-
pressure condition has been corrected. ning. If the light is ON when the engine is running, the
coolant and engine are too hot. Stop the engine and check
Cooling System the coolant level in the coolant recovery reservoir.
WARNING Make sure the coolant level is between the ADD and FULL
DO NOT remove the radiator cap from the radiator marks on the auxiliary coolant reservoir (See Figure 51).
when the engine is hot. When the radiator cap is The coolant will expand as it is heated and the level in the
removed, the pressure is released from the system. If auxiliary coolant reservoir will increase.
182
www.duma-rent.com
Maintenance
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
If coolant is added, use the correct mixture of water and
ethylene glycol shown in the Maintenance Schedule.
WARNING
Compressed air can move particles so that they cause
injury to the user or to other personnel. Make sure that
the path of the compressed air is away from all person-
nel. Wear protective goggles or a face shield to prevent
injury to the eyes.
Turn 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.
Figure 51. Auxiliary Coolant Reservoir
183
www.duma-rent.com
Maintenance
Legend for Figure 51 Lift System Operation
1. RADIATOR CAP 4. ADD MARK
2. FILL CAP 5. FULL MARK (COLD) WARNING
3. AUXILIARY COOLANT 6. FULL MARK (HOT)
When working on or near the mast, see Safety Proce-
RESERVOIR
dures When Working Near the Mast in the Periodic
Maintenance 8000 SRM 1957.
Steering System
Lower the lift mechanism completely. Never allow any
WARNING person under a raised carriage. Do not put any part of
The lift truck has hydraulic power steering. The steer- your body in or through the lift mechanism unless all
ing can be difficult if the engine is not running and can parts of the mast are completely lowered and the
cause injury to personnel. engine is STOPPED. Serious injury to personnel can
result if lift mechanism is not lowered completely.
Make sure the steering system operates smoothly and pro-
vides good steering control. Make sure the steering column If the mast cannot be lowered, use chains on the mast
can be adjusted and the gas cylinder function is correct. weldments and carriage so that they cannot move.
Make sure the moving parts are attached to a part that
Control Levers and Pedals does not move. See the Periodic Maintenance section
of the Service Manual for additional information.
Check that the control levers for the transmission, mast,
and attachment operate as described in Table 3. Check Do not try to find hydraulic leaks by putting hands on
that the pedals operate correctly as described in Table 3. pressurized hydraulic components. Hydraulic oil can
be injected into the body by the pressure and cause
serious injury to personnel.
Perform the following checks and inspections:
184
www.duma-rent.com
Maintenance
1. Turn engine OFF and check for leaks in the hydraulic Air Filter
system. Check the condition of the hydraulic hoses and
tubes. There is an indicator light on the Display Switch Cluster
(see Figure 6 and Table 2) for the air filter. The amber light
NOTE: Some parts of the mast move at different speeds is ON when the key switch is in the START position or the
during raising and lowering. Power ON/OFF button is pressed, and must go OFF when
2. Slowly raise and lower the mast several times without a the engine is running. If the light is ON when the engine is
load. Raise the mast to its full height at least once. The running, there is a restriction in the air filter. Turn engine
mast components must raise and lower smoothly in the OFF and remove restriction from air filter. See the Periodic
correct sequence. Hose must track properly during opera- Maintenance section of the Service Manual for proce-
tion. dures. See Figure 52.
3. The inner weldments and the carriage must lower com-

pletely.
4. Raise the mast 1 m (3 ft) with a capacity load. The inner
weldments and the carriage must raise smoothly. Lower
the mast. All moving components must lower smoothly.
5. Lower the load to approximately 0.3 m (1 ft). Tilt the
mast forward and backward. The mast must tilt smoothly
and both tilt cylinders must stop evenly.
6. Check that the controls for the attachment operate the
functions of the attachment. See the symbols by each of
the controls. Make sure all of the hydraulic lines are con-
nected correctly and do not leak.
185
www.duma-rent.com
Maintenance
Fuel/Water Separator Filter, Kubota Diesel

Engine
On the Kubota 3.8L diesel engine, this amber indicator light
(see Figure 6 and Table 2) will illuminate if the sensor on
the fuel/water separator filter indicates that water must be
drained from the filter. See Figure 42 or Figure 44. Check
Kubota 3.6L fuel/water separator filter daily for water accu-
mulation. See Figure 43. See Periodic Maintenance 8000
SRM 1957 for procedures to drain water and change the fil-
ter.
How to Add Fuel to the Lift Truck
WARNING
1. AIR FILTER COVER Stop the engine. Turn the key switch to OFF, if truck is
2. RESTRICTION INDICATOR PORT
3. AIR OUTLET
equipped with a key switch; or press the Power
4. DUST DISCHARGE VALVE ON/OFF button. The operator must be off the lift truck
5. AIR INLET while fuel is added.
6. COVER LATCHES
No smoking.
Figure 52. Air Filter
All fuels for internal combustion engines are very flam-
mable.
Fill the fuel tank only in a designated area with good
ventilation. Have a fire extinguisher available.
186
www.duma-rent.com
Maintenance
Never fill the fuel tank near an open flame or near Only trained and authorized personnel are permitted to
equipment that can create sparks. Never check fuel operate filling equipment.
level or check for leaks with an open flame.
Use only the LPG tank indicated on the label on the
Breathing fuel vapor may cause nausea, unconscious- tank bracket. Do not use an LPG tank that is damaged.
ness, or death. Long-term exposure to gasoline vapors A damaged LPG tank must be removed from service.
may cause liver or kidney damage and cancer. Avoid
breathing vapor. WARNING
LPG tanks are heavy. The weight of an LPG tank can
Liquefied Petroleum Gas (LPG) exceed the maximum recommended weight for safe
lifting by an individual. Get assistance when lifting or
WARNING lowering an LPG tank. Use correct lifting procedures.
Close the fuel valve on the tank when the lift truck is
not in active use. Do not park the lift truck near heat or LPG can cause an explosion. Do not cause sparks or
ignition sources. permit flammable material near the LPG system. LPG
fuel systems can be disconnected indoors only if the
LPG is extremely flammable. When checking or filling lift truck is at least 8 m (26 ft) from any open flame,
an LPG tank: No smoking. Stop engine. motor vehicles, electrical equipments, or ignition
Frost on the surface of the tank, the valves, or the fit- source.
tings and the odor of LPG fuel indicates a leak. Inspect Removable LPG tanks must be removed from the fork
the LPG system and repair a leak immediately. An LPG lift before filling. If the lift truck is equipped with a non-
fuel leak creates an explosion and fire hazard. Do not removable LPG tank, make sure all components
attempt to start the engine if there is a leak in the LPG (engine, transmission, muffler, catalytic muffler) have
fuel system. surface temperatures that have cooled to below 427 °C
(800 °F).
187
www.duma-rent.com
Maintenance
LPG Tank, Removal 2. Turn the shutoff valve clockwise until the valve is com-
pletely closed.
NOTE: The single or dual LPG tank(s) and bracket(s) are
mounted on the right side step weldment of lift truck frame. 3. Run the engine until it stops, then turn the key switch to
The procedures described below are for the dual LPG the OFF position if truck is equipped with key switch, or
tanks and brackets. Single tank and bracket procedures press the Power ON/OFF button if truck is equipped with
are similar. keyless start option.
1. Removable LPG tanks can be replaced indoors only if 4. Disconnect the quick-disconnect fittings on the LPG
the lift truck is a minimum of 8 m (26 ft) from any open tanks. See Figure 53.
flame, motor vehicles, electrical equipment, or ignition
5. Unlatch the four latches and open the front covers.
source. Move lift truck to an area where LPG tanks are
Remove LPG tanks from tank brackets. See Figure 53.
changed.
188
www.duma-rent.com
Maintenance
1. QUICK
DISCONNECT
FITTING
2. TANK BRACKET
3. FRONT COVER
4. LPG TANK
5. LATCH
Figure 53. LPG Tank and Bracket
189
www.duma-rent.com
Maintenance
LPG Tank, Fill Make sure the correct adapter is used to connect the sup-
ply hose to the auxiliary fill fitting.
WARNING
5. Open the vent valve on the liquid level indicator.
Read and follow all the refueling precautions and
instructions under Liquefied Petroleum Gas (LPG). 6. Open the fuel valve on the LPG tank.
Removable LPG tanks must be removed from the fork
7. Open the valve on the end of the supply hose.
lift before filling.
8. Watch for a discharge from the vent valve on the liquid
NOTE: The following instructions are general procedures.
level indicator. When a cloud of visible vapor appears, the
There is a variation in equipment for filling LPG tanks. The
LPG tank is full. Do not fill the LPG tank to more than the
local authorities that have jurisdiction have specific rules
maximum level indicated by the liquid level indicator.
and regulations for filling LPG tanks. Make sure these rules
Immediately close the valve at the end of the supply hose.
and regulations are available and understood.
9. Close the vent valve on the LPG tank.
1. Check the gauge on tank to make sure it needs filling.
During the fill operation, the LPG tank must be in a position 10. Close the fuel valve on the LPG tank.
so that the liquid level indicator will always be in the vapor
11. Disconnect the hose supply.
space above the liquid level.
12. Stop the pump.
2. Open the liquid outlet valve and bypass return valve on
the storage tank. 13. Close the liquid outlet and the bypass return valve on
the storage tank.
3. Start the pump.
LPG Tank, Install
4. Connect the supply hose to the quick disconnect fitting
on the LPG tank (see Figure 53). If the LPG tank has an NOTE: The single or dual LPG tank(s) and bracket(s) are
auxiliary fill fitting, connect the supply hose to this fitting. mounted on the right side step weldment of lift truck frame.
190
www.duma-rent.com
Maintenance
The procedures described below are for the dual LPG tank Diesel Fuel
and brackets. Single LPG tank and bracket procedures are
similar. WARNING
1. Unlatch the four latches and open the front covers. When fuel is added, keep the funnel or fuel nozzle in
Install each LPG tank into tank brackets. See Figure 53. contact with the metal of the fuel tank to reduce the
possibility of static electric sparks. Clean any spilled
2. Connect the quick-disconnect fittings on the LPG tanks. fuel.
3. Turn the shutoff valves counterclockwise until the valves 1. Remove the fuel cap. Make sure the fuel tank is filled
are completely open. with the correct fuel for the type of engine in the lift truck.
4. Inspect the fuel system for leaks when the fuel valve is See Table 6. Clean the fuel cap.
open. There are four methods used to inspect the fuel sys- 2. Replace the fuel cap.
tem for leaks:
Diesel Exhaust Fluid (DEF)
a. Sound - Listen for sound of LPG escaping from a
tank fitting or hose connection. Refilling DEF Tank
b. Smell - LPG has a very distinctive odor. If you smell NOTE: DEF must meet ISO 22241, see Maintenance
LPG, DO NOT start the engine. Schedule for fluid specifications.
c. Soapy Water - This method is used in conjunction 1. Turn key or keyless switch to OFF position.
with Step b above. If the odor of LPG is present but
escaping fuel cannot be heard, apply soapy water to the 2. Unlock and loosen DEF tank cap. See Figure 54.
fittings and observe for bubbles. 3. Wipe cap and fill port to remove contaminants.
d. Frost - If the amount of LPG escaping is sufficient, 4. Fully open and remove tank cap.
frost may appear on the fittings.
191
www.duma-rent.com
Maintenance
5. Fill tank with DEF. Storage of DEF
6. Install and tighten tank cap. Make sure cap locks. NOTE: DEF must meet ISO 22241, see Maintenance
Schedule for fluid specifications.
Store DEF in a tightly sealed container to avoid evapora-
tion of water content. Container should not be exposed to
direct sunlight and storage area should be well ventilated.
Ensure storage container is polyethylene or stainless steel,
clean, and free of any contaminants such as water, dirt,
dust, other chemicals, or oils.
Shelf life of DEF varies depending on storage temperature.
See Table 7.
Wheels and Tires
General
The lift trucks covered in the Operating Manual are equip-
ped with pneumatic tires or solid rubber tires that look like
pneumatic tires. These variations in tires also cause a var-
1. DEF TANK CAP iation in the types of wheels and the disassembly and
2. FILL PORT assembly procedures.
Figure 54. DEF Cap
192
www.duma-rent.com
Maintenance
Pneumatic Tire With Tube, Repair WARNING

Remove Wheels From Lift Truck Wheels must be changed and tires repaired by trained
personnel only.
WARNING Deflate tire completely before removing the wheel from
A solid rubber tire that is the same shape as a pneu- the lift truck. If dual wheels are used, deflate both tires.
matic tire can be installed on a three-piece or four- Air pressure in the tires can cause the tire and rim
piece wheel for a pneumatic tire. DO NOT make parts to explode causing serious injury or death.
changes in the parts of the rim if this type of solid rub- Always wear safety glasses.
ber tire is installed instead of a pneumatic tire.
Changes to the parts of the rim can cause a failure of Never loosen the nuts that hold the inner and outer
the wheel and cause an accident. wheel halves together when there is air pressure in the
tire.
The type of tire and the tire pressure (pneumatic tires)
are shown on the Nameplate. Make sure the Nameplate CAUTION
is correct for the type of tires on the lift truck. If the
Not all makes of radial tires have sufficient side wall
truck is equipped with bias-ply tires, the ply rating lis-
strength for successful use on forklift trucks. This can
ted on the Nameplate is the minimum ply rating that
affect stability and ride quality. Check with your dealer
must be installed. Tires with ply rating greater than or
whether a specific radial tire is approved for use on
equal to the Nameplate listed ply rating may be accept-
Hyster trucks.
able. Check with your dealer whether a specific bias-
ply tire is approved for use on Hyster trucks. 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 air from the tire. Remove the valve core to
make sure that all of the air is out of the inner tube. Push a
193
www.duma-rent.com
Maintenance
wire through the valve stem to make sure that the valve Remove Tire From Wheel
stem does not have a restriction.
When disassembling wheels, see Figure 55. There are
3. Remove the wheel nuts and remove the wheel and tire several types of wheels used on this series of lift trucks.
from the lift truck. Lift truck tires and wheels are heavy. See Tire Removal, Two-Piece Wheel and Tire Removal,
Three- and Four-Piece Wheels.
194
www.duma-rent.com
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 55. Types of Pneumatic Wheels
195
www.duma-rent.com
Maintenance
Tire Removal, Two-Piece Wheel
WARNING
Make sure all of the air pressure is removed from the
tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode caus-
ing 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
the wheel rims together.
2. Loosen the tire bead from the wheel rim.
3. Remove the wheel rims from

tire. Remove the inner tube and
flap.
196
www.duma-rent.com
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. Air pressure in the seat, remove it.
Keep tire tools in firm contact with the wheel parts. If 3. Loosen the bead from the other
the tool slips, it can move with enough force to cause side of the wheel rim. Remove the
an injury. valve stem from the wheel.
1. Loosen the tire bead from
the side flange.
197
www.duma-rent.com
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.
198
www.duma-rent.com
Maintenance
Keep tire tools in firm contact with the wheel parts. If
WARNING
Do not lubricate the tire bead with antifreeze or petro-
an injury.
cause an explosion during inflation or use. 1. Install the inner tube and the rubber flap
in the tire.
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.
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. 2. Install the wheel rim in the
tire. Make sure the stem of the
7. Install the two-piece wheel in the tire as shown in Tire inner tube is aligned with the
Installation Two-Piece Wheel. slot in the rim.
Tire Installation Three- or Four-Piece Wheel
WARNING
Make sure all of the air pressure is removed from the
tire before a wheel is disassembled. Air pressure in the
199
www.duma-rent.com
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 56. 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
there is enough hose to permit the operation to stand
200
www.duma-rent.com
Maintenance
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 56.
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
specified pressure. See Nameplate. Figure 56. Add Air to Tires With Tube
5. Check that all wheel parts are correctly installed. If Install the Wheels
installation is not correct, remove all of the air pressure
from the tire. Remove the valve core to make sure all of the Install the wheel on the hub. Tighten the nuts in a cross
air pressure has been removed and then make adjust- pattern to torque value of 610 to 680 N•m (450 to 500 lbf ft)
ments. The clearance at the ends of the lock ring will be for both the drive wheel and steer wheel nuts. If the wheels
approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire are the two-piece rims, make sure the nuts that fasten the
has the correct air pressure. rim halves together are toward the brake drum when they
are installed.
201
www.duma-rent.com
Maintenance
Pneumatic Tubeless Tire, Repair 1. Put the lift truck on blocks as described in How to Put a
Remove Tire From Lift Truck
2. Remove the valve cap and core to remove all air from
the tire.
WARNING
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 Remove Tire From Wheel
the lift truck. If dual wheels are used, deflate both tires.
Air pressure in the tires can cause the tire and rim WARNING
parts to explode causing serious injury or death. Make sure all of the air pressure is removed from the
Always wear safety glasses. tire before a wheel is disassembled. Air pressure in the
Never loosen the nuts that hold the inner and outer ing serious injury or death.
wheels halves together when there is air pressure in
the tire. Keep tire tools in firm contact with the wheel parts. If
The Tubeless Bead Seal (TBS) enables tubeless tires to be an injury.
used on wheel rims that were designed to be used with a
tube. NOTE: There are several types of wheels used on these lift
trucks. When disassembling wheels, see Figure 56.
The main component of the TBS is a special rubber ring
that fits inside the tire between the tire beads to ensure the
airtightness of the existing wheel and the tubeless tire
assembly. See Figure 57.
202
www.duma-rent.com
Maintenance
1. If wheel rim is a three- or 3. Remove the loose flange
four-piece rim, turn the valve locking ring and the advance
1/4 turn and remove valve band (four-piece wheel only)
from wheel. using a tire tool.
2. Put wheel and tire assem- 4. Remove the press and

bly on the press. Position the remove the loose flange lock-
feet of the press on the loose ing ring and the advance
flange. Push press down on band (four-piece wheel only)
loose flange to expose the from the tire and wheel
locking ring. assembly.
203
www.duma-rent.com
Maintenance
5. Push the TBS toward the • DO NOT mix parts between different types or manu-
inside of the tire to remove it. facturers of wheels.
• DO NOT mix types of tires, type of tire tread, or
wheel assemblies of different manufacturers on any
one lift truck.
WARNING
WARNING
Install Tire on Wheel Do not lubricate the tire bead with antifreeze or petro-
WARNING cause an explosion during inflation or use.
Damage to the tire and wheel assembly and injury or
death can occur if you do not do the following proce-
dures:
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 that wheel assembly.
204
www.duma-rent.com
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
NOTE: If the wheel rim
two-piece wheel is being
width is less than six
used, leave valve in valve
inches, the TBS will con-
hole.
tain one valve hole to
accommodate the needle valve. If the wheel rim width is If the TBS has two valve holes, lubricate the plastic plug
greater than six inches, the TBS will have two holes for the and insert into valve hole that will not be used.
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
small plastic plug. the tire to note the position of
the valve hole in the TBS.
205
www.duma-rent.com
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:
• Advance band (four-piece
wheel only)
• Loose flange
• Locking ring
206
www.duma-rent.com
Maintenance
7. Position the advance band. Ensure that it does not go in 8. Insert tire tool into the lock-
too far and damage the valve. Position the arms of the ing ring groove, and a vise
press onto the loose flange. grip on other end. Remove
vise grip. Release the press
Push down on press to
and check that all component
depress the tire beads until
parts are correctly positioned.
the locking ring groove is fully
Replace the valve core.
exposed.
9. Inflate tire to 103 kPa
(15 psi). Tap wheel with a
mallet to ensure all compo-
nents 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 57. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck that fas-
tens onto the valve stem. Make sure there is enough
hose to permit the operator to stand away from the
safety cage when air pressure is added to the tire. Do
not sit or stand by the safety cage.
1. Put tire in safety cage. See Figure 57.
207
www.duma-rent.com
Maintenance
2. Add air to tire to the recommended pressure that is the two-piece rims, make sure the nuts that fasten the rim
shown on the Nameplate. Install valve cap to ensure air halves together are toward the brake drum when they are
stays in the tire. installed.
Solid Rubber Tires on Pneumatic Wheels,
Change
WARNING
Wheels must be changed and tires repaired by trained
personnel only.
Always wear safety glasses.
1. Put the lift truck on blocks as described in How to Put a
2. Remove the wheel nuts and remove the wheel and tire
from the lift truck. Lift truck tires and wheels are heavy.
Remove Tire From Wheel
Figure 57. Add Air to Tubeless Tire
WARNING
Install the Wheels Keep tire tools in firm contact with the wheel. If the tool
slips, it can move with enough force to cause serious
Install the wheel on the hub. Tighten the nuts in a cross
injury.
pattern to torque value of 610 to 680 N•m (450 to 500 lbf ft)
for both drive wheel and steer wheel nuts. If the wheels are
208
www.duma-rent.com
Maintenance
NOTE: When disassembling wheels, see Figure 55. There 3. Turn the tire over. Put a
are several types of wheels used on these series of lift support under the wheel rim.
trucks. Make sure the wheel rim is at
least 150 to 200 mm (6 to
1. Put the wheel rim on the
8 in.) from the bed of the
bed of the press. Put the
press.
cage in position on the tire.
Use press to push the tire
away from the side flange.
2. Put the tire tool into the

slot between the lock ring
and the wheel rim. Remove
the lock ring and side flange.
209
www.duma-rent.com
Maintenance
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
• DO NOT mix type of tires, type of tire tread, or wheel
rim.
assemblies of different manufacturers on any one
lift truck.
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
13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the
Install Tire on Wheel clearance is wrong, the wrong part has been used.
NOTE: When disassembling wheels, see Figure 55. There
WARNING are several types of wheels used on these series of lift
Damage to tire and wheel assembly and injury or death trucks.
can occur if you do not do the following procedures:
CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.
• Make sure that all parts of the wheel are the correct
parts for the wheel assembly.
210
www.duma-rent.com
Maintenance
1. Lubricate the wheel rim 3. Remove the cage and put
and the inner surface of the the flange seat (if used), the
tire with tire lubricant or side ring, and the lock ring
soap. 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.
2. Put the wheel rim on the

bed of the press. Put the tire 4. While the cage is holding
over the wheel rim. Put the the tire on the wheel rim,
cage in position on the tire. install the lock ring. Use a
Use press to install the tire on tire tool to make sure the
the wheel rim. lock ring is in the correct
position.
211
www.duma-rent.com
Maintenance
Dual Drive Wheels, Install

NOTE: Some lift trucks have dual drive wheels. The follow-
ing procedures describe the steps to install the dual sets of
wheels.
1. Install inner wheel on hub. If the wheels are the two-
piece rims, make sure nuts that fasten rim halves together
are toward brake drum when they are installed.
2. Install wheel adapter spacers on the inner wheel studs
and tighten spacers to 100 to 125 N•m (74 to 92 lbf ft).
Install the dual hub assembly and inner wheel nuts on the
spacers and tighten the wheel nuts to 610 to 680 N•m (450
to 500 lbf ft). See Figure 58.
3. Install outer wheel on dual hub assembly. Tighten nuts
to a torque value of 610 to 680 N•m (450 to 500 lbf ft). If
the wheels are the two-piece rims, make sure nuts that fas-
ten rim halves together are toward brake drum when they
are installed.
4. Install the valve extension bracket and tighten the
attaching nut to 8 N•m (70 lbf in). Install the valve exten-
sion hose into the bracket. See Figure 58.
Figure 58. Dual Drive Wheels Installation
212
www.duma-rent.com
Maintenance
Legend for Figure 58 Always wear safety glasses.
1. TIRE 1. Put the lift truck on blocks as described in How to Put a
2. DUAL HUB ASSEMBLY
3. WHEEL NUT
4. WHEEL 2. Remove the wheel nuts and remove the wheel and tire
5. WHEEL ADAPTER SPACER
6. VALVE EXTENSION
from the lift truck. Lift truck tires and wheels are heavy.
7. BRACKET
NOTE: See Figure 59 when you disassemble the wheels.
Snap-On-Tire, Change There are several types of wheels used on these series of
lift trucks.
WARNING
Wheels must be changed and tires repaired by trained
personnel only.
213
www.duma-rent.com
Maintenance
Figure 59. Snap-On-Tires and Rim Configurations
214
www.duma-rent.com
Maintenance
Remove Snap-On-Tire, Solid Tire From Wheel 2. Put the cage in position on
the tire. Use the press to
WARNING push the tire from the wheel
Keep tire tools in firm contact with the wheel. If the tool rim.
slips, it can move with enough force to cause serious
injury.
1. Put a support under the
wheel rim. Make sure the
wheel rim is at least 150 to
200 mm (6 to 8 in.) from the
bed of the press.
Install Snap-On-Tire, Solid Tire on Wheel
NOTE: When wheels are disassembled, see Figure 59.
There are several types of wheels used on this series of lift
trucks.
WARNING
Failure to follow these procedures will cause damage
to the tire and wheel assembly and can cause injury.
215
www.duma-rent.com
Maintenance
• Make sure that all parts of the wheel are the correct 2. Put the wheel rim on the
parts for the wheel assembly. bed of the press. Put the tire
over the wheel rim. Put the
• DO NOT mix parts between different types or manu-
cage in position on the tire.
facturers of wheels.
Use the press to install the
• DO NOT mix type of tires, type of tire tread, or wheel tire on the wheel rim.
assemblies of different manufacturers on any one
lift truck.
CAUTION
Too much lubricant can cause the tire to slide and
move around the wheel rim.
1. Lubricate the wheel rim Jump-Starting the Lift Truck
and the inner surface of the
tire with tire lubricant.
Jump-Starting Using a Battery Charger
CAUTION
DO NOT try to start the engine by pushing or towing
the lift truck. Damage to the transmission can occur if
engine is started by pushing or towing lift truck.
If the battery becomes discharged and requires a booster
battery to start the engine, follow these procedures care-
fully when connecting the jumper cables:
216
www.duma-rent.com
Maintenance
1. Disconnect the negative battery terminal of the lift truck 2. Always connect jumper cable, that is the ground cable,
being started. last.
2. Always connect positive jumper cable to positive termi- 3. Always connect jumper cables to discharge lift truck bat-
nal of discharged battery and negative jumper cable to tery before connecting them to the fully charged lift truck
negative terminal. battery.
3. Always connect jumper cable, that is the ground cables, Operating Procedures for a New or Rebuilt
last. Engine
4. Always connect jumper cables to discharged battery
A new or rebuilt engine must be operated under special
before connecting them to booster battery.
conditions during the first 50 hours. These special condi-
Jump-Starting Using Another Lift Truck tions prevent damage to the engine until the new parts can
wear and adjust to fit each other.
WARNING 1. Make sure the fluid levels of oil and coolant are correct.
To prevent possible arcing between the two lift trucks,
make sure that the lift trucks are not touching. 2. Start and run the engine at approximately one-half throt-
tle for 30 minutes for the first operation. Check the gauges
CAUTION and indicators for the correct operation during this first
DO NOT try to start the engine by pushing or towing operating period. Check for leaks.
the lift truck. Damage to the transmission can occur if 3. If the work conditions are slow and the loads are less
engine is started by pushing or towing lift truck. than 50% of the truck capacity, a simulated work condition
1. Always connect positive jumper cable to positive termi- must be used during the first four hours of operation. Oper-
nal of discharged battery and negative jumper cable to ate the lift truck with a minimum load of 75% capacity.
negative terminal. Operate the engine through cycles from idle to full throttle
217
www.duma-rent.com
Maintenance
and back to idle. Avoid long periods of high engine speeds Before placing any lift truck in storage, you must choose an
with a light load during the first 50 hours of operation. High area that is clean, dry, and free from airborne contami-
engine speeds with a light load can cause damage to the nates. For safety and increased usable floor area, remove
cylinders in the engine. the forks and tag them with the lift truck serial number. For
best protection, operate your internal combustion engine lift
Changes to the Overhead Guard truck for a short period each month.
WARNING The following storage procedures are for conditions and

Do not operate the lift truck without the overhead temperatures above 0 °C (32 °F). Adjust these procedures
guard correctly fastened to the lift truck. for local conditions and any changes in conditions during
storage. The preparations necessary for storage are also
Do not make changes to the overhead guard by weld- determined from the following conditions:
ing. Changes that are made by welding, or by drilling
holes that are too big in the wrong location, can reduce • Short-term storage is from one to six months. Long-term
the strength of the overhead guard. storage is over six months.
See your dealer for Hyster lift trucks BEFORE perform- • Storage Location. A lift truck stored indoors will not
ing any changes to the overhead guard. require as much external protection as a lift truck stored
outdoors.
How to Put Internal Combustion Engine (ICE)
Short-Term Storage
Trucks in Storage
Perform the following steps to prepare your lift truck for
It is important to store your lift truck properly to protect it.
storage from one to six months:
The main areas of concern are engines, hydraulic compo-
nents, and truck batteries. The length of storage time and 1. Check lubricant and fluid levels. Completely fill the fuel
the storage location determines what procedures you tank. Make sure the coolant mixture will protect cooling
should follow. system and engine to lowest temperature expected during
218
www.duma-rent.com
Maintenance
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
removed, tilt mast BACKWARD until cylinders are com- Long-Term Storage
pletely retracted. This protects the cylinder rods. Do the following steps to prepare the lift truck for storage
3. Check that all switches and accessories are in the OFF for 6 months or longer:
position. 1. Complete all short-term storage procedures.
4. Activate each control lever to relieve hydraulic pressure. 2. Wrap or cover all exterior lights, radiator grill, and air
5. Install blocks, front and rear, at the drive wheels. If the vents with a moisture barrier cover. Use tape to hold the
lift truck must be left on an incline, put blocks on the down- covers in place.
hill side of all wheels so that the lift truck cannot move. DO 3. Remove the battery or batteries from the lift truck. Store
NOT USE THE PARKING BRAKE. the battery or batteries in an approved space. Be sure to
6. Disconnect the battery cables from the battery. Apply a follow local regulations. Batteries that are stored for long
protective coating to the cable connectors and battery ter- periods can become damaged. Either keep batteries in
minals to prevent corrosion. service or follow the battery storage procedures below.
7. Check the tire pressure, if applicable. Make sure the 4. Spray exterior surfaces and frame with preservative
tires have the correct pressure (see the Nameplate.) coating.
219
www.duma-rent.com
Maintenance
While the Lift Truck is in Storage Lead acid batteries will slowly "self-discharge" over a
period of time due to their chemical makeup. If the self-dis-
Each month make a visual inspection for leaks or signs of charge is left uncontrolled, excessive sulphation can occur
deterioration. Take corrective action immediately. Check which is difficult to reduce and can damage the anodes. A
the fluid level in engine, radiator, hydraulic tank, and brake discharged battery with a specific gravity of 1.000 will
master cylinder. freeze at −7.8 °C (18 °F) A fully-charged battery with a spe-
NOTE: Do not shut down an engine before it reaches oper- cific gravity of 1.280 will freeze at −66 °C (−87 °F).
ating temperature. This "self-discharge" is due to a chemical reaction; there-
Each month set the park brake, start engine, and run until fore, that chemical reaction can be accelerated by heat
normal operating temperature is reached. This will coat the resulting in more rapid "self-discharge." The rate of dis-
internal engine components with a film of oil and rid the charge can amount to an average of about 0.001 point
engine of built-up condensation. drop in specific gravity per day.
Each month all hydraulic cylinders must be cycled several The following procedure can be followed when placing a
times to keep the seals active and to coat the interior walls battery in storage or when not in operation for more than
with oil. Actuate each cylinder, in both directions, until it 30 days.
reaches the stops. 1. Give an equalizing charge prior to placing new batteries
Return lift truck to its storage state for another month. in storage. Used batteries are to be fully charged, then
allowed to balance for approximately three more hours.
How to Put Batteries in Storage
2. Neutralize and clean the battery. Clean with a solution of
Batteries are to be placed on a wooden pallet and stored in 100 grams (3.5 oz) of sodium bicarbonate (baking soda)
a dry, moderately cool area. per 1 liter (0.25 gal) of water.
3. Store in a cool, dry location.
220
www.duma-rent.com
Maintenance
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. Before the lift truck is moved on a transport, check the
selected route to make sure there is enough clearance for
5. Protect batteries from ambient contamination. the lift truck as loaded on the transport vehicle. Bridges,
If a greasy film forms on the top of a battery, this is acid overpasses, powerlines, and natural barriers can prevent
and must be neutralized with the solution described above. clearance. Removal of the mast can be necessary.
Putting a Stored Lift Truck Back Into Service If a trailer is the method of transportation, use blocks in
front and back of the trailer tires to prevent movement of
1. Remove all tape, covers, and preservation materials. the trailer when the lift truck is loaded and unloaded. If a
loading ramp is used, make sure that the ramp is the cor-
2. Check the lift truck for damage and missing components.
rect design and capacity.
Repair damage and/or replace missing components.
If the lift truck is equipped with lifting eyes, use a crane to
NOTE: If the lift truck has been stored longer than one
load and unload the lift truck from the transport. If the truck
year, all lubricants and fluids must be drained and
is not equipped with approved lifting eyes, do not lift the
replaced. See the Periodic Maintenance section of your
truck by attaching a lifting device to any other part of the lift
service manual for the procedures.
truck for the purposes of loading or unloading.
3. Clean the battery cables and terminals. Check the bat-
tery voltage. If the voltage is not correct, charge battery. Loading
Connect battery cables to battery.
WARNING
4. When a lift truck is to be put into service after storage, it The straps or chains used to fasten the lift truck to the
must be given the 500-hour inspection shown in the Rec- transport must be directly connected to the lift truck
ommended Schedule of Maintenance. frame or to a component (drive axle, tow pin) that is
221
www.duma-rent.com
Maintenance
solidly attached to the frame. Do not fasten a strap or transmission, leave the gears of the transmission engaged.
chain to the mast or any attachment to hold the lift DO NOT leave a manual transmission in NEUTRAL (N).
truck on the transport.
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
CAUTION
button, if truck is equipped with a keyless option. Check
Make sure that any straps or chains used to fasten the
that all switches and accessories are turned OFF.
lift truck to the transport do not contact any tubes,
hoses, hydraulic cylinders, or other parts of the truck 5. Put blocks in front and back of the lift truck tires to pre-
that are easily damaged. vent any movement of the lift truck. Make sure the blocks
are attached to the load surface.
If components and attachments must be removed for trans-
port of the lift truck, see the Service Manual for removal 6. Tie the lift truck to the transport vehicle using straps or
procedures. chains. The straps or chains must be directly connected to
the lift truck frame or to a component such as the drive
The operator must never leave a lift truck in a condition so
axle, tow pin in the counterweight, or the two center grill
that it can cause damage and injury. When the lift truck is
bars in the counterweight for lift trucks equipped with a lea-
loaded on the transport, do the following operations:
ded counterweight without a tow pin (see Figure 29).
1. Apply the parking brake.
If the lift truck is equipped with an LPG fuel system and is
2. If the mast is mounted on the lift truck, fully lower the not in active use, close the fuel valve at the tank. If the lift
forks or carriage. Tilt the mast FORWARD until the tips of truck is going to be left overnight or longer, the truck must
the forks touch the surface. be parked outside or the LPG tank must be removed and
stored outside.
3. Put the direction control lever for the powershift trans-
mission in NEUTRAL (N). If the lift truck has a manual If the lift truck is transported in severe weather or any other
condition that can damage the lift truck, cover the lift truck.
222
www.duma-rent.com
Maintenance
Make sure the protective cover is designed for the applica- Preparation for Use
tion and is securely fastened.
After being transported or stored, the lift truck must be pre-
Unloading pared for use for proper operation. All problems must be
corrected before use of the lift truck, see the Service Man-
If components normally attached to the lift truck were
ual for procedures.
removed for transport, see the Service Manual for installa-
tion procedures. Preparation After Transport
1. If used, remove any protective cover. 1. Complete the unloading procedures.
2. Make sure the parking brake is applied. 2. Inspect the lift truck for damage and missing compo-
3. Disconnect the straps or chains. nents.
4. Remove the wheel blocks. 3. Follow the steps in the section How to Make Checks
With the Engine Stopped.
5. Check that all switches and accessories are turned OFF.
6. Unload the lift truck.
223
www.duma-rent.com
Maintenance
Maintenance Register
Protect your investment in materials handling equipment! This Maintenance Register is used to record the time of
Keep a high-residual value in your Hyster lift truck! Do the each periodic inspection and maintenance. The dealer's
maintenance according to the Maintenance Schedule in stamp or authorized signature confirms that maintenance
this Operating Manual. and inspection was done at regular intervals by authorized
personnel.
Your dealer for Hyster lift trucks has the equipment and
trained service personnel to do a complete program of
inspection, lubrication, and maintenance.
1. 2. 3. 4.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
224
www.duma-rent.com
Maintenance
17. 18. 19. 20.
21. 22. 23. 24.
25. 26. 27. 28.
29. 30. 31. 32.
33. 34. 35. 36.
37. 38. 39. 40.
41. 42. 43. 44.
225
www.duma-rent.com
NOTES
226
www.duma-rent.com
Spacer
9/18 (4/18)(10/17)(4/17)(10/16)(4/16)(3/16)(1/16)(9/15)
OPERATING MANUAL
FORTENS
H6.0FT, H7.0FT (L006)

www.duma-rent.com
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4139132 9/18

Operating Manual: H6.0FT, H7.0FT (L006)

Uploaded by

Copyright:

Available Formats

Operating Manual: H6.0FT, H7.0FT (L006)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operating Manual: H6.0FT, H7.0FT (L006)

Uploaded by

Copyright:

Available Formats

www.duma-rent.

H6.0FT, H7.0FT (L006)

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4139132 9/18

LIFT TRUCK MODEL SERIAL NUMBER

DRIVE TIRE SIZE STEERING TIRE SIZE

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2018. All Rights Reserved.

©HYSTER COMPANY 2018 4139132 - ENGLISH-UK 1

CAUTION On the lift truck, the WARNING symbol is on an orange

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT IC ENGINE POWERED

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

OTHER APPLICABLE DIRECTIVES:

LIMITED/NEDERLAND B.V., CRAIGAVON, NORTHERN IRELAND/NIJMEGEN, THE

KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

Figure 1. Model View Showing Major Components

A. NAMEPLATE (CE C. INCOMPLETE LABEL

Figure 2. Nameplate and Labels

Figure 3. Warning and Safety Labels (Sheet 1 of 5)

Figure 3. Warning and Safety Labels (Sheet 2 of 5)

Figure 3. Warning and Safety Labels (Sheet 3 of 5)

Figure 3. Warning and Safety Labels (Sheet 4 of 5)

Figure 3. Warning and Safety Labels (Sheet 5 of 5)

Display Switch Cluster Display Switch Cluster – Right-Side Display

NOTE: On the lift truck models covered in this manual, the

Figure 4. Display Switch Cluster

Figure 5. Display Switch Cluster - Right Side Display Inputs

A. LCD SCREEN B. WARNING AND INDICATOR LIGHTS

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

Display, Diesel Particulate Filter (DPF) • Auto/Active Regeneration (Regeneration Level 1)

The DPF display will illuminate the appropriate icon(s)

1. DPF DISPLAY Figure 8. Refer to Operator Manual Icon

CAN Communication Lost Passive Regeneration Only

Figure 9. CAN Communication Lost Icon

Figure 11. Partial Soot Level

Parked Regeneration Request WARNING

Warning Level Service Level

Diesel Exhaust Fluid (DEF) g. Derate is none.

NOTE: The status of the DEF tank is indicated on the DPF

Bad DEF Quality

A. UNITS WITH MONOTROL® PEDAL AND E-HYDRAULICS

Figure 22. Operator Controls

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

Figure 23. Operator Compartment Pedal Configurations

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

Auxiliary Control Levers

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

Operating Techniques Basic Operating Procedures