J117 Operating Manual

OPERATING MANUAL
Challenger
H40-52XM-16CH (J117)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4222750 12/20

Spacer
LIFT TRUCK MODEL SERIAL NUMBER

ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE GROUP NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE STEERING TIRE SIZE
DRIVE TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2020. All Rights Reserved.
HYSTER, , FORTIS, MONOTROL and YARDMASTER are Registered trademarks of Hyster-Yale Group, Inc. HSS, DURAMATCH, UNISOURCE, and
are Trademarks in the United States and certain other jurisdictions.
Foreword
Foreword
To OWNERS, USERS, and OPERATORS: It is the responsibility of the employer to make sure that the
operator can see, hear, and has the physical and mental
The safe and efficient operation of a lift truck requires ability to operate the equipment safely.
skill and alertness on the part of the operator. To develop
the skill required, the operator must: NOTE: A comprehensive operator training program is
available from Hyster Company. For further details, con-
• Receive training in the proper operation of this lift truck. tact your dealer for Hyster lift trucks.
• Understand any potential hazards that may exist in the This Operating Manual is the original instruction and con-
work place where the lift truck is intended to be used. tains information necessary for the operation and mainte-
• Understand the capabilities and limitations of the lift nance of a basic lift truck. Optional equipment is
truck. sometimes installed that can change some operating char-
acteristics described in this manual. Make sure the neces-
• Become familiar with the construction of the lift truck and sary instructions are available and understood before
see that it is maintained. operating the lift truck.
• Read and properly understand the warnings, instruc- Some of the components and systems described in this
tions, and operating procedures in this manual. Operating Manual will NOT be installed on your unit. If
In addition, a qualified person, experienced in lift truck you have a question about any item described, contact
operation, must guide a new operator through several driv- your dealer for Hyster lift trucks.
ing and load handling operations before the new operator
attempts to operate the lift truck alone.
©HYSTER COMPANY 2020 4222750 - ENGLISH-UK 1

Foreword
Additional information as specified Whole-body vibration:

inMachinery Directive 2006/42/EC: • Measured whole body vibration at the operator position,
based on standard production truck with full-suspension
Dimensional Details seat is listed below.
Certain information is shown on the truck Nameplate. For • Declared whole-body vibration emission value is in
additional dimensional details on this or any other specific accordance with EN 12096.
truck, consult your dealer.
• Measured vibration emission value aW,Z = 0.3 m/s2
Noise Levels
• Uncertainty, K = 0.09 m/s2
The measured Operators Ear Lpaz Value is 76 dB(A) per
EN 12053 for Stage IIIA engines. The measured Operators • Values determined according to EN 13059.
Ear Lpaz Value is 74 dB(A) per EN 12053 for Stage IV Hand-arm vibration:
engines.
Hand-arm vibration emission value = <2.5 m/s2
Human Vibration (Whole-Body and Hand-
ArmVibration) Hazardous Atmosphere:
NOTE: The whole-body vibration level is measured accord- Before any lift truck within the European Community can be
ing to standard EN 13059 which contains specific test crite- operated in a Potentially Explosive Atmosphere, it is neces-
ria (load, speed, roadway surface, etc.) Worksite vibration sary that the lift truck is suitably converted for the applica-
levels may vary depending on actual operating and surface tion. Conversions should only be carried out by a Hyster
conditions. approved supplier. Confirmation of the conversion can be
made by referring to the lift truck Declaration of Conformity
which will confirm compliance with European Directive
2
Foreword
94/9/CE. If you are in doubt, please contact your Hyster NOTE: The following symbols and words indicate safety
dealer for assistance. information in this manual.
Manufacturer: WARNING
Hyster Europe, Centennial House, Building 4.5, Frimley Indicates a hazardous situation which, if not avoided,
Business Park, Frimley, Surry GU16 7SG, United Kingdom could result in death or serious injury.
The EC Conformity: CAUTION

Indicates a hazardous situation which, if not avoided,
Each lift truck ships with a unique EC Declaration of Con-
could result in minor or moderate injury and property
formity certificate. See the end of this section for a sample
damage.
EC Declaration of Conformity certificate which complies
with Machinery Directive 2006/42/EC. On the lift truck, the WARNING symbol is on orange
background. The CAUTION symbol is on yellow back-
NOTE: Hyster lift trucks are not intended for use on public
ground.
roads.
3
Foreword
Atmospheric Conditions
This range of lift trucks is designed to work in the following atmospheric conditions:
Average ambient temperature for continuous duty: +45 °C (109 °F)

Maximum ambient temperature, short term (up to 1 h): +50 °C (122 °F)
Lowest ambient temperature for trucks intended for use in normal outdoor conditions: -20 °C (10 °F)
Altitude: Up to 2,000 m (6,562 ft)
From 30% to 95%
Relative humidity:
(noncondensing)
4
Foreword
Lifting tion to a powered industrial truck, provided, however, that

the user shall:
1. Arrange for the modification or alteration to be
designed, tested, and implemented by an engineer(s)
expert in industry trucks and their safety;
Lifting eyes and instruction decal are optional. DO NOT lift 2. Maintain a permanent record of the design, test(s),
a lift truck other than by jacks under the lift truck unless the and implementation of the modification or alteration;
lifting eye option or special lifting eyes are installed. 3. Approve and make appropriate changes to the
capacity plate(s), decals, tags and instruction hand-
Truck Modification book;
Unauthorized truck modification is not permitted. To obtain 4. Affix a permanent and readily visible label to the truck
authorization contact your Hyster dealer. stating the manner in which the truck has been modi-
Only in the event that the truck manufacturer is no longer in fied or altered together with the date of modification or
business and there is no successor in the interest of the alteration, and the name and address of the organiza-
business, the user may arrange for a modification or alteration 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
LIMITED/NEDERLAND B.V., CRAIGAVON, NORTHERN IRELAND/NIJMEGEN, THE
NETHERLANDS.
NAME
POSITION PLANT MANAGER
(BLOCK LETTERS)
SIGNATURE
DATE
Note that some products have options for equipment that are subject to Radio Equipment
Directive 2014/53/EU. Where applicable, product/option meets the requirements outlined in
this Directive.
UK DECLARATION OF CONFORMITY
WE HYSTER EUROPE
CENTENNIAL HOUSE
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 SUPPLY OF MACHINERY (SAFETY) REGULATIONS 2008.

COMPLIANCE WITH THESE REGULATIONS IS ESTABLISHED BY MEETING THE
TECHNICAL REQUIREMENTS OF THE RELEVANT STANDARDS, INCLUDING BS EN ISO
3691-1:2015+A1:2020
OTHER APPLICABLE REGULATIONS:

EMC REGULATIONS 2016
NOISE EMISSION IN THE ENVIRONMENT BY EQUIPMENT FOR USE OUTDOORS
REGULATIONS 2001
TYPICAL VALUE dB
GUARANTEED VALUE, dB
IS IN CONFORMITY WITH THE REQUIREMENTS OF OUTDOORS REGULATIONS 2001

TECHNICAL FILE CONTROLLED BY:
NAME
POSITION PLANT MANAGER
(BLOCK LETTERS)
SIGNATURE
DATE
7
Foreword
Contents
Contents
Foreword ..................................................................... 1 Cabin Tip-Up Function ............................................. 79
TO OWNERS, USERS, AND OPERATORS: ............. 1 Automatic Extend/Retract Function .......................... 81
ADDITIONAL INFORMATION AS SPECIFIED Optional 30 Foot Lock Switch ................................... 82
INMACHINERY DIRECTIVE 2006/42/EC: ............... 2 Twist Lock and Lift Interrupt Screen Area ................ 84
ATMOSPHERIC CONDITIONS .................................. 4 General Information Screen Area ............................. 86
LIFTING ...................................................................... 5 Special Alerts ........................................................... 88
TRUCK MODIFICATION ............................................ 5 DISPLAY MENUS ...................................................... 90
Warning ....................................................................... 12 Performance Menu ................................................... 91
Model Description ...................................................... 15 System Menu ........................................................... 92
GENERAL .................................................................. 17 System Settings Menu ........................................... 92
OPERATOR PROTECTION EQUIPMENT ................ 17 Changing a Setting ................................................. 93
NAMEPLATE .............................................................. 18 System Information Menu ...................................... 96
SAFETY LABELS ....................................................... 19 Greasing Menu ......................................................... 97
SEAT ADJUSTMENT CONTROLS ............................ 22 Greasing Information Menu .................................... 97
SPRING-ASSISTED ARMREST ADJUSTMENT ....... 27 Greasing Intensity Settings Menu .......................... 100
DRIVING CONTROLS AND SIGNALS ...................... 29 Truck Settings Menu ................................................ 101
ARMREST AND JOYSTICK CONTROLS .................. 35 Automated Services Setup Menu ........................... 102
SIDE CONSOLE CONTROLS .................................... 42 Automatic Engine Shutdown Setup Menu .............. 103
INSTRUMENTS AND INDICATORS .......................... 53 REAR VIEW CAMERA ............................................... 105
Regeneration ............................................................ 66 Operating Procedures ................................................ 109
Stationary Regeneration Procedure ......................... 66 GENERAL .................................................................. 109
INFORMATION DISPLAY .......................................... 73 Know Your Lift Truck ................................................ 109
Display Buttons ........................................................ 73 Stability and Center of Gravity .................................. 110
Display Screen Areas ............................................... 77 Capacity (Weight and Load Center) ......................... 112
8
Contents
INSPECTION BEFORE OPERATION ........................ 113 Load Handling, How to Handle Containers .............. 128
Checks With the Engine Stopped ............................. 113 Indicator Lights and LEDs ........................................ 129
MOUNTING AND DISMOUNTING ............................. 114 System Interrupts ..................................................... 130
STARTING PROCEDURES ....................................... 114 System Interrupt Overrides ...................................... 130
Starting a truck with Telemetry Access Option ......... 115 Lift Interrupt Override ............................................... 130
Starting a truck with Telemetry VerificationOption ... 115 Twist Lock Override .................................................. 131
Starting the Truck ..................................................... 116 Lowering Interrupt Override ...................................... 131
HEATING HYDRAULIC OIL ....................................... 117 How to Pick Up a Container ..................................... 132
MANUAL SHUTDOWN PROCEDURES .................... 117 Load Handling, Traveling With a Container .............. 133
DERATING AND AUTOMATIC SHUTDOWN How to Deposit a Container ..................................... 136
PROCEDURES ........................................................ 117 ATTACHMENTS ......................................................... 137
Empty Seat Engine Shutdown (Optional) ................. 118 STOPPING ................................................................. 137
OPERATOR PRESENCE SYSTEM (OPS) ................ 118 PARKING ................................................................... 137
AUTOMATIC GREASING SYSTEM (OPTIONAL) ..... 119 Maintenance ................................................................ 139
CHECKS FROM THE DRIVER'S SEAT WITH THE GENERAL .................................................................. 139
ENGINE RUNNING .................................................. 119 Serial Number Data .................................................. 139
OPERATING TECHNIQUES ...................................... 120 HOW TO MOVE A DISABLED LIFT TRUCK ............. 139
General ..................................................................... 121 How to Tow the Lift Truck ......................................... 141
Basic Operating Procedures .................................... 121 HOW TO PUT A LIFT TRUCK ON BLOCKS ............. 142
Driving and Direction Changes ................................. 122 How to Raise the Drive Tires .................................... 144
Inching/Braking ......................................................... 123 How to Raise the Steer Tires ................................... 144
Steering (Turning) .................................................... 124 HOW TO CLEAN A LIFT TRUCK ............................... 145
Load Handling, General ........................................... 126 HOW TO ADD FUEL TO THE LIFT TRUCK .............. 145
Load Handling, Lifting, Lowering, and Tilting ........... 126 HOW TO ADD DEF TO THE LIFT TRUCK ................ 146
CONTAINER HANDLING ........................................... 128 Periodic Maintenance Schedule ................................ 148
9
Contents
Container Attachment Maintenance ......................... 167 DEF Level ................................................................. 188
Maintenance Procedures Every 8 Hours or Daily .... 173 Control Levers and Pedals ....................................... 188
HOW TO MAKE CHECKS WITH THE ENGINE Parking Brake ........................................................... 188
STOPPED ................................................................ 173 Service Brakes ......................................................... 188
Warning and Safety Labels ...................................... 173 Steering System ....................................................... 188
Mast, Carriage, and Attachments ............................. 174 Mast, Carriage, and Attachment ............................... 189
Header Hose Assembly ............................................ 175 Signals from the Container Handler Control System 189
Fuel, Oil, or Coolant Leaks ....................................... 175 Transmission ............................................................ 190
Radiator Sections for Engine Coolant, Charge Air Operator Presence System ...................................... 190
Cooler, Transmission and Hydraulic Oil ............... 176 Transmission Oil ....................................................... 190
Windshield Washer Fluid .......................................... 176 Attachments ............................................................. 191
Hydraulic System Oil ................................................ 176 WHEELS AND TIRES ................................................ 191
Engine Oil ................................................................. 179 Wheels, Tires and Tire Pressure .............................. 191
HOW TO MAKE CHECKS WITH ENGINE Remove Wheels from Lift Truck ............................... 194
RUNNING ................................................................. 182 Remove Tire from Wheel ......................................... 194
Seat Belt, Seat Rails, and Steering Column ............. 183 Install Tire on Wheel ................................................. 198
Steering Column Latch ........................................... 184 Adding Air Pressure to Tires .................................... 201
Gauges, Lights, Horn, Fuses, and Relays ................ 184 Install Wheels on Lift Truck ...................................... 202
Main Fuses ............................................................. 184 Drive Wheels .......................................................... 203
Windows and Mirrors ................................................ 184 Steer Wheels .......................................................... 204
Fault Codes .............................................................. 184 Wheel Nuts on Drive and Steer Wheels ................... 204
Engine Air Filter ........................................................ 184 HOW TO PUT INTERNAL COMBUSTION ENGINE
Coolant Level ........................................................... 185 (ICE) TRUCKS IN STORAGE .................................. 205
High Pressure Brake Cooling Filter .......................... 186 Short-Term Storage .................................................. 205
Fuel Level ................................................................. 188 Long-Term Storage .................................................. 206
10
Contents
WHILE THE LIFT TRUCK IS IN STORAGE ............... 206 OPERATING PROCEDURES FOR A NEW OR
HOW TO PUT BATTERIES IN STORAGE ................ 207 REBUILT ENGINE ................................................... 210
PUTTING A STORED LIFT TRUCK BACK INTO CHANGES TO THE OPERATOR'S CAB ................... 210
SERVICE .................................................................. 207 Capacities and Specifications ................................... 211
HOW TO MOVE A LIFT TRUCK ON A LIFT CHAIN LUBRICANT REQUIREMENTS ............. 216
TRANSPORT ........................................................... 208 FUSES AND RELAYS ................................................ 216
Loading ..................................................................... 209 Side Console ............................................................ 216
Unloading ................................................................. 209 Main Electrical Supply .............................................. 220
PREPARATION AFTER TRANSPORT ...................... 210
11
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 lift truck.
• TRAVEL in reverse if load blocks forward vision.
• KNOW operating, inspection, and maintenance instruc-
• MAKE SURE tail swing area is clear.
tions in Operating Manual.
• SOUND horn at intersections or where vision is blocked.
• DO NOT operate or repair the lift truck unless trained
and authorized. • WATCH clearances, especially overhead.
• INSPECT lift truck before use. KNOW YOUR LOADS:
• DO NOT operate if lift truck needs repair. Tag lift truck • HANDLE only stable loads within specified weight and
and remove key. Repair lift truck before use. Always use load center. See Nameplate on lift truck.
Hyster Approved parts when making repairs. Replace-
USE COMMON SENSE:
ment parts must meet or exceed the specifications of the
original equipment manufacturer. • DO NOT use lift truck to lift people unless there is no
other practical option. Then, use only a securely
• USE auxiliary equipment (attachments) for intended pur-
attached special work platform. Follow instructions in
pose only.
this Operating Manual.
• OBEY traffic rules. Yield right-of-way to pedestrians.
12
Warning
WARNING
• BE in complete control at all times. • DO NOT start if fuel is leaking.

• ALLOW NO ONE under or near lift mechanism or load. • KEEP vent caps clear when charging battery.
• OPERATE lift truck only from operator's seat. • DISCONNECT battery during servicing.
• KEEP arms, legs, and head inside operator's compart- • CHECK dockboard width, capacity, and security.
ment.
PROTECT YOURSELF FASTEN YOUR SEAT BELT!
• DO NOT move lift truck if anyone is between lift truck
• AVOID bumps, holes, and loose materials.
and stationary object.
• AVOID sudden starts or stops.
• BEFORE PARKING, neutralize shift lever, lower car-
riage, and set brake. • NEVER turn on or angle across an incline.
• WHEN PARKING, also shut off power and block wheels • TRAVEL on inclines with load uphill or when unloaded
on inclines. with lift mechanism downhill.
KNOW THE AREA: • TRAVEL forward with the load or carriage approximately
1 m (3.3 ft) above seat height.
• FILL fuel tank or charge battery only in designated area.
• SLOW DOWN before turning, especially without load.
• TURN OFF engine when fueling.
• AVOID sparks or open flame. Provide ventilation.
13
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN

CAUSE THE LIFT TRUCK TO TIP.
DO NOT JUMP off if the lift truck tips over. HOLD steer-
ing wheel firmly. BRACE your feet. LEAN FORWARD
and AWAY from point of impact.
14
Model Description
Model Description
Figure 1. Model View Showing Major Components
15
Model Description
Legend for Figure 1
1. MAST 5. DRIVE AXLE
2. OPERATOR COMPARTMENT 6. ATTACHMENT
3. COUNTERWEIGHT 7. GANTRY
4. STEER AXLE
16
Model Description
Model Description
General Operator Protection Equipment
This Operating Manual is for the following models of lift The operator compartment is intended to offer reasonable
trucks: protection to the operator from falling objects, but cannot
protect against every possible falling object. Therefore, it
H40-52XM-16CH (J117)
must NOT be considered a substitute for good judgment
The lift trucks have a Cummins QSM11 or a Cummins QSL and care when handling loads. See Figure 1.
9 turbocharged diesel engine and a TE27/32 Powershift™
The seat belt provides an additional method to help the
transmission with four speeds FORWARD and four speeds
operator keep the head and body substantially within the
REVERSE.
confines of the lift truck frame and operator compartment if
A shift lever is on the left side of the steering column. It a tipover occurs. This restraint system is intended to
controls the FORWARD, NEUTRAL, and REVERSE oper- reduce the risk of the head and body being trapped
ation as well as the four transmission speed ranges. An between the truck and the ground, but it cannot protect the
accelerator pedal controls the speed of the engine. operator against all possible injury in a tipover. Always fas-
ten the seat belt.
17
Model Description
Nameplate When a lift truck is shipped incomplete from the factory, the
nameplate is covered by an INCOMPLETE label as shown
WARNING in Figure 2. If the equipment on the truck is changed, the
DO NOT add to or modify the lift truck. Any change to nameplate is covered by a NOTICE label as shown in Fig-
the lift truck, the tires, or its equipment can change the ure 2. If your lift truck has either of these labels, DO NOT
lifting capacity. The lift truck must be rated as equip- operate the lift truck. Contact your dealer for Hyster lift
ped and the nameplate must show the correct capacity trucks to obtain a complete correct nameplate.
rating or personal injury may occur.
The capacity for the lift truck, as it is equipped, must be
shown on the nameplate. If the lift truck nameplate already
has a rating for special load handling equipment, it will be
shown. If the lift truck nameplate does NOT show the rated
capacity, or if the lift truck equipment does NOT match that
shown on the nameplate, the lift truck must NOT be oper-
ated until the correct rated capacity is known.
18
Model Description
Safety Labels
Safety labels are installed on the lift truck to give informa-
tion about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 3. See your dealer for Hyster lift trucks for more
information.
A. NAMEPLATE
B. NOTICE LABEL
C. INCOMPLETE LABEL
Figure 2. Nameplate and Labels
19
Model Description
SEE THE PARTS MANUAL FOR LABEL PART NUMBER AND LOCATION.
Figure 3. Warning and Safety Labels
20
Model Description
Legend for Figure 3
1. OPERATION WARNING LABEL 6. FAN WARNING LABEL
2. MAST WARNING LABEL 7. ETHER WARNING LABEL
3. MAST WARNING LABEL 8. OPERATOR RESTRAINT LABEL
4. NAMEPLATE 9. RADIATOR CAP WARNING LABEL
5. NO RIDERS WARNING LABEL
21
Model Description
Seat Adjustment Controls
A. STANDARD SEAT
Figure 4. Seat Adjustment Controls
22
Model Description
Table 1. Seat Adjustment Controls (See Figure 4)
Item Item Function

No.
1 Seat Belt and Seat Belt Retractor Seat belt must be properly fastened before starting lift truck operations.
2 Arm Rest Adjustment Turn the knob to adjust the tilt angle of the armrest.
3 Back Rest Adjustment Controls the vertical angle of the backrest.
LIFT the lever to release and adjust the backrest.
PUSH down the lever to lock the backrest in position.
4 Forward/Backward Controls the FORWARD and BACKWARD movement of the seat on the seat
Seat Movement rails.
LIFT lever to release the seat for adjustment.
PUSH lever down to lock the seat in position.
5 Mechanical Seat Allows fine adjustment of the seat height over a limited range. Rotate this knob
Height Fine Adjustment to raise or lower the height of the seat.
Mechanical Seat Use both hands to lift the seat until it latches in the next higher level. After the
Height Level Adjustment top level has been reached, the seat will latch into the lowest height level.
6 Back Rest Extension (Optional) Move the back rest up or down to adjust the height.
Move the top of the back rest forward or backward to adjust the back rest
angle.
23
Model Description
Figure 5. Sears Deluxe Seat Adjustment Controls
24
Model Description
Table 2. Sears Deluxe Seat Adjustment Controls (See Figure 5)
Item Item Function

No.
1 Seat Belt and Seat Belt Retractor Seat belt must be properly fastened before starting lift truck operations.
2 Lumbar Adjustment Push top of switch to increase lumbar support.
Push bottom of switch to decrease lumbar support.
3 Seat Heating Switch (Optional) Push top of switch to switch heating ON.
Push bottom of switch to switch heating OFF.
4 Height/Weight Adjustment To change the height for individual needs, push top of switch to raise and push
bottom of switch to lower the seat.
5 Armrest Tilt Adjustment Turn the knob to adjust the tilt angle of the armrest.
6 Back Rest Adjustment Lift the lever to release and adjust the backrest.
Push down on the lever to lock the backrest in position.
7 Fore/Aft Isolator Lift lever to allow fore/aft suspension.
Press lever down to lock fore/aft suspension.
8 Swivel Adjustment Seat can be swiveled into three 7° increments to the right and left.
Lift lever and swivel seat into desired position.
Release the lever to lock.
25
Model Description
Table 2. Sears Deluxe Seat Adjustment Controls (See Figure 5) (Continued)
Item Item Function

No.
9 Damper Adjustment Turn knob clockwise to increase rigidity of the suspension.
Turn knob counterclockwise to achieve a smoother suspension.
10 Fore/Aft Seat Assembly The lever controls the 200 mm (7.8 in.) forward and backward position adjust-
Adjustment ment of the seat assembly in 10 mm (0.3 in.) increments.
Lift the lever to release the seat for adjustment.
Push lever down to lock the seat in position.
11 Fore/Aft Cushion Adjustment The lever controls the 60 mm (2.3 in.) forward and backward position adjust-
ment of the cushion in 10 mm (0.3 in.) increments.
Lift the lever to release the cushion for adjustment.
Push lever down to lock the cushion in position.
12 Seat Cushion Tilt Adjustment The lever controls the tilt position of the cushion in two increments of 5
degrees.
Lift the lever to release the cushion for adjustment.
Push lever down to lock the cushion in position.
13 Head Rest Move the head rest forward or backward for adjustment.
26
Model Description
Spring-Assisted Armrest Adjustment
Figure 6. Spring-Assisted Armrest Adjustment
27
Model Description
Table 3. Spring-Assisted Armrest Adjustment (See Figure 6)
Item No. Item Function

1 Lever PULL AND HOLD lever to unlock spring-assisted armrest.
PUSH OR PULL armrest until it has reached the desired position.
RELEASE lever to lock spring-assisted armrest.
2 Front/Rear Adjustment TURN counterclockwise to allow adjustment.
TURN clockwise firmly to secure in desired position.
3 Sideways Adjustment TURN counterclockwise to allow adjustment.
TURN clockwise firmly to secure in desired position.
28
Model Description
Driving Controls and Signals
Figure 7. Driving Controls and Signals
29
Model Description
Table 4. Driving Controls and Signals (See Figure 7)
Item Item Function

No.
1 Shift Lever The travel directions are controlled by the shift lever.
PUSH the shift lever to move to FORWARD (F) to travel in the forward posi-
tion.
PULL the shift lever to move to REVERSE (R) to travel in the reverse posi-
tion.
When in the reverse position, the reverse lights and backup alarm will be ON.
For trucks with a Forward Alarm, the alarm will be ON when the shift lever is
in the forward position.
Move the shift lever into the center position to put the transmission in NEU-
TRAL (N).
Place the shift lever in NEUTRAL (N) position or depress inching/brake pedal
if shift lever is in FORWARD (F) or REVERSE (R) position before the engine
can be started.
30
Model Description
Table 4. Driving Controls and Signals (See Figure 7) (Continued)
Item Item Function

No.
1 Shift Lever Transmission shift lever has four range positions:
(cont)
1 - First position. Transmission will stay in first gear until operator selects
another gear.
2 - Second position. Transmission will automatically shift between first, sec-
ond and third gear, depending on speed.
3 - Third position. Transmission will automatically shift between second, third
and fourth gear, depending on speed.
4 - Fourth position. Transmission will automatically shift between all gears,
depending on speed.
NOTE: All four speeds are available in the FORWARD and REVERSE direc-
tion of travel as selected by the operator.
NOTE: The transmission will automatically shift to NEUTRAL (N) if the trans-
mission oil pressure is low or if the oil is too hot. This will occur with the lever
in any position. To override the transmission protection in case of emergency,
turn the key switch OFF and then ON and restart the engine. This will allow lift
truck movement in first gear for 30 seconds.
NOTE: The transmission will automatically shift to NEUTRAL (N) when the
parking brake is activated.
31
Model Description
Item Item Function

No.
2 Steering Column
WARNING
Adjustment
Make sure steering column adjustment lever is locked into place before
moving lift truck. Never attempt to adjust steering column when lift truck
is moving or personal injury may occur.
Steering column tilts FORWARD, BACKWARD, and TELESCOPES for
adjustment. Release the lever and move the steering column to the desired
position, then fasten the lever.
3 Steering Wheel Steering wheel controls the position of the steer tires.
32
Model Description
Item Item Function

No.
4 Central Warning
WARNING
Lights
When these red lights are ON, there is a fault condition with the lift truck.
Stop the truck and look at the console to determine which system has a
malfunction or lift truck damage or personal injury may occur.
5 Horn Horn button controls the operation of the horn.
6 Cab Vent Cab vent provides fresh air to the operator's cab from the heater or air condi-
tioning units.
33
Model Description
Item Item Function

No.
7 Turn Signal Lever Turn signal lever is mounted on the right side of the steering column. When
operating the turn signal lever, the red light in the lever blinks.
PUSH lever FORWARD for a left-side turn signal.
PULL lever BACKWARD for a right-side turn signal.
8 Electronic Throttle This pedal controls the speed of the engine and is operated by the operator's
Accelerator Pedal right foot.
NOTE: This pedal is used on lift trucks that have a shift lever.
9 Brake Pedal The brake pedal is located to the left of the accelerator pedal. This pedal con-
trols the application of the service brakes.
10 Inching/Brake Pedal Inching/brake pedal is located left of brake pedal. Slightly pushing inching/
brake pedal will apply service brakes, and further pushing will fully disengage
transmission.
NOTE: When releasing inching/brake pedal, transmission will only engage if
engine speed is below 1500 rpm.
34
Model Description
Armrest and Joystick Controls
Figure 8. Armrest and Joystick Controls
35
Model Description
Table 5. Switches on Armrest Controls (See Figure 8)
Item Item Function

No.
1 Joystick Lift/Lower Con- PULL the joystick back to RAISE the carriage and attachment.
trol
PUSH the joystick forward to LOWER the carriage and attachment.
NOTE: Engine idle speed will increase when pulling the joystick.
2 Joystick Tilt Control MOVE the joystick to the RIGHT to tilt the mast and attachment forward.
MOVE the joystick to the LEFT to tilt the mast and attachment backward.
3 Optional 30-Foot Stop Switch The spreader can be extended to the optional 30-foot position by manually
extending/retracting the spreader and pushing the 30-foot stop switch when
nearing the 30-foot position. After the spreader has locked into the 30-foot
position, release both the extension button and the 30-foot stop switch.
4 Blank No standard function.
36
Model Description
Table 5. Switches on Armrest Controls (See Figure 8) (Continued)
Item Item Function

No.
5 Lock/Unlock Control PUSH top side of switch to lock the twist locks.
Switch
PUSH bottom side of switch to unlock the twist locks.
6 Front Window Wiper This switch controls the front window wiper.
Switch
PUSH top of switch for Intermittent wiping.
PUSH bottom of switch for continuous wiping.
Return switch to neutral position to switch OFF.
7 Top Window Wiper This switch controls the top window wiper.
Switch
37
Model Description
Item Item Function

No.
8 Rear Window Wiper This switch controls the rear window wiper.
Switch
9 Front Window Washer PUSH and hold bottom of switch for wash/wipe operation. Release switch to
Switch switch OFF.
10 Top Window Washer PUSH and hold bottom of switch for wash/wipe operation.
Switch
Release switch to switch OFF.
38
Model Description
Item Item Function

No.
11 Rear Window Washer PUSH and hold bottom of switch for wash/wipe operation.
Switch
Release switch to switch OFF.
12 Horn PUSH on upper end of switch to activate horn.
13 Reach Forward / PUSH top side of switch to move the attachment backwards. Push bottom
Backward Switch side of switch to move the attachment forwards.
14 Unlock Control PUSH the button to unlock the twistlocks.

Switch Button.
39
Model Description
Item Item Function

No.
15 Extend/Retract Con-
WARNING
trol Switch
Before operating the extend/retract function, check the spreader icon on
the display if the function is in Automatic or Manual Mode. When in
Automatic Mode an initiated extend/retract movement can be stopped by
pushing the extend/retract switch again.
When in Manual Mode, PUSH and HOLD the right side of switch to extend
the attachment until it is in the 30 foot or 40 foot position. PUSH and HOLD
left side of switch to retract the attachment until it is in the 30 foot or 20 foot
position.
In AUTO mode the spreader extension/retraction is initiated by shortly push-
ing the extend/retract control switch.
Extend/retract movement will be completed until the 40 foot or 20 foot position
has been reached.
Make sure that the spreader end beam will not hit any object while extending/
retracting. Push the control switch again if extension/retraction must be stop-
ped immediately. Alternatively, turn the key switch to the OFF position.
40
Model Description
Item Item Function

No.
15 Extend/Retract Con- See Table 5 item 3 for a description of the optional 30 foot position switch.
(Cont) trol Switch
Different Spreader Extend/Retract Icons reflect spreader extend movement or
extended position. See Automatic Extend/Retract Function.
16 Side Shift PUSH left button to sideshift attachment to the left.
PUSH right button to sideshift attachment to the right.
17 Power Pile Slope Rotate wheel up to move left-hand side of attachment up and/or right side
Switch down.
Rotate wheel down to move left side of attachment down and/or right side up.
18 Rotation of Attachment Rotation of the joystick controls rotation of the attachment. Rotate joystick
clockwise for attachment rotation clockwise. Rotate joystick counterclockwise
for attachment rotation counterclockwise.
41
Model Description
Side Console Controls
Figure 9. Side Console Controls
42
Model Description
Table 6. Side Console Controls (See Figure 9)
Item Item Function

No.
A Dash Panel Switches Heater control panel.
(Optional)
B Dash Panel Switches Air conditioning control panel.
(Optional)
Battery disconnect lever is located at the right hand side of the truck behind
the battery door. Operation of lever is shown on the label.
NOTE: DO NOT operate battery disconnect lever until 100 seconds after key
switch is in OFF position.
Battery
Disconnect Lever
43
Model Description
Table 6. Side Console Controls (See Figure 9) (Continued)
Item Item Function

No.
1 The key switch has three positions:
No. 1 Position: OFF. De-energizes all electric circuits except for the horn and
headlights.
No. 2 Position: ON. Energizes all electric circuits except the starter circuit.
The key switch will be in this position during normal operation.
No. 3 Position: START. Energizes the starter motor and the cold start sole-
noid for starting the engine. A spring returns the key to the No. 2. Position
Key Switch (ON) when the key is released.
NOTE: There is a mechanical lockout that prevents the key switch from being
returned to the START position without first being returned to the OFF posi-
tion.
2 12 VDC Max 10 Amps outlet.
Auxiliary 12 V/DC Power Outlet

(Optional)
44
Model Description
Item Item Function

No.
3 Override Key Switch The override key switch, in combination with the override button F5 on the
display, allows overriding of different systems that normally prevent entering
0 = OFF position
hazardous situations. To override systems, the override key switch must be in
1 = ON position the ON position, the override button F5 must be pushed, and the relevant
function control must be operated simultaneously, while observing the respec-
tive warnings.
Normally the override key switch must be in the OFF position.
4 Set/Select Button 1. This button is used to select and set the different climate modes. See Fig-
(Optional) ure 9.
PUSH and TURN the button to select the desired mode.
PUSH the button again to set the desired mode.
45
Model Description
Item Item Function

No.
5 Power ON/OFF Button (Optional) PUSH the button to switch the electronic climate control unit ON and OFF.
6 KNOB controls the fan SPEED for the heater, defroster, and A/C systems.
Turn the knob to the right to increase the speed of the fan.
At position 0 the fan is OFF.
Heater/Air
Conditioner
Fan Knob
46
Model Description
Item Item Function

No.
7 Knob controls the heater valve.
To close the heater valve, turn knob counterclockwise.
When knob is turned to the left, cab heat decreases.
When knob is turned to the right, cab heat increases.
Heat Control Knob

8 Knob controls fresh air ventilation in the cab through the cab vents.
When knob is turned to the left, fresh air enters the cab.
When knob is turned to the right, air is recirculated in the cab.
Air Control Knob
47
Model Description
Item Item Function

No.
9 Switch controls the operation of the air conditioning (A/C) system.
PUSH top of switch to turn the air conditioning system ON, make sure that the
fan is ON.
PUSH bottom of switch to turn air conditioning system OFF.
NOTE: When the A/C is switched ON, set the cabin heating control to the
cold position.
Optional A/C Switch
10
WARNING
Before applying the park brake, make sure the lift truck has come to a
complete stop.
Always apply the parking brake before leaving the truck or lift truck
damage or personal injury may occur. Always apply the brake before
starting the engine.
Parking Brake Knob
48
Model Description
Item Item Function

No.
10 PULL the red knob to engage the park brake. The light in the knob will be
(Cont) ON.
PUSH the red knob to disengage the park brake. The light in the knob will be
OFF.
After operating the knob, a spring returns the knob to its neutral position.
The park brake applies automatically when the key switch is in the OFF posi-
tion.
Parking Brake Knob
The optional automatic park brake applies automatically 10 - 30 seconds after
the operator has left the seat. The light in the knob will flash when the park
brake has been applied automatically.
The buzzer sounds when the parking brake is NOT applied and the operator
is NOT seated.
11 Switch controls lights for the container attachment.
PUSH top of switch to turn lights ON.
Attachment Work Light PUSH bottom of switch to turn lights OFF.
49
Model Description
Item Item Function

No.
12 This switch controls the side, tail, and front fender lights.
PUSH top of switch to move the switch from OFF to position 1 and 2.
Light Switch PUSH bottom of switch to return the switch from position 2 to position 1 and
OFF.
In position 1, the side and tail lights are ON.
In position 2, the side, tail, and front fenders lights are ON.
13 This switch can either be a one position switch or a two position switch.
PUSH top of switch to move the switch from OFF to position 1 and 2.
Flood Lights PUSH bottom of switch to return the switch from position 2 to position 1 and
Switch OFF.
As a one position switch it either switches the rear working lights ON, or the
flood, side and tail lights. As a two position switch the flood, side and tail lights
are ON in position 1. In position 2 the optional rear working lights are also
ON.
50
Model Description
Item Item Function

No.
14 The strobe light can be provided without or with an optional switch.
Without the optional switch, the strobe light will be ON when the key switch is
Optional Switch for Strobe Light in the ON position.
With the optional switch, the strobe light can be switched ON as well, when
the key switch is in the OFF position.
PUSH top of switch to turn the strobe light ON.
PUSH bottom of switch to turn the strobe light OFF.
NOTE: Leaving the strobe light ON will drain the batteries when the engine is
not running.
15 This switch controls the hazard warning lights.
PUSH top of switch to turn lights ON.
PUSH bottom of switch to turn lights OFF.
Hazard Switch
16 Diagnostic Switch This switch is used to access and exit the fault log mode. The procedure to
access and exit is described in the SRMs listed in Table 8.
51
Model Description
Item Item Function

No.
17 Blank No standard function.
18 Top Window This switch controls the electrical heating of the top window.
Heating Switch (Optional)
Push top of switch to put window heating ON.
Push bottom of switch to put window heating OFF.
52
Model Description
Instruments and Indicators
Figure 10. Instruments and Indicators (Sheet 1 of 2)
53
Model Description
Figure 10. Instruments and Indicators (Sheet 2 of 2)
54
Model Description
Table 7. Instruments and Indicators (See Figure 10)
Item
Item Function
No.
1 Central Warning
WARNING
Lights
When these red lights are ON, there is a fault condition with the lift
truck. Stop the truck and look at instrument panel to determine which
system has a fault condition or lift truck damage or personal injury may
occur.
2 Coolant Gauge indicates coolant temperature when the key switch is in the ON posi-
Temperature tion. When the temperature is near a critical value, the gauge symbol will
Gauge FLASH red and the engine warning light and the central warning lights will
come ON. A fault code will be displayed. Engine performance may
decrease. When the temperature has exceeded a critical value, the engine
stop light will be ON and the buzzer will sound. Immediately shut down the
engine, or damage to the lift truck will occur.
NOTE: For emergency situations, automatic engine shutdown can be reset.
Turn the key switch to OFF, and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a limited time.
55
Model Description
Table 7. Instruments and Indicators (See Figure 10) (Continued)
Item
Item Function
No.
3 Hourmeter/Fault The hourmeter operates while the engine is running. Periodic maintenance
Code Display recommendations are based on these hours. It also displays engine, trans-
mission, and hydraulic faults. Additional information is indicated when faults
occur. If more than one fault is present, the faults will scroll.
The explanation of fault codes is located in Table 8 and Table 9.
4 Engine Warning This warning light is ON when an engine fault has been detected. The cen-
Light tral warning lights will be ON. Determine which fault is present and take
appropriate action immediately.
5 Engine Stop If the red engine stop warning light comes ON, there is a critical fault condi-
Warning Light tion. A fault code will be displayed. The buzzer will sound. The central warn-
ing lights will be ON. Immediately shut down the engine, or damage to
the lift truck will occur.
NOTE: For emergency situations automatic engine shutdown can be reset.
Turn the key switch to OFF and then to ON, and restart the engine. If the
fault is still present, the engine will only run for a limited time.
56
Model Description
Item
Item Function
No.
6 Transmission This warning light is ON when a transmission fault has been detected. The
Warning Light central warning lights will be ON. A fault code will be displayed. Determine
which fault is present and take appropriate action immediately.
7 Transmission This orange light is ON when the transmission calibration mode has been
Calibration activated. For normal truck operations, the transmission calibration warning
Warning Light light must be OFF.
8 Transmission Oil This gauge indicates transmission oil temperature when the key switch is in
Temperature the ON position. When the temperature is near a critical value, the gauge
Gauge symbol will FLASH red, the transmission warning light and the central warn-
ing lights will be ON. A fault code will be displayed. Engine performance may
decrease. When the temperature has exceeded a critical value, the buzzer
will sound. Immediately shut down the engine, or lift truck damage will
occur.
57
Model Description
Item
Item Function
No.
9 Hydraulic System This orange warning light is ON when an hydraulic system malfunction has
Malfunction been detected. The central warning lights will be ON.
Warning Light
A fault code will be displayed. Determine which fault is present and take
appropriate action immediately.
10 Hydraulic Brake This light is ON when the hydraulic brake cooling filter is clogged. Replace
Cooling Filter the filter when the light is ON. The central warning lights will be ON.
Warning Light
11 Hydraulic Oil High

CAUTION
Temperature Warning
Do not continue to operate the lift truck when the red light is ON, or lift
Light
truck damage may occur.
Red warning light comes ON when the hydraulic oil temperature is high. The
buzzer sounds. The central warning lights will be ON.
58
Model Description
Item
Item Function
No.
12 Brake Oil Tempera- The red light will be ON when brake oil temperature is high. A fault code will
ture Warning Light be displayed. The central warning lights will be ON and the buzzer will
sound. Reduce brake usage e.g., by limiting travel speed.
13 Brake System
WARNING
Low Pressure
Do not operate the lift truck when the red light is ON. Immediately shut
Warning Light
down the engine, or personal injury may occur.
Red warning light comes ON when the brake pressure is low. The buzzer
will sound. The central warning lights will be ON.
After starting the engine, wait until the light is OFF, before releasing the park
brake or operating the lift truck.
14 Parking Brake Red warning light is ON when the parking brake is applied. The red warning
Warning Light light flashes when the park brake has been applied automatically.
The buzzer sounds when the parking brake is NOT applied and the operator
is not seated.
59
Model Description
Item
Item Function
No.
15 Voltmeter Gauge The voltmeter indicates the system voltage. When the ignition is ON and the
engine is not running, the gauge symbol will be red. When the engine is run-
ning and the system voltage is below 22.5 VDC, the gauge symbol will
FLASH red. The central warning lights will be ON.
16 Fuel Level Gauge When the fuel level is 10% or less of the tank capacity, the gauge symbol
will FLASH red. The central warning lights will be ON. Avoid low fuel level.
Refuel in time.
Tank capacity: 830 liter (219 gal).
See Table 28 for approved fuel specifications.
60
Model Description
Item
Item Function
No.
17 Engine When the engine is running, the needle is approximately in the middle of the
Oil Pressure gauge, indicating normal engine oil pressure. When engine oil pressure is
Gauge near a critical value, the gauge symbol will FLASH red, the engine warning
light and the central warning lights will come ON, and a fault code will be
(Tier 3 Stage III
displayed. Engine performance may decrease. When engine oil pressure is
Only)
below a critical value, the engine stop light will be ON and the buzzer will
sound. Immediately shut down the engine, or damage to the lift truck
will occur.
NOTE: For emergency situations automatic engine shut down can be reset.
Turn the key switch to OFF, and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a limited time.
17 DEF Level Gauge The gauge indicates the Diesel Emission Fluid level when the key switch is
in the ON position. When the level is between 10% and 5% of tank capacity,
(Tier 4(f) Stage IV
the gauge symbol will be permanently ON. The code ‘dEF’ will be displayed
Only)
on the display. When DEF level is 5% of tank capacity or less, the gauge
symbol will be flashing. The engine warning light will be ON when the level is
below 2,5%. The central warning lights will be ON. The engine will start to
de-rate in case the tank is empty and the engine stop warning light may be
ON. See Table 28 for approved DEF specifications.
61
Model Description
Item
Item Function
No.
18 Seat Belt
WARNING
Warning Light
Before driving the lift truck, always fasten your safety belt or personal
injury may occur.
Orange light is ON for 10 seconds after the key is placed in the ON position.
19 Water in Fuel Warn- The red light comes ON when there is too much water in the fuel filter. A
ing Light fault code will be displayed. The engine warning light will be ON. The central
warning lights will be ON. Maintenance is required to release water from the
fuel filter.
20 Engine Coolant Level The red light comes ON when coolant level is low in the coolant reservoir. A
Warning Light fault code will be displayed. Engine performance may decrease. The engine
stop light will be ON and the buzzer will sound. The central warning lights
will be ON. Immediately shut down the engine, or damage to the lift truck will
occur. Inspect the cooling system, repair as needed, and add coolant to the
maximum level.
62
Model Description
Item
Item Function
No.
21 Engine Oil Pressure The red light comes ON when engine oil pressure is low. A fault code will be
Warning Light displayed. Engine performance may decrease. The engine stop light will be
ON and the buzzer will sound. The central warning lights will be ON. Imme-
diately shut down the engine, or damage to the lift truck will occur.
22 Engine Air Filter Orange engine air filter warning light is ON when the air filter is dirty or has
Warning Light an obstruction. If the light is ON, replace the main filter element. The central
warning lights will be ON.
Also replace the safety element every third time the main element is
replaced.
23 Engine Wait to This warning light is ON for 15 seconds after the key is turned to the ON
Start Light position when engine temperature is below −3 °C (27 °F). It indicates that
the cold start aid has been activated. After 15 seconds, the light will go OFF
to indicate that the engine can be started.
63
Model Description
Table 8. Explanation of Fault Codes
Code Starts With System Reference or Explanation

E Engine See Engine Fault Code Guide 600 SRM 1101.
E5631 Engine See Regeneration at the end of this section.
E5632 Engine See Regeneration at the end of this section.
t Transmission See APC312 Fault Code Guide.
tE Transmission See Table 9.
h Hydraulics, Spreader, See Hydraulic Control System .
Automatic Greasing,
Joystick, Display,
Cabin Tip up.
hCold Hydraulics Hydraulic oil temperature in the reservoir is below −5 °C (23 °F). All hydraulic
functions can be operated normally, but the controller limits engine speed pro-
portional to the hydraulic oil temperature. At −20 °C (−4 °F), the engine speed is
limited to 1000 rpm. Above −5 °C (23 °F), the controller does not limit engine
speed. Limitation of the engine speed reduces maximum hydraulic perform-
ance. Apply hydraulic functions to raise hydraulic oil temperatures.
hHot Hydraulics Hydraulic oil temperature in the reservoir exceeds 90 °C (194 °F). Reduce
hydraulic oil temperature by reducing hydraulic power demand until code hHot
has disappeared.
64
Model Description
Table 8. Explanation of Fault Codes (Continued)
Code Starts With System Reference or Explanation

bHot Brakes Hydraulic oil temperature at the brakes exceeds 110 °C (230 °F). Reduce
hydraulic oil temperature by reducing usage of the brakes eg by limiting travel
speed.
fUel Engine Fuel level is 10% or less of tank capacity. Refuel soon.
dEF Engine DEF level is 10% or less of tank capacity. Refill soon.
65
Model Description
Regeneration Activate the Hydraulic Service Switch in the side console

and press and release the Regeneration Switch.
Fault codes E5631 and E5632 indicate that the engine has
been switched OFF, before an automatic regeneration ses- Observe that engine speed raises to high idle, which indi-
sion could be completed. cates that regeneration has started.
To rectify these fault codes, follow the procedures descri- Pushing the Regeneration Switch will start a regeneration
bed under Stationary Regeneration Procedure. only, if fault codes E5631 and/or 5632 are displayed.
Solve further inhibit related problems if these fault codes If engine speed does not rise, investigate and solve further
are still displayed after completion of a Stationary Regen- fault code(s) displayed.
eration Procedure. Regeneration will be completed after 15 to 20 minutes.
This is indicated by engine speed returning to low idle.
Stationary Regeneration Procedure
Observe that no fault code is displayed. De-activate the
Move the truck to an area that allows high exhaust system Hydraulic Service Switch and put the truck in service.
temperatures reaching 400 °C (752 °F).
Apply the parking brake and let the engine run at idle
speed.
66
Model Description
Table 9. Transmission Exceed Codes
Code Explanation Operator Action

tE001 The vehicle speed is too high to make the requested Slow down the vehicle to allow the controller to down-
downshift. shift.
tE101 The vehicle speed is too high to make the requested Be aware that the controller has put the transmission
direction change. into neutral. Slow down the vehicle to allow the con-
troller to change direction.
tE201 The engine speed is too high to make the requested Lower engine speed.
direction change or re-engagement..
tE300 The reduced vehicle speed limitation is active. Be aware.
tE301 The reduced vehicle speed limitation is active, how- Reduce vehicle speed below the maximum vehicle
ever, the vehicle speed is above the speed limitation. speed.
tE302 The vehicle speed is above the maximum vehicle Reduce vehicle speed below the maximum vehicle
speed limit. speed.
tE400 Abnormal deceleration is detected. One or both drive wheels are skidding. Automatic
shifting is disabled. Adjust braking effort to floor condi-
tions.
tE401 Abnormal acceleration is detected. One or both drive wheels are spinning. Automatic
shifting is disabled. Apply throttle according driving
conditions.
67
Model Description
Table 9. Transmission Exceed Codes (Continued)
Code Explanation Operator Action

tE501 Transmission needs recalibration. Contact Maintenance to have the transmission recali-
brated.
tE600 Operator is not seated and shift lever is NOT in Neu- Shift lever to neutral and apply parking brake. Code
tral and/or parking brake is NOT activated. tE600 also appears when the hydraulic service switch
is activated. This switch is located near the fuse
panel.
tE701 Turbine speed exceeds the limit. Reduce vehicle speed. The controller has reduced
engine speed to idle.
68
Model Description
Table 10. Climate Control Operating Instructions
Controls 1. LCD Display

During normal operation, the selected temperature, blower
speed, operation mode and air circulation selection are dis-
played. In Test/Diagnostic mode, error messages will be dis-
played on screen for troubleshooting. Display's contrast is
automatically compensated for all temperatures.
2. SET/SELECT Knob
The SET/SELECT knob is used for selecting between the differ-
ent modes. In Test/Diagnostic mode, the button is used to test
and diagnose the different HVAC components.
3. Power Button
Switch the HVAC unit ON or OFF.
69
Model Description
Table 10. Climate Control Operating Instructions (Continued)
Main Display Screen 1. Air Circulation Setting

The air mix can be set between full fresh air and full re-circula-
ted air.
2. Operation Mode
The HVAC system mode can be set to Automatic, Heat, Cool or
Defrost.
3. Selected Temperature
Displays the selected temperature.
4. Blower Speed
Displays the current blower speed setting.
Operation Menus
Main Screen:
After switching on the power button, the main screen appears. The
selected temperature, operation mode, air circulation and blower
speed are displayed.
A symbol will be displayed when there is a fault in the HVAC

system.
70
Model Description
Blower Speed Settings:

Press the SET knob until the blower icon appears, then turn the knob
clockwise to increase blower speed and counterclockwise to
decrease blower speed with 5% increments. Blower speed cannot be
adjusted in defrost mode.
Climate Control Mode Settings:

Press the SET knob until the climate control mode icon appears, then rotate
the SET knob until required control mode is displayed.
AUTO: The HVAC system automatically maintains the selected tem-
perature.
Cool: Cycling of the A/C compressor controls interior temperature.
The heater valve will remain closed,
Heat: Interior temperature is regulated with the electronic heater
valve. A/C compressor will remain off when heat mode is activated.
Defrost: When defrost mode is activated, the A/C compressor is
turned on, blower is turned on full speed and heater valve is fully
opened.
71
Model Description
Air Circulation Settings:

Press the SET knob until the air circulation mode icon appears. Turn
the knob clockwise for full recirculated air or counterclockwise for full
fresh air.
Display Settings:
To adjust display settings and temperature scale, keep the SET knob
pressed until the display settings screen appear. Turn the SET knob
clockwise or counterclockwise to adjust settings.
Turning HVAC System OFF:

In the main screen, press the Power button to switch the HVAC sys-
tem OFF. The back light will switch off and the cab interior tempera-
ture will be displayed on screen.
72
Model Description
Information Display
Display Buttons
Figure 11. Display Buttons
73
Model Description
Item Item Function

No.
1 Button F1 Non-functional
Button F2 PUSH button F2 to change screen brightness between DAY MODE, indicated
DAY- NIGHT MODE by a sun icon next to the F2 button , or NIGHT MODE, indicated by a moon
icon.
Button F3 PUSH button F3 to change the spreader extend/retract function between
SPREADER EXTEND/RETRACT MANUAL and AUTOMATIC mode.
MODE (Optional)
Button F3 is only active, when your service provider has activated the Auto-
matic Mode and a spreader icon is shown at the top left screen area and next
to button F3.
See Table 12 for the operation of the spreader extend and retract function.
Button F4 PUSH button F4 to scroll between OFF, ON and AUTO mode for the Cabin
CABIN TIP-UP MODE (Optional) Tip-Up Function.
Button F4 is only active, when your service provider has activated the Cabin
Tip Up Mode and a cabin icon is shown at the top left screen area and next to
button F4.
See Cabin Tip-Up Function for a description of its operation.
74
Model Description
Item Item Function

No.
1 Button F5 NOTE: Before using the override function, first read System Interrupt Over-
(Cont) OVERRIDE rides for a description.
ENABLE the override key switch on the side console. The blue override icon
next to the F5 button appears.
PUSH and HOLD button F5 to activate override functions. A blue message
bar appears with the message OVERRIDE ACTIVE and the buzzer is activa-
ted. See Indicator Lights and LEDs.
Proceed carefully while operating the disabled function.
Deactivate the override function by releasing the F5 button and turning the
override key switch to the OFF position.
2 DOWN or DECREASE button Use the DOWN or DECREASE button to move to the next lower presented
option, or to decrease a selected value.
See System Menu for further detail.
3 UP or INCREASE button Use the UP or INCREASE button to move to the next higher presented option,
or to increase a selected value.
See System Menu for further detail.
4 HOME button Returns to the Main Operation Screen.
5 BACK button Returns to the previously selected menu or sub-menu.
75
Model Description
Item Item Function

No.
6 SELECT button Confirms the selected screen or selected value.
7 Buttons F6 to F10 MENUS PUSH button F6 to F10 to navigate through the different menus and their sub-
menus. Buttons F6 to F10 are operational only, when a system icon is dis-
played adjacent to the button.
See Display Menus for further explanation.
76
Model Description
Display Screen Areas
Figure 12. Display Screen Areas
77
Model Description
Item Item Function

No.
1 Cabin Tip-Up Icon (Optional) This icon is shown when the Cabin Tip Up function has been activated. When
activated, the words OFF, ON or AUTO appear under the icon to indicate the
selected mode. See Cabin Tip-Up Function for a description.
Extend/Retract Icon (Optional) This icon is shown when the Automatic Extend/Retract option has been activa-
ted. When activated the words MANUAL or AUTO appear under the icon to
indicate the selected mode.
See Automatic Extend/Retract Function mode for a description.
Container Counter The number under the icon indicates the number of containers handled since
last container counter reset.
2 Button Activation Indicators An indicator bar is shown above the Display Operation Buttons. If the indicator
is YELLOW, the button beneath is activated. If the indicator is GRAY, the but-
ton beneath is not activated.
3 General Information Area The General Information Area shows menu information according the chosen
menu (Buttons F6 to F10).
4 Menu Area A system icon is displayed adjacent to buttons F6 to F10, to indicate that a
menu or sub-menu can be selected.
5 Twist Lock and Lift Interrupt Area The icons indicate the locked, unlocked and seated position of the twist locks
or side clamps, and activation of the lift/lower interrupt.
See Twist Lock and Lift Interrupt Screen Area.
78
Model Description
Cabin Tip-Up Function When the Cabin Tip-Up function is not activated, the cab
remains in the lowered position and the Cab Icon is not dis-
played next to button F4, nor at the top left screen area.
In mode OFF, the cab will be lowered and remain in the
lowered position.
In mode ON, the cab will be tipped up and remain in the
tipped up position.
In mode AUTO, the cab tips up when the spreader is lifted
higher than 10 meter. The cab tips down when the
spreader has lowered below 10 meter.
Figure 13. Cabin Tip-Up Function When the cab is in the tipped-up position a speed limiter is
The Cabin Tip-Up Icon is shown when this function has active.
been activated. When activated, the words OFF, ON or Different Cabin Tip-Up Icons reflect cab tipping movement
AUTO appear under the cab icon to indicate the selected and cab tipped position. See Table 11.
mode.
79
Model Description
Table 11. Cabin Tip-Up Icons
Icon Item
Cab in lowered position Cab tipping down
Cab tipping up Cab in tipped up position
80
Model Description
Automatic Extend/Retract Function The Spreader Auto Extend/Retract Icon is shown when this
function has been activated. When activated, the words
MANUAL or AUTO appear under the spreader icon to indi-
cate the selected mode.
When the auto extend/retract function is not activated, the
function is always in the Manual Mode and the spreader
icon is not displayed next to button F4, nor at the top left
screen area.
In MANUAL mode the spreader is extended/retracted by
pushing and holding the extend/retract control switch until
the desired end position has been reached. See Figure 8 ,
Figure 14. Spreader Extend/Retract Function item 13.
WARNING
Before operating this function, observe the spreader
icon on the display to notice whether the extend/retract
function is in the Automatic or in the Manual Mode.
When in the Automatic Mode an initiated extend/retract
movement can be stopped by pushing the extend/
retract switch again.
81
Model Description
The spreader can be extended to the optional 30 foot posi- Extend/retract movement will be completed automatically.
tion by manually extending/retracting the spreader and Make sure that the spreader end beam will not hit any
pushing the 30 foot lock switch when nearing the 30 foot object while extending/retracting. Push the control switch
position. After the spreader has locked into the 30 foot again if extension/retraction must be stopped immediately.
position, release both the extension button and the 30 foot
lock switch. Optional 30 Foot Lock Switch
In AUTO mode the spreader extension/retraction is initi- Different Spreader Extend/Retract Icons reflect spreader
ated by shortly pushing the extend/retract control switch. extend movement or extended position. See Table 12.
82
Model Description
Table 12. Spreader Extend/Retract Icons
Icon Item
Spreader retracting
Spreader retracted
Spreader extending
Spreader extended
83
Model Description
Twist Lock and Lift Interrupt Screen Area
Figure 15. Twist Lock and Lift Interrupt Screen Area
Item
Color Item Indicator Light ON Indicator Light OFF
No.
Twist locks at left-hand side
1 Amber Left-Hand Seated Twist locks at left-hand side are SEATED
are NOT SEATED
Twist locks are NOT
Twist locks are LOCKED / Container
2 Green Locked LOCKED / Container NOT
PRESENT
PRESENT
84
Model Description
Item
Color Item Indicator Light ON Indicator Light OFF
No.
Twist locks are NOT
Twist locks or are UNLOCKED / Con-
3 Red Unlocked UNLOCKED / Container
tainer NOT PRESENT
NOT PRESENT
Twist locks at right-hand side are Twist locks at right-hand
4 Amber Right-Hand Seated
SEATED side are NOT SEATED
Lift Interrupt is active.
Read the section System Interrupt
5 Blue Lift Interrupt Lift Interrupt is NOT active
Overrides before operating the Override
Button.
85
Model Description
General Information Screen Area
Figure 16. General Screen Area
86
Model Description
Item No. Item Function

1 Vehicle Speed Indicator Indicates the actual vehicle speed in km/h or mph, depend-
ing on the selected unit of measure.
ECO Mode Indicator ECO is displayed when the Engine ECO Mode is activated.
ECO is OFF when the Engine ECO Mode is OFF.
2 Time Indicates the current time in either 12 h or 24 h mode.
3 Gear Indicator Indicates the actual engaged transmission gear.
The arrows indicate the travel direction.
N indicates the transmission is in Neutral.
4 RPM Gauge Bar and Icon Shows the current engine speed in RPM x 1000 in a graphi-
cal bar.
5 Speed Limiter Shows the currently activated speed limit.
87
Model Description
Special Alerts A special alert is shown in the lower part of the operation
screen when:
• Function Override System has been activated
• Automatic engine shutdown has started
1. BLUE COLOURED BACKGROUND

2. SYSTEM ICON
3. MESSAGE
Figure 17. Special Alerts
88
Model Description
Icon Message
The engine will shut down after countdown.
When engine shut down is completed, the message changes into: Engine automatically OFF.
The Function Override System has been activated by switching the override key to the ON posi-
tion and pushing and holding display button F5.
89
Model Description
Display Menus
On the Main Operating Screen, there are 4 menu choices,
as shown in Display Menus.
1. PERFORMANCE MENU 4. TRUCK SETTINGS MENU

2. SYSTEM MENU 5. (F10) NON FUNCTIONAL
3. GREASING MENU
Figure 18. Display Menus
90
Model Description
Performance Menu
Figure 19. Performance Menu Screen

Starting at the Main Operating Screen, push the F6 button Starting at the Main Operating Screen, push the F6 button
to enter the Performance menu. to read Engine Running Hours.
The Performance menu shows the Engine Running Hours.
91
Model Description
System Menu The system menu consists of two sub menus; System Set-
tings (F6) and System Information (F7).
On the Main Operating Screen, push the F7 button to enter
the System Menu. System Settings Menu
Figure 20. System Settings Screen
92
Model Description
The System Settings screen shows the current system set- → Press the - and + sign or ▼ and ▲ button to choose the
tings and provides the possibility to change the settings. desired value.
Changing a Setting → Confirm the value by pressing the ENTER button.
→ Press the ENTER button to select the first setting. → Press the BACK button to leave the modification mode.
→ If necessary, use the UP or DOWN button to go to the These instructions are the same for all System Settings.
desired setting.
See Table 13 for an overview of the System Settings and
→ Press the ENTER button again to activate modification the available choices.
mode. A - and + sign or ▼ and ▲ appear.
93
Model Description
Table 13. System Settings Overview
Icon Item Available option or values

Brightness 40 - 100
Time adjustment Set the correct time
12/24 Hours • 12-Hours

• 24-Hours
94
Model Description
Table 13. System Settings Overview (Continued)

Language • English
• French
• German
• Italian
• Brazilian
• Spanish
Unit • Metric
• Imperial
95
Model Description
System Information Menu
Figure 21. System Information Screen

From the System Settings menu, select the F7 button to go
to the System Information menu.
The System Information screen shows the software and
hardware identification codes of the display.
96
Model Description
Greasing Menu The greasing menu consists of a Greasing Information

screen and Greasing Intensity Settings screen.
On the Main Operating Screen, select the F8 button to
enter the Greasing menu (only if a greasing system is Greasing Information Menu
present on the truck).
Figure 22. Greasing Information Screen
97
Model Description
The Greasing Information screen shows the current greas-
ing settings for the truck and is directly shown when enter-
ing the Greasing Menu. See Figure 22.
Table 14. Greasing Settings Overview

Lubrication Mode lock • Locked
• Not Locked
Lubrication Cycle Time • Light duty

set
• Medium duty
• Heavy duty
Lubrication Operation • Automatic mode
mode
• Manual Service mode
• Single Test Cycle
• Multiple Test Cycle
• Auto Fast Test Cycle
98
Model Description
Table 14. Greasing Settings Overview (Continued)

Lubrication Pump enable • Enabled
• Disabled
Lubrication Timing cycle • Pause

• Enable
99
Model Description
Greasing Intensity Settings Menu
Figure 23. Greasing Intensity Settings Screen

Starting from the Greasing Information menu, select the F7 change the settings in three intensity steps, Light duty,
button to go to the Greasing Intensity Settings menu. Medium duty or Heavy duty. See Changing a Setting.
The Greasing Intensity Settings screen shows the current
greasing intensity settings and provides the possibility to
100
Model Description
Truck Settings Menu The settings menu consists of two sub menus; Automated
Services setup and Automatic Engine Shutdown setup.
On the Main Operating Screen, select the F9 button to
enter the Truck Settings menu.
101
Model Description
Automated Services Setup Menu
Figure 24. Automated Services Setup Screen
102
Model Description
NOTE: The automatic services functions are only active, the functions are active, the Auto Tip-Up function can be
when your service provider has activated the functions. set to OFF or AUTO. The Extend retract function can be
set to MANUAL or AUTO. See Figure 25.
The Automated Services setup screen shows the status of
the Auto Tip-Up function and the Extend/Retract function. If Automatic Engine Shutdown Setup Menu
Figure 25. Automatic Engine Shutdown Setup Screen
103
Model Description
From the Automated Services setup menu, select the F7 When selecting the Automated Engine Shutdown time
button to go to the Automated Engine Shutdown menu. setup bar, the password protection screen appears.
Figure 26. Automated Services Setup Password Screen

Select the code ‘4482’ to edit the time. Set the requested
time and press ENTER. See Changing a Setting.
104
Model Description
Rear View Camera
WARNING
The rear view camera is a viewing aid while making the
transition from forward to reverse driving. Objects in
the monitor are closer than they appear. The field of
vision of the camera may not reveal persons or objects
in every situation. Always look in the direction of
travel.
The rear view camera option consists of a camera and a
monitor, which are activated when the key switch is in the
ON position.
Figure 27. Rear View Camera

The monitor shows an image after the shift lever has been
moved into the reverse (R) position. When the shift lever is
not in the reverse (R) position, the monitor screen is black
except for an activation icon in the top left hand corner.
105
Model Description
During the initial 5 seconds the monitor displays a dis-
claimer:
The monitor has function buttons for the preferred image
setting. Some buttons are operational only after entering
the service menu.
CAUTION
Do not operate display functions during safety critical
operations. Objects in the monitor are closer than they
appear.
Figure 28. Monitor
106
Model Description
Figure 29. Monitor Keyboard

1. LED indicator selected camera. The LED at C1 should a. Automatic brightness day-night mode, adjusts the
be ON. If the LED at C2 or at C3 is ON, use the Camera screen according ambient light.
Selection button to select C1.
b. Fixed day setting, puts the screen at maximum illumi-
2. Camera Selection Button. Press the Camera Selection nation.
Button once. The Camera Selection LED flashes to indi-
c. Fixed night setting, puts the screen at minimum illumi-
cate that Camera Selection is enabled. Use the minus and
nation.
plus buttons to select the desired camera. A LED at the
codes C1, C2 or C3 indicates the selected camera. Select d. Automatic red screen, for continuous dark operation.
C1 and press the Camera Selection button again to store
e. Automatic blue screen, for continuous dark operation.
the setting and de-activate the Camera Selection Button.
Select red or blue screen as preferred.
The Camera Selection LED will be OFF.
4. Contrast Setting Button. Press the Contrast Setting
3. Brightness Control Button. Press the Brightness Con-
Button once. The Contrast Setting Selection LED flashes to
trol Button to change to the next mode of five available
indicate that the Contrast Setting is enabled. Use the minus
brightness settings.
107
Model Description
and plus buttons to set the required contrast. Press the flashes to indicate that the Brightness Setting is enabled.
Contrast Setting Button again to store the setting and de- Use the minus and plus buttons to set the required bright-
activate the Contrast Setting. The Contrast Setting LED will ness. Press the Brightness Setting Button again to store
be OFF. the setting and de-activate the Brightness Setting. The
Brightness Setting LED will be OFF.
5. Color Saturation Button. Simultaneously press the
Contrast (3) and Brightness (6) button once. The Contrast 7. Service Button. This button is for service use only.
and Brightness Selection LED’s flash to indicate that the
8. Minus Button. Press this button to decrease the inten-
Color Saturation Setting is enabled. Use the minus and
sity of a function.
plus buttons to set the required color saturation. Simultane-
ously press the Contrast and Brightness buttons again to 9. Plus Button. Press this button to increase the intensity
store the setting and de-activate the Color Saturation Set- of a function.
ting. The Contrast and Brightness Selection LED’s will be
10. Service Button. This button is for service use only.
OFF.
6. Brightness Setting Button. Press the Brightness Set-
ting Button once. The Brightness Setting Selection LED
108
Operating Procedures
General WARNING
Know Your Lift Truck FIRE HAZARD
The hot engine surfaces and exhaust of internal com-
bustion engine powered lift trucks can present fire haz-
WARNING ards when operating in areas containing flammable
EXHAUST GASES gases, vapors, liquids, dusts, fibers, or paper debris.
Exhaust from internal combustion engines contains Engine and exhaust component surface temperatures
carbon monoxide and other harmful chemicals. Carbon can exceed the ignition temperatures of common sol-
monoxide is a colorless, odorless poison and can vents, fuels, oil, paper, and other organic materials
cause unconsciousness or death without warning. (wood, wheat, cotton, wool, etc.). Exhaust emitted
Long-term exposure to exhaust or chemicals in the sparks can ignite these materials as well. Engine and
exhaust can cause cancer, birth defects, and other exhaust surface temperatures increase after engine
reproductive harm. Avoid exposure to engine exhaust. shutoff, presenting increased fire hazard. Check the
If engines are operated in confined spaces, maintain engine compartment frequently in areas containing
adequate ventilation or vent exhaust to the outside. DO combustible dusts, fibers, or paper and remove any
NOT exceed applicable air contaminant limits. foreign materials. Contact your local Hyster dealer for
lift truck modifications that may be appropriate in envi-
DO NOT use diesel engines indoors where soot can ronments with fire hazards.
accumulate.
Operate the lift truck only in areas that have been
Follow the inspection and maintenance schedule and approved for lift truck operation.
procedures in this manual. DO NOT alter exhaust, igni-
tion, or fuel systems. Only the designated types of approved lift trucks may
be used in areas classified as hazardous by the
109
authority having jurisdiction. Areas classified as haz- The lift truck is based on the principle of two weights bal-
ardous must be identified by signs to show the type of anced on opposite sides of a pivot (fulcrum). This is the
approved lift truck required for operation in the area. same principle used for a seesaw. In order for this principle
Modifications or poor maintenance can result in the lift to work for a lift truck, the load must be balanced by the
truck being unsuitable for operation in areas classified weight of the lift truck. The location of the center of gravity
as hazardous. of both the truck and the load is also a factor.
This lift truck is designed to pick up and transport 20-40' This basic principle is used for picking up a load. The ability
containers on firm and essentially flat surfaces. The truck of the lift truck to handle a load is discussed in terms of
has lift and mast tilt mechanisms. An integral attachment to center of gravity and both forward and side stability.
engage the containers can be extended and retracted for
containers of different lengths and may feature sideshift Stability and Center of Gravity
and powered pile slope functions to aid in the handling of The center of gravity (CG) of any object
containers. There is a variety of methods available of is the single point about which the object
engaging the containers. is balanced in all directions.
In order to understand how the lift truck can pick up a load, Every object has a CG. When the lift
you must first know some basic things about the lift truck. truck picks up a load, the truck and load
have a new combined CG.
110
A. CG LOAD B. CG TRUCK C. COMBINED CG
The stability of the lift truck is determined by the location of

A. CG LOAD B. COMBINED CG C. CG TRUCK
its CG, or if the truck is loaded, the combined CG.
The lift truck has moving parts and, therefore, has a CG The center of gravity, and therefore the stability of the loa-
that moves. The CG moves forward and back as the mast ded lift truck, is affected by a number of factors such as
is tilted forward and back. The CG moves up and down as size, weight, shape, and position of the load; the height to
the mast moves up and down. which the load is raised; the amount of forward and back-
ward tilt; tire pressure; and the dynamic forces created
when the truck is moving. These dynamic forces are
caused by things like acceleration, braking, turning, and
operating on uneven surfaces or on an incline. These fac-
tors must be considered when traveling with an unloaded
truck, as well, because an unloaded truck will tip over to
111
the side easier than a loaded truck with its load in the low- Dynamic forces can cause the center of gravity to move
ered position. outside of the stability triangle. Operators must be trained
to understand the effects of dynamic forces and how their
In order for the lift truck to be stable (not tip over forward or
actions can have either a positive or negative influence on
to the side), the CG must stay within the area of the lift
such forces. Operators should practice defensive driving
truck represented by a triangle drawn between the drive
and recognize the need to operate at speeds commensu-
axle and the pivot of the steering axle.
rate with surface conditions, other vehicular traffic, pres-
ence of pedestrians, weather conditions, etc. At all times,
the operator should be in control and travel at speeds
which will allow the operator to bring the truck safely to a
stop.
Capacity (Weight and Load Center)
The capacity of the lift truck is shown on the Nameplate.
The capacity is listed in terms of weight and load center.
The weight is specified in kilograms and pounds. The load
center is specified in millimeters and inches. The capacity
A. DRIVE AXLE C. CG - TRUCK WILL TIP OVER is the maximum load that the lift truck can handle. This load
B. STEERING AXLE must weigh less than the maximum weight for a load center
shown on the Nameplate. See Figure 30.
If the CG moves forward of the drive axle, the lift truck will
tip forward. If the CG moves outside of the line represented
by the lines drawn between the drive wheels and the steer-
ing axle pivot, the lift truck will tip to that side.
112
Inspection Before Operation
WARNING
Report damage or faulty operation immediately. DO
NOT operate a lift truck that needs repair. A lift truck
will only do its job when it is in proper working order. If
repairs are required, install a tag in the operator's area
stating DO NOT operate and remove the key from the
key switch.
Figure 30. Nameplate Checks With the Engine Stopped

The load center of a load is determined by the location of Inspect the lift truck before use and every 8 hours or daily
its center of gravity. The load center is measured from the as described in the Maintenance section of this Operating
front face of an attachment, to the center of gravity of the Manual. Make sure that the area around the lift truck is
load. Both the vertical and horizontal load centers are clear before making any operational checks. Use caution
specified on the Nameplate. when making these checks.
Loads should be transported while centered on the center- Before using the lift truck, make the following checks:
line of the lift truck.
• Fuel level, DEF level.
The operator must know whether or not a load is within the
maximum capacity of the lift truck before the load is han- • Oil level in the engine and hydraulic tank.
dled. • Coolant level in the cooling system and condition of the
drive belts.
113
• Condition of the engine compartment. Ensure all surfa- contact simultaneously with two hands and one foot or
ces are free of oils, lubricants, fuel, and organic dusts or with two feet and one hand while climbing on or off the
fibers (paper, wood, cotton wool, agricultural grass/ lift truck.
grain, etc.). Remove all foreign materials.
Place feet carefully. Always face the lift truck when climb-
• Condition of the radiator. Clean if necessary. ing on or off. Use added care when surfaces are slippery.
Keep hands free of any obstacles such as food, beverages,
• Condition of attachments and operator's compartment.
or tools.
• Check for presence and readability of safety labels. See
Figure 3. Starting Procedures
• Leaks from the engine, transmission, hydraulic system, Do not start or operate the lift truck, including any of its
and fuel system. functions or attachments, from any place other than the
designated operator's position. If equipped, be sure cab
• Condition of wheels and tires. Check the air pressure in door is secured in the closed position before starting lift
the pneumatic tires. truck operations.
• Seat belt fastens correctly. Retractor operates correctly.
WARNING
• Mirrors are clean and adjusted. DO NOT use starting fluid (ether) or other flammable
• Windows are clean. liquids as starting aids. The engine is equipped with an
electric heater for a starting aid. Use of ether or other
Mounting and Dismounting flammable liquids can cause a fire and exposion, caus-
ing serious personal injury and engine damage.
WARNING
To avoid serious injury when entering or exiting the lift
truck, ALWAYS USE 3 POINTS OF CONTACT. Maintain
114
Starting a truck with Telemetry Access Option 2. A buzzer will sound.
If the lift truck is equipped with Telemetry Acces with an 3. Turn the key switch from the OFF to the ON position.
RFID card, proceed as follows. The buzzer will be OFF. Do not yet turn the key switch to
the START position.
1. Operator must be seated.
4. Swipe the Telemetry RFID card over the Telemetry
2. A buzzer will sound. decal at the RH side of the steering column.
3. Turn the key switch from the OFF to the ON position. 5. When a buzzer responds with short buzzes, the truck
The buzzer will be OFF. Do not yet turn the key switch to cannot be started. Contact your supervisor.
the START position.
6. When a buzzer responds with one continuous buzz, use
4. Swipe the Telemetry RFID card over the Telemetry the buttons on the Checklist Display to answer the pre-start
decal at the RH side of the steering column. questions shown on the display.
5. When a buzzer responds with short buzzes, the truck 7. If one or more questions have been answered incor-
cannot be started. Contact your supervisor. rectly, the truck cannot be started. Raise from the seat and
6. When the buzzer responds with one continuous buzz, restart the procedure.
proceed with starting the truck. See Starting the Truck. 8. When the questions have been answered correctly, the
display will indicate that the truck may now be started.
Starting a truck with Telemetry
VerificationOption 9. Proceed with starting the truck. See Starting the Truck.
If the lift truck is equipped with Telemetry Verification, pro- After the truck has started, use the buttons on the Checklist
ceed as follows: Display to answer the After-Starting Questions on the dis-
play. NOTE that the Telemetry System will initiate an auto-
1. Operator must be seated. matic shut down if the After-Starting Questions have NOT
115
been answered within a few minutes after starting the 2. When the key switch is still in the OFF position, turn the
truck. key to the ON position. Wait until the Engine Wait to Start
Light is OFF. The Central Warning Lights, The Brake Sys-
Starting the Truck tem Low Prerssure Warning Light, and the Parking Brake
DO NOT engage the starter for more than 10 seconds Warning Light will remain ON. All other lights must be OFF.
at a time. If the engine does not start, turn the key 3. Turn key to the START position to engage the starter.
switch to OFF. Wait two minutes before engaging the Allow the key to return to the ON position when the engine
starter again. starts. Only engage the starter for a maximum of 10 sec-
1. If lift truck is NOT equipped with the optional Seat Belt onds..
Sequencer, either: 4. If the engine does not start after four attempts, get help
• Apply the parking brake, and/or from authorized service personnel.
• Put the directional control lever for the transmission in 5. With the engine running at idle, check the gauges and
the N (NEUTRAL) position, and/or indicator lights for correct operation. See Seat Adjustment
Controls section in this Operating Manual.
• Completely depress the inching/brake pedal.
6. Check for fault codes on the instrument cluster. The
1. If lift truck is equipped with the optional Seat Belt engine, transmission and hydraulic system are controlled
Sequencer, perform following steps in the sequence and monitored by controllers. In case of a fault condition a
shown. fault code is displayed and a warning light for these sys-
a. Operator must be in seat. tems will come ON. Certain fault codes may shift the trans-
mission to neutral, reduce engine performance or even
b. Seat belt must be fastened. shut down the engine automatically. See Table 3, Table 8
c. Make sure parking brake is applied. and Table 9.
116
7. Operate a cold engine at a reduced load and speed until 2. Apply parking brake.
the needle of the Coolant Temperature Gauge has reached
3. Put the shift lever for the transmission in the NEUTRAL
the green area.
(N) position.
8. If the truck is equipped with the Telemetry Verification
Option do not forget to answer the After-Starting Questions CAUTION
on the Checklist Display. If the After-Starting Questions The turbocharger can be severely damaged when
have NOT been answered correctly within a few minutes switching off a hot engine when the 3 to 5 minute idle
after starting the truck, the Telemetry System will initiate an period is not performed.
automatic shut down.
4. Allow the turbocharger of the engine to cool down and to
Heating Hydraulic Oil obtain the lowest possible turbo speed before stopping the
engine. If engine coolant temperature is low to moderate,
When hydraulic oil temperature in the reservoir is below keep the engine at lowest idle for 3 minutes before turning
−5 °C (23 °F), the hydraulic controller limits engine speed the key switch to OFF. If engine temperature is high, keep
proportional to the hydraulic oil temperature. The fault code the engine at lowest idle for at least 5 minutes before turn-
display will show 'hCold'. At −20 °C (−4 °F), the engine ing the key switch to OFF.
speed is limited to 1000 rpm. Above −5 °C (23 °F), the con-
troller does not limit engine speed. Apply hydraulic func- Derating and Automatic Shutdown
tions to raise hydraulic oil temperature. For a quicker rise of Procedures
hydraulic oil temperature, apply hydraulic functions against
relief. When activated, the central warning light and the fault code
display warn the driver that certain limits are exceeded.
Manual Shutdown Procedures Always attend to fault codes immediately.
1. Place the lift truck on a solid, level surface. Under circumstances the engine control system will derate
engine output or it will even shut down the engine.
117
Avoid excessive temperatures that cause a shutdown of The OPS feature has an electrical switch in the seat which
the engine by reacting to indicators and warning lights. senses the presence of the operator. When the operator is
in the seat, the transmission can be engaged and hydraulic
Reduce hydraulic oil temperature by reducing hydraulic
functions can be operated. When the operator is absent,
power demand and usage of brakes.
the transmission will disengage and hydraulic mast func-
Reduce transmission oil temperature by limiting inching tions cannot be operated. The OPS is designed with a
mode and torque converter stall. slight delay in the seat switch to allow the operator to repo-
sition himself without disabling the transmission and all
Reduce engine temperatures by limiting engine output
hydraulic functions.
demand.
To check operation of the Standard OPS, there must be no
Empty Seat Engine Shutdown (Optional) operator in the seat for at least 2.5 seconds. Verify the
The engine shuts down if the operator is not on the seat hydraulic functions do not operate and that the transmis-
during a certain time. This time has been set by the factory sion is disengaged.
at 15 minutes and can be adjusted by your dealer between To check operation of the Optional OPS, an additional
3 and 15 minutes. To restart the engine, turn the key switch check is required. With operator in the seat and seat belt
to OFF and follow the normal starting procedures. NOT fastened for at least 2.5 seconds, verify the hydraulic
mast functions do not operate and the transmission is dis-
Operator Presence System (OPS)
engaged.
The lift trucks covered in this manual are equipped with an If the OPS does not operate as expected, remove truck
Operator Presence System (OPS). Some lift trucks are from service until repairs are completed.
equipped with an optional Operator Presence System
which will not allow the truck to travel or operate hydraulic To reset the OPS and allow full truck operation, the opera-
mast functions unless the operator is in the seat and the tor must be seated. For trucks equipped with the Optional
seat belt is also fastened. Operator Presence System, the seat belt must be fastened
118
after the operator has seated. Engage the transmission
using any of the following actions: Checks from the Driver's Seat with the
• Depress the inching brake pedal more than 75%. Engine Running
• Move the gear selector into the NEUTRAL position, and
then move the gear selector into travel mode. WARNING
FASTEN SEAT BELT
• Make a direction change using the MONOTROL® pedal. If Lift Truck Tips Over:
Automatic Greasing System (Optional) • DO NOT Jump – Stay On Truck
Different automated greasing options are available, each • Hold Firmly To Steering Wheel – Brace
providing grease to certain components. When performing Feet – Lean Forward And Away From
maintenance at the scheduled interval either apply grease Impact
manually or check presence of grease provided by the
The seat belt is installed to help the opera-
automated greasing system. See Automatic Greasing
tor stay on the truck if the lift truck tips
System 8000SRM2141 for more information.
over. IT CAN ONLY HELP IF IT IS FAS-
TENED.
119
The operator must be aware that the lift truck can tip • Check the oil level in the powershift transmission when
over. There is a great risk that the operator or someone the oil is at operating temperature. Make sure the trans-
else can be killed or injured if trapped or hit by the mission is in NEUTRAL, the parking brake is applied,
truck as it tips over. The risk of injury can be reduced if and the engine is running at idle speed.
the operator stays on the truck. If the truck tips over,
• Operate the LIFT, TILT, and AUXILIARY functions to
DO NOT jump off!
check for correct operation of the mast, carriage, and
The seat belt provides a means to help the operator keep attachments.
the head and torso substantially within the confines of the
• Check the operation of the shift lever and accelerator
operator's cab frame and overhead guard if a tipover
pedal.
occurs. This protection system is intended to reduce the
risk of the head and torso being trapped between the truck • Check the operation of the service brakes and parking
and the ground, but it cannot protect the operator against brake.
all possible injuries in a tipover.
• Check the operation of the steering system.
Make sure that the area around the lift truck is clear before
starting the engine or making any operational checks. Be Operating Techniques
careful when making the checks. If the lift truck is station-
ary during a check, apply the parking brake and verify the WARNING
direction control is in NEUTRAL. Proceed carefully. Before operating the lift truck,
FASTEN YOUR SEAT BELT.
Check the operation of the following functions as described
in the Maintenance section: There are a number of opera-
tions, if not performed carefully,
• Check the operation of the horn, gauges, and indicator that can cause the lift truck to tip. If you have not read
lights. the WARNING page in the front of this Operating Man-
ual, do so NOW. As you study the following
120
information about how to properly operate a lift truck, The following discussion lists basic procedures applicable
remember the WARNINGS. to lift truck operation.
General 1. AUTHORIZED AND TRAINED OPERATOR ONLY. This
means the operator must be trained to drive the lift truck
NOTE: When the Emergency Locking Retractor (ELR) seat and it means that the operator must thoroughly understand
belt is properly buckled across the operator, the belt will the procedures for lift truck operation. It also means that a
permit slight operator repositioning without activating the qualified person experienced in lift truck operation must
locking mechanism. If the truck tips, travels off a dock, or guide the operator through several driving and load han-
comes to a sudden stop, the locking mechanism will be dling operations before the operator attempts to operate
activated and hold the operator's lower torso in the seat. the lift truck alone. A basic education in proper driving and
load handling techniques is absolutely necessary to pre-
Basic Operating Procedures
pare the new operator for proper defensive driving and to
Many people make the mistake of thinking that operating a expect the unexpected.
lift truck is the same as driving an automobile. This is not 2. Operate the lift truck only on firm and essentially flat sur-
true. It is true that some lift truck operating procedures are faces in areas which have been approved for lift truck oper-
as simple and obvious as driving an automobile (e.g., look ation. Certain areas contain hazardous flammable gases,
where you are going, start and stop smoothly, etc.). But a liquid, dust, fibers or other materials. Lift trucks that are
lift truck is a special machine designed to do a much differ- operated in these areas must have special fire safety
ent job than an automobile. Because of the close areas in approval.
which a lift truck operates and its other operating character-
istics (like rear wheel steering and tail swing), every opera-
tor must receive additional training, even if they have a
license to drive an automobile.
121
3. NO RIDERS. This lift truck is built for maximum two per-
sons inside the cab with fastened seat belts. It is danger-
ous for anyone else to ride on the lift truck.
4. Drive carefully, observe traffic rules, and be in
full control of the lift truck at all times. Be com-
pletely familiar with all the driving and load-han-
These areas must be designated to show the type of lift
dling techniques contained in this Operating
truck approval required for operation in the area. Changes
Manual.
to special equipment or poor maintenance can make the lift
truck lose its special approval. Driving and Direction Changes
These lift trucks have a four-speed powershift transmis-
sion. Operate the transmission as follows:
The shift lever for the transmission is on the left side of the
steering column. Push the shift lever FORWARD (F) to
travel FORWARD. Pull the shift lever back (R) to travel in
REVERSE. Move the shift lever to the center (N) position
to put the transmission in NEUTRAL. An audible reverse
alarm is activated whenever the shift lever is in the
WARNING REVERSE position. The transmission controller will NOT
allow gear engagement and/or direction changes if the
The lift truck is designed and intended for handling
engine speed is more than 1500 rpm or truck speed is
containers. A lift truck is not designed to lift people. Do
more than 4 km/h (2.5 mph).
not lift or move people that are outside of the cab.
122
Range selection is by rotation of the handle of the shift Inching/Braking
lever. Rotate the handle to one of the four ranges for auto-
matic shifting up and down through the ranges as descri- WARNING
bed in Table 4. All four speeds are available in the Inching requires coordinated movement of the inching/
FORWARD or REVERSE direction of travel as selected. brake pedal and the accelerator. New operators must
To change directions, use the brake pedal to slow, less practice this procedure before attempting to handle
than 4 km/h (2.5 mph), or stop the lift truck. Change direc- loads.
tions with the shift lever. The transmission will shift to NEU- The lift truck has a brake pedal and an inching/brake pedal.
TRAL if a reversal is attempted when the speed is too fast. The brake pedal (middle pedal) applies only the brakes.
The lift truck has the capability of making directional shifts Slightly pushing the inching/brake pedal (left-hand pedal)
at travel speeds up to a walking pace, but the mast must will apply the service brakes and, further pushing the pedal,
not be raised and the load must be stable. If the lift truck is will fully disengage the transmission.
moving rapidly, slow to a walking speed before changing The inching/brake pedal is used to control the inching oper-
the direction of travel. ation. When the inching/brake pedal is initially applied, the
NOTE: During the operation of the truck, the transmission clutch in the transmission is partially disengaged and the
controller may display transmission exceed codes on the movement of the truck is slow. When the inching/brake
hourmeter/fault code display. These codes are shown in pedal is fully applied, the transmission is completely disen-
Table 9. gaged and the brakes are applied. Use the accelerator
pedal to keep the engine speed high while inching.
In the event of a transmission failure, contact your local
service representative.
123
WARNING
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR
FEET, AND LEAN FORWARD AND AWAY FROM THE
POINT OF IMPACT.
Most operators can understand the need to be careful
when handling loads but some operators do not realize that
A. FAST B. SLOW a tipover can occur with an empty lift truck because similar
dynamic forces are present. In fact, the lift truck will
Steering (Turning) actually tip over easier sideward when empty, than when
loaded with the load lowered. Mast tilt, off-center loads,
WARNING and uneven ground will aggravate these conditions and
TRAVEL SLOWLY WHEN TURN- cause the lift truck to become unstable. Failure to observe
ING. Lift trucks can tip over even the tail swing area when making a turn can lead to injury or
at very slow speeds. The combi- death.
nation of speed and the sharp-
ness of a turn can cause a WARNING
tipover. A lift truck is less stable Failure to observe the tail swing area when making a
when the attachment mechanism turn can injure or kill someone.
is raised, with or without a con-
tainer attached.
124
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.
The right hand is used to operate
A. TAIL SWING
the lift, tilt, and attachment 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
When turning the lift truck from a wide aisle into a narrow
death.
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.
125
Load Handling, General Load Handling, Lifting, Lowering, and Tilting

1. The capacity is the maximum load that the lift truck can The LIFT and TILT functions are controlled by separate
handle for the load condition shown on the Nameplate. The levers or by a joystick. Refer toFigure 7 and Table 4 for
operator must know whether or not a load is within the proper operation.
maximum capacity of the lift truck before the load is han-
The speed of the hydraulic functions is controlled by the
dled.
position and the control levers and the speed of the engine.
However, such factors as weak surfaces, uneven terrain, The farther the hand lever is moved from the NEUTRAL
special load handling attachments, or loads having a high position, the faster the speed of the hydraulic function.
center of gravity can mean that the safe working load is
Do not lift or hit anything that can fall on the operator or a
less than the rated capacity. When such conditions exist,
bystander.
the operator must reduce the load so that the lift truck will
remain stable. Remember, a lift truck equipped with a Hyster cab with
integral overhead guard provides reasonable protection to
2. Check the condition of the driving surface. Make sure
the operator from falling objects, but cannot protect against
the surface will support the weight of the lift truck and the
every possible impact.
load.
The operator must exercise extreme care while working
3. Avoid fast starts. Sudden movement can cause the lift
near objects. It is permitted to travel with the container a
truck to tip. People can be hurt or killed and material can
maximum of 1 m (3.3 ft) above the seat height and mast
be damaged.
fully back tilted.
4. Approach the load carefully. Make sure that the truck is
perpendicular to the load. Raise the attachment to the
proper height for engaging the load.
126
Lift and lower with the mast vertical or tilted slightly back-
WARNING
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
If the lift mechanism is raised to pick up or deposit a load,
NEVER put hands, arms, head, or legs through the
keep the tilt angle in either direction to a minimum. Back-
mast or near the carriage or lift chains. This warning
ward and forward tilt are helpful, but they affect side and
applies not only to the operator but also a helper. A
forward stability. DO NOT tilt in either direction more than
helper must not be near the load or lift mechanism
necessary when handling elevated loads. The lift truck can
while the operator is attempting to handle a load. The
tip forward if the mast is tilted forward with a load in the
lift mechanism has moving parts with close clearances
raised position.
that can cause serious injury.
127
WARNING WARNING
The lift truck can tip over forward when the load is Failure to follow these instructions can cause serious
raised. Forward tipping is even more likely when tilting injury or death.
forward, braking when traveling forward, or accelerat-
ing in reverse. CAUTION
Do not hit the attachment on other containers or
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!
objects. The attachment can be damaged by hitting
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR
other objects. This is especially important when
FEET, AND LEAN AWAY FROM POINT OF IMPACT.
extending or retracting the attachment.
1. Before using the container attachment, inspect the
attachment for damage and make sure all of the controls
operate as specified in Table 4.
2. Always put the attachment in the center of the lift truck
when not carrying a container. Use the sideshift function to
put the attachment in the center position.
3. Use the sideshift function to keep the container as level
Container Handling as possible when carrying a container.
Load Handling, How to Handle Containers 4. Watch the clearance around the complete length of the
container. Avoid hitting objects, such as stacked material,
The following discussion describes the use of the 20- to 40- that can fall.
ft extendable attachment used for handling containers. The
inspection and maintenance instructions for the attachment 5. Never lift a container that is heavier than the capacity
are in the Service Manual. shown on the nameplate of the lift truck.
128
6. Always be careful of winds while handling containers. • Left-hand amber light and left-hand icon indicate that the
Strong wind force on raised containers can tip the lift truck. attachment is seated at the left-hand side and ready to
DO NOT stack containers in winds above 45 km/h have twist locks activated.
(28 mph).
• Green light and icon indicate that both twist locks are in
7. DO NOT use the override function while a container is locked position and ready to lift the container.
being carried by the attachment. See System Interrupts.
• Red light and icon indicate that both twist locks are in
8. When traveling with the load, keep the mast tilted fully unlocked position. It is possible to move the twist locks
backward. This will give additional forward stability at brak- into or out of the corner pockets.
ing when traveling forward.
• Right-hand amber light and right-hand LED indicate that
In addition to the indicator lights, a buzzer is provided. It the attachment is seated at the right-hand side and if
gives an acoustic signal during the sequence of picking up ready to have the twist locks activated.
and depositing a container. The buzzer can be switched
• Blue icon (display only) indicates that the over-lowering
ON or OFF. When switched ON, the volume can be adjus-
or the lift interrupt function is activated.
ted to suit the operator. When the override function is
selected, the buzzer is always activated. In this mode it Blinking lights may occur for the amber lights (seated func-
beeps intermittently and at maximum volume. tion), green light (locked function), and red light (unlocked
function). A light will start blinking if one of its related sen-
Indicator Lights and LEDs sors is faulty and/or incorrectly adjusted. This may also
This lift truck has one set of four indicator lights at the right- imply that the spreader system senses an incorrect position
hand side of the spreader. See Figure 31. In addition there of the seated pins or twist locks. To rectify the situation, the
are five illuminating icons on the display in the operator's sensors for that particular system have to be checked and
cab. The indication is as follows: readjusted and correct movement of seated pins and twist
locks has to be established.
129
System interrupts can be triggered by different situations:
• Lift interrupt when the twist locks are being locked or
unlocked.
• Lowering interrupt when a seated signal is present.
• Optional lowering interrupt when an extension beam is
pushed up.
System Interrupt Overrides
Under exceptional circumstances it may be required to
override a system interrupt. Move the key switch on the
side console to the ON position and push button F5 on the
1. AMBER 3. RED display to manually override a system interrupt while
2. GREEN
observing the respective warnings.
Figure 31. Indicator Lights, One Set of Four Always be extra careful when using an override function.
System Interrupts Lift Interrupt Override

System Interrupts protect mast and attachment during posi-
WARNING
tioning and locking on a container. When a system interrupt
Never try to lift a container when the Lift Interrupt is
is activated, the audible alarm and the blue Lift Interrupt
activated, or personal injury may occur. Never use the
Icon are ON.
override function when the container is not properly
Check the attachment indicator lights and establish which positioned on surface or other container.
action is required before proceeding.
130
During locking or unlocking of the twist locks, lifting is disa- Turn the override key switch on the side console to the ON
bled. The blue Lift Interrupt Icon on the display is ON to position, push and hold the F5 button on the display and
indicate activation of the lift interrupt. operate the twist lock switch to lock or to unlock.
If one of the twist locks is not able to complete the rotation Lowering Interrupt Override
movement, it can be desired to lift and/or tilt the attachment
slightly. WARNING
Turn the override key switch on the side console to the ON After having used the lowering override function, make
position, push and hold the F5 button on the display and sure that chains, hoses and cables will align properly
operate the lift and/or tilt lever to move the attachment when operating the lift function again.
slightly. Make sure to NOT move the container. Lowering is disabled when the four attachment corners
Twist Lock Override have provided a seated signal. If one of the twist locks is
not able to complete the rotation movement, it can be
desired to further lower the attachment slightly.
WARNING
Never use the override function when the container is Turn the override key switch on the side console to the ON
not properly positioned on the ground or another con- position, push and hold the F5 button on the display while
tainer, or personal injury may occur. the lowering command is given.
Circumstances may prevent rotation of the twist locks into When operating the lift function again, initially move the lift
the locked or unlocked position. The twist lock override lever gently to make sure that chains, hoses and cables
function allows initiation or reversal of twist lock rotation. are properly tensioned and aligned before lifting at speed.
Make sure the container is properly positioned on the
ground or another container.
131
How to Pick Up a Container the container. The amber lights on the attachment and Dis-
play will come ON when all four corners of the attachment
NOTE: The attachment may only be used to lift 20 foot and are in contact with the container.
40 foot containers. If the attachment is equipped with the
optional 30 Foot Lock Switch, then also 30 foot containers 5. When seated, the twist locks will automatically be
can be lifted. locked. The green lights on the attachment and Display will
come ON when the twist locks are in the locked position.
1. Retract the stops (optional) and adjust the length of the Make sure the indicator flags for the twist locks are in the
attachment to the size of the container. Extend the stops locked (orange flag) position.
when the extension beams are close to the desired 30 foot
position. Release the switch for extension / retraction when NOTE: If the twist locks of a container attachment are not
the end position has been reached. engaged, change the position of the container to allow the
twist locks to engage.
2. Put the lift truck in a position so that the attachment is
approximately centered with the container. Raise the
attachment high enough above the container to provide
good visibility. Move the lift truck as close as possible to
the stack of containers. Operate the side shift, rotate and
mast functions to position the attachment accurately over
the container corners.
3. Check that the red light on the attachment and the red
twist lock icon on the Display are ON. This indicates that
the twist locks are in the UNLOCKED position.
4. When the attachment is aligned with the container, lower
the attachment so that the twist locks enter the corners of
132
WARNING Load Handling, Traveling With a Container

Make sure twist locks are engaged with the container.
If the green lights do not come ON, start the procedure WARNING
again. If there is still a problem, contact authorized When traveling DO NOT raise the container higher than
service personnel. maximum 1 m (3.3 ft) above seat height. Special care
must be exercised during these operations. Pay partic-
WARNING ular attention to wind and uneven travel surfaces that
In case of a faulty or damaged sensor in the safety sys- can reduce the stability of the lift truck while the con-
tem there will be a flashing light system that will warn tainer is raised.
the operator of a dangerous situation. The twist locks 1. Travel with the mast and spreader raised a maximum of
are unlocked with the red LED ON, and the green LED 1 m (3.3 ft) above seat height to see under the container.
FLASHING. Retract both slew cylinders completely. Travel with the
6. Lift the container. Tilt the mast slightly backward. The mast in the full back tilted position.
amber lights must go OFF. Use the sideshift function to This lift truck has been designed for the express purpose of
center the point of gravity. moving and stacking containers. It is allowable to travel in
7. If the container is stacked, move lift truck away from the the forward direction with the container(s) raised sufficiently
stack and lower the container to travel position of a maxi- to see underneath. While transporting containers, the bot-
mum of 1 m (3.3 ft) above seat height. tom of the container should be placed no higher than maxi-
mum 1 m (3.3 ft) above seat height with the mast fully back
8. Tilt the mast fully backward. Retract both slew cylinders tilted.
completely.
9. Container can now be moved.
133
2. Watch out for pedestrians at all times.
WARNING
DO NOT drive up to anyone standing in
Dependant upon travel speed, braking with the mast/
front of an object.
load elevated can cause forward tipover. At all times,
travel at speeds which will allow the lift truck to be Use extra care at intersections and
safely brought to a stop. Stop the lift truck as gradually other locations where pedestrians can
as possible. step into the path of travel of the lift
truck.
With the mast and attachment raised with or without load,
forward or side stability may be reduced in certain circum- Slow down when approaching blind intersections or turns
stances. The ability of the lift truck to resist side tipping can and sound the horn. The horn is to warn pedestrians that
be less on a lift truck without a load than it is on a lift truck there is a vehicle in the area and to be alert to possible
with a load in the lowered (travel) position. Therefore, a lift danger.
truck without a load is more likely to tip sideward, espe-
cially in a turn, than a lift truck with a load carried in the
lowered position.
WARNING
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 3. Watch clearances, especially around the load (contain-
must NOT be used as such when operating in reverse. ers), mast spreader, and tail swing.
Always look in the direction of travel to avoid damage
to something or injury to someone.
134
A lift truck is designed to perform a wide variety of func-
tions within limited space. Serious accidents can be caused
by the mast, spreader, or operator's compartment hitting
pipes, wires or containers.
4. Anytime the lift truck is moving
keep arms, legs, etc., inside the
operator’s compartment. Arms and
6. DO NOT indulge in stunt driving or horseplay.
legs outside the machine can be
injured during operation.
5. Avoid bumps, holes, slick spots,
and loose materials that may
cause the lift truck
to swerve or tip. If
unavoidable, slow
down. Always make
sure you pick the
smoothest route for
your lift truck.
7. DO NOT pass another lift truck travelling in the same
direction at intersections, blind spots, or at other dangerous
locations.
8. Stay away from the edge of the road. Keep the wheels of
the lift truck, particularly the steer wheels, on the roadway.
135
If the wheels are allowed to run off the edge of the travel How to Deposit a Container
surface onto soft ground, the lift truck can tip over.
1. Keep the mast vertical when depositing the container.
WARNING Use caution not to damage or move the adjacent contain-
Remember when traveling in the forward direction and ers.
the steering wheel is turned to move the lift truck away 2. Locate a stable, even surface or another container and
from the edge of the dock the rear will swing toward line up with the container.
the edge. This can cause the lift truck to fall off the
dock. 3. Lower the container until the attachment rests on the
container. Tilt the mast slightly forward. The amber light on
9. Stay away from the edge of docks. the attachment and the display will switch ON.
4. . Make sure the red lights are OFF and the amber lights
are ON. Push the button on joystick to unlock the twist
locks.
NOTE: The audible alarm on the Display will sound when
the twist lock switch is pushed to unlock the twist locks. If
for any reason the twist locks do not move to the unlock
position, the alarm will continue to sound.
WARNING
10. Under all travel conditions, operate the lift truck at a In case of a faulty or damaged sensor in the safety sys-
speed that will permit it to be brought to a stop in a safe tem there will be a flashing light system that will warn
manner. the operator of a dangerous situation. The twist locks
136
are locked with the green light ON, and the red light If an attachment is installed on the lift truck, make sure the
FLASHING. operating instructions are available and understood before
operating the attachment. For the operation of attachment
5. The green light and icon will switch OFF. The red light
controls, see Figure 7 and Table 4.
on the attachment and the display will switch ON.
Attachments must be removed or installed by trained per-
6. Lift the attachment until the twist locks are free of the
sonnel only.
corner castings.
7. Place truck in reverse and move straight away from the Stopping
container.
Attachments
WARNING
Make sure the Nameplate is correct if an attachment
has been installed.
Stop the lift truck as gradually as possible. Hard braking
and wheel sliding can cause the lift truck to tip forward and
damage the load or cause personal injury.
Parking
NOTE: The parking brake, when in good condition and cor-
rectly adjusted, will hold a lift truck with a capacity load on
a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft in
10 ft)].
137
NOTE: Do not park the lift truck so that it limits access to 4. After idling for 3-5 minutes, turn the key switch to OFF to
fire aisles, stairways, and fire equipment. stop the engine.
The operator must never leave a lift truck in a condition so 5. Immediately check engine compartment and remove any
that it can cause damage and injury. When parking the lift foreign materials if operating in areas containing combusti-
truck, do the following operations: ble material.
1. Stop the lift truck and apply the parking brake. 6. If the lift truck must be left on an incline, put blocks on
the downhill side of the wheels so that the lift truck cannot
2. Retract beams and fully lower the attachment.
move.
3. Put the shift lever for the transmission in NEUTRAL.
138
Maintenance
Maintenance
General ments that are not correct can make a dangerous oper-
ating condition.
The Truck Periodic Maintenance Schedule has hour
intervals for inspection, lubrication, and component DO NOT operate a lift truck that needs repairs. Report
replacement for your lift truck. When in addition a calendar the need for repairs immediately. If repair is necessary,
interval is mentioned, then the first expiring interval must put a DO NOT OPERATE tag in the operator's area.
be observed. Remove the key from the key switch.
Your dealer for Hyster lift truck has the equipment and WARNING
trained service personnel to do a complete program of Disposal of lubricants and fluids must meet local envi-
inspection, lubrication, and maintenance. A regular pro- ronmental regulations.
gram of inspection, lubrication, and maintenance will help
your lift truck give more efficient performance and operate Serial Number Data
for a longer period of time.
The serial number for the lift truck is on the Nameplate. It is
Some users have service personnel and equipment to do also on top of the right-hand frame channel, near the coun-
the inspection, lubrication, and maintenance shown in the terweight.
Maintenance Schedule. Service Manuals are available
from your dealer for Hyster lift truck to help users who do How to Move a Disabled Lift Truck
their own maintenance. While the lift truck is being towed the engine must stay run-
ning in order to generate sufficient hydraulic oil pressure.
WARNING Without hydraulic pressure the steering system and service
DO NOT make repairs or adjustments unless you have
both authorization and training. Repairs and adjust-
139
Maintenance
brake system do not operate, and the park brake will auto-
matically apply. The parking brake can be manually
released if no hydraulic pressure is available.
WARNING
When the parking brake is manually released, the lift
truck does not have any brake function. Block the
wheels to prevent the lift truck from moving. If the
wheels are not blocked, serious personal injury and
damage to components can occur.
NOTE: If the parking brake is manually released, it will
need to be adjusted before the lift truck is returned to serv-
ice. With hydraulic pressure applied to the parking brake,
adjust play between brake disc and park brake pads to
1.0 mm (0.04 in.).
The parking brake caliper is mounted on a support bracket
at the differential carrier assembly. To manually release the 1. ADJUSTMENT BOLT
parking brake, perform following steps: 2. LOCK NUT
1. Place blocks on both sides (front and rear) of the drive Figure 32. Releasing the Parking Brake
and steering tires to prevent movement of the lift truck.
2. Loosen the lock nut.
3. Turn the adjustment bolt or socket counterclockwise until
the brake disc is free.
140
Maintenance
4. Tighten the lock nut. system. This can make the control of the lift truck diffi-
cult. Poor traction can cause the disabled lift truck or
NOTE: If the parking brake is manually released, it will
towing vehicle to slide. Steep grades will increase the
need to be adjusted before the lift truck is returned to serv-
required brake effort.
ice.
NEVER lift and move a disabled lift truck unless the
With hydraulic pressure applied to the parking brake, adjust
disabled lift truck MUST be moved and cannot be
play between brake disc and park brake pads to 1.0 mm
towed.
(0.004 in.) .
1. The towed lift truck must have an operator.
How to Tow the Lift Truck
2. Make sure transmission oil level is above minimum.
WARNING Observe a maximum towing speed of 5 km/hr and a maxi-
DO NOT tow the lift truck if a load is attached. mum towing distance of 5 km (3 miles).
Use extra caution when moving a lift truck if any of the 3. Use a lifting device to raise the carriage and forks
following conditions exist: approximately 30 cm (12 in.) from the surface. Install a
chain around the mast crossmember and the carriage to
• Brakes do not operate correctly. prevent the carriage and mast channels from moving.
• Steering does not operate correctly. 4. If another lift truck is used to tow the disabled lift truck,
• Tires are damaged. that lift truck must have an equal or larger capacity than the
disabled lift truck. Install an approximate half-capacity load
• Traction conditions are bad. on the forks of the lift truck that is being used to tow the
• The lift truck must be towed on a slope. disabled lift truck. This half-capacity load will increase the
traction of the lift truck. Keep the load as low as possible.
If the engine cannot run, there is no hydraulic pressure
available for the steering system and service brake
141
Maintenance
5. Use a towing link made of steel that fastens to both lift 2. Before removing the counterweight, put blocks
trucks. Connect the towing link to an adequate provision, under the mast assembly so that the lift truck can-
such as a towing pin or lifting eye. not fall forward.
6. After towing is completed, place blocks on both sides The surface must be solid, even, and level when the lift
(front and rear) of all drive and steering tires and re-apply truck is put on blocks. Make sure that any blocks used
the parking brake. to support the lift truck are solid, one-piece units. Put a
steel plate on top of the block.
How to Put a Lift Truck on Blocks
NOTE: Some lift trucks have lifting eyes. These lifting eyes
WARNING can be used to raise the lift truck so that blocks can be
The lift truck must be put on blocks for some types of installed.
maintenance and repair. The removal of the following NOTE: The lifting eyes of the counterweight are for lifting of
assemblies will cause large changes in the center of the counterweight only. Never use the lifting eyes or the
gravity: mast, drive axle, engine and transmission, and counterweight to lift the truck.
the counterweight. When the lift truck is put on blocks,
put additional blocks in the following positions: CAUTION
1. Before removing the mast and drive axle, put Do not place blocks under fuel or hydraulic tanks.
blocks under the counterweight so that the lift
truck cannot fall backward. See Figure 33.
142
Maintenance
1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES
Figure 33. Put a Lift Truck on Blocks
143
Maintenance
How to Raise the Drive Tires 3. Put blocks between the steering axle and the frame. See
Figure 34.
1. Put blocks on each side (front and rear) of the steer tires
to prevent movement of the lift truck. See Figure 33.
2. Put the mast in a vertical position. Put a block under
each outer mast channel.
3. Tilt the mast fully forward until the drive tires are raised
from the surface.
4. Put additional blocks with steel plates under the frame
behind the drive tires.
5. If the hydraulic system will not operate, use a hydraulic
jack under the drive axle. Make sure that the jack has a
capacity equal to at least half the weight of the lift truck.
See the nameplate. 1. FRAME
2. BLOCKS BETWEEN FRAME AND AXLE
How to Raise the Steer Tires 3. SUPPORT BLOCKS
4. STEERING AXLE
1. Apply the parking brake. Put blocks on both sides (front 5. WHEEL
6. AXLE PIVOT POINT
and rear) of the drive tires to prevent movement of the lift
truck. See Figure 33. Figure 34. Steering Axle on Blocks
2. Use a hydraulic jack to raise the steer tires. Make sure
CAUTION
that the jack has a capacity of at least 2/3 of the total
DO NOT put the jack under the counterweight to raise
weight of the lift truck as shown on the nameplate.
the lift truck.
144
Maintenance
4. Place a hydraulic jack under the center of steering axle How to Add Fuel to the Lift Truck
to raise the steering tires. Make sure that the jack has a
capacity of at least 2/3 of the total weight of the lift truck. WARNING
See the Nameplate. Stop the engine. Turn the key switch to OFF. The oper-
5. Put blocks with steel plates under both sides of the ator must be off of the lift truck while fuel is added.
steering axle to support the truck. No smoking.
How to Clean a Lift Truck All fuels for internal combustion engines are very flam-
mable.
CAUTION
Fill the fuel tank only in a designated area with good
Your lift truck may be damaged if water or cleaning
ventilation. Have a fire extinguisher available.
agents come in contact with electrical components. DO
NOT directly spray any electrical components, espe- Never fill the fuel tank near an open flame or near
cially connectors, switches, electro-hydraulic controls, equipment that can create sparks. Never check fuel
battery area, and dash display during the cleaning level or check for leaks with an open flame.
process.
WARNING
Portions of your lift truck may be washed with a non-heated
Breathing fuel vapor may cause nausea, unconscious-
pressure washer. Steam cleaning is not recommended in
ness, or death. Long-term exposure to gasoline vapors
most instances, as condensation may form in electrical
may cause liver or kidney damage and cancer. Avoid
components causing damage or erratic behavior. For
breathing vapor.
cleaning guidelines and components to avoid, see the Peri-
odic Maintenance section of the Service Manual for your
lift truck.
WARNING
When adding fuel, keep the funnel or fuel nozzle in
contact with the metal of the fuel tank to reduce the
145
Maintenance
possibility of static electric sparks. Clean any spilled 1. Clean the surroundings of the DEF cap to prevent debris
fuel. from falling into the tank.
1. Remove the fuel cap. Make sure to fill the tank with the 2. Remove the cap and make sure it does not pick up any
correct fuel for the engine in the lift truck. Clean the fuel dirt.
cap.
3. Insert the DEF nozzle completely into the inlet adapter.
2. Install the fuel cap.
4. Fill the tank until the nozzle automatically shuts off.
How to Add DEF to the Lift Truck 5. Do not depress the nozzle handle again after the initial
shut off.
WARNING
Stop the engine. Turn the key switch to OFF. The oper- 6. Remove the DEF nozzle.
ator must be off the lift truck while DEF is added. 7. Make sure the DEF cap is clean and replace it on the
Fill the DEF tank only in a designated area with good tank.
ventilation. In emergency situations it is possible to fill DEF through a
Contact with DEF causes irritation to skin and eyes. DEF canister instead of using a DEF nozzle. Follow the
Avoid contact with DEF. normal filling procedure while additionally observing follow-
ing warnings and instructions.
Fill the DEF tank with DEF only, using an approved
DEF nozzle. Filling DEF with a container must be limi- WARNING
ted to emergency situations. DEF releases ammonia vapors, which may cause skin
Do not use DEF beyond its expiration date. Do not add and eye irritation. Fill in a well-ventilated area only.
degraded DEF.
146
Maintenance
Protect yourself against contact with DEF fluid. Use 2. Fill only enough DEF to enable reaching the nearest fill
Personal Protective Equipment to include, but not limi- station.
ted to goggles and gloves.
3. Flush any spilled DEF immediately with fresh water. DEF
1. Make sure that the equipment to be used is clean, and promotes corrosion and causes skin irritation.
no pollution enters the tank.
147
Maintenance
Periodic Maintenance Schedule
Figure 35. Filters and Lubrication Points
148
Maintenance
Legend for Figure 35
1. CARRIAGE LOAD ROLLER 10. DEF PUMP AND SUCTION FILTER
2. MAST LOAD ROLLER 11. TIE ROD PINS AND KING PINS
3. LIFT CHAIN 12. STEER WHEEL HUB
4. MAST PIVOT PIN 13. BRAKE COOLING FILTER
5. TILT CYLINDER PIVOT PIN 14. FUEL FILTER
6. DRIVE SHAFT 15. WATER SEPARATOR
7. TRANSMISSION OIL FILTER 16. HYDRAULIC TANK BREATHER
8. CRANKCASE BREATHER 17. HYDRAULIC RETURN FILTER
9. ENGINE OIL FILTER 18. FUEL TANK BREATHER
149
Maintenance
Table 15. Daily Condition Check
Item Procedure
Warning and Safety Labels • Check for presence and readability. For position and replacement, see Parts
Manual.
Frame, Mast, and Carriage • Make sure retaining hardware is tightened and in good condition.
• Check for cracks and deformation. In particular after any collision or when any
unusual noise is heard. Repair as required.
Lift Chains • Check proper lubrication.
• Check condition of link plates and pins. Replace chains as required. See Parts
Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves. Replace as required. See
Parts Manual.
Wheels, Tires and Tire Pressure • Check condition and absence of damage.
• Check pressure as specified on nameplate. Correct or replace as required.
Wheel Nuts on Drive and Steer Wheels • Re-torque 2-5 hours after replacement of a wheel, and 8 hours after a nut could
be turned at re-torqueing. Torque to 380 to 410 N•m (280 to 305 lbf ft).
Fuel, Oil, DEF, or Coolant Leaks • Check for leaks. Repair as required.
150
Maintenance
Table 15. Daily Condition Check (Continued)
Item Procedure
Radiator Assembly • Check that radiator is clean and not obstructed.
• Check radiator, hoses and connections for leakage. Clean and repair as
required.
Engine Compartment • Remove combustible materials.
• Remove all foreign materials.
Windows and Mirrors • Clean windows, wipers and mirrors.
• Adjust and replace as required. See Parts Manual.
151
Maintenance
Table 16. Daily Fluid Level Checks
Item Procedure
Windshield Washer Fluid Level • Check level in reservoir.
• Add fluid as required.
Hydraulic System Oil • Check level indicator with mast fully lowered.
• Add hydraulic oil as required through tank return filter and record added volume
and hour meter reading. Use JDM-J20C.
Engine Oil Level • Maintain level halfway of full range on dipstick when cold. See Table 29 for
required specifications.
152
Maintenance
Table 17. Daily Checks from the Driver Seat with Engine Running
Daily Checks from the Driver Seat with Procedure

Engine Running
Operator Restraint System • Check condition and operation of seat belt, seat rails and steering column
latch. Repair as required.
Horn, Gauges, Lights, Alarms and Control • Visual and audible verification. Repair as required.
System
Fault Codes • The display should be free of fault codes. The central warning light will be
ON when a fault code is shown.
• Switch the engine to OFF when the Engine Stop Warning Light is ON.
• Report any fault code to have the fault diagnosed and repaired.
Engine Air Filter • Replace Main Filter Element when warning light is ON, and record hour
meter reading.
• Also replace the Safety Element at every third time replacement of the
Main Filter Element. See Parts Manual.
Fuel/Water Separator • Drain water/sediment when the warning light is ON.
Coolant Level • Add coolant when warning light is ON, and record added volume and
hour meter reading. For details, see Table 29.
Fuel Level • Avoid low fuel level. Refuel in time. For details, see Table 29.
153
Maintenance
Table 17. Daily Checks from the Driver Seat with Engine Running (Continued)
Daily Checks from the Driver Seat with Procedure

Engine Running
Control Levers, Switches and Pedals • Check operation as described in the Operating Manual. Repair as
required.
Parking and Service Brakes • Check operation. Repair as required.
Steering System • Check operation. Repair as required.
Mast, Carriage and Attachment • Check operation. Repair as required.
Container Handler Control System Signals • Check operation. Repair as required.
Transmission • Check operation. Repair as required.
Operator Presence System • Check operation. Repair as required.
Transmission Oil Level • Check oil level. Add Dexron® III as required.
154
Maintenance
Table 18. First Inspection after First 100 Hours of Operation
Initial 100 Hours Inspection Procedure

Lift Chains • Adjust and lubricate lift chains. Make sure chains are slack during park-
ing.
Transmission Oil Filter • Change 2 filters. See Parts Manual.
Hydraulic Tank Return Filter • Change 2 filters. See Parts Manual.
Brake Cooling Filter • Change filter. See Parts Manual.
155
Maintenance
Table 19. First Inspection After First 250 Hours of Operation
Initial 250 Hours Inspection Procedure

Steer Wheel Hub Bearings • Re-torque bearings to 500 N•m (369 lbf ft).
Oil in Steer Wheel Hub • Change oil. Inspect and clean magnetic plugs. For details, see Table 29.
Drive Axle Hub Bearings. • Re-torque bearings to 650 N•m (479 lbf ft).
Oil in Drive Axle Hub • Change oil. Inspect and clean magnetic plugs. For details, see Table 29.
Oil in Drive Axle Differential • Change oil. Inspect and clean magnetic plugs. For details, see Table 29.
Engine Oil (QSM11 T3- only) • Change engine oil. For details, see Table 29.
Engine Oil Filter (QSM11 T3-only) • Replace filter. See Parts Manual.
156
Maintenance
Table 20. Inspect and Adjust
Inspect and Adjust Procedure

Every 250 Hours
Lift Chains • Check condition and adjustment. Replace as required. See Parts Manual.
Header Hose Assembly • Check condition of hoses, clamps and sheaves.
• Check proper tracking during operation. Replace as required. See Parts
Manual.
Wheels, Tires and Tire Pressure • Check condition.
• Check pressure as specified on nameplate. Correct or replace as required.
See Figure 2 and Wheels and Tires.
Wheel Nuts on Drive and Steer Wheels • Check torque if a wheel was replaced during the past 250 hours. Required
torque is 380 to 410 N•m (280 to 305 lbf ft) .
Fuel, Oil, DEF, or Coolant Leaks • Check for leaks. Repair as required.
Radiator Assembly • Check radiator, hoses and connections for leakage. Clean and repair as
required.
Engine Compartment • Remove combustible materials.
• Remove all foreign materials.
157
Maintenance
Table 20. Inspect and Adjust (Continued)

Hydraulic System Oil • Check level indicator.
• Add hydraulic oil as required through the hydraulic return filter.
• If oil is added, check for leaks, and record added volume and hour meter
reading. For details, see Table 29.
Coolant Level • Inspect level at expansion tank.
• If level is below fill tube, inspect for leaks, repair as required. Record added
volume and hour meter reading. For coolant specification, see Table 29.
Engine Oil Level • Maintain level halfway full range on dipstick when cold. See Table 29.
Fuel Filter/Water Separator • Drain water until clear fuel flows from the filter.
Every 500 Hours
Cab Air Filter • Check and clean element. Replace filter when required. See Parts Manual.
Engine Air Filter • Verify maintenance records to establish if normal air filter replacement is
due. Make sure Tier 3/Stage IIIA air filter sensor performs properly.
• If required, replace the Main Filter Element, clean the inside of the housing
and record filter replacement.
• At every third replacement of the Main Filter Element, also replace the
Safety Filter Element.
158
Maintenance

Automatic Greasing System (Optional) • Check pump and primary/secondary lines for damage and leakage.
• Check grease level in tank and grease level at grease points.
• Check duty Cycle. For more information see the manual Automatic Greas-
ing System 8000SRM2141.
Frame, Mast, and Carriage • Make sure retaining hardware is tightened and in good condition. Re-torque
or replace as required.
• Look for deformations in the material and irregular lines in welds. Repair as
required.
Drive Axle and Differential • Inspect magnetic plugs and oil level.
• If oil is added, check for leaks and record added volume and hour meter
reading.
• Inspect wear parts on plugs, clean plugs and reinstall. For details, see
Table 29.
159
Maintenance

Steer Wheel Hubs • Inspect magnetic plugs and oil level.
• If oil is added, check for leaks and record added volume and hour meter
reading.
• Inspect wear parts on plugs, clean plugs and reinstall. For details, see
Table 29.
Transmission Oil Level • Check oil level and add Dexron® III as required. If oil is added, check for
leaks and record added volume and hour meter reading.
Hydraulic Tank Breather • Inspect restriction indicator. Replace element as required. See Parts Man-
ual.
Every 1, 000 Hours
Transmission Clutch Calibration • Perform clutch calibration at each transmission oil change.
Every 2,500 Hours
Drive Axle Hub Bearings • Re-torque bearings to 650 N•m (479 lbf ft).
Steer Wheel Hub Bearings • Re-torque bearings to 500 N•m (369 lbf ft).
Every 5,000 Hours
Engine Valve Adjustment • Check valve clearance. See engine identification plate for valve adjustment.
160
Maintenance
Table 21. Annual Inspection
Item Procedure
Operator Restraint System • Check condition and operation of seat belt, seat rails and steering column
latch. Repair as required.
Horn, Gauges, Lights, Alarms and Control • Visual and audible verification. Repair as required.
System
Parking Brake and Service Brakes • Check condition and operation. Repair as required.
Operator Presence System • Check operation. Repair as required.
Turbocharger • Inspect for leaks.
• Tighten clamps and mounting nuts.
Warning and Safety Labels • Check for presence and readability. For position and replacement, see
Parts Manual.
Engine Air Intake Piping and Charge Air • Check for air leaks and loose connections. Repair as required.
Piping
Coolant Hoses • Inspect for cracks, cuts, and collapsing. Replace as required.
Engine Drive Belt • Check tension and condition. Replace as required.
Cooling Fan • Check for cracks and damage. Replace fan when required. See Parts Man-
ual.
161
Maintenance
Table 21. Annual Inspection (Continued)
Item Procedure
Coolant Quality • Measure and record acidity and freezing point every 1,000 Hours, but at
least every 6 Months.
• Compare measurement with earlier records and take appropriate action. For
coolant see Table 29.
Brake System Accumulator • Make sure pre-charge pressure is 10.35 ±0.5 MPa (1501 ±73 psi) @ 20 °C
(68 °F). Replace as required. See Parts Manual.
Inching Pedal Sensor Calibration • Check calibration value and adjust as required.
Lift System Accumulator (Optional) • Make sure pre-charge pressure is 10.00 ±0.5 MPa (1450 ±38 psi)@ 20 °C
(68 °F). Correct if required.
Engine and Transmission Mounts • Check isolators and hardware. Replace as necessary. See Parts Manual.
DEF Tank Fill Cap • Check cap sealing and membrane breathing capabilities.
• Rinse off DEF crystals as necessary.
Engine Drive Belt Tensioner and Pulleys • Verify if the bearings for the hubs and pulleys produce more noise during
operation than normal.
• Check tension and belt condition. Repair or replace as required. See Parts
Manual.
162
Maintenance
Table 22. Lubricate
Lubricate Procedure
Every 250 Hours
Lift Chains • Lubricate every 250 Hours, but at least every 3 Months.
• Make sure chains are slack during re-lubrication. Use engine oil SAE
15W-40.
Chain Sheave Bearings • Lubricate 2 fittings. Use multipurpose grease.
Inner Mast Load Rollers • Lubricate 4 fittings. Use multipurpose grease.
Mast Pivot Pins* • Lubricate 2 fittings under no load condition. Use multipurpose grease.
Tilt Cylinder Pivot Pins* • Lubricate 4 fittings. Use multipurpose grease.
Carriage Load Rollers • Lubricate 4 fittings. Use multipurpose grease.
Every 500 Hours
Steering Axle Tie Rod Pins* • Lubricate 4 fittings. Use multipurpose grease.
Steering Axle King Pins* • Lubricate 4 fittings. Use multipurpose grease.
Steering Axle Pivot* • Lubricate 1 fitting. Use multipurpose grease.
Automatic Greasing System (Optional) • Check grease level in tank and grease level at grease points. Refill as
necessary.
• For more information see the manual Automatic Greasing System
8000SRM2141.
163
Maintenance
Table 22. Lubricate (Continued)
Lubricate Procedure
Every 1,000 Hours
Cab Door Hinges • Lubricate 4 fittings. Use multipurpose grease.
Every 2,000 Hours
Drive Shaft • Lubricate 2 fittings. Use multipurpose grease.
NOTE: The items marked with an asterick (*) do not require manual greasing when the truck is equipped with the automatic
greasing system.
164
Maintenance
Table 23. Change
Change Procedure
Every 500 Hours or 6 Months
Engine Oil • Change engine oil. See Table 29.
Engine Oil Filter • Replace filter. See Parts Manual.
Fuel/Water Separator and Fuel Filter • Replace filter. See Parts Manual.
Every 1,000 Hours
Brake Cooling Filter • Replace filter (also replace after major hydraulic system repair). See
Parts Manual.
Transmission Oil • Change transmission oil. For details, see Table 29.
Transmission Oil Filter • Replace filter. See Parts Manual.
Every 2,500 Hours
Crankcase Breather Element (QSL9 ONLY) • Inspect and replace crank case breather element as required. See Parts
Manual.
Oil in Steer Wheel Hubs • Change oil and clean magnetic plugs. For details, see Table 29.
Oil in Drive Axle Differential • Change oil and clean magnetic plugs. For details, see Table 29.
Oil in Drive Axle Hub • Change oil and clean magnetic plugs. For details, see Table 29.
Fuel Tank Breather • Replace tank breather. See Parts Manual.
165
Maintenance
Table 23. Change (Continued)
Change Procedure
Every 3,000 Hours
Hydraulic System Oil • Take oil sample and follow instructions from the laboratory report. For
details, see Table 29 when replacing oil.
Hydraulic Oil Suction Filters • Replace or clean filters at each hydraulic oil change. See Parts Manual.
Hydraulic Tank Return Filters • Replace filter at each hydraulic oil change and replace after major
hydraulic system repair. See Parts Manual.
Every 5,000 Hours
Air Conditioning System • Replace fluids every 5,000 hours but at least every 36 Months.
• Contact certified AC specialist for replacing dryer, lubricant and refriger-
ant. For Dryer, see Parts Manual. For Lubricant, see Compressor
Nameplate. For Refrigerant use 1300 ±50 grams (2.87 ±0.11 lb) of
R134a.
DEF Tank Suction Filter • Replace filter. See Parts Manual.
DEF Pump Filter • Replace filter. See Parts Manual.
Automatic Greasing System Filter • Replace filter in fill coupler every 10 times after the reservoir has been
filled. See Automatic Greasing System 8000SRM2141 for further infor-
mation.
166
Maintenance
Container Attachment Maintenance
Figure 36. Container Attachment Maintenance Points
167
Maintenance
Table 24. Container Attachment Maintenance − Inspect and Adjust
Item No. Item Interval Procedure

Container Attachment 250 hr Check Condition and Operation. Check for
damage, cracks and distortion. Check for
leakage of hydraulic components.
Signals from Container Handler Control Sys- 250 hr Check for correct operation.
tem.
1 Twist Locks (4) 250 hr Check for wear and possible damage of the
twist locks and the twist lock sleeves.
Replace when necessary.
2 Attachment Bearing Pads 500 hr Replace bearing pads if thickness is 18 mm
(0.70 in.) or less. Make sure that retaining
hardware is torqued to 63 N•m (46 lbf ft).
See Figure 36 for Item Nos.
168
Maintenance
Table 25. Container Attachment Maintenance − Lubricate
Item Item Interval Quantity Specification

No.
*5 Hanger rods (ELME 818) 250 hr 12 fittings for Multipurpose grease EP2/3.
MPS,
8 fittings for PPS.
*1 Twist Locks 250 hr 8 fittings Multipurpose grease EP2/3.
Power Pile Slope Cylinders 250 hr 4 fittings Multipurpose grease EP2/3.
* Power Pile Slope Pivot Points 250 hr 10 fittings Multipurpose grease EP2/3.
*3 Slewing and Side Shift Cylinders 500 hr 6 fittings Multipurpose grease EP2/3.
Locking Plate for Stop Cylinder 500 hr 2 plates Multipurpose grease EP2/3.
Bearing Pad Tracks for Extension Beams 500 hr 20 tracks Multipurpose grease EP2/3.
*7 Stop Cylinder (Optional) 500 hr 2 fittings Multipurpose grease EP2/3.
6 Extension Cylinder Support Pad 1000 hr 4 tracks Multipurpose grease EP2/3.
NOTE: The items marked with * do not require manual greasing when the truck is equipped with the Automatic Greasing
System for truck and attachment.
169
Maintenance
Table 26. Container Attachment Maintenance − Replace
Item No. Item Interval Quantity Specification

1 Twist Locks 5000 hr 4 See Parts Manual.
170
Maintenance
Table 27. Approved Fuels and Engine Oils
Emission Legislation WWFC Fuel ASTM Engine Oil Quantity

Tier 4(f)/Stage IV Diesel No. 4 D S15 ACEA E9 22.8 liter (24 qt)
Engines API CJ-4
Tier 3/Stage IIIA Diesel No. 4 D S15 ACEA E7 or E9 34 liter (36 qt)
Engines API CI-4 or CJ-4
Diesel No. 2 D S50 ACEA E7
API CI-4
Non-compliance Diesel No. 1 D S500 ACEA E7 (see notes) 34 liter (36 qt)
API CI-4 (see notes)
NOTE: 1. To comply with emission legislation, sulfur content in the applied diesel fuel must be limited. See column WWFC
Fuel.
NOTE: 2. Sulfur content in diesel fuel determines the required engine oil specification.
NOTE: 3. Maintain engine oil level halfway to the full range on dipstick when cold.
NOTE: 4. When using Diesel No. 1 in countries without emission legislation, the factory-filled CJ-4 engine oil must be
replaced at initial 250 hours by API CI-4 specification oil. API CI-4 engine oil allows 500 hour oil change intervals when
using Diesel No. 1.
NOTE: 5. Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content does not exceed 5 per-
cent of total volume.
NOTE: 6. Diesel No. 1 is not allowed in countries with Tier 3/Stage IIIA or more stringent emission legislation.
171
Maintenance
Temperature Range Engine Oil Viscosity

−15 °C (5 °F) and above 15W-40
−20 °C (−4 °F) to 20 °C (68 °F) 10W-30
Below 0 °C (32 °F) 0W-30
NOTE: Ambient temperatures determine the viscosity of the oil to be selected.
Diesel Exhaust Fluid
AUS32
Equal to DIN 70070 and ISO 22241.
Tank Capacity: 57 liter (15 gal).
172
Maintenance
Maintenance Procedures Every 8 Hours or Daily

How to Make Checks With the Engine Check that all safety labels are installed in the correct loca-
Stopped tions on the lift truck. See the Parts Manual for the correct
location of the safety labels.
WARNING If new labels must be installed, use the following proce-
Do not operate a lift truck that needs repairs. Report dures:
the need for repairs immediately. If repair is necessary,
put a DO NOT OPERATE tag in the operator's area. WARNING
Remove the key from the key switch. Cleaning solvents can be flammable and toxic and can
cause skin irritation. When using cleaning solvents,
Put the lift truck on a level surface. Lower the carriage and
always follow the recommendations of the manufac-
forks, stop the engine, and apply the parking brake. Open
turer.
the hood and check for leaks and conditions that are not
normal. Clean any oil or fuel spills. Verify all surfaces are 1. Verify the surface is dry and has no oil or grease. Do not
free of oils, lubricants, fuel, and organic dust or fibers use solvent on new paint. Clean the surface of old paint
(paper, wood, cotton, wool, agricultural grass/grain, etc.). with a cleaning solvent.
Warning and Safety Labels 2. Remove the paper from the back of the label. Do not
touch the adhesive surface.
WARNING 3. Carefully hold the label in the correct position above the
Safety labels are installed on the lift truck to give infor- surface. The label cannot be moved after it touches the
mation about operation and possible hazards. It is surface. Put the label on the surface. Make sure that all air
important that all safety labels are installed on the lift is removed from under the label and the corners and edges
truck and can be read. are tight.
173
Maintenance
Mast, Carriage, and Attachments 4. Replace any damaged or broken parts that are used to
keep forks locked in position.
WARNING 5. Check that the lift chains are correctly lubricated. Use
Never work under a raised carriage, forks, or mast SAE 15W-40 oil to lubricate the lift chains.
channel. Lower the carriage or use blocks and chains
on the mast weldments and carriage so they cannot 6. If lift truck is equipped with a sideshift carriage or attach-
move. Verify the moving parts are attached to a part ment, inspect parts for cracks and wear. Verify parts that
that does not move. fasten sideshift carriage or attachment to carriage are in
good condition.
Do not try to correct the alignment of the fork tips by
bending the forks or adding shims. Replace damaged 7. Inspect lift chains for cracks or broken links and pins.
forks. See Figure 37.
Never repair damaged forks by heating or welding. 8. Inspect chain anchors and pins for cracks and damage.
Forks are made of special steel using special proce- 9. Verify the lift chains are adjusted so that they have equal
dures. Replace damaged forks. tension. Adjustment or repair of the lift chains must be
1. Inspect welds on mast, carriage, and frame for cracks. done by authorized personnel.
Verify that the nuts and bolts are tight.
2. Inspect channels for wear in areas where rollers travel.
Inspect rollers for wear or damage.
3. Inspect forks for cracks and wear. Check that the fork
tips are aligned within 3% of fork length. Check that bottom
of the fork is not worn.
174
Maintenance
2. Check for hose slippage and proper hose tension. Check
proper functioning of hose tensioning device.
3. Check hoses and fittings for hydraulic leaks.
4. Check the hose covers for cuts, cracks, or exposed rein-
forcement.
5. Check the clamps/sheaves for defective or broken parts.
6. Adjust, repair, or replace hoses and/or components as
necessary.
Fuel, Oil, or Coolant Leaks
WARNING
1. WORN PIN 5. LOOSE LEAVES All fuels are very flammable and can burn or cause an
2. CRACKS 6. DAMAGED PIN explosion. Do not use an open flame to check the fuel
3. EDGE WEAR 7. RUST level or to check for leaks in the fuel system. If there is
4. HOLE WEAR
a leak in the fuel system, extra care must be used dur-
ing the repair. Do not operate the lift truck until the
Figure 37. Lift Chains Check
leak is repaired.
Header Hose Assembly Make a visual check for leaks on and under the lift truck. If
1. Check if hoses are kinked, crushed, flattened, twisted, possible, find and repair the leak at the source. Leaks often
hard, or charred. indicate a need for repair of damaged or worn components.
175
Maintenance
Check the fuel system for leaks and the condition of parts. Windshield Washer Fluid
When fuel is added to the lift truck, see the section How to
Make Checks With the Engine Running. The reservoir is located at the left rear corner of the opera-
tor's cab. Check the level in the reservoir through the three
Also, check the condition of the radiator and heater hoses. holes in the operator's cab frame. Add fluid, if needed, by
Soft or cracked hoses need to be replaced before a leak using the fill opening located outside the operator's cab.
occurs.
Hydraulic System Oil
Radiator Sections for Engine Coolant, Charge
Air Cooler, Transmission and Hydraulic Oil WARNING
At operating temperature, the hydraulic oil is HOT. Do
WARNING not permit the oil to contact the skin and cause a burn.
Compressed air can move particles so that they cause
injury to the user or to other personnel. Make sure that CAUTION
the path of the compressed air is away from all person- Do not permit dirt to enter the hydraulic system when
nel. Wear protective goggles or a face shield to prevent the oil level is checked or the filter is changed. Never
injury to the eyes. operate the hydraulic pumps without oil in the
Clean the radiator with compressed air or water as needed. hydraulic system. The operation of the hydraulic
Be careful not to bend the radiator fins. pumps without oil will damage the pumps.
Inspect the radiator sections for leakage, loose hose Only use the oil specified in the Table 28.
clamps, hose connections, and fin damage.
CAUTION
Replace damaged sections and hoses. Tighten the clamps. Additives in the hydraulic system oil may damage the
hydraulic system. Before using additives, contact your
local HYSTER dealer.
176
Maintenance
Check the hydraulic oil level when the carriage is lowered hydraulic oil level is in the yellow area when oil is cold,
and the engine is stopped. See Figure 38. Add hydraulic there is a risk that during operation hydraulic oil will leak
oil only as needed. from the breather.
Hydraulic oil level is correct when it is in the green area. Check the hydraulic system for leaks and damaged or
Add hydraulic oil if the oil level is in the red area. When loose components.
177
Maintenance
1. HYDRAULIC RETURN FILTERS
2. BREATHERS
3. COVER
4. LEVEL INDICATOR
5. INSPECTION COVER
6. SUCTION FILTERS
7. HYDRAULIC TANK
Figure 38. Hydraulic Tank
178
Maintenance
Engine Oil After the engine has stopped, wait one minute before
checking the oil level. Keep the oil at the correct level as
WARNING indicated on the dipstick. See Figure 39 and Figure 40.
Long term exposure to used engine oil can cause skin Use the correct oil as shown in the Table 28.
irritation or cancer. Use caution when checking or add-
ing oil to the engine. If oil comes in contact with skin,
wash with detergent and water.
179
Maintenance
A. LEFTHAND VIEW B. RIGHTHAND VIEW

1. OIL DIPSTICK 5. COOLANT FILTER
2. ENGINE OIL FILL CAP 6. ENGINE OIL DRAIN PLUG
3. FUEL FILTER 7. ELECTRONIC CONTROL MODULE (ECM)
4. OIL FILTER 8. ALTERNATIVE ENGINE OIL FILL
Figure 39. Engine Maintenance Points Tier 3
180
Maintenance
A. LEFTHAND VIEW B. RIGHTHAND VIEW

1. OIL DIPSTICK 4. OIL FILTER
2. ENGINE OIL FILL CAP 5. EXHAUST GAS RECIRCULATION VALVE (EGR)
3. FUEL FILTER 6. ENGINE OIL DRAIN PLUGS
Figure 40. Engine Maintenance Points Tier 4
181
Maintenance
How to Make Checks With Engine Running • Follow the inspection and maintenance schedule
and procedures in this manual. Do not alter exhaust,
WARNING ignition, or fuel systems.
Exhaust from internal combustion engines contains FASTEN YOUR SEAT BELT! The seat belt is installed
carbon monoxide and other harmful chemicals. Carbon to help the operator stay on the truck if the lift truck
monoxide is a colorless, odorless poison and can tips over. IT CAN ONLY HELP IF IT IS FASTENED.
cause unconsciousness or death without warning.
Long term exposure to exhaust or chemicals in the Verify that the area around the lift truck is clear before
exhaust can cause cancer, birth defects, and other starting the engine or making any operational checks. Be
reproductive harm. Avoid exposure to engine exhaust: careful when making the checks. If the lift truck is station-
ary during a check, apply the parking brake and put the
• Do not use diesel engines indoors where soot can transmission in NEUTRAL. Make the checks carefully.
accumulate.
• If engines are operated in confined spaces, maintain
adequate ventilation or vent exhaust to the outside.
Do not exceed applicable air contaminant limits.
182
Maintenance
Seat Belt, Seat Rails, and Steering Column

The seat belt, seat, and mounting are all part of the opera-
tor restraint system. Each item must be checked to make
sure it is attached securely, functions correctly, and is in
good condition. See Figure 41.
Verify the seat rails are not loose. The seat rails must lock
securely in position, but move freely when unlocked. The
seat rails must be securely attached to the mounting sur-
face.
The end of the seat belt must fasten correctly in the latch.
Verify the seat belt pulls from the retractor assembly and
retracts smoothly. The seat belt must be in good condition.
A seat belt that is damaged or torn will not give protection
when it is needed. If the seat belt cannot be pulled from the
retractor assembly, replace the seat belt assembly.
1. SEAT BELT RETRACTOR
2. SEAT BELT LATCH
3. SEAT RAIL
Figure 41. Safety Belt and Seat Rails
183
Maintenance
Steering Column Latch Fault Codes
Verify the latch for the steering column operates correctly. If the engine, transmission or hydraulic controller detects a
The latch must NOT allow the column to move unless the fault, the hourmeter/fault code display will show a fault
latch is released. code instead of the engine hours. The instrument cluster
Gauges, Lights, Horn, Fuses, and Relays logs the fault code. If a fault appears, report the fault imme-
diately. DO NOT operate the lift truck until the fault is cor-
Start the engine. Check the gauges and lights for correct rected. The central warning lights will be illuminated when
operation. See Table 7, Figure 9, and Table 4. Check the there is a fault condition. When all faults have been cleared
operation of the horn, the reverse warning alarm and the or repaired, the hourmeter/fault code display will show
optional forward alarm. The fuse panel is located behind engine running hours again.
the door at the left side of the instrument panel. The relays
See Cummins Engine Fault Code Guide for engine fault
are located left of the fuse panel. See Figure 51 and Fig-
codes.
ure 52.
See APC312 Fault Code Guide for transmission fault
Main Fuses
codes.
Fuses and relays for controllers and for the engine are
See Hydraulic Control System for hydraulic system fault
located in the battery compartment. See Figure 53 .
codes.
Windows and Mirrors
Engine Air Filter
Make sure the windows of the cab are clean, and the win-
dow wipers operate correctly. Have the mirrors correctly CAUTION
adjusted. If the air filter container is not cleaned during mainte-
nance or replacement of the air filter, dirt will gradually
build up in the filter housing. This may cause the filter
184
Maintenance
unit to function incorrectly. If the filter element has the system is hot, the steam and boiling coolant can
been forced into place, the filter housing can crack cause burns.
over time, allowing dirt to enter into and damage the
engine. CAUTION
DO NOT operate the engine when the coolant tempera-
The air filter canister should not be opened until an air filter
ture gauge needle is in the red area. Engine damage
element replacement is required.
can occur.
Replace the main filter element when the air flow restriction
indicator light on the instrument panel illuminates. CAUTION
Additives in the coolant may damage the cooling sys-
Open the clamps on the air filter cover and remove the
tem. Before using additives, contact your local Hyster
cover and filter elements as necessary.
dealer.
The safety element should only be changed every third
Add coolant when the Coolant Level Warning Light is ON.
time the main element is replaced.
Before opening the radiator cap, wait until the cooling sys-
Clean the inside of the canister when changing filters. tem has cooled down. If coolant must be added, use the
coolant specified in the Maintenance Schedule. DO NOT
Replace the elements and re-clamp the filter cover.
mix coolants. Add coolant until coolant level just touches
Coolant Level the tube in the filler neck of the overflow tank. Report the
date and quantity of coolant that has been added. Check
WARNING the cooling system for leaks if more than 1 liter (33.8 oz)
DO NOT remove the radiator cap when the engine is must be added per 3000 running hours.
hot. When the radiator cap is removed from the expan- Use the coolant specified in the Maintenance Schedule.
sion tank, the pressure is released from the system. If DO NOT mix coolants.
185
Maintenance
High Pressure Brake Cooling Filter 3. Use a wrench to loosen the bowl that holds the filter car-
tridge. See Figure 42.
Replace the high pressure hydraulic filter when the warning
light is ON. 4. Remove and replace the filter cartridge and reinstall the
bowl. Torque to 20 N•m (177.02 lbf in).
1. Lower the mast, shut down the engine, and apply the
parking brake.
2. Apply the brake pedal a minimum of ten times to relieve
the hydraulic pressure.
186
Maintenance
1. BRAKE FILTER ELEMENT 3. PRESSURE SENDER

2. FILTER ADAPTOR
Figure 42. Brake Filter
187
Maintenance
Fuel Level pulled. The parking brake must release when the knob is
pushed.
Read the Fuel Level Gauge regularly. Avoid low fuel level
and running out of fuel. Refuel in time. See How to Add The parking brake applies automatically 10 - 30 seconds
Fuel to the Lift Truck for procedure. after the operator has left the seat and when the key switch
is in the OFF position.
DEF Level
Service Brakes
Read the DEF Level Gauge regularly. Avoid low DEF level.
The engine will de-rate when the DEF tank is empty. Refill Check the operation of the service brakes. The service
in time. See How to Add DEF to the Lift Truck for proce- brakes must apply when the service brake pedal or the
dure. declutch/brake pedal is depressed.
NOTE: Slightly pushing the declutch/brake pedal will apply
Control Levers and Pedals
the service brakes. Further pushing will fully disengage the
Check that the control levers for the transmission, mast, transmission.
attachment, and the pedals operate as described in the
Operating Manual.
Steering System
Parking Brake WARNING

The lift truck has hydraulic power steering. Steering is
NOTE: The parking brake, when in good condition and cor-
not possible when the engine is not running.
rectly adjusted, will hold a lift truck with a capacity load on
a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft in Verify the steering system operates smoothly and gives
10 ft)]. good steering control.
Check the operation of the parking brake. The parking
brake must apply when the knob for the parking brake is
188
Maintenance
Mast, Carriage, and Attachment • Slowly raise and lower the mast several times without a
load. Raise the mast to its full extension height at least
WARNING once. The mast components must raise and lower
Lower the lift mechanism completely. NEVER allow smoothly in the correct sequence.
anyone under a raised carriage. DO NOT put any part • The inner weldment and the carriage must lower com-
of your body in or through the lift mechanism unless pletely.
all parts of the mast are completely lowered and the
engine is STOPPED. • Raise the mast 1 m (3 ft) with a capacity load. The inner
weldment and the carriage must raise smoothly. Lower
If the mast cannot be lowered, use chains on the mast the mast. All moving components must lower smoothly.
weldments and carriage so that they cannot move.
Make sure the moving parts are attached to a part that Check that the controls for the attachment operate the
does not move. See the procedures at the end of this functions of the attachment correctly as described in this
section. Operating Manual. See the symbols by each of the con-
trols. Make sure all of the hydraulic lines are connected
DO NOT try to locate hydraulic leaks by putting hands correctly and do not leak.
on pressurized hydraulic components. Hydraulic oil
can be injected into the body by pressure. Signals from the Container Handler Control
NOTE: Some parts of the mast move at different speeds
System
during raising and lowering. Check that the control lights on the attachment and on the
Perform the following checks and inspections: Display work correctly for the positions: seated, locked and
unlocked.
• Check for leaks in the hydraulic system. Check the con-
dition of the hydraulic hoses and tubes.
189
Maintenance
Transmission • To reset the OPS for the hydraulic functions, the opera-
tor must be seated.
Inspect for leaks and the condition of all hoses and external
components of the transmission. Make sure the transmis- • To reset the OPS for the transmission, the operator
sion is shifting smoothly. If a problem is present, report the must be seated and re-engage the transmission.
problem immediately. Do not operate the lift truck until the To re-engage the transmission the operator must either:
problem is corrected.
• Depress the inching brake pedal more then 75%.
Operator Presence System
• Move the gear selector into the NEUTRAL position or
NOTE: The Operator Presence System (OPS) is designed and then move the gear selector into travel mode.
to function after a slight delay (2.5 sec.) to allow the opera- • Make a direction change using the MONOTROL® pedal.
tor to reposition himself without disengaging the transmis-
sion. Transmission Oil
The OPS feature has an electrical switch in the seat, which NOTE: Check with transmission hot.
senses the presence of the operator. When the operator is
in the seat, the transmission can be engaged and hydraulic CAUTION
functions can be operated. When the operator is absent, DO NOT operate the engine when the gauge needle is
the transmission will disengage and hydraulic lift, lower, in the red area.
and tilt functions cannot be operated.
There is an oil temperature warning light, oil temperature
In order to check operation of the OPS, you must raise gauge, and an oil pressure gauge for the transmission. The
yourself from the seat for more than 2.5 sec. to make sure red light is ON when the key switch is in the START posi-
that the system will disengage the transmission and the tion and must go OFF when the engine is running. During
hydraulic functions with the absence of the operator. normal operation, the needle of the temperature gauge will
190
Maintenance
be in the green area, the needle of the pressure gauge will Remove all of the air from the tires before the tires are
be approximately in the middle of the scale. removed from the lift truck.
Apply the parking brake. Check the oil level in the transmis- If the air pressure is less than 80% of the correct air
sion when the engine is running at idle speed and the pressure, the tire must be removed before air is added.
range selector lever is in the NEUTRAL position. The dip- Follow the procedures described in the section:
stick and fill tube is on the left-hand side of the engine. Use Remove Wheels from Lift Truck and the section: Add-
the correct oil as shown in the Table 28. Keep the oil level ing Air Pressure to Tires.
at the "FULL" mark on the dipstick.
Always use a tire inflator with a clip-on chuck when
Attachments deflating or adjusting the tire pressure. The tire inflator
must be equipped with a pressure gauge and a hose of
Check that the control levers for the attachment operate as at least 3 m (10 ft) in length. During deflation or when
described in Table 4. See symbols by each of the controls. adjusting the tire pressure, the technician must not
Verify all of the hydraulic lines are connected correctly and stand in-line with the axis of the wheel. See Figure 43.
do not leak.
Adjusting tire pressure is allowed only if residual air
Wheels and Tires pressure exceeds 80% of the pressure as indicated on
the nameplate.
Wheels, Tires and Tire Pressure
If the tire is removed from the truck and flat on the
WARNING ground, the technician should not have any body part
within the diameter of the tire when adjusting the tire
Air pressure in pneumatic tires can cause tire and
pressure. See Figure 44.
wheel parts to explode. The explosion of wheel parts
can cause serious injury or death. Wheels can explode and cause injury or death if the
above procedures are not followed.
191
Maintenance
1. HOSE LONG ENOUGH FOR USER TO STAND OUTSIDE

POTENTIAL TRAJECTORY OF EXPLOSION
Figure 44. Adjusting Tire Pressure Position

1. ACCURATE IN-LINE PRESSURE GAUGE
Figure 43. Adjusting and Deflating Position
192
Maintenance
Daily and Every 250 Hours
Keep the tires at the correct air pressure as specified on
the lift truck name plate. Using a tire pressure gauge,
check the tire pressure when the tires are at ambient tem-
perature. If it is necessary to add air to a tire that is warm,
check one of the other tires on the same axle and add air
to the tire that has lowest pressure so that the air pressures
are equal. The air pressure of warm tires must always be
equal to or greater than the specification for air pressure for
cold tires.
Check the tires for damage. See Figure 45. Inspect the
tread and remove any objects that will cause damage.
Check for bent or damaged rims. Check for loose or miss- 1. CHECK TIRE PRESSURE
2. CHECK FOR DAMAGE
ing parts. Remove any wire, straps, or other material wrap-
ped around the axle. Figure 45. Tire Check
193
Maintenance
Remove Wheels from Lift Truck blockage causing a flow restriction. For dual tires, remove
air pressure from both tires using the described procedure
WARNING before loosening the wheel nuts.
Lift truck wheels are very heavy, use caution when 3. Remove the wheel nuts and remove the wheel from the
removing wheels or personal injury may occur. lift truck. Be careful NOT to damage the studs when remov-
1. Raise the lift truck as described in How to Put a Lift ing the wheels.
Truck on Blocks in this manual. 4. Use a tire jack to remove the wheel assembly.
2. Attach a tire inflator as described above. Note tire pres- Remove Tire from Wheel
sure. After air is drained from tire, check the tire pressure
to ensure there is no residual pressure. Remove chuck. NOTE: This series of lift trucks uses one type of side flange
Remove the tire stem valve core. Push a wire through the locking, which is used for both 25 and 33 inch pneumatic
valve stem to make sure that the stem does not have a tires. See Figure 46 and Figure 47.
194
Maintenance
Figure 46. Wheel Arrangement
195
Maintenance
A. STEER WHEEL B. DRIVE WHEEL
1. TIRE 8. FLANGE SEAT
2. WHEEL NUT 9. LOCK RING
3. RIM CLAMP 10. O-RING
4. WHEEL HUB 11. 28° BEVEL
5. WEDGE BAND 12. WHEEL RIM
6. SPACER 13. KINGPIN
7. SIDE FLANGE
196
Maintenance
WARNING
Completely remove the air pressure from the tire
before it is removed from the lift truck. If dual wheels
are installed, remove the air from both tires. Air pres-
sure in the tires can cause the tire and rim to explode
causing serious injury or death.
WARNING
Keep tire tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
serious injury.
1. Use a press to loosen the tire from the side flange. On
25 inch rims remove the driver key when installed. Remove
the lock ring.
1. DRIVER KEY
2. FLANGE SEAT
3. RIM
Figure 47. Driver Key (for 25 inch rims)
197
Maintenance
2. Push the flange seat together with the side flange down- Install Tire on Wheel
ward and remove the seal ring.
NOTE: This series of lift trucks uses one type of side flange
locking, which is used for both 25 and 33 inch pneumatic
tires. See Figure 47.
WARNING
The type of tire and the tire pressure (pneumatic tires)
are shown on the Nameplate. Make sure the Nameplate
is correct for the type of tires on the lift truck. If the
truck is equipped with bias-ply tires, the ply rating lis-
ted on the Nameplate is the minimum ply rating that
3. Remove the side flange and flange seat. must be installed. Tires with ply ratings greater than or
4. Loosen the tire from the other side of the wheel rim. equal to the Nameplate listed ply rating may be accept-
Remove the rim from the tire. able. Check with your Hyster dealer whether a specific
bias-ply tire is approved for use on Hyster trucks.
WARNING
Not all makes of radial tires have sufficient sidewall
strength for successful use on forklift trucks. This can
affect stability and ride quality. Check with your Hyster
dealer whether a specific radial tire is approved for use
on Hyster trucks.
198
Maintenance
• DO NOT mix types of tires, type of tire tread, or
WARNING
wheel assemblies of different manufacturers on any
Wheels can explode and cause injury or death if the
one lift truck.
following procedures are not followed:
• Check with your dealer whether a specific tire is
• Clean and inspect all parts of the wheel before
approved for use on this truck.
installing the tire.
Do not use a steel hammer on the wheel. Use a rubber,
• Inspect all wheel components for deformation, cor-
lead, plastic, or brass hammer to put parts together.
rosion and fractures.
Make sure that the lock ring is in the correct position.
• Look for fractures at the contact area between tire The ends of the lock ring must not touch. The clear-
and wheel parts in particular. ance at the ends of the lock ring will be approximately
8 to 15 mm (0.3 to 0.6 in.) after it is installed. If the
• Unacceptable deformation includes progressed
clearance is wrong, the wrong part has been used.
wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the CAUTION
above defects, and replace by new ones. Too much lubricant can cause the tire to slide and
move around the wheel rim.
• DO NOT use any damaged or repaired wheel parts.
1. Clean and inspect all parts of the wheel. Paint any parts
• Make sure that all parts of the wheel are the correct
that have rust or corrosion.
parts for that wheel assembly.
• DO NOT mix parts between different types or manu- WARNING
facturers of wheels. Do not lubricate the tire bead with antifreeze or petro-
leum based liquid. Vapors from these liquids can
cause an explosion during inflation or use.
199
Maintenance
2. Make sure the rim is the correct size for the tire. Lubri-
cate the part of the wheel that contacts the bead and flap.
3. Put the rim on blocks, install the side flange. Make sure
the side flange is engaged with the rim.
5. Install the flange seat and the side flange.

6. For 25 inch rims, align the brackets for the driver key on
the rim and the flange seat. See Figure 47.
4. Install the valve stem in the rim. Install the tire on the
rim.
7. Push the flange seat down for access to the groove for
the seal ring. Install the seal ring.
200
Maintenance
Adding Air Pressure to Tires
WARNING
Add air pressure to the tires only in a safety cage.
Inflating or adjusting tire pressure outside of a cage is
allowed only if residual air pressure exceeds 80% of
the pressure as indicated on the nameplate.
8. Install the lock ring. Make sure all parts are correctly
aligned. When correctly installed, there will be a 8 to Inspect the safety cage for damage before use.
15 mm (0.3 to 0.6 in.) clearance between the ends of the Always use a tire inflator with a clip-on chuck when
lock ring. inflating or adjusting the tire pressure. The tire inflator
9. For 25 inch rims, install the driver key in the lug. must be equipped with a pressure gauge and a hose of
at least 3 m (10 ft) in length. During inflation the techni-
cian must stand away from the safety cage. See Fig-
ure 48.
Do not use a hammer to try and correct the position of
the side flange or lock ring when the tire has air pres-
sure greater than 20 kPa (3 psi).
WARNING
Wheels can explode and cause injury or death if the
10. Add air pressure to the tire in a safety cage. See Add- above procedures are not followed.
ing Air Pressure to Tires.
201
Maintenance
3. Check that all wheel parts are correctly installed. Hit the
side ring and/or lock ring lightly to make sure that it is in the
seat.
4. If installation is correct, add air pressure to the tire. The
correct pressure is shown on the Nameplate.
5. Check that all wheel parts are correctly installed. If
installation is not correct, remove all of the air pressure
from the tire. Remove the valve core to make sure all of the
air pressure has been removed and make adjustments.
The clearance at the ends of the lock ring will be 8 to
15 mm (0.3 to 0.6 in.) when the tire has the correct air
pressure.
Install Wheels on Lift Truck
Match the wheels on dual assemblies. The maximum diam-
eter variation for dual wheels is 13 mm (0.5 in.) when infla-
ted to the correct pressure.
1. QUICK-RELEASE COUPLING Exceeding the maximum diameter variation causes over-
Figure 48. Adding Air Pressure to the Tire Position loading and fast wear of the bigger tire.
1. Put the tire in a safety cage. See Figure 48. Use a tire jack to align and install the wheel(s) on the hub.
2. Add 20 kPa (3 psi) of air pressure to the tire.
202
Maintenance
Drive Wheels
1. Make sure that rim and hub are free from damage and
dirt, in particular at the 28° mounting bevel.
2. Align the valve stem with the wheel hub and use a lifting
device to install and keep the inner wheel centered on the
hub.
3. Install the valve extension tube and the spacer.
4. Use a lifting device to install and keep the outer wheel
centered on the hub. Tie the valve extensions together with
a strap.
5. Install the wedge band, the rim clamps and the wheel
nuts.
6. Tighten all wheel nuts to 35 N•m (26 lbf ft) in the
sequence shown on Figure 49 or Figure 50.
7. Tighten all wheel nuts to 100 N•m (74 lbf ft) in the A. INITIAL TORQUE VALUE
sequence shown on Figure 49 or Figure 50. B. RE-TORQUE VALUE
8. Make sure the wheel is correctly aligned and tighten the Figure 49. Wheel Nut Tightening Sequence Drive and
nuts in the correct sequence to the initial torque value Steer Wheel With Single Clamps or Clamp Ring
shown in Figure 49 or Figure 50.
9. Remove the lifting devices.
203
Maintenance
Steer Wheels
1. Make sure that rim and hub are free from damage and
dirt, in particular at the 28° mounting bevel.
2. Align the valve stem with the wheel hub and use a lifting
device to install and keep the wheel centered on the hub.
3. Install the clamp ring or the 28 rim clamps and the wheel
nuts.
6. Make sure the wheel is correctly aligned and tighten the
nuts in the correct sequence to 380 to 410 N•m (280 to
305 lbf ft) shown on Figure 49 or Figure 50.
A. INITIAL TORQUE VALUE 7. Remove the lifting device.
B. RE-TORQUE VALUE
Wheel Nuts on Drive and Steer Wheels
Figure 50. Wheel Nut Tightening Sequence Drive Wheel
with Dual Clamps CAUTION
Too little torque of the wheel nuts can cause the wheel
to slip on the hub and cause damage. Too much nut
torque can damage studs, spacer bands and wheels.
204
Maintenance
Check all wheel nuts after 2 to 5 hours of operation after a best protection, operate your internal combustion engine lift
wheel has been removed and installed. truck for a short period each month.
Apply the sequence and the re-torque value as shown in The following storage procedures are for conditions and
Figure 49 or Figure 50. temperatures above 0 °C (32 °F). Adjust these procedures
for local conditions and any changes in conditions during
If a wheel nut can be turned when checking wheel nut tor-
storage. The preparations necessary for storage are also
que, then check wheel nut torque again after further 8
determined from the following conditions:
hours of operation.
• Short-term storage is from one to six months. Long-term
Do a final torque check 250 hours after installation of the
storage is over six months.
wheel.
• Storage Location. A lift truck stored indoors will not
How to Put Internal Combustion Engine (ICE) require as much external protection as a lift truck stored
Trucks in Storage outdoors.
It is important to store your lift truck properly to protect it. Short-Term Storage
The main areas of concern are engines, hydraulic compo-
nents, and truck batteries. The length of storage time and Perform the following steps to prepare your lift truck for
the storage location determines what procedures you storage from one to six months:
should follow. 1. Change engine oil. Check lubricant and fluid levels.
Before placing any lift truck in storage, you must choose an Completely fill the fuel tank. Make sure the coolant mixture
area that is clean, dry, and free from airborne contami- will protect cooling system and engine to lowest tempera-
nates. For safety and increased usable floor area, remove ture expected during storage. Make sure all caps and dip-
the forks and tag them with the lift truck serial number. For sticks are installed correctly.
205
Maintenance
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. 3. Remove the battery or batteries from the lift truck. Store
6. Disconnect the battery cables from the battery Apply a the battery or batteries in an approved space. Be sure to
protective coating to the cable connectors and battery ter- follow local regulations. Batteries that are stored for long
minals to prevent corrosion. periods can become damaged. Either keep batteries in
service or follow the battery storage procedures below.
7. Check the tire pressure, if applicable. Make sure the
tires have the correct pressure (see the Nameplate). 4. Spray exterior surfaces and frame with preservative
coating.
8. Clean the lift truck and engine compartment to prevent
corrosion. While the Lift Truck is in Storage
Each month make a visual inspection for leaks or signs of
deterioration. Take corrective action immediately. Check
206
Maintenance
the fluid level in engine, radiator, hydraulic tank, and brake Inspect battery voltage at least once per month and main-
master cylinder. tain battery voltage above 12.50 volts. A discharged battery
with a specific gravity of 1.000 will freeze at −7.8 °C
NOTE: DO NOT shut down an engine before it reaches
(18 °F). A fully-charged battery with a specific gravity of
operating temperature.
1.280 will freeze at −66 °C (86.8 °F).
Each month set the park brake, start engine, and run until
The following procedure can be followed when placing a
normal operating temperature is reached. This will coat the
battery in storage or when not in operation for more than
internal engine components with a film of oil and rid the
30 days.
engine of built-up condensation.
1. Give an equalizing charge prior to placing new batteries
Each month all hydraulic cylinders must be cycled several
in storage. Used batteries are to be fully charged, then
times to keep the seals active and to coat the interior walls
allowed to balance for approximately three more hours.
with oil. Actuate each cylinder, in both directions, until it
reaches the stops. 2. Clean the battery. Clean with a solution of 100 grams
(3.5 oz) of sodium bicarbonate (baking soda) per 1 liter
Return lift truck to its storage state for another month.
(0.25 gal) of water.
How to Put Batteries in Storage 3. Store in a cool, dry location.
Batteries are to be placed on a wooden pallet and stored in 4. Maintain battery voltage above 12.50 volts.
a dry, moderately cool area.
5. Protect batteries from ambient contamination.
Lead acid batteries will slowly "self-discharge" over a
period of time due to their chemical makeup. Damage to Putting a Stored Lift Truck Back Into Service
the battery will occur when battery voltage drops below
1. Remove all tape, covers, and preservation materials.
12.0 volts.
207
Maintenance
2. Check the lift truck for damage and missing components. rear will swing toward the edge. This can cause the lift
Repair damage and/or replace missing components. truck to fall off the dock.
NOTE: If the lift truck has been stored longer than one
WARNING
year, all lubricants and fluids must be drained and
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO NOT
replaced, or perform oil analysis to determine condition of
JUMP OFF! HOLD FIRMLY TO STEERING WHEEL,
lubricant and replace, if necessary. See the Periodic Main-
BRACE YOUR FEET, AND LEAN FORWARD AND
tenance section of your Service Manual for the proce-
AWAY FROM THE POINT OF IMPACT.
dures.
Before the lift truck is moved on transport, check the selec-
3. Clean the battery cables and terminals. Check the bat-
ted route to make sure there is enough clearance for the lift
tery voltage. If the voltage is not correct, charge battery.
truck as loaded on the transport vehicle. Bridges, over-
Connect battery cables to battery.
passes, power lines, and natural barriers can prevent clear-
4. When a lift truck is to be put into service after storage, it ance. Removal of the mast can be necessary.
must be given the 500-hour inspection shown in the Rec-
If a trailer is the method of transportation, use blocks in
ommended Schedule of Maintenance.
front and back of the trailer tires to prevent movement of
How to Move a Lift Truck on a Transport the trailer when the lift truck is loaded and unloaded. If a
loading ramp is used, make sure that the ramp is the cor-
WARNING rect design and capacity.
Stay a safe distance from the edge of docks, ramps, A crane can only be used to load or unload the lift truck if
platforms, and other similar working surfaces. Watch the lift truck is equipped with lifting eyes. Otherwise, the lift
the "tail swing". Remember when traveling in the for- truck must be driven on or off the transport.
ward direction and the steering wheel is turned to
move the lift truck away from the edge of the dock, the
208
Maintenance
Loading 2. If the mast is mounted on the lift truck, fully lower the
forks or carriage. Tilt the mast FORWARD until the tips of
WARNING the forks touch the surface.
The straps or chains used to fasten the lift truck to the 3. Put the direction control lever for the powershift trans-
transport must be directly connected to the lift truck mission in NEUTRAL (N).
frame or to a component (drive axle, tow pin) that is
solidly attached to the frame. DO NOT fasten a strap or 4. Turn the key switch to OFF to stop the engine. Check
chain to the mast or any attachment to hold the lift that all switches and accessories are turned OFF.
truck on the transport. 5. Put blocks in front and back of the lift truck tires to pre-
vent any movement of the lift truck. Make sure the blocks
CAUTION are attached to the load surface.
Make sure that any straps or chains used to fasten the
lift truck to the transport DO NOT contact any tubes, 6. If the lift truck is transported in severe weather or any
hoses, hydraulic cylinders, or other parts of the truck other condition that can damage the lift truck, cover the lift
that are easily damaged. truck. Make sure the protective cover is designed for the
application and is securely fastened.
If components and attachments must be removed for trans-
port of the lift truck, see the Service Manual for removal Unloading
procedures.
When the lift truck is to be unloaded from the transport,
The operator must never leave a lift truck in a condition so perform the following operations:
that it can cause damage or injury. When the lift truck is
1. If used, remove any protective cover.
loaded on the transport, do the following operations:
2. Make sure the parking brake is applied.
1. Apply the parking brake.
3. Disconnect the straps or chains.
209
Maintenance
4. Remove the wheel blocks. Operating Procedures for a New or Rebuilt
5. If the lift truck is equipped with lifting eyes and a crane is Engine
to be used to unload, check that all switches and accesso-
A new or rebuilt engine must be operated normally, while
ries are turned OFF.
avoiding following operating conditions.
6. If lift truck is to be driven off transport, follow starting pro-
• Usage below normal operating temperature.
cedures.
• Idling periods in excess of 5 minutes.
7. Unload the lift truck.
If a rebuilt engine did not receive a new oil filter and new oil
Preparation After Transport after being tested, then replace oil and filter after the first
After being transported, the lift truck must be prepared for 100 hours of operation.
proper operation. All problems must be corrected before New Tier 3 engines in new trucks require an initial oil and
use of the lift truck, see the Service Manual for proce- filter change after the first 250 hours of operation.
dures. Perform the following operations:
New Tier 4(f) engines in new trucks do not need an initial
1. Complete the unloading procedures. oil and filter change.
2. If components normally attached to the lift truck were Changes to the Operator's Cab
removed for transport, see the Service Manual for assem-
bly instructions.
WARNING
3. Inspect the lift truck for damage and missing compo- Do not make changes to the operator's cab by welding
nents. Repair or replace as necessary. or drilling. Welding or drilling holes that are too big in
the wrong location can reduce the strength of the oper-
4. Follow the steps in the section How to Make Checks
ator's cab. See your dealer for Hyster lift trucks before
With the Engine Stopped.
making any changes to the operator's cab.
210
Maintenance
Capacities and Specifications

Table 28. Approved Fuel and Engine Oil
Engine Emission Legisla-

WWFC Diesel Fuel ASTM D975 No. 2-D Engine Oil Quantity
tion
ACEA E9
Tier 4/Stage IV Engines Category 4 S15 22.8 liter (24 qt)
API CJ-4
ACEA E7 or E9 API
Category 4 S15
CI-4 or CJ-4
Tier 3/Stage IIIA Engines Category 2 S50 ACEA E7 API CI-4 34 liter (36 qt)
ACEA E7 API CI-4
Category 1 S500
(see NOTES)
211
Maintenance
Table 28. Approved Fuel and Engine Oil (Continued)
Engine Emission Legisla-

WWFC Diesel Fuel ASTM D975 No. 2-D Engine Oil Quantity
tion
• To comply with emission legislation, sulfur content in the applied diesel fuel must be limited. See column WWFC Diesel
Fuel.
• Sulfur content in diesel fuel determines the required engine oil specification.
• Maintain engine oil level halfway to the full range on dipstick when cold.
• Diesel No. 1 is not allowed in countries with Tier 3/Stage IIIA or more stringent emission legislation
• When using Diesel No. 1 in countries without emission legislation, the factory-filled CJ-4 engine oil must be replaced at
initial 250 hours by API CI-4 specification oil. API CI-4 engine oil allows 500 hour oil change intervals when using Diesel
No. 1.
• Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content does not exceed 5 percent of
total volume.
212
Maintenance
Table 29. Approved Oils, Fluids, and Greases
Fluid Specification Truck/Engine Type Quantity

Oils
Air Conditioner ZXL 100PG, See Compressor
Tier 3/ Stage IIIA 190 ± 10 CC
Compressor Lubri- Nameplate
cant SP-15, See Compressor Nameplate Tier 4F/ Stage IV 200 ± 10 CC
Chain Oil 15W-40 Engine Oil -- As required
MIL-PRF-2104F, APIGL- 5, SAE
Differential Oil -- 80 liter (21 gal)
80W-90
ACEA E7 API CI-4 QSM11 Tier 3/ Stage IIIA 33 liter (34.9 qt)
Engine Oil
ACEA E9 API CJ-4 QSL9 Tier 4F/Stage IV only 22.7 liter (24 qt)
Standard Tank (Below 15550 mm
617 liter (163 gal)
Hydraulic System lift height)
John Deere JDM-J20C
Oil Large Tank (For 15550 mm lift
705 liter (185 gal)
height)
Planetary Gear Oil MIL-PRF-2104F, APIGL- 5, SAE
-- 12.5 liter (13.2 qt)
(each side) 80W-90
*Do not mix. When changing to a different Cummins CES 14603 approved coolant, the cooling system will need to be
drained and flushed.
213
Maintenance
Table 29. Approved Oils, Fluids, and Greases (Continued)

Steer Wheel Hub MIL-PRF-2104F, APIGL- 5, SAE
-- 4 liter (4.2 qt)
Oil (each side) 80W-90
Transmission Oil Dexron® III -- 65 liter (68.7 qt)
Fuel
Fuel See Table 28 -- 830 liter (219.3 gal)
Fluids
Air Conditioner 1300 ± 50 grams (45.8 ±
R134a --
Refrigerant 1.8 oz)
*BASF Glysantin G40 ready mix. QSM11 Tier 3/ Stage IIIA 40 liter (42.3 qt)
First used on SN: J117E01571U
Coolant *3174102 - Shell Rotella ELC
QSL9 Tier 4F/ Stage IV 44 liter (46.5 qt)
3116456 - Eurol Coolant XL-NM
or equivalent OAT type coolant
Diesel Exhaust
AUS 32, ISO 22241-1 QSL9 Tier 4F/Stage IV only 57 liter (15 gal)
Fluid (DEF)
214
Maintenance
Table 29. Approved Oils, Fluids, and Greases (Continued)

Windshield Washer Clean water with detergent and anti-
-- 5 liter (5.3 qt)
Fluid freeze as required.
Grease
Multipurpose EP2/3
-- --
Grease EP2/3 with 2-4% MoS2.
215
Maintenance
Table 30. Engine Oil Viscosity
Ambient Temperatures Temperature Range Oil Viscosity

All Seasons -15 °C (5 °F) and above 15W-40
Winter Conditions -20 °C (-4 °F) to 20 °C (68 °F) 10W-30
Arctic Conditions Below0 °C (32 °F) 0W-30
Lift Chain Lubricant Requirements Fuses and Relays

Chain lubricant must be mineral or synthetic engine oil. Oil If an electrical component does not function properly,
viscosity must match ambient temperature, so that oil check the related fuse and relay in the side console. See
remains viscous and can penetrate to the contact area Figure 51.
between link pin and intermediate links.
If several components malfunction, check the main electri-
• Use SAE 20W to 30W oil in ambient temperatures of -30 cal supply. See Figure 53.
to 5 °C (-22 to 41 °F).
Before replacing a failed fuse or relay, first repair the defect
• Use SAE 15W-40 oil in ambient temperatures of -10 to that caused the fuse or relay to fail. Have any failed com-
35 °C (14 to 95 °F). ponent replaced.
• Use SAE 40 oil in ambient temperatures of 5 to 45 °C Side Console
(41 to 113 °F).
The side console is located at the right side of the opera-
• Use SAE 50 oil in ambient temperatures above 45 °C tor’s cab, underneath the instrument panel. See Figure 51.
(113 °F).
216
Maintenance
1. FUSE PANEL 1 (SEE TABLE 31)
6. ECO-HIP SWITCH
7. HYDRAULIC SERVICE SWITCH
8. RELAY PANEL (SEE FIGURE 52)
9. DIAGNOSTIC PLUG
10. BUZZER
11. REGENERATION CONTROL SWITCH (TIER 4 ONLY)
Figure 51. Side Console
217
Maintenance
Table 31. Fuse Locator
FUSE PANEL 1 FUSE PANEL 2
5A IGN SIGNAL 5A INTERIOR LIGHTING
30A SUPPLY IGN KEY/ENGINE START 10A REVERSE LIGHTS/ALARM/STROBE
5A XMSN B+ 5A BRAKE LIGHTS
7.5A XMSN IGN/SERVICE SWITCH 15A FRONT DRIVE LIGHTS
5A ECM IGN/ECO-eLo/HIP SWITCH 5A SUPPLY FLOOD LIGHTS SWITCH
10A EAS SENSORS 15A ATTACHMENT SUPPLY 3
10A INSTRUMENTATION / CAN DISPLAY IGN 5A DIRECTION INDICATORS
5A ALTERNATOR SUPPLY 10A REAR DRIVE LIGHTS
5A JOYSTICK/DC-DC RELAY/OVERRIDE 10A SIDE/TAIL LIGHTS
SWITCH
-- -- 30A FLOOD LIGHTS RELAY
FUSE PANEL 3 FUSE PANEL 4
10A FRONT SCREEN WASH WIPE -- --
10A ROOF SCREEN WASH WIPE 10A POWER SOCKET 12V
10A REAR SCREEN WASH WIPE 10A RADIO/CB/INTERCOM
25A HEATER/AC/VENTILATION FAN 10A CAN DISPLAY B+
10A AUTOMATIC GREASING 5A HAZARD LIGHTS
15A SEAT SUSPENSION COMPRESSOR 15A AC CONDENSER FAN 1
10A HORN 15A AC CONDENSER FAN 2
25A SPED POWER B+ 15A POWER SOCKET 24V B+
10A CONVERTER FOR ACCESSORIES 5A LED BEACON B+
10A ATTACHMENT SUPPLY 2 -- --
218
Maintenance
Table 31. Fuse Locator (Continued)
FUSE PANEL 5
30A HYDRAULIC CONTROLLER
10A ATTACHMENT SUPPLY 1
5A SUPPLY SWITCHES
5A POWER SOCKET 24V SWITCHED
5A SPED POWER IGN
5A REAR VIEW CAMERA
-- --
5A LOW BRAKE PRESSURE WARNING
5A SEAT BELT SEQUENCER
5A TELEMETRY
219
Maintenance
1. RELAY-MAIN POWER 24V
2. RELAY-LIGHTS 24V
3. RELAY-HORN 24V
4. RELAY-2ND HORN 24V
5. RELAY-FLOOD LIGHT 24V
6. FLASHER UNIT (OPTIONAL) 24V
7. RELAY-START ENABLE 24V
8. RELAY-IGN 24V
9. RELAY-REVERSE LIGHTS 24V
10. RELAY-AC3 24V
11. RELAY-START INHIBIT 24V
12. --
13. RELAY-AC2 24V
14. RELAY-AC1 24V
15. RELAY-12V 24V
16. RELAY-HYDRAULIC CONTROLLER 24V
17. --
18. DIODE BLOCK 24V
Main Electrical Supply

Fuses and relays for the main electrical supply are located
in the battery box. See Figure 53.
Figure 52. Relays
220
Maintenance
1. DEF TANK UNIT HEATER RELAY
2. DEF HOSE 1 RELAY - CPS127
5. ALTERNATOR FUSE
6. CAB FUSE
7. GRID HEATER FUSE
8. GRID HEATER RELAY
9. ECM B+ FUSE
10. --
11. DEF TANK UNIT HEATER FUSE
12. DEF HOSE HEATER FUSE
13. --
14. ENGINE COMPARTMENT LIGHT FUSE
15. CAB TIP UP FUSE
16. XMSN B+ FUSE
Figure 53. Main Fuses
221
NOTES
222
Spacer
12/20 (7/20)(9/18)(6/18)
OPERATING MANUAL
Challenger
H40-52XM-16CH (J117)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4222750 12/20

J117 Operating Manual

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OPERATING MANUAL

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4222750 12/20

LIFT TRUCK MODEL SERIAL NUMBER

TRANSMISSION TYPE GROUP NUMBER

MAST LIFT HEIGHT GROUP NUMBER

CARRIAGE TYPE STEERING TIRE SIZE

DRIVE TIRE SIZE

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2020. All Rights Reserved.

©HYSTER COMPANY 2020 4222750 - ENGLISH-UK 1

Additional information as specified Whole-body vibration:

The EC Conformity: CAUTION

Average ambient temperature for continuous duty: +45 °C (109 °F)

Lifting tion to a powered industrial truck, provided, however, that

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:

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT IC ENGINE POWERED

IS IN CONFORMITY WITH THE SUPPLY OF MACHINERY (SAFETY) REGULATIONS 2008.

OTHER APPLICABLE REGULATIONS:

IS IN CONFORMITY WITH THE REQUIREMENTS OF OUTDOORS REGULATIONS 2001

KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

• BE in complete control at all times. • DO NOT start if fuel is leaking.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN

Figure 1. Model View Showing Major Components

Figure 2. Nameplate and Labels

Figure 3. Warning and Safety Labels

Seat Adjustment Controls

Figure 4. Seat Adjustment Controls

Item Item Function

Figure 5. Sears Deluxe Seat Adjustment Controls

Item Item Function

Item Item Function

Spring-Assisted Armrest Adjustment

Figure 6. Spring-Assisted Armrest Adjustment

Item No. Item Function

Driving Controls and Signals

Figure 7. Driving Controls and Signals

Item Item Function

Item Item Function

Item Item Function

Item Item Function

5 Horn Horn button controls the operation of the horn.

Item Item Function

Armrest and Joystick Controls

Figure 8. Armrest and Joystick Controls

Item Item Function

Item Item Function

Item Item Function

Item Item Function

12 Horn PUSH on upper end of switch to activate horn.

14 Unlock Control PUSH the button to unlock the twistlocks.

Item Item Function

Item Item Function

Side Console Controls

Figure 9. Side Console Controls

Table 6. Side Console Controls (See Figure 9)

Item Item Function

Item Item Function