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OPERATING MANUAL

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CHALLENGER

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H165--280XL [E007]

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H300--360XL [D019]

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H330--360XL--EC [D019]
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DO NOT REMOVE THIS MANUAL FROM THIS UNIT
HYSTER COMPANY PART NUMBER 897342
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LIFT TRUCK MODEL SERIAL NUMBER

ENGINE MODEL SERIAL NUMBER

TRANSMISSION TYPE SERIAL NUMBER

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MAST LIFT HEIGHT GROUP NUMBER

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CARRIAGE TYPE GROUP NUMBER

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DRIVE TIRE SIZE STEERING TIRE SIZE

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SPECIAL EQUIPMENT OR ATTACHMENTS

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REGISTERED TRADEMARKS
Hyster, Am
, Challenger, SpaceSaver, Monotrol, RACKLOADER, SitDrive and StanDrive are trademarks of
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Hyster Company.
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 FOREWORD

FOREWORD
TO OWNERS, USERS, AND OPERATORS: It is the responsibility of the employer to make sure that
the operator can see, hear, and has the physical and men-
The safe and efficient operation of a lift truck requires tal ability to operate the equipment safely.
skill and alertness on the part of the operator. To develop Various laws and regulations require the employer to train
the skill required the operator must:

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lift truck operators. These laws and regulations include:

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· receive training pursuant to OSHA 1910.178(1) dated Occupational Safety and Health Act (USA)
12/98, in the proper operation of THIS lift truck. Canada Material Handling Regulations

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NOTE: A comprehensive operator training program is avail-
· understand the capabilities and limitations of the lift

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able from HYSTER COMPANY. For further details, contact
truck.
your dealer for HYSTER lift trucks.

· This OPERATING MANUAL contains information neces-

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become familiar with the construction of the lift truck
and see that it is maintained in good condition. sary for the operation and maintenance of a basic fork lift
truck. Optional equipment is sometimes installed that can

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change some operating characteristics described in this
· read and understand the warnings and operating pro-
manual. Make sure the necessary instructions are avail-
cedures in this manual.

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able and understood before operating the lift truck.
In addition a qualified person, experienced in lift truck op- Some of the components and systems described in this

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eration, must guide a new operator through several driving OPERATING MANUAL will NOT be installed on your unit.
and load handling operations before the new operator at- If you have a question about any item described, contact
tempts to operate the lift truck alone. your dealer for HYSTER lift trucks.
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ã HYSTER COMPANY 2002 1
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 FOREWORD
Additional information that describes the safe operation · “Guide for Users of Industrial Lift Trucks” describes lift
and use of lift trucks is available from the following truck safety, good maintenance practices, and training
sources: programs. Available from your dealer for HYSTER lift
trucks. HYSTER Part No. 897342
· employment safety and health standards or regulations
NOTE: HYSTER lift trucks are not intended for use on
(Examples: “Occupational Safety and Health Stan-
public roads.
dards (USA)”, “Canada Material Handling Regulations”.

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NOTE: The following symbols and words indicate safety in-

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· safety codes and standards (Example: American Na- formation in this manual:
tional Standard, ANSI B56.1, Safety Standard For Low
Lift And High Lift Trucks. WARNING

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Indicates a condition that can cause death or injury!

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· publications from government safety agencies, govern-
ment insurers, private insurers and private organiza- CAUTION
tions (Example: Accident Prevention Manual For Indus- Indicates a condition that can cause injury or property

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trial Operations, from the National Safety Council). damage!

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 CONTENTS

CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Checks With The
TO OWNERS, USERS, Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AND OPERATORS: . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATING TECHNIQUES . . . . . . . . . . . . . . . . . . 39
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Basic Operating Procedures . . . . . . . . . . . . . . . 39
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Driving And Direction Changes . . . . . . . . . . . . . 42
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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MODEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering (Turning) . . . . . . . . . . . . . . . . . . . . . . . . 44

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Load Handling, General . . . . . . . . . . . . . . . . . . . 45
Load Handling, Lifting,
OPERATOR PROTECTION EQUIPMENT
Lowering And Tilting . . . . . . . . . . . . . . . . . . . . . . 47
(See FIGURE 1.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Load Handling, How To Engage
NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 And Disengage A Load . . . . . . . . . . . . . . . . . . . . 49

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SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Load Handling, How To Handle
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . 15 Empty Containers . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . 31 Load Handling, Traveling . . . . . . . . . . . . . . . . . . 55

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 HIGHWAY TRUCKS, RAILROAD
Know Your Lift Truck . . . . . . . . . . . . . . . . . . . . . . 31 CARS AND DOCKS . . . . . . . . . . . . . . . . . . . . . . . . . 58
Stability And Center Of Gravity . . . . . . . . . . . . . 33 ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Capacity (Weight And Load Center) . . . . . . . . . 34 STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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INSPECTION BEFORE OPERATION . . . . . . . . . . 35 PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checks With The MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . 35 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Starting Procedures (Diesel) . . . . . . . . . . . . . . . 35 Serial Number Data . . . . . . . . . . . . . . . . . . . . . . . 62
Starting Procedures, LPG Engine . . . . . . . . . . . 36 HOW TO MOVE A DISABLED LIFT TRUCK . . . . 62
Shutdown Procedures, Turbo Engines . . . . . . . 37 How To Tow The Lift Truck . . . . . . . . . . . . . . . . . 63
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 CONTENTS
HOW TO PUT A LIFT TRUCK Forks, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ON BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Forks, Installation . . . . . . . . . . . . . . . . . . . . . . . . . 83
How To Raise The Drive Tires Inspection Of Forks, Mast And Lift Chains
(See FIGURE 8.) . . . . . . . . . . . . . . . . . . . . . . . . . 64 (See FIGURE 17. and FIGURE 18.) . . . . . . . . . 84
How To Raise The Steering Tires Tires And Wheels (See FIGURE 19.) . . . . . . . . 85
(See FIGURE 8.) . . . . . . . . . . . . . . . . . . . . . . . . . 65 Operator Restraint System
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . 76 (See FIGURE 20.) . . . . . . . . . . . . . . . . . . . . . . . . 87

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EVERY 8 HOURS OR DAILY . . . . . . . . . . . . . . . . . . . . 76 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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HOW TO MAKE THE CHECKS Check For Fuel, Oil And Coolant Leaks . . . . . . 88
WITH THE ENGINE STOPPED . . . . . . . . . . . . . . . 76 HOW TO MAKE THE CHECKS
Hydraulic System Oil

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WITH THE ENGINE RUNNING . . . . . . . . . . . . . . . 88
(See FIGURE 14.) . . . . . . . . . . . . . . . . . . . . . . . . 76 Gauges, Lights, Horn and Fuses . . . . . . . . . . . . 89

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Engine Oil Control Levers And Pedals . . . . . . . . . . . . . . . . . 89
(See FIGURE 13. And FIGURE 11.) . . . . . . . . . 77
Transmission Oil (See FIGURE 22.) . . . . . . . . . 89
Cooling System (See FIGURE 12.) . . . . . . . . . 78
Lift System Operation . . . . . . . . . . . . . . . . . . . . . 90

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Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Primary Fuel Filter, Diesel
(See FIGURE 13.) . . . . . . . . . . . . . . . . . . . . . . . . 79 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Steering Column Latch . . . . . . . . . . . . . . . . . . . . 92
Battery (See FIGURE 14.) . . . . . . . . . . . . . . . . . 80 HOW TO ADD FUEL TO THE LIFT TRUCK . . . . 92

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Pre--Cleaner For Engine Air Filter Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
(See FIGURE 15.) . . . . . . . . . . . . . . . . . . . . . . . . 81 Liquefied Petroleum Gas (LPG) . . . . . . . . . . . . . 92

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Air Filters (See FIGURE 16.) . . . . . . . . . . . . . . . 81 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . 96
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Remove The Wheels From
Forks, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 82 The Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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 CONTENTS

Pneumatic Tires, Remove The Install the Wheels (See FIGURE 30.) . . . . . . . . 106
Tire From The Wheel (See FIGURE 25.) . . . . . 99 HOW TO PUT INTERNAL COMBUSTION
Pneumatic Tires, Install The ENGINE (I.C.E.) TRUCKS IN STORAGE . . . . . . . 107
Tire On The Wheel (See FIGURE 26.) . . . . . . . 99 HOW TO PUT BATTERIES IN STORAGE . . . . . . 108
Add Air To The Tires (See FIGURE 27.) . . . . . 102 OPERATING PROCEDURES FOR A
Solid Rubber Tires, Remove The NEW OR REBUILT ENGINE . . . . . . . . . . . . . . . . . . 108
Tire From The Wheel (See FIGURE 28.) . . . . . 103 CHANGES TO THE OVERHEAD GUARD . . . . . . 109

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Solid Rubber Tires, Install The Tire
On The Wheel (See FIGURE 29.) . . . . . . . . . . . 103

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 6
CONTENTS

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NOTES

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 WARNING

A WARNING
label with this
information
must be on the
lift truck.

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 8
WARNING

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NOTES

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 MODEL DESCRIPTION

1. OPERATOR COMPARTMENT AND CAB 1

(OVERHEAD GUARD) 6
2. CARRIAGE AND LOAD BACKREST H300--360XL
3. COUNTERWEIGHT
4. STEERING AXLE
3 7
5. DRIVE AXLE
6. MAST

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2
7. HOOD 6

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8. FORKS

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H165--280XL 8

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3 7 4 5

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4 5 12438

FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS

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MODEL DESCRIPTION
MODEL DESCRIPTION
GENERAL These lift trucks can be equipped with attachments such
as fork positioners, a side--shift carriage or a container at-
This Operating Manual covers the following models of lift tachment.
trucks:
OPERATOR PROTECTION EQUIPMENT

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H165XL, H190XL, H210XL, H230XL, H250XL, H280XL (SEE FIGURE 1.)

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The OVERHEAD GUARD or CAB is intended to offer rea-
H300XL, H330XL, H360XL
sonable protection to the operator from falling objects, but

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cannot protect against every possible impact. Therefore, it
H330XL--EC, H360XL--EC
must not be considered a substitute for good judgement

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and care when handling loads.
The models in these series of lift trucks have a capacity
range from 16,500 to 36,000 pounds.These lift trucks are The SEAT BELT and HIP RESTRAINT provide additional

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available with either a Perkins 1006.6 diesel engine or a means to help the operator keep the head and torso sub-
GM V--8 engine that uses LPG fuel. stantially within the confines of the lift truck frame and
overhead guard or cab if a tipover occurs. This restraint

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All units have a powershift transmission with three forward system is intended to reduce the risk of the head and

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and three reverse speeds. Forward and reverse travel is torso being trapped between the lift truck and the ground,
controlled by either a Monotrol pedal or the transmission but it can not protect the operator against all possible in-
control lever. The control lever also controls the transmis- jury in a tipover. The hip restraint bracket will help the op-

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sion speed ranges. The transmission in diesel powered erator resist side movement if the seat belt is not fas-
units is controlled by the Autoshift system. In LPG pow- tened. It is not a substitute for the seat belt. Always fasten
ered units the transmission is manually controlled. the seat belt.
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 MODEL DESCRIPTION
NAMEPLATE SAFETY LABELS
Safety labels are installed on the lift truck to give informa-
The rated capacity for the lift truck, as it is equipped, must tion about possible hazards. It is important that all safety
be shown on the nameplate. See FIGURE 2. If the lift labels are installed on the lift truck and can be read. See
truck nameplate already has a rating for special load han- FIGURE 3.
dling equipment, it will be shown. If the lift truck nameplate

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does not show the rated capacity, or if the lift truck equip-

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ment does not match that shown on the nameplate, the lift
truck must not be operated until its capacity is known.

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WARNING

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When a lift truck is shipped incomplete from the fac-
tory, the nameplate is covered by a label as shown in

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FIGURE 2. If your lift truck has this type of decal, do NAMEPLATE
not operate the lift truck. Contact your HYSTER lift TRUCK MODEL

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Serial no.
truck dealer to obtain a complete nameplate. Approx. weight
NOTICE TO USER
This unit was shipped incomplete from factory/
The U.S.A. Occupational Safety and Health Act of 1970 and other

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national safety codes require the installation of a completed nameplate
DO NOT add to or modify the lift truck. Any change to showing unit configuration and rated capacity. Completed nameplates
may be obtained through your HYSTER dealer.
1304058R
the lift truck, the tires or its equipment can change 0

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the lifting capacity. The lift truck must be rated as
NOTICE LABEL INCOMPLETE LABEL
equipped and the nameplate must show the new ca-
pacity rating. FIGURE 2. NAMEPLATE AND LABELS
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MODEL DESCRIPTION

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SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS

FIGURE 3. WARNING AND SAFETY LABELS (1 of 2)

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 MODEL DESCRIPTION

MOVING MAST-
10 1. WARNING, OPERATION
CRUSH POINTS
11 2. CASE WITH OPERATING MANUAL
9 3. NAMEPLATE
4. NO RIDERS
5. OVERHEAD GUARD WARNING
6. WINDOW MATERIAL WARNING
7. NO ONE ON OR UNDER FORKS

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8. TIPOVER WARNING

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12 9. MAST WARNING
10. FAN WARNING
11. ETHER WARNING

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12. PARKING BRAKE WARNING
13. FLAMMABLE LP--GAS
(GM V--8 ENGINE ONLY)

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SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS

FIGURE 3. WARNING AND SAFETY LABELS (2 of 2)

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MODEL DESCRIPTION

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FIGURE 4. INSTRUMENTS
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 MODEL DESCRIPTION
INSTRUMENTS AND CONTROLS

WARNING
If any of the instruments, levers, or pedals do not op-
erate as described in the following tables, report the
problem immediately. DO NOT operate the lift truck
until the problem is corrected.

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TABLE 1. INSTRUMENTS (See FIGURE 4.)

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ITEM ITEM FUNCTION
NO.

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1 This gauge indicates the air pressure in the brake system.

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Air Pressure
Gauge

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2 Low Air Pressure This red indicator light illuminates when the air pressure in the brake system is
Indicator less than 415 kPa (60 psi).

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WARNING

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Do not operate the lift truck when the light is illuminated or the alarm
sounds.

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MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
3 Autoshift The red light flashes when the transmission oil pressure is low or the oil is too
Transmission hot. The transmission shifts to Neutral (N) when the light comes on. This
Warning Light happens with the lever in any position. For emergency conditions, move the
key to the OFF position and then to the ON position to allow lift truck

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movement in first gear for 16 to 31 seconds (normally 30 seconds).

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The transmission warning light also flashes when a transmission overspeed
condition is detected. The engine goes into the de--throttle mode until the
transmission output speed falls to acceptable pre--set limits.

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4 Coolant This gauge indicates engine coolant temperature when the key switch is in the
Temperature ON position. During normal operation the gauge needle will be in the green

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Gauge area.
CAUTION

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Do not continue to operate the lift truck when the gauge indicates that
the engine is too hot (needle in the red zone).
5 Hour Meter The hour meter operates when the key switch is in the ON position. Periodic

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Maintenance recommendations are based on these hours.

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 MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
6 Fuel Gauge This gauge indicates the amount of fuel in the fuel tank.
(Diesel Only)

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7 Warning Light, The light will be ON when the key switch is ON and the engine is not running.
Alternator The light must go OFF when the engine is running.
CAUTION

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Do not continue to operate the lift truck if the red light is ON at engine
speeds above idle.

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8 Warning Light, The red light is ON when the key switch is in the ON position and must go OFF
Engine Oil when the engine is running.

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Pressure CAUTION
Stop the engine immediately if the red light is ON while the engine is
running.

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9 Warning light, The red light is ON when the key switch is in the START position and must go

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Transmission OFF when the engine is running.
Oil Pressure CAUTION

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Do not continue to operate the lift truck if the red light is ON.
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MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
10 Warning light, The red light is ON when the key switch is in the START position and must go
Transmission OFF when the engine is running.
Oil Temperature CAUTION
Do not continue to operate the lift truck if the red light is ON.

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 MODEL DESCRIPTION

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11

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10
7
8 9

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6 16

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5 17
4 14
3

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FIGURE 5. SWITCHES
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MODEL DESCRIPTION

TABLE 2. SWITCHES (See FIGURE 5.)

ITEM ITEM FUNCTION
NO.
1 Parking Brake Knob This knob controls the operation of the parking brake.
(Some lift trucks have this The square, yellow knob works as follows: With the knob pushed in, the

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type of knob.) parking brake is applied and the transmission with Monotrol control is in
NEUTRAL. When the knob is pulled out, the parking brake is released and the

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transmission with Monotrol control is engaged.
NOTE: The parking brake must be applied before starting the engine.

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SQUARE, YELLOW KNOB WARNING
Apply parking brake before leaving truck. Parking brake is NOT

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automatically applied.
1 Parking Brake Knob This knob controls the operation of the parking brake.

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(Some lift trucks have this The round, black knob operates as follows: With the knob pushed in, the
type of knob.) parking brake is released and the transmission with Monotrol control is
engaged. When the knob is pulled out, the parking brake is applied and the

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transmission with Monotrol control is in NEUTRAL.
NOTE: The parking brake must be applied before starting the engine.

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ROUND, BLACK KNOB WARNING

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Apply parking brake before leaving truck. Parking brake is NOT
automatically applied.
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 MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
2 Parking Brake This light is illuminated when the parking brake is applied or when there is not
Indicator Light enough air pressure to release the parking brake.

3 Switch This switch controls the lights on the empty container attachment. Push on the

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front of the switch to turn the lights ON.

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4 Switch This switch controls the floodlights. Push on the front of the switch to turn the
lights ON.

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Windshield Wiper and There is a switch for each windshield wiper/windshield washer. Push the front

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Washer Switches of the switch to the first position to turn ON the windshield wiper. Push the front
5 Rear Wiper/ Washer of the switch past the ON position to activate the windshield washer.
6 Top Wiper/ Washer

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7 Front Wiper/ Washer

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8 Switch This switch is for optional accessories.
9 Light Switch This switch controls the front drive lights, marker lights and tail lights. Push on

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the front of the switch to turn the lights ON.

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MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
10 Light Switch This switch controls the front work lights or front drive lights, rear drive lights
and tail lights. Push on the front of the switch to turn the lights ON.

11 Container Attachment The controls for the container attachment operate as follows:

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Controls Amber Lights (Top): The amber lights illuminate when the right and left ends of

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the attachment are set down on the container and the attachment is in position
to be locked or unlocked. Both lights must be illuminated before the controls will
operate.

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Green Lights (Bottom): The green lights illuminate when the lock pins are

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extended. Each lock pin operates a light.
Lock Pin Switch: Push on the front of the rocker switch to engage the lock pins
with the container. Push on the rear of the switch to disengage the lock pins

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from the container.
NOTE: An audible alarm is activated whenever the attachment is seated and
the rear of the lock pin switch is pushed to disengage the lock pins.

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

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 MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
13 Key The key switch has three positions:
Switch No. 1 Position: OFF position. Deenergizes all electric circuits except for the
1 horn and headlights.
2 No. 2 Position: ON position. Energizes all electric circuits except the starter

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circuit. The key switch will be in this position during normal operation.

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3 No. 3 Position: START position. Energizes the starter motor for starting the
engine. A spring returns the key to position No. 2 (ON position) when the key is

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released.
NOTE: There is a mechanical lockout that prevents the key switch from being

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returned to the START position without first being returned to the OFF position.

14 Cold Start Aid The cold start aid is used to help start the engine in cold weather. With the key
in the ON position, push and hold the button to energize the cold start aid. See

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the STARTING PROCEDURES in this manual.

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15 Fan Switch This switch controls the operation of the fan. The location of the switch is on
the fan.

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MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
16 Heat Control This knob controls the heater valve. When the knob is pushed to the left, the
Knob heater valve is closed (no heat). When the knob is pushed to the right, the
heater valve is open and hot water enters the heater (heat to the cab).

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17 Heater Fan This switch controls the fan for the heater and defroster system. Turn the switch

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Switch to the right to increase the speed of the fan.

18 Air Control This knob controls the air vent for the heater. When the knob is pushed to the

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Knob left, the heater vent is open. When the air vent is open the heater gets air from
outside the cab. When the knob is pushed to the right the vent is closed and
the heater gets air from inside the cab.

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19 Override Button The Override Button operates as follows:

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The override button permits the operator to retract the lock pins when the
attachment is not seated on a container. Push on the override button and the
rear of the lock pin switch at the same time to retract the lock pins.

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NOTE: Each time the engine is shut off, the lock pins automatically extend.
When the engine is started, the lock pins must be retracted by using the

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override button and the lock pin switch.

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 MODEL DESCRIPTION

5 or
4 5A 5B

2 3A

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1

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6

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7
8
10 9 11

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FIGURE 6. CONTROLS
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MODEL DESCRIPTION

TABLE 3. CONTROLS (See FIGURE 6.)

ITEM ITEM FUNCTION
NO.
1 Autoshift If the lift truck does not have a Monotrol pedal, travel direction is controlled by
Control Lever the Autoshift lever. Move the Autoshift lever to the Forward (F) position to travel
in the forward direction. Move the Autoshift lever to the Reverse (R) position to

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travel in the reverse direction. The center position is Neutral (N). The Autoshift
lever must be in the Neutral (N) position before the engine can be started. The

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lever does not move if there is a Monotrol pedal.
The Autoshift lever has four range positions:
1 -- First gear. The transmission stays in this gear until the operator selects

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another speed range.
2 -- Second gear. The transmission stays in this gear until the operator selects

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another speed range.
1--2 -- This third position allows the transmission to automatically shift between
first and second gears.

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D --This position allows the transmission to automatically shift between all three
gears.
NOTE: The transmission automatically shifts to Neutral (N) if the transmission

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oil pressue is low or if the oil is too hot. This happens with the lever in any
position. For emergency conditions, move the key to the OFF position and then

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to the ON position to allow lift truck movement in first gear for 16 to 31 seconds
(normally 30 seconds).

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 MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
2 Steering Wheel The steering wheel controls the position of the steer tires.
3 Lift/Lower The lift/lower lever is the first control lever to the right of the steering wheel. Pull
Control back on the lever to raise the carriage and forks. Push the lever forward to
Lever lower the carriage and forks.

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3A Lift/Lower Control Le- The button on the knob for the lift/lower lever lets the operator lift at a higher
ver with Two--Speed than normal speed when the pressure in the hydraulic system is less than 13.8
Lift Switch (Used with MPa (2000 psi). (A solenoid valve on the hydraulic pump senses hydraulic

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Empty Container At- pressure.) Pull back on the lever and push the button to lift at the higher speed.
tachment)

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4 Tilt Control Lever The tilt control lever is on the right of the lift/lower control lever. Push the
control lever forward to tilt the mast and forks forward. Pull backward on the
control lever to tilt the mast and forks backward.

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5 Auxiliary Control Lever If the lift truck is equipped with an attachment, such as a side--shift carriage, an
additional lever for the control of this attachment will be installed to the right of

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the tilt control lever. (See TABLE 4.)

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5A Side--Shift Control Push the lever forward to move the attachment to the left. Pull back on the
Lever (Used with lever to move the attachment to the right.

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Empty Container
Attachment) of
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MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
5B Extend/Retract Push the lever forward to extend the attachment to the 40 foot position. Pull
Control Lever back on the lever to retract the attachment to the 20 foot position.
(Used with Empty
Container Attach-
ment)

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6 MONOTROL The MONOTROL pedal controls the speed and direction of the lift truck.
Pedal Pushing on the right side of the pedal causes the lift truck to move in
REVERSE. Pushing on the left side of the pedal causes the lift truck to move in

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FORWARD. The speed of the engine increases as the pedal is depressed.
7 Accelerator Pedal This pedal controls the speed of the engine and is operated by the operator’s

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right foot. It is used on units that have a direction control lever.

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8 Brake Pedal The brake pedal is located to the left of the accelerator pedal. This pedal
controls the application of the service brakes.

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 MODEL DESCRIPTION

ITEM ITEM FUNCTION

NO.
9 Inching/Brake By varying the position of the inching/brake pedal, the operator can move the
Pedal lift truck slowly while a high engine speed is used for lifting loads. Completely
depressing the pedal disengages the transmission and applies the service
brakes. On units with a MONOTROL pedal, the engine can be started when the
inching/brake pedal is fully depressed or when the parking brake is applied.

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10 Steering Column Adjustment The steering column tilts forward and backward for adjustment. Pull up on the
lever and move the steering column to the desired position, then release the

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lever.
11 Autoshift Con- The autoshift controller bypass unit is located under the operator’s seat. It

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J1
troller Bypass consists of a black connector (J1) and a white connector (J2). In the event of a
J2
Unit autoshift controller failure, the bypass unit provides the truck with full shift
capabilities through the column mounted gear selector.

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To use the controller bypass unit, disconnect the wiring harness connectors
from the autoshift controller and plug it into the corresponding connectors on
the controller bypass unit. The connectors are color coded for easy

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identification.

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MODEL DESCRIPTION
TABLE 4. AUXILIARY CONTROL LEVERS
FUNCTION DIRECTION OF MOVEMENT
The control levers will be arranged in
the following order from left to right. LOAD OR EQUIPMENT CONTROL LEVER
1 REACH Retract/Extend Backward/Forward
2 SIDE--SHIFT Right/Left Backward/Forward

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3 PUSH--PULL Backward/Forward Backward/Forward

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4 ROTATE Clockwise/Counterclockwise Backward/Forward
5 UPENDER Up/Down Backward/Forward
6 SCOOP Up/Down Backward/Forward

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7 LOAD STABILIZER Down (Clamp)/Up (Release) Backward/Forward

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8 SWING (FORKS) Right/Left Backward/Forward
9 SWING (CLAMP) Right/Left Backward/Forward
10 L.H. FORK POSITIONER Together/Apart Backward/Forward

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11 R.H. FORK POSITIONER Together/Apart Backward/Forward
12 FORK SPREAD Together/Apart Backward/Forward

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13 CLAMP Clamp/Release Backward/Forward

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14 EXTEND/RETRACT Extend/Retract Backward/Forward

1 2 3 4 5 6 7 8 9 10 11 12 13 14

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 OPERATING PROCEDURES

OPERATING PROCEDURES

GENERAL
WARNING
Know Your Lift Truck FIRE HAZARD

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WARNING The hot engine surfaces and exhaust of internal com-

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EXHAUST GASES bustion engine powered lift trucks can present fire
hazards when operating in areas containing flam-
Exhaust from internal combustion engines contains

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mable gases, vapors, liquids, dusts or fibers. Engine
carbon monoxide and other harmful chemicals. Car- and exhaust component surface temperatures can
bon monoxide is a colorless, odorless poison and

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exceed the ignition temperatures of common sol-
can cause unconsciousness or death without war-
vents, fuels, oil, paper, and other organic materials
ning. Long term exposure to exhaust or chemicals in
(wood, wheat, cotton, etc.). Exhaust emitted sparks

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the exhaust can cause cancer, birth defects and other
reproductive harm. Avoid exposure to engine ex- can ignite these materials as well. Engine and ex-
haust. haust surface temperatures increase after engine

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shut--off, presenting increased fire hazard. Check the
If engines are operated in confined spaces maintain engine compartment immediately following truck op-

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adequate ventilation or vent exhaust to the outside. eration in areas containing combustible dusts, fibers
Do not exceed applicable air contaminant limits.
or paper, and remove any foreign material.

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Follow the inspection and maintenance schedule and
procedures in this manual. Do not alter exhaust, igni- Operate the lift truck only in areas that have been ap-
tion or fuel systems. proved for lift truck operation.
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OPERATING PROCEDURES

S OSHA regulations prohibit the use of lift trucks in In order to understand how the fork lift truck can pick up a
areas containing hazardous concentrations of cer- load, you must first know some basic things about the lift
tain flammable gases or vapors. truck.

S OSHA regulations require operating areas to be

classified as hazardous or nonhazardous, and that
the lift trucks used in designated locations be of

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the minimum type specified (see Guide For Users

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Of Industrial Trucks, Appendix C and Table N--1).
Only the designated types of approved lift trucks can
be used in areas classified as hazardous by the au-

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thority having jurisdiction. Areas classified as haz- The lift truck is based on the principle of two weights bal-
anced on opposite sides of a pivot (fulcrum). This is the

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ardous must be identified by signs to show the type
of approved lift truck required for operation in the same principle used for a see--saw. In order for this princi-
area. Modifications or poor maintenance can result in ple to work for a lift truck, the load on the forks must be

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the lift truck being unsuitable for operation in areas balanced by the weight of the lift truck. The location of the
classified as hazardous. center of gravity of both the truck and the load is also a
factor.

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The fork lift truck is designed to pick up and move materi-
als. The basic lift truck has a lift mechanism and forks on This basic principle is used for picking up a load. The abil-

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the front to engage the load. The lift mechanism lifts the ity of the lift truck to handle a load is discussed in terms of
load so that it can be moved and stacked. center of gravity and both forward and side stability.

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 OPERATING PROCEDURES

Stability And Center Of Gravity CG Load

The lift truck has
moving parts and
therefore has a CG
The center of gravity (CG) of any ob- that moves. The
ject is the single point about which CG moves forward
the object is balanced in all direc- and back as the
tions. Every object has a CG. When Combined CG mast is tilted for-

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the lift truck picks up a load, the ward and back. The

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truck and load have a new combined CG Truck CG moves up and
CG. down as the mast
moves up and

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

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The center of gravity, and therefore the stability, of the
of its CG, or if the truck is loaded, the combined CG.
loaded lift truck is affected by a number of factors, such
as size, weight, shape, and position of the load; the height

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CG Truck to which the load is raised; the amount of forward and
backward tilt; tire pressure; and the dynamic forces cre-
ated when the truck is moving. These dynamic forces are

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CG Load caused by things like acceleration, braking, turning, and
operating on uneven surfaces or on an incline. These fac-

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tors must be considered when traveling with an unloaded
Combined CG
truck, as well, because an unloaded truck will tip over

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OPERATING PROCEDURES

to the side easier than a loaded truck with its load in the The load center is specified in millimeters or inches. The
lowered position. capacity is the maximum load that the lift truck can han-
dle. This load must weigh less than the maximum weight
In order for the lift truck to be stable (not tip over forward for a load center shown on the nameplate.
or to the side) the CG must stay within the area of the lift
truck represented by a triangle drawn between the drive
wheels and the pivot of the steering axle.

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Drive Axle Steering Axle

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CG - Truck Will Tip Over

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If the CG moves forward of the drive axle the lift truck will
The load center of a load is determined by the location of
tip forward. If the CG moves outside of the line repre-
its center of gravity. The load center is measured from the
sented by the lines drawn between the drive wheels and

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front face of the forks, or the load face of an attachment,
the steering axle pivot, the lift truck will tip to that side.
to the center of gravity of the load. It is also assumed that

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Capacity (Weight And Load Center) the location of the center of gravity in the vertical direction
is no greater than the specified horizontal dimension.

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The capacity of the fork lift truck is shown on the Name-
plate. The capacity is listed in terms of weight and load The operator must know whether or not a load is within
center. The weight is specified in kilograms or pounds. the capacity of the lift truck before the load is handled.
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 OPERATING PROCEDURES

INSPECTION BEFORE OPERATION · Condition of forks, carriage, chains, mast, attachments

and operator compartment.
Checks With The
· Leaks from the engine, transmission, hydraulic system
Engine Stopped and fuel system.

Inspect the lift truck before use and every eight hours or
· Condition of wheels and tires. Check air pressure in
pneumatic tires.

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daily as described in the MAINTENANCE section of this

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OPERATING MANUAL. Inspect more frequently if used · Seat belt latches properly.
in severe operating conditions.
· Mirrors are clean and adjusted.

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Before using the lift truck, make the following checks:
· Windows are clean.

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· Fuel level and drain water from the primary fuel filter.
WARNING
· Electrolyte level of the battery (unless maintenance Report damage or faulty operation immediately. Do

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free). not operate a damaged or defective lift truck. A lift
truck will only do its job when it is in proper working
· Oil level in the engine and hydraulic tank. order. If repairs are required, install a tag in the op-

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erator’s area stating “DO NOT OPERATE” and re-
· Coolant level in the cooling system and condition of move the key from the key switch.

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the drive belts.
Starting Procedures (Diesel)

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· Condition of the radiator. Clean if necessary. Do not start or operate the lift truck, including any of its
functions or attachments, from any place other than the
· Pre--cleaner for the air filter. designated operator’s position.
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OPERATING PROCEDURES

1. Make sure the parking brake is applied. 4. If the engine does not start after four attempts, get help
from authorized service personnel.
2. On units without a monotrol pedal, put the autoshift
5. When the engine is running, check the gauges and in-
control lever in the N (Neutral) position.
dicator lights for the correct operation. See the Instru-
ments And Controls section for a description of the cor-
NOTE: The engine can also be started while completely rect operation.

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depressing the inching/brake pedal.
Starting Procedures, LPG Engine

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3. Turn the key to START to engage the starter. If the out-
side temperature is 7°C (45°F) or below, crank the engine 1. If the lift truck uses LPG fuel, open the fuel valve on the

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two revolutions to prime the fuel system. Turn the key to LPG tank.
the OFF position. Push the HEAT button and hold it for

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20--25 seconds, then engage the starter again for 10 sec- WARNING
onds. LPG is very flammable. An odor of LPG fuel can indi-
cate a leak in the fuel system. DO NOT start the en-

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gine until the fuel leak is repaired.
CAUTION
Do not engage the starter for more than 30 seconds 2. Make sure the parking brake is applied or push on the

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at a time. If the engine does not start, turn the key inching/brake pedal.
switch to OFF. Wait 60 seconds before engaging the

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starter again. 3. If equipped, put the direction control lever for the trans-
mission in the NEUTRAL (N) position.

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Use only approved starting aids. Use of non--ap-
proved starting aids can result in engine damage and 4. Turn the key to the START position to engage the start-
void engine warranty. er.
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 OPERATING PROCEDURES

CAUTION Checks With The

Do not engage the starter for more than 30 seconds Engine Running
at a time. If the engine does not start, turn the key
switch to OFF. Wait 60 seconds before engaging the
starter again.
WARNING
5. If the engine does not start after four attempts, get help

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from authorized service personnel. FASTEN SEAT BELT

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6. When the engine is running, check the gauges and in- If Lift Truck Tips Over
dicator lights for the correct operation. See the IN-

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STRUMENTS AND CONTROLS section in this OPERAT- · Do Not Jump -- Stay On Truck
ING MANUAL for a description of the correct operation.

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· Hold Firmly To Steering Wheel --
Shutdown Procedures, Turbo Engines Brace Feet --

1. Put the control lever for the transmission in the Neutral Lean Forward And Away From Im-

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(N) position. pact

2. With the engine at idle speed, wait 3 to 5 minutes

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The seat belt is installed to help the operator stay on
before turning key switch to OFF.
the truck if the lift truck tips over. IT CAN HELP ONLY

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3. Apply parking brake. IF IT IS FASTENED.

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OPERATING PROCEDURES

The operator must be aware that the lift truck can tip over.
There is a great risk that the operator or someone else WARNING
can be killed or injured if trapped or hit by the lift truck as Exhaust from internal combustion engines contains
it tips over. The risk of injury can be reduced if the opera- carbon monoxide and other harmful chemicals. Car-
tor stays on the lift truck. If the lift truck tips over do not bon monoxide is a colorless, odorless poison and
jump off. can cause unconsciousness or death without warn-
ing. Long term exposure to exhaust or chemicals in

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The SEAT BELT and HIP RESTRAINT provide a means the exhaust can cause cancer, birth defects and other
to help the operator keep the head and torso substantially

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reproductive harm. Avoid exposure to engine exhaust
within the confines of the truck frame and overhead guard
Do not use diesel engines indoors where soot can
if a tipover occurs. This protection system is intended to
accumulate.

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reduce the risk of the head and torso being trapped be-
tween the lift truck and the ground, but it can not protect If engines are operated in confined spaces maintain

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the operator against all possible injury in a tipover. adequate ventilation or vent exhaust to the outside.
Do not exceed applicable air contaminant limits.
Follow the inspection and maintenance schedule and

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procedures in this manual. Do not alter exhaust, igni-
tion or fuel systems.

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Make sure that the area around the lift truck is clear be-
fore starting the engine or making any operational checks.

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Be careful when making the checks. If the lift truck is sta-
tionary during a check, apply the parking brake and put

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the transmission in NEUTRAL. Proceed carefully.
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 OPERATING PROCEDURES

Check the operation of the following functions as de- OPERATING TECHNIQUES

scribed in the Periodic Checks and Maintenance section.
WARNING
Before operating the lift truck
· Check the operation of the horn, gauges and indicator FASTEN YOUR SEAT BELT.
lights.
There are a number of operations, if not performed

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carefully, that can cause the lift truck to tip. If you

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· Check the oil level in the transmission when the engine have not read the WARNING page in the front of this
is running at idle speed. OPERATING MANUAL, do so NOW. As you study the
following information about how to properly operate

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a lift truck, remember the WARNINGS.
· Operate the LIFT, TILT and auxiliary functions to

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check for the correct operations. Basic Operating Procedures

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Many people make the mistake of thinking that operating
· Check the operation of the transmission, the control a lift truck is the same as driving an automobile. This is
lever or Monotrol pedal. not true. It is true that some lift truck operating procedures

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are as simple and obvious as driving the family automo-
bile. (e.g. Look where you are going, start and stop

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· Check the operation of the service brakes and parking smoothly, etc.) But a lift truck is a special machine de-
brake. signed to do a much different job than an automobile. Be-

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cause of the close areas in which a lift truck operates and
its other operating characteristics (like rear wheel steering
· Check the operation of the steering system. and tail swing), every operator must receive additional
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OPERATING PROCEDURES

training, even if they have a license to drive an automo- driving and load handling techniques is absolutely neces-
bile. sary to prepare the new operator for proper defensive
driving and to expect the unexpected.
The following discussion lists basic
procedures applicable to lift truck 2. Operate the lift truck only in areas
operation. that have been approved for lift truck
operation.

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1. AUTHORIZED AND TRAINED OPERATOR ONLY. Certain areas contain hazardous flammable gases, liquid,
This means the operator must be trained to drive the lift dust, fibers or other materials. Lift trucks that are oper-
truck and it means that the operator must thoroughly un- ated in these areas must have special approval.

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derstand the procedures for lift truck operation. It also
means that a qualified person experienced in lift truck op- These areas must be designated to show the type of lift

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eration must guide the operator through several driving truck approval required for operation in the area. Changes
and load handling operations before the operator attempts to special equipment or poor maintenance can make the
to operate the lift truck alone. A basic education in proper lift truck loose its special approval.

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 OPERATING PROCEDURES

and may not meet the requirements

3. NO RIDERS. A lift truck is built of ANSI A92.6 for lifting people. Do
for only one person ---- the opera- not use a lift truck to lift people un-
tor. It is dangerous for anyone to
less it has been determined that
ride on the forks or anywhere else
there is no other practical option
on the lift truck.
(scaffolds, raised work platforms,
aerial baskets, etc.) to perform the

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WARNING
needed work.

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This lift truck is designed and intended for handling
materials. A lift truck is not designed to lift people If a lift truck is used to elevate a worker, a safety plat-
form must be attached to the forks and carriage. The

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platform must be specially built to meet or exceed the
requirements of ANSI B56.1. It must have a solid floor

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with a surface to prevent the feet of the worker from
slipping, hand rail, toe board and a screen or shield
at least 2 metres (7 feet) high between the people on

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the platform and the lift mechanism.
Before anyone is allowed in the platform, lift and

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lower the mast slowly with the platform in place to
make sure the mast functions properly. Apply the

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parking brake. Do not travel with people in the plat-
form. The operator must remain at the controls.

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Watch for overhead obstructions.
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OPERATING PROCEDURES

4. Do not drive a lift truck into an elevator unless author- Driving And Direction Changes
ized to do so. Approach the elevator slowly. After the ele-
The transmission can have either an Autoshift Control Le-
vator is properly leveled, the
ver with direction change function or an Autoshift Control
Lever without the direction change function. The Monotrol
pedal is installed if the Autoshift Control Lever does not
have the direction change function. The Autoshift Control

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Lever controls the three speeds of the transmission. If the
lift truck has a Monotrol pedal, push on the left side of the

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pedal to go Forward or the right side of the pedal to go in
Reverse. If not, move the Autoshift Control Lever toward

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the front of the lift truck to go Forward. Move the Autoshift
lift truck must be centered so that the elevator is bal- Control Lever toward the rear of the lift truck to go in Re-

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anced. When the lift truck is in the proper position in the verse. To move the lift truck, push on the brake pedal and
elevator, set the brakes, put the controls in NEUTRAL, release the parking brake. Now, push down on the Mono-
and shut off the power. It is advisable that all other per- trol pedal or the accelerator pedal while releasing the

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sonnel leave the elevator before the lift truck enters or brake pedal.
leaves. A loaded or unloaded lift truck can usually start to move

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with the range lever in the 2 position. Start in the 1 posi-
5. Drive carefully, observe traffic rules and tion when the lift truck is on a grade. After the lift truck is

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be in full control of the lift truck at all times. STOP moving, push forward on the range lever to increase
Be completely familiar with all the driving speed or pull back to select a lower range as necessary.
and load handling techniques contained in

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this Operating Manual. The lift truck has the capability of making directional shifts
at travel speeds up to a walking pace, but the mast must
not be raised and the load must be stable. If the lift truck
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 OPERATING PROCEDURES

is moving rapidly, slow to a walking speed before chang- The inching/brake pedal (left--hand pedal) allows the di-
ing the direction of travel. rection clutch in the transmission to slip and also applies
the service brakes. When the inching/brake pedal is par-
WARNING
tially applied, the clutch in the transmission is partially dis-
Do not start to move the lift truck until the air pres-
sure gauge indicates approximately 90 psi. engaged and the movement of the lift truck is slow. When
Do not operate the lift truck if the low air pressure in- the inching/brake pedal is fully applied, the transmission is

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dicator or warning alarm is on. completely disengaged and the service brakes are ap-

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plied.
CAUTION
The drive train can be damaged if the lift truck is trav-

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eling too fast when the controls are changed to the
opposite direction.

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FAST
Inching
Inching is the movement of a lift truck that allows a slow

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travel speed while keeping the engine speed high for fast
operation of the lift mechanism.

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The lift truck has a brake pedal and an inching pedal. The SLOW
brake pedal (right--hand pedal) applies only the brakes.

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OPERATING PROCEDURES

namic forces are present. In fact, the lift truck will ac-
WARNING tually tip to the side easier when empty, than when
Inching requires coordinated movement of the inch- loaded with the load lowered. Rearward tilt, off--cen-
ing/brake pedal and the accelerator. New operators ter loads and uneven ground will aggravate these
must practice this procedure before attempting to conditions.
handle loads.
Steering (Turning) IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!

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HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR

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WARNING FEET, AND LEAN FORWARD AND AWAY FROM THE
TRAVEL SLOWLY WHEN TURN- POINT OF IMPACT.
ING. Lift trucks can tip over

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even at very slow speeds. The
Because lift trucks are designed to work in a relatively

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combination of speed and the
sharpness of a turn can cause a small space, they can turn sharper than some other vehi-
tipover. cles.

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Most lift trucks are steered by the rear wheels and the

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A lift truck is less stable when the forks are raised, rear of the lift truck can move to the side very fast during
with or without a load. Most operators can under- a turn. This movement is called ”tail swing”. An operator

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stand the need to be careful when handling loads. must be aware of tail swing and always check to make
But some operators do not realize that a tipover can sure the tail swing area is clear before turning.

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occur with an empty lift truck because similar dy-
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 OPERATING PROCEDURES

steers with the left hand. The right hand is used to oper-
ate the lift, tilt, and attachment controls.

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“TAIL
SWING”

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When turning the lift truck from a wide aisle into a narrow
WARNING

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aisle, start the turn as close to the opposite stock pile as
Failure to observe the tail swing area when making a tail swing will permit. This action allows the lift truck to en-
turn can injure or kill someone. ter the narrow aisle going straight ahead.

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Do not turn on an incline. To reduce Load Handling, General
the possibility of a tipover, a lift truck 1. Handle only loads

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must not be driven across an incline. within the rated capacity
as shown on the name-

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plate. This rating repre-
sents the maximum load

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that can be lifted.
When possible, keep both hands on the steering wheel.
During most loading or unloading operations, the operator
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OPERATING PROCEDURES

However, such factors as weak floors, uneven terrain, or mum support of the load. Center the weight of the load
loads having a high center of gravity can mean that the between the forks.
safe working load is less than the rated capacity. When
such conditions exist, the operator must reduce the load
so that the lift truck will remain stable.

2. Handle only stable loads. A load

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can have unstable items that can
easily shift and fall on someone.

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If the weight of the load is not centered between the forks,

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WARNING the load can fall off the forks when you turn a corner or hit
Do not handle a load if any loose part of it is above a bump. An off center load will increase the possibility of
the top of the carriage or any part of the load is likely

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the truck tipping over to the side.
to fall. Loads such as bundles of lumber or empty
Make sure the pins that keep the forks in position are en-

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containers can fall backwards onto the truck if they
extend past the top of the carriage and mast. gaged so that the forks cannot move.

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3. Position each fork the same distance from the center of 4. Check the condition of the driving surface. Make sure
the carriage. This action will help center the load on the the floor will support the weight of the lift truck and the
carriage. Set the forks as far apart as possible for maxi- load.
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 OPERATING PROCEDURES

Load Handling, Lifting, Lowering And Tilting Remember, a lift truck equipped with a HYSTER over-
head guard provides reasonable protection to the operator
The LIFT and TILT functions are controlled by separate from falling objects, but cannot protect against every pos-
levers. Refer to the Instruments and Controls section sible impact.
for proper operation.
The speed of the hydraulic functions is controlled by the A lift truck without an overhead guard provides no such
position of the control levers and the speed of the engine. protection and other personnel have no overhead protec-

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The farther the hand lever is moved from the NEUTRAL tion. Avoid hitting objects such as stacked material that

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position, the faster the speed of the hydraulic function. could become dislodged and fall.

Do not lift or hit anything that can fall on the operator or a The operator must exercise extreme care while working

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bystander. near such objects. Whether the lift truck is loaded or
empty, do not travel with the load or carriage in a raised

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position.

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WARNING
Keep yourself and all others

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clear of the lift mechanism. Nev-
er allow anyone under or on the

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forks.

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NEVER put hands, arms, head or legs
through the mast or near the carriage
or lift chains.
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OPERATING PROCEDURES

This warning applies not only to

the operator but also a helper. A WARNING
helper must not be near the load or
MOVING MAST-
CRUSH POINTS The lift truck can tip over forward when the load is
lift mechanism while the operator raised. Forward tipping is even more likely when tilt-
is attempting to handle a load. The ing forward, braking when traveling forward or accel-
lift mechanism has moving parts erating in reverse.
with close clearances that can

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cause serious injury.

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Lift and lower with the mast vertical or tilted slightly back-
ward from vertical. Tilt elevated loads forward only when

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directly over the unloading place. If the lift mechanism is
raised to pick up or deposit a load, keep the tilt angle in

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either direction to a minimum. Backward and forward tilt
are helpful, but they affect side and forward stability. Do
not tilt in either direction any more than necessary when

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handling elevated loads. The lift truck can tip forward if
the mast is tilted forward with a load in the raised position.

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 OPERATING PROCEDURES

Approach the load carefully. Make sure that the truck is

perpendicular to the load. Raise the forks to the proper
height for engaging the load.

2. Move forward slowly

until the forks are in posi-
tion under the load. The
IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF!

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forks must support at
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR

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least two--thirds (2/3) of
FEET, AND LEAN AWAY FROM POINT OF IMPACT. the length of the load.
Load Handling, How To Engage And Disengage Make sure that the load is centered between the forks.

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A Load Make sure that the forks do not extend past the load so

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that loads or equipment that are behind the load being
1. Avoid fast starts. lifted are not damaged.
Sudden movement
can cause the lift If the forks are longer than the load, move the forks under

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truck to tip. People the load so that the tips of the forks do not extend beyond
can be hurt or killed the load. Lift the load from the surface. Move backward a

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and material can be few inches,then lower the load onto the surface and inch
damaged. forward to engage the load against the carriage. Tilt the

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OPERATING PROCEDURES

mast backward just far enough to lift the load from the
surface.

Be Careful of Forks
Beyond the Load 4. If the load is being removed from a stack, slowly move

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the lift truck away from the stack. When the load is clear
of the stack, lower the load for traveling.

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3. When a load is put on the floor, tilt the mast forward to
a vertical position and lower the load. Tilt the mast for-
ward to permit smooth removal of the forks. Carefully

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move the lift truck backward to remove the forks from un- Always travel with the load as low as possible and tilted

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der the load. backward. Lowering speed is controlled by the position of

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 OPERATING PROCEDURES

the control lever. Lower slowly and smoothly. Slowly re-

turn the control lever to the neutral position so that the
load is not dropped or that the lift truck is not tipped over
due to the rapid stop of the load.

WARNING
Move carefully and smoothly when the load is raised

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over a stack. When the load is raised the center of

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gravity of the lift truck and the load is much higher.
The lift truck can tip over when the load is raised.

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IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE 5. To put the load on a stack, align the lift truck with the
OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY stack. Raise the load higher than the point where it will be

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TO STEERING WHEEL, BRACE YOUR FEET, AND placed. Do not raise the load to a point below where the
LEAN FORWARD AND AWAY FROM THE POINT OF load is to be placed and ”jog” the load up into posi-
IMPACT. tion.This operation uses added energy. Be careful not to

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damage or move adjacent loads.
Move forward slowly. When the load is in position for low-
ering on a stack, tilt the mast to a vertical position and

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lower the load. Lower the forks just enough to remove

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them from under the load. Do not lower the forks so that
they will drag on the surface under the load. Tilt the mast

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OPERATING PROCEDURES

forward just enough to permit smooth removal of the forks Tilt the mast fully backward to help keep the load on the
from under the load. Carefully move the lift truck back- forks.
ward to remove the forks from under the load. Lower the
forks when traveling.

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NOTE: Not every load can be lifted using only the forks of
a lift truck. Some loads will require a special attachment.

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Load Handling, How To Handle Empty

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Containers

The following discussion describes the use of the 20 to 40

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6. When lifting round objects, use a block behind the ob- foot extendable attachment used for handling empty con-
ject. Tilt the mast forward so that the forks can slide along tainers.
the floor under the object to be lifted.

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WARNING

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Failure to follow these instructions can cause serious
injury or death.

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1. Follow these instructions and the operating, inspection
and maintenance instructions in the SERVICE MANUAL.
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 OPERATING PROCEDURES

2. Before using the container attachment, inspect the at- HOW TO PICK UP A CONTAINER
tachment for damage and make sure all of the controls
1. When the engine is shut--off the lock pins extend. The
operate as specified in Table 3.
green lights on the control panel for the attachment will be
illuminated when the lock pins are extended. The lock
3. Always put the attachment in the center of the lift truck pins must be retracted before the attachment can be put
when not carrying a container. Use the side--shift function in position so that the container can be picked up.
to put the attachment in the center position.

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2. The lock pins can not be locked or unlocked unless the

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4. Use the side--shift function to keep the container as attachment is seated on a container.
level as possible when carrying a container. NOTE: There is an override button that permits the lock

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pins to be retracted without the attachment being seated
5. Watch the clearance around the whole length of the on a container. See Item 19, TABLE 2.

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container.
3. Put the lift truck in a position so that the attachment is
approximately centered with the container. Raise the at-
6. Never lift a container that is heavier than the capacity

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tachment to the height of the container. If necessary, ex-
listed on the nameplate of the lift truck. tend or retract the attachment to match the length of the
container.

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7. Always be careful of winds while handling containers.
Strong wind force on raised containers can tip the lift 4. Use the side--shift function to align the attachment with

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truck. Do not stack containers in winds above 45 km/hr the container. Move forward until the guides on the verti-
(27 mph). cal end beams contact the container.

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5. When the attachment is aligned with the container,
8. Do not use the override button while a container is be- lower the attachment so that both vertical guide pins enter
ing carried by the attachment. the top openings in the corner pockets of the container.
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OPERATING PROCEDURES

The amber lights on the control panel will come on when sure the indicator flags for the lock pins are in the en-
both ends of the attachment are in contact with the con- gaged position. See FIGURE 7.
tainer.
NOTE: If both lock pins are not engaged, an audible
alarm will sound. Change the position of the container to
1 allow the pins to engage.

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WARNING
1. INDICATOR FLAG

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DO NOT lift the container unless both lock pins are
2 2. CONTAINER fully engaged.
ATTACHMENT
7. Tilt the mast rearward a small amount. Lift the con-

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LOCK PIN ENGAGED tainer. The amber lights must go OFF. Use the side--shift
1

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function to move the center of gravity of the load to the
center--line of the lift truck.
8. Do not travel with the container higher than necessary

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for adequate ground clearance.
2 12692
9. Move the container.

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LOCK PIN DISENGAGED
HOW TO DEPOSIT A CONTAINER

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FIGURE 7. INDICATOR FLAG
1. Keep the mast vertical when picking up or depositing
the container.

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6. Push on the front of the lock pin switch to extend the
lock pins. The green lights on the control panel will come 2. Put the container on a stable, even surface or contain-
on when the lock pins are in the engaged position. Make er.
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 OPERATING PROCEDURES

3. Lower the container and attachment until the amber Load Handling, Traveling
lights come on.
1. When traveling with the load lowered, keep the load
against the carriage and the mast tilted fully backward.
4. Tilt the mast slightly forward.
This will help keep the load on the forks and give good
forward and side stability.
5. Push on the rear of the lock pin switch to retract the
lock pins. Make sure the green lights are off. Also check 2. Travel with the lift mechanism raised only enough to

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that the indicator flags are in the disengaged position. See clear the ground or obstacles.

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FIGURE 7.

NOTE: The audible alarm will beep when the lock pin

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switch is pushed to retract the lock pins. If for any reason
the lock pins do not move to the disengaged position, the

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alarm will continue to make a sound.

6. Lift the attachment from the container. The amber lights When the mast, carriage or load is in a raised position the

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will go off. Move the lift truck and lower the attachment for stability of the lift truck is reduced. This is also critical
travel. when the lift truck is not carrying a load. The ability of the

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lift truck to resist side tipping can be less on a lift truck
CAUTION without a load than it is on a lift truck with a load in the

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Do not hit the attachment on other containers or ob- lowered (travel) position. Therefore, a lift truck without a
jects. The attachment can be damaged by hitting load is more likely to tip sideways, especially in a turn,

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than a lift truck with a load carried in the lowered position.
other objects. This is especially important when ex-
tending or retracting the outer booms of the attach- 3. For better visibility with large loads, travel with the load
ment. trailing, but always keep a proper lookout in the direction
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OPERATING PROCEDURES

of travel. Normally, direction of travel is determined by the 4. When traveling up or down a grade with a heavily
best visibility available to the operator. If the lift truck must loaded lift truck, the load should be kept upgrade to main-
travel in a direction where visibility is obstructed, a lookout tain control.
helper may be required.

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When operating an unloaded lift truck on a steep grade,
keep the counterweight upgrade.

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WARNING 5. Watch out for pedestrians at all

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Some lift trucks have mirrors for viewing along the times. Do not drive up to anyone

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side to observe the tail swing area. These mirrors are standing in front of an object.
an aid to the driver, but are NOT driving mirrors and Use extra care at cross--aisles, doorways and other loca-

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must NOT be used as such when operating in re- tions where pedestrians can step into the path of travel of
verse. Always look in the direction of travel to avoid the lift truck. Slow down when approaching blind intersec-
damage to something or injury to someone. tions or turns and sound the horn. This is done to warn
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 OPERATING PROCEDURES

pedestrians that there is a vehicle in the area and to be are designed to operate on relatively smooth surfaces. Lift
alert to possible danger. trucks with pneumatic tires can adapt to more uneven
ground. Always make sure you pick the smoothest route
6. Anytime the lift truck is moving for your lift truck.
keep arms, legs, etc., inside the
operator’s compartment. Arms 8. Watch clearances, especially forks, masts, overhead
and legs outside the machine guard and tail swing. A lift truck is designed to perform a

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can be injured when passing ob- wide variety of functions within limited space. Make sure
structions. that the forks do not extend past the load so that loads

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being lifted are not damaged.

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7. Avoid bumps,
holes, slick spots

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and loose materi-
als that may cause
Serious accidents can be caused by masts and overhead
the lift truck to
guards hitting pipes and beams near the ceiling.

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swerve or tip. If
unavoidable, slow 9. Do not indulge in stunt
down. driving or horseplay.

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Different models of lift trucks are designed to operate un-

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der different conditions. Lift trucks with solid rubber tires

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OPERATING PROCEDURES

10. Do not pass another HIGHWAY TRUCKS, RAILROAD CARS AND

lift truck traveling in the DOCKS
same direction at intersec-
tions, blind spots or at WARNING
other dangerous locations. Maintain a safe distance from
the edge of docks, ramps,
platforms and other similar

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working surfaces. Watch the

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11. Stay away from the edge of the road. Keep the wheels ”tail swing”. Remember when
of the lift truck, particularly the steer wheels, on the road- traveling in the forward direc-

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way. If the wheels are allowed to run off the edge of the tion and the steering wheel is
travel surface onto soft ground, the lift truck can tip over. turned to move the lift truck

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away from the edge of the
dock the rear will swing to-
ward the edge. This can cause

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the lift truck to fall off the
12. Under all travel conditions, oper-
dock.
ate the lift truck at a speed that will

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permit it to be brought to a stop in a WARNING
safe manner. IF THE LIFT TRUCK FALLS OFF THE DOCK, DO NOT

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JUMP OFF! HOLD FIRMLY TO STEERING WHEEL,
BRACE YOUR FEET, AND LEAN FORWARD AND

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AWAY FROM THE POINT OF IMPACT.
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 OPERATING PROCEDURES

Before operating in a highway truck or railroad car, ob- Make sure the dockboard is secured, in good condition
serve the following: and of the proper capacity.

S DO NOT use a lift truck to move a railroad car. ATTACHMENTS

If an attachment is installed on the lift
S DO NOT use a lift truck to open or close the door on a truck, make sure the operating in-
railroad car unless the lift truck has an attachment that structions are available and under-

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is specifically designed for opening and closing railroad stood before operating the attach-

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car doors and the operator is trained in its use. ment. See TABLE 4. for the operation
of attachment control levers.
S Check to make sure that the brakes on the highway

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truck are set and that wheel blocks have been placed
on both sides of the rear wheels (unless a dock locking WARNING

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mechanism is engaged). Fixed jacks may be neces- Make sure the nameplate is correct if an attachment
sary to support the front and rear of a semi--trailer to has been installed.

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prevent it from moving during loading or unloading.
STOPPING
S Make sure that the railroad car brakes are set and the Stop the lift truck as

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wheels are blocked while loading or unloading. Do this gradually as possible.
so that the railroad car will not move due to the move- Hard braking and

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ment of the lift truck in and out of the railroad car. wheel sliding can
cause the load to fall

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S Check the condition of the driving surface. Make sure off of the forks and
the floor will support the weight of the lift truck and the damage the load or
load. hurt someone.
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OPERATING PROCEDURES

PARKING 5. If the lift truck must be left on an incline, put blocks on

the down hill side of the wheels so that the lift truck can
The operator must never leave a lift truck in a condition so not move.
that it can cause damage and injury. When parking the lift
6. Check engine compartment if operating in areas con-
truck, do the following operations:
taining combustible material. (See page 29, FIRE HAZ-
1. Stop the lift truck and apply the parking brake. ARD)

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If the lift truck is equipped with an LPG fuel system and is

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2. Fully lower the forks, carriage or attachment. Tilt mast parked more than momentarily, close the fuel valve at the
forward until the tips of the forks touch the ground. tank. If the lift truck is going to be left over night or longer,
the truck must be parked outside or the LPG tank must be

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3. On units with a direction control lever, put the control removed and stored outside.
lever for the transmission in NEUTRAL.

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Do not park the lift truck so that it limits access to fire
4.Turn the key switch to OFF to stop the engine. aisles, stairways, and fire equipment.

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 MAINTENANCE

MAINTENANCE

GENERAL Some users have service personnel and equipment to do

the inspection, lubrication, and maintenance shown in the
This section contains a MAINTENANCE SCHEDULE and MAINTENANCE SCHEDULE. Service Manuals are avail-
the instructions for maintenance and inspection. able from your dealer for Hyster lift trucks to help users

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who do their own maintenance.
The MAINTENANCE SCHEDULE has time intervals for

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inspection, lubrication and maintenance for your lift truck.
The recommendation for the time intervals are for eight WARNING
hours of operation per day. The time intervals must be de-

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creased from the recommendations in the MAINTE- Do not make repairs or adjustments unless you have
NANCE SCHEDULE for the following conditions: both authorization and training. Repairs and adjust-

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ments that are not correct can make a dangerous op-
a. If the lift truck is used more than eight hours per erating condition.
day.

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Do not operate a lift truck that needs repairs. Report
b. If the lift truck must work in dirty operating condi-
the need for repairs immediately. If repair is neces-
tions.

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sary, put a “DO NOT OPERATE” tag in the operator’s
Your dealer for Hyster lift trucks has the equipment and area. Remove the key from the key switch.

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trained service personnel to do a complete program of in-
spection, lubrication and maintenance. Regular inspec-

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tion, lubrication, and maintenance will help your lift truck CAUTION
give more efficient performance and operate for a longer Disposal of lubricants and fluids must meet local en-
period of time. vironmental regulations.
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MAINTENANCE

Serial Number Data Make sure the release bolt is engaged in the piston before
the nut is tightened. On the H300--360XL models, the re-
The serial number for the lift truck is on the nameplate lease bolt is permanently installed in the piston.
and is stamped on the frame.
WARNING
HOW TO MOVE A DISABLED LIFT TRUCK Use extra caution when towing a lift truck if any of
NOTE: If there is no air pressure in the brake system, the the following conditions exist:

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parking brake must be manually released. To manually re-

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a. Brakes do not operate correctly.
lease the parking brake, use the release bolt at each air
chamber to compress the spring that applies the brake. b. Steering does not operate correctly.
Tighten the release bolt or nut until the brake is released.

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c. Tires are damaged.
On the H165--280XL models, the release bolt, washer and

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nut are in a receptacle on the side of the air chamber. d. Traction conditions are bad.

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 MAINTENANCE

e. The lift truck must be towed on a slope. How To Tow The Lift Truck
If the engine cannot run, there is no power available NOTE: Disconnect the drive line before towing the lift
for the hydraulic steering system and the service truck if the engine or transmission are disabled.
brakes. This condition can make the lift truck difficult
to steer and stop. If the lift truck uses power from the
engine to help apply the brakes, the application of 1. The towed lift truck must have an operator.

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the brakes will be more difficult. Poor traction can

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cause the disabled lift truck or towing vehicle to 2. Tow the lift truck slowly.
slide. A slope will also make the lift truck more diffi-
cult to stop.

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3. Raise the carriage and forks approximately 30 cm (12
inches) from the surface. Install a chain to prevent the
Never lift and move a disabled lift truck unless the

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carriage and mast channels from moving.
disabled lift truck MUST be moved and cannot be
towed. A lift truck used to move a disabled lift truck
MUST have a capacity rating equal to or greater than 4. If another lift truck is used to tow the disabled lift truck,

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the weight of the disabled lift truck. The capacity of that lift truck must have an equal or larger capacity than
the lift truck used to move a disabled lift truck must the disabled lift truck. Install approximately 1/2 of a capac-

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have a load center equal to half the width of the dis- ity load on the forks of the lift truck that is being used to
abled lift truck. See the nameplate of the disabled lift tow the disabled lift truck. This 1/2 capacity load will in-

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truck for the approximate total weight. The forks crease the traction of the lift truck. Keep the load as low
must extend the full width of the disabled lift truck. as possible.

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Put the weight center of the disabled lift truck on
load center of the forks. Be careful to not damage the 5. Use a towing link made of steel that attaches to the tow
under side of the lift truck. pins in the counterweights of both lift trucks.
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MAINTENANCE

HOW TO PUT A LIFT TRUCK ON BLOCKS NOTE: Some lift trucks have lifting eyes. These lift points
can be used to raise the lift truck so that blocks can be in-
WARNING stalled.
The lift truck must be put on blocks for some types of How To Raise The Drive Tires
maintenance and repair. The removal of the following
(See FIGURE 8.)
assemblies will cause large changes in the center of
gravity: mast, drive axle, engine and transmission, 1. Put blocks on each side (front and back) of the steering

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and the counterweight. When the lift truck is put on tires to prevent movement of the lift truck.

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blocks, put additional blocks in the following posi-
tions to maintain stability: 2. Put the mast in a vertical position. Put a block under
each outer mast channel.

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a. Before removing the mast and drive axle, put
blocks under the counterweight so that the lift 3. Tilt the mast fully forward until the drive tires are raised

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truck can not fall backward. from the surface.

b. Before removing the counterweight, put blocks 4. Put additional blocks under the frame behind the drive

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under the mast assembly so that the lift truck tires. Make sure the blocks are under the frame and not
can not fall forward. the hydraulic or fuel tanks.

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The surface must be solid, even, and level when the 5. If the hydraulic system will not operate, use a hydraulic
lift truck is put on blocks. Make sure that any blocks jack under the side of the frame near the front. Make sure

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used to support the lift truck are solid, one piece that the jack has a capacity equal to at least half the
units. Put a steel plate on top of the block. weight of the lift truck. See the nameplate.

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 MAINTENANCE

How To Raise The Steering Tires jack under the steering axle or frame to raise the lift truck.
(See FIGURE 8.) Make sure that the jack has a capacity of at least 2/3 of
the total weight of the lift truck as shown on the name-
1. Apply the parking brake. Put blocks on both sides (front plate.
and back) of the drive tires to prevent movement of the lift
truck. 3. Put blocks under the frame to support the lift truck.
Make sure the blocks are under the frame and not the hy-

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2. Use a hydraulic jack to raise the steering tires. Put the draulic or fuel tanks.

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12438

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STEERING TIRE DRIVE TIRE
FIGURE 8. PUT A LIFT TRUCK ON BLOCKS
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MAINTENANCE

6 7 8 9 10 11 12 13 14 13 16 18 19 20 21 23 24 25
15 17 22
1 26
2

27

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3

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4

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5

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28

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1 11 12473

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36
30 7 8 25 10 35 34 33 32 31 30 21 29

FIGURE 9. MAINTENANCE POINTS (DIESEL ENGINE SHOWN)

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 MAINTENANCE

TABLE 5. MAINTENANCE SCHEDULE

ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION
NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.

30 TIRES X Check Condition See Parts Manual

TIRE PRESSURE X See Nameplate

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1 FORKS X X Check Condition

3 MAST, CARRIAGE, ATTACHMENT X Check Condition and

Operation

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6 LIFT CHAINS X X, L Check Condition and Engine Oil

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Lubrication
X Check Adjustment
X Check Length

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SAFETY LABELS X Replace If Necessary See Parts Manual

SAFETY BELT AND SEAT RAILS X Check Condition

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CHECK FOR LEAKS— X Check for leaks

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FUEL, OIL, COOLANT

33 FUEL TANK (Diesel) X 120 liter (31.7 gallons) Diesel No. 2

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LPG (Option) (2) 43.5 lb tanks LPG — HD--5

X= Check C=Change L=Lubricate

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MAINTENANCE

ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.

24 COOLING SYSTEM X C 26.0 liter (27.5 qt) 50% water with

50% Ethylene Glycol

28 RADIATOR HOSES X Check Condition See Parts Manual

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23 DRIVE BELTS X Check Condition See Parts Manual

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X Check Tension

19 PRIMARY FUEL FILTER X C Drain Water See Parts Manual

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13 BATTERY X Clean See Parts Manual

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ELECTROLYTE LEVEL X Check Level 2 Batteries

15 HYDRAULIC SYSTEM X C --18°C (0°F) and Above

H8.00--12.00XL 113 liter SAE 10W

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(H165--280XL) (31.7 gallons) API CC or CC/SE/SF/SG
H13.00--16.00XL) 142 liter
(H300--360XL) (37.5 gallons)

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18 PRE--CLEANER FOR ENGINE X Clean See Parts Manual

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AIR FILTER

32 AIR FILTER, ENGINE AND X Clean or Replace See Parts Manual

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AIR COMPRESSOR (See NOTE 3)

X= Check C=Change L=Lubricate NOTE 3: Very dirty conditions will require a daily clean and check.
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ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.
17 WINDSHIELD WASHER FLUID X Check Level
21 ENGINE OIL AND FILTER X C 15.1 liter (16.0 qt) greater than --18°C (0°F)
22 Perkins Diesel 1 Filter SAE 10W--30 API SE/SG
See Parts Manual

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See NOTES 1 & 2

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21 ENGINE OIL AND FILTER X C 10 liter (9.5 qt) API SE/SF
22 GM V--8 1 Filter greater than --18°C (0°F)
See NOTES 1 & 2 SAE 10W--30

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See Parts Manual
HORN, GAUGES, LIGHTS, X Check Operation

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ALARMS, AND MIRRORS
31 TRANSMISSION OIL X C Hyster Part No. 336830

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HYSTER T--50 28 liter (29 qt) Hyster Part No. 336831
Hyster Part No. 336832

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STEERING X Check Operation
9 BRAKES, X Check Operation

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SERVICE AND PARKING X Check Condition
NOTE 1: Change filters after first 100 hours of operation on a new lift truck.

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X= Check C=Change L=Lubricate
NOTE 2: Change engine oil and filters every 400 hours.
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ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.
35 AIR TANK X Drain Moisture
12 DRIVE SHAFT L 3 Fittings Multi--Purpose Grease
See NOTE 4

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STEERING AXLE See NOTE 4

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27 TIE RODS L 4 Fittings Multi--Purpose Grease
26 LOWER SPINDLE BEARINGS L 2 Fittings Multi--Purpose Grease

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10 SHAFT FOR BRAKE ACTUATORS L 2 Fittings Multi--Purpose Grease
See NOTE 4

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5 DRIVE AXLE AND X C SAE 85W--140
DIFFERENTIAL
H8.00--12.00XL 23.7 liter (25.0 qt)

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(H165--280 XL)
H13.00--16.00XL 24.6 liter (26 qt)
(H300--360XL)

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14 HYDRAULIC TANK X 1 See Parts Manual

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BREATHER Clean as Necessary
X= Check C=Change L=Lubricate NOTE 4: Multi--purpose grease with 2--4% molybdenum disulfide.

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 MAINTENANCE

ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.

AIR FILTER, HEATER X 1 See Parts Manual

Clean (See NOTE 3)
25 WHEEL NUTS
DRIVE WHEELS X Check Torque 640 to 680 Nm

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STEER WHEELS X Check Torque (470 to 500 lbf ft)

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11 BRAKE ACTUATOR ARMS X 2
Check Adjustment

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MAST See NOTE 4
8 PIVOTS L 2 Fittings Multi--Purpose Grease

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36 SLIDING SURFACES L As Necessary Multi--Purpose Grease
4 SIDE SHIFT CARRIAGE L 4 Fittings Multi--Purpose Grease

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2 FORK GUIDES L As necessary Engine Oil
7 TILT CYLINDER PIVOT PINS L 4 Fittings Multi--Purpose Grease
CHAIN ANCHORS L 2 Multi--Purpose Grease

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(Top of Mast)

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X= Check C=Change L=Lubricate NOTE 3: Very dirty conditions will require a daily clean and check.
NOTE 4: Multi--purpose grease with 2--4% molybdenum disulfide.

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MAINTENANCE

ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.

PEDALS, LEVERS, LINKAGES, L As Necessary Engine Oil

CABLES, HINGES, SEAT RAILS
ENGINE SPEED (DIESEL) Adjust as Necessary
IDLE SPEED X 725 to 775 rpm

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GOVERNED SPEED X 2660 to 2760 rpm

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ENGINE SPEED (GM V--8) Adjust as Necessary
IDLE SPEED X 725 to 750 rpm

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GOVERNED SPEED X 2700 to 2800 rpm
TIMING, INJECTION PUMP X Adjust as Required 23° BTDC Static

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TIMING, GM V--8 X Adjust as Required 6° to 8° BTDC
VALVE ADJUSTMENT (DIESEL) X Adjust as Required

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INLET (Cold) 0.20 mm (0.008 in)
EXHAUST (Cold) 0.45 mm (0.018 in)

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GM V--8 NO VALVE ADJUSTMENT
SPARK PLUGS (GM V--8) C 8 0.89 mm (0.35 in)

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See Parts Manual
X= Check C=Change L=Lubricate NOTE 4: Multi--purpose grease with 2--4% molybdenum disulfide.

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 MAINTENANCE

ITEM ITEM 8 Hr./ 150 350 1000 2000 PROCEDURE OR SPECIFICATION

NO. Daily Hr./ Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 6 mo. 1 yr.

20 FINAL FUEL FILTERS (DIESEL) C 2 See Parts Manual

FUEL FILTER (LPG) C See Parts Manual
34 TRANSMISSION OIL FILTER C 1 (See NOTE 1) See Parts Manual

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16 HYDRAULIC SYSTEM OIL FILTER C 1 (See NOTE 1) See Parts Manual

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29 HUB BEARINGS, STEER WHEELS C As Necessary Multi--Purpose Grease
See NOTE 4

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ENGINE COMPARTMENT X Remove Combustible
Materials

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X= Check C=Change L=Lubricate NOTE 1: Change filters after first 100 hours of operation on a new lift truck.
NOTE 4: Multi--purpose grease with 2--4% molybdenum disulfide.

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MAINTENANCE

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12698

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FIGURE 10. MAINTENANCE POINTS, EMPTY CONTAINER ATTACHMENT
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 MAINTENANCE

TABLE 6. MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT

(Item Numbers Reference FIGURE 10.)
ITEM ITEM 150 350 2000 PROCEDURE OR SPECIFICATION
NO. Hr./ Hr./ Hr./ QUANTITY
2 mo. 2 mo. 1 yr.
1 SIDE--SHIFT ROLLERS L 8 Fittings Multi--Purpose Grease4

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2 SIDE--SHIFT CYLINDER PINS L 2 Fittings Multi--Purpose Grease4

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3 LOCK PINS L 2 Fittings Multi--Purpose Grease4
4 BEARING BLOCKS X, L As Necessary Multi--Purpose Grease4

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5 ACCUMULATORS X Drain Moisture

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6 LOCK PIN CYLINDERS L Lubricate Internally See Service Manual

X= Check C=Change L=Lubricate NOTE 4: Multi--purpose grease with 2--4% molybdenum disulfide.

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MAINTENANCE

MAINTENANCE PROCEDURES

EVERY 8 HOURS OR DAILY

faces are free of oils, lubricants, fuel and organic dust or
WARNING

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fibers (paper, wood, cotton, agricultural grass/grain, etc.).

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Do not operate a lift truck that needs repairs. Report Hydraulic System Oil (See FIGURE 14.)
the need for repairs immediately. If repair is neces-
sary, put a “DO NOT OPERATE” tag in the operator’s WARNING

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area. Remove the key from the key switch. At operating temperature the hydraulic oil is HOT. Do

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not permit the oil to contact the skin and cause a
burn.
HOW TO MAKE THE CHECKS WITH THE

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ENGINE STOPPED CAUTION
Do not permit dirt to enter the hydraulic system when
Put the lift truck on a level surface. Lower the carriage the oil level is checked or the filter is changed.

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and forks, stop the engine and apply the parking brake. Never operate the hydraulic pump without oil in the

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Open the hood and check for leaks and conditions that hydraulic system. The operation of the hydraulic
are not normal. Clean any oil or fuel spills. Ensure all sur- pump without oil will damage the pump.

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 MAINTENANCE

Check the hydraulic oil level when the oil is at operating

1
temperature, the carriage is lowered and the engine is
2 stopped. Add hydraulic oil only as needed. If more hy-
draulic oil is added than the ”FULL” level, the hydraulic oil
will leak from the breather during operation.
Check the hydraulic system for leaks and damaged or

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loose components.

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Engine Oil (See FIGURE 13. And FIGURE 11.)
After the engine has stopped, wait one minute before

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checking the oil level. Keep the oil at the correct level as
indicated on the dipstick. Use the correct oil as shown in

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the MAINTENANCE SCHEDULE.

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1. ENGINE OIL DIPSTICK, GM V8

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2. FILL CAP, ENGINE OIL
(OIL FILTER ON OTHER SIDE OF ENGINE)
FIGURE 11. ENGINE MAINTENANCE, GM V8
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Cooling System (See FIGURE 12.)

2
WARNING
DO NOT remove the pressure cap from the radiator
when the engine is hot. When the pressure cap is re-
moved from the radiator, the pressure is released
from the system. If the system is hot, the steam and

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boiling coolant can cause burns.

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Check the coolant level at the auxiliary coolant reservoir.
Make sure the coolant level is between the ”FULL” and

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the ”ADD” mark on the auxiliary coolant reservoir. The
coolant will expand as it is heated and the level in the

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1
12453 auxiliary coolant reservoir will increase.
1. AUXILIARY COOLANT RESERVOIR If coolant is added, use the correct mixture of water and

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2. RADIATOR ethylene glycol. See the MAINTENANCE SCHEDULE.
FIGURE 12. AUXILIARY COOLANT RESERVOIR Check the radiator fins. Clean the radiator with com-

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pressed air or water as needed. Be careful not to bend
the radiator fins.

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 MAINTENANCE

Check the condition of the radiator hoses and heater

hoses.

Fuel System

WARNING

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All fuels are very flammable and can burn or cause
an explosion. Do not use an open flame to check the

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fuel level or to check for leaks in the fuel system. If
there is a leak in the fuel system, extra care must be

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used during the repair. Do not operate the lift truck
until a leak is repaired.

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Check the fuel system for leaks and the condition of parts. 3
2 1 12454
When adding fuel to the lift truck, refer to the How To

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Add Fuel To The Lift Truck procedures in this OPERAT- 3. PRIMARY FUEL
1. ENGINE OIL
ING MANUAL. DIPSTICK FILTER
2. ENGINE OIL FILTER 4. FINAL FUEL FILTER

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Primary Fuel Filter, Diesel (See FIGURE 13.)
FIGURE 13. DIESEL ENGINE MAINTENANCE

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Drain the water from the primary fuel filter as follows:
2. Close the valve.

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1. Open the valve on the bottom of the filter canister. Drive Belts
Drain some fuel (and any water) into a cup until clean fuel
flows from the filter. Check the drive belts for wear or damage.
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Battery (See FIGURE 14.)

1 2
WARNING
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area. Use
a solution of sodium bicarbonate (soda) to make the
acid neutral. Acid in the eyes must be flushed with

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water immediately.
3

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Wear eye protection. Batteries generate explosive
fumes. Keep the vents in the caps clean. Keep sparks

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or open flame away from the battery area. Do not
make sparks from the battery connections. Discon-

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nect the battery ground cable when doing mainte-
nance.
1. DIPSTICK FOR HYDRAULIC OIL

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Keep the batteries and cable terminals clean. Check the
electrolyte level (unless maintenance--free). Keep the 2. HYDRAULIC OIL FILTER
electrolyte level above the separators and plates. Use dis- 3. BATTERY 12454

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tilled water. Do not fill the battery past the bottom of the FIGURE 14. MAINTENANCE POINTS
internal filler neck.

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 MAINTENANCE

If the batteries become discharged and require a boost

from another charged battery, follow these procedures 1
carefully:

a. Always connect the positive jumper cable to the

positive terminal of the discharged battery and the
negative jumper cable to the negative terminal.

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b. Always connect the jumper cable that is the ground
cable last.

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2
c. Always connect the jumper cables to the dis-

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charged battery before connecting them to the 1. COVER
2. BOWL
booster battery. 12471

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FIGURE 15. PRE--CLEANER FOR THE ENGINE AIR
Pre--Cleaner For Engine Air Filter FILTER
(See FIGURE 15.)

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Air Filters (See FIGURE 16.)

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Clean the pre--cleaner for the air filter as necessary. Re- There are air filters for the engine and the air compressor.
move the cover for the pre--cleaner, then remove the dirt Clean or replace the air filter as necessary. Use com-

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from the bowl. Install the bowl and cover. pressed air to clean the filter element. Air pressure must
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MAINTENANCE

be less than 210 kPa (30 psi). Apply the air from the in- To inspect the element, put a bright light inside and look
side to the outside of the element. for holes or other damage. If the element is damaged, re-
place it with a new element. Clean the inside of the canis-
ter when changing filters.
Forks
The identification of a fork is determined by how it is con-

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nected to the carriage. These lift trucks have pin forks.

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Pin forks are fastened to the carriage with large fork pins.
Forks, Adjustment

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A lock pin for each fork fits into the top carriage bar and a
slot in the fork. These lock pins hold the fork in position.

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Adjust the forks as far apart as possible for maximum
support of the load. Make sure the lock pin is engaged in

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the carriage bar and the fork. The fork must be locked into
position after the adjustment is made.
Forks, Removal

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WARNING

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1. AIR FILTER 12472
2. FINAL FUEL FILTER Do not try to remove a fork without a lifting device.
The forks can weigh up to 370 kg (800 lb) each.

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FIGURE 16. AIR FILTER AND FINAL FUEL
FILTERS, DIESEL Put the lift truck on a level surface and lower the forks. Tilt
the mast so that the forks have stability. Remove the re-
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 MAINTENANCE

tainers for the fork pins and push the pins from the car- carriage.
riage. Move the lift truck away from the forks.

Forks, Installation 2. Slowly move the lift truck toward the forks until the fork
pins can be installed. Install the fork pins, fork guides and
1. Put the forks approximately 1 m (3 ft) in front of the the retainers.

1. TIP ALIGNMENT 3. FORK PIN DAMAGE

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X (MUST BE WITHIN 3% 4. MUST BE 90% OF

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OF FORK LENGTH) DIMENSION X
3
3 2. CRACKS 5. FORK WEAR

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2 1 FORK TIP ALIGNMENT

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LENGTH OF FORKS 3% DIMENSION

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1220 mm (48 in) 37 mm (1.45 in)
1830 mm (72 in) 55 mm (2.15 in)
2440 mm (96 in) 74 mm (2.90 in)

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4
5

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11195

FIGURE 17. CHECK THE FORKS

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MAINTENANCE

Inspection Of Forks, Mast And Lift Chains 2. Inspect the channels for wear in the areas where the
(See FIGURE 17. and FIGURE 18.) rollers travel. Inspect the rollers for wear or damage.

WARNING 3. Inspect the forks for cracks and wear. Check that the
Never work under a raised carriage, forks or mast fork tips are aligned within 13 mm (0.5 in) of each other
channel. Lower the carriage or use blocks and chains (item 1, FIGURE 17.). Check that the bottom of the fork is
on the mast weldments and carriage so that they can not worn (item 4, FIGURE 17.).

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not move. Make sure the moving parts are attached

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4. Replace any damaged or broken parts that are used to
to a part that does not move.
keep the forks locked in position.
Do not try to correct fork tip alignment by bending

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the forks or adding shims. Replace damaged forks. 5. Check that the lift chains are correctly lubricated. Use
Never repair damaged forks by heating or welding. engine oil to lubricate the lift chains.

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Forks are made of special steel using special proce-
dures. Replace damaged forks. 6. If the lift truck is equipped with a side--shift carriage or
attachment, inspect the parts for cracks and wear. Make

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1. Inspect the welds on the mast and carriage for cracks. sure the parts that fasten the side--shift carriage or attach-
Make sure that the nuts and bolts are tight. ment to the carriage are in good condition.

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1 9. Make sure the lift chains are adjusted so that they have
7
equal tension. Adjustment or repair of the lift chains
must be done by authorized personnel.
Tires And Wheels (See FIGURE 19.)

WARNING
5

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6 Air pressure in tires can cause tire and wheel parts to
2
explode. The explosion of wheel parts can cause se-

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4
3 rious injury or death.
Remove all of the air from the tires before the tires

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are removed from the lift truck.
6705
If the air pressure is less than 80% of the correct

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1. WORN PIN
2. CRACKS 5. LOOSE LEAVES pressure the tire must be removed before air is
3. EDGE WEAR 6. DAMAGED PIN added. Put the tire in a safety cage when adding air

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4. HOLE WEAR 7. CORROSION pressure to the tire. Follow the procedures under
FIGURE 18. CHECK THE LIFT CHAINS ADD AIR TO THE TIRES.
When air is added to the tires, a remote air chuck

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must be used so that the person adding air can stand

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to the side and not in front of the tire.
7. Inspect the lift chains for cracks or broken links and
pins. See FIGURE 18. Keep the tires at the correct air pressure. (See the Name-

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plate.) Check the air pressure with a gauge when the tires
8. Inspect the chain anchors and pins for cracks and dam- are cold. If it is necessary to add air to a tire that is warm,
age. check one of the other tires on the same axle and add air
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MAINTENANCE

to the tire that has low pressure so that the air pressures 1
3
are equal. The air pressure of warm tires must always be
equal to or greater than air pressures specified for cold
tires. 2

Check the tires for damage. Check the tread and remove

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any objects that will cause damage. Check for bent or 1

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damaged rims. Check for loose or missing hardware. Re-
move any wire, strapping or other material that is wrapped
around the axle. 9447

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1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND
OTHER OBJECTS FROM THE TREAD)

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Make sure the wheel nuts are tight. Tighten the wheel 2. MAKE SMOOTH EDGES
nuts in a cross pattern (to the correct torque value shown 3. CHECK THE TIRE PRESSURE (PNEUMATIC TIRES)
in the MAINTENANCE SCHEDULE table. See

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FIGURE 30. FIGURE 19. CHECK THE TIRES

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 MAINTENANCE

CAUTION 1. SEAT BELT

Check all wheel nuts after 2 to 5 hours of operation 2. HIP RESTRAINT
when new trucks are put into operation or when 3. SEAT RAIL
wheels have been removed and installed. Tighten the 4. SEAT BELT RETRACTOR
nuts in a cross pattern to the correct torque value
shown in the MAINTENANCE SCHEDULE table. When 1

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the nuts stay tight for eight hours, the interval for

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checking the torque can be extended to 150 hours. 2

NOTE: Whenever a wheel is removed, it will be neces-

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sary to lubricate the wheel nuts and studs. (See
FIGURE 30.) Put two drops of engine oil (or other lubri- 4

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cant) between the flange and body of the wheel nut. Also
put two drops of oil on the threads of the studs.

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Operator Restraint System (See FIGURE 20.)
12478
The seat belt, hip restraint brackets, seat and mounting

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are all part of the operator restraint system. Each item
3
must be checked to make sure it is attached securely,

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functions correctly and is in good condition. FIGURE 20. CHECK THE SEAT

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The seat belt must latch securely. Make sure the seat belt
extends and retracts smoothly and is not damaged or Make sure the seat rails are not loose. The seat rails must
torn. lock securely in position, but move freely when unlocked.
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MAINTENANCE

The seat rails must be securely attached to the mounting Make a visual check for leaks on and under the lift truck.
surface. If possible, find and repair the leak at the source. Leaks
often indicate a need for repair of damaged or worn com-
Safety Labels ponents. Leaks in the LPG fuel system are usually not
visible unless ice is visible. There is however, usually a
WARNING strong odor. Fuel leaks MUST be repaired NOW.
Safety labels are installed on the lift truck to give in-
Check the fuel system for leaks and the condition of parts.

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formation about operation and possible hazards. It is
When fuel is added to the lift truck, see the section, How

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important that all safety labels are installed on the lift
To Add Fuel To The Lift Truck.
truck and can be read.
Also check the condition of the radiator or heater hoses
Check that all safety labels are installed in the correct lo-

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that are not leaking. Soft or cracked hoses need to be re-
cations on the lift truck. See the PARTS MANUAL for the placed before a major leak occurs.
correct location of the safety labels. The instructions to in-

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stall the labels are also in the PERIODIC MAINTENANCE HOW TO MAKE THE CHECKS WITH THE
section ENGINE RUNNING

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Check For Fuel, Oil And Coolant Leaks WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed
WARNING

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to help the operator stay on the truck if the lift truck
All fuels are very flammable and can burn or cause tips over. IT CAN ONLY HELP IF IT IS FASTENED.

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an explosion. Do not use an open flame to check the Make sure that the area around the lift truck is clear be-
fuel level or to check for leaks in the fuel system. If fore starting the engine or making any operational checks.

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there is a leak in the fuel system, extra care must be Be careful when making the checks. If the lift truck is sta-
used during the repair. Do not operate the lift truck tionary during a check, apply the parking brake and put
until a leak is repaired. the transmission in Neutral (N). Proceed carefully.
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 MAINTENANCE

Gauges, Lights, Horn and Fuses

Start the engine. Check the gauges and lights for correct
operation as described in TABLE 1. Check the operation
of the horn.
The fuses are under the instrument panel on the left side.
(See FIGURE 21.)

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Control Levers And Pedals

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Check that the control levers for the transmission, mast
and attachment operate as described in Tables 2 and 3.
Check that the pedals operate as described in Table 2.

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Transmission Oil (See FIGURE 22.)

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Apply the parking brake. Check the oil level in the power-
shift transmission when the engine is running at idle
speed and, if equipped, the direction control lever is in the

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N (NEUTRAL) position. Use the correct oil as shown in
the Maintenance Schedule. Keep the oil level at the

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”FULL” mark on the dipstick.

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Am FIGURE 21. FUSES
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MAINTENANCE

Lift System Operation

1
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. Do not put any part
of your body in or through the lift mechanism unless

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all parts of the mast are completely lowered and the

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engine is STOPPED.

If the mast cannot be lowered, use chains on the

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mast weldments and carriage so that they can not
move. Make sure the moving parts are attached to a

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part that does not move. See the PERIODIC MAINTE-
2 NANCE section that was included with your lift truck
for additional information.

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1. TRANSMISSION OIL DIPSTICK
Do not try to locate hydraulic leaks by putting hands
2. FUEL CAP 12472
on pressurized hydraulic components. Hydraulic oil

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FIGURE 22. TRANSMISSION OIL can be injected into the body by pressure.

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 MAINTENANCE

Do the following checks and inspections: f. Check that the controls operate the functions of the
attachment correctly. (See the symbols next to
a. Check for leaks in the hydraulic system. Check the each of the controls.) Make sure all of the hydraulic
condition of the hydraulic hoses and tubes. lines are connected correctly and do not leak.

b. Slowly raise and lower the mast several times with- Brakes
out a load. Raise the mast to its full extension

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height at least once. The mast components must Check that the service and parking brakes operate cor-

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raise and lower smoothly in the correct sequence. rectly. The service brakes must apply when the brake
pedal is depressed. The parking brake must apply or re-
NOTE: Some parts of the mast move at different speeds lease with the knob movement described on page 14. On

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during raising and lowering. lift trucks with a Monotrol pedal, applying the parking
brake puts the transmission in NEUTRAL.

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c. The inner weldment and the carriage must lower
completely. NOTE: Full application of the inching/brake pedal applies
the service brakes and disengages the transmission.

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d. Raise the mast one metre (three feet) with a capac-
ity load. The inner weldment and the carriage must Steering System

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raise smoothly. Lower the mast. All moving compo-
nents must lower smoothly. WARNING

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The lift truck has hydraulic power steering. The steer-
e. Lower the load to approximately 0.3 metre (one ing can be difficult if the engine is not running.

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foot) from the floor. Tilt the mast forward and back-
ward. The mast must tilt smoothly and both tilt cyl- Make sure the steering system operates smoothly and
inders must stop evenly. gives good steering control.
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MAINTENANCE

Steering Column Latch Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to gasoline
vapors may cause liver or kidney damage and cancer.
Make sure the latch for the steering column operates cor- Avoid breathing vapor.
rectly. The latch must NOT allow the column to move un-
less the latch is released. Diesel Fuel

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1. Remove the fuel cap. Make sure the fuel tank is filled

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HOW TO ADD FUEL TO THE LIFT TRUCK with the correct fuel for the type of engine in the lift truck.
Clean the fuel cap.

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WARNING 2. Replace the fuel cap.
Stop the engine. Turn the key switch to OFF. The op-

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erator must be off of the lift truck while fuel is added. WARNING
When adding fuel, keep the funnel or fuel nozzle in
No smoking. contact with the metal of the fuel tank to reduce the

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possibility of static electric sparks. Clean any spilled
All fuels for internal combustion engines are very fuel.
flammable.

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Liquefied Petroleum Gas (LPG)
Fill the fuel tank only in a designated area with good

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ventilation. Have a fire extinguisher available.
WARNING

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Never fill the fuel tank near an open flame or near Close the fuel valve on the tank when parking the lift
equipment that can create sparks. Never check fuel truck more than momentarily. Do not park the lift
level or check for leaks with an open flame. truck near heat or ignition sources.
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Do not store LPG tanks near heat or an open flame.

For complete instructions on the storage of LPG WARNING
fuels, refer to ANSI/NFPA 58 & 505. LPG tanks are heavy. The weight of an LPG tank can
LPG is extremely flammable. When checking or filling exceed the maximum recommended weight for safe
an LPG tank: No smoking. Stop engine. lifting by an individual. Get assistance when lifting or
lowering an LPG tank. Use correct lifting procedures.
Frost on the surface of the tank, the valves or fittings
Fill LPG tanks outdoors. Stay at least 15 meters (50

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and the odor of LPG fuel indicates a leak. Inspect the
feet) from buildings, motor vehicles, electrical equip-

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LPG system and repair a leak immediately. An LPG
ment or other ignition sources. Stay at least 5 meters
fuel leak creates an explosion and fire hazard. Do not
(15 feet) from LPG storage tanks.
attempt to start the engine if there is a leak in the

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LPG fuel system. Use the following procedure to remove the LPG tank:
Only trained and authorized personnel are permitted a. Removable LPG tanks can be replaced indoors

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to operate filling equipment. only if the lift truck is a minimum of 8 meters (25
feet) from any open flame or ignition source.
Use only the LPG tank indicated on the label on the

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tank bracket. Do not use an LPG tank that is dam- b. Move the lift truck to the area where LPG tanks are
aged. A damaged LPG tank must be removed from changed.
service. c. See FIGURE 23. Turn the fuel valve clockwise until

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the fuel valve is completely closed.

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d. Run the engine until it stops, then turn the key
switch to the OFF position.

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e. Disconnect the tank at the quick disconnect fitting.
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5 1 11

4 2

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3
1. FUEL VALVE

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2. QUICK DISCONNECT FITTING 6
3. FUEL GAUGE
4. PLUG

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5. LIQUID LEVEL INDICATOR 8
6. HOLE FOR ALIGNMENT PIN

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7. TANK RELIEF VALVE 9
8. STEPS (REFERENCE)
9. LATCH AND STRAP

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10. ACCESS PANEL
11. FRAME (REFERENCE)

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NOTE: Some LPG tanks have an auxiliary fill fitting
instead of a plug for Item 4.
FIGURE 23. LPG TANK
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 MAINTENANCE

f. Release the latch that holds the LPG tank in its d. Turn the fuel valve counterclockwise to open the
bracket. Remove the LPG tank from the bracket. fuel valve.

Use the following procedure to install the LPG tank: e. Inspect the fuel system for leaks when the fuel
valve is open. Frost on the surface of the tank,
a. Before the LPG tank is installed on the lift truck, valves or fittings or a strong odor of LPG fuel indi-
check the operation of the fuel gauge. Look at the cates a leak.

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fuel gauge and move the tank. If the gauge needle

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does not move, a new tank must be installed. Use the following procedure to fill the LPG tank:

WARNING WARNING

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Make sure the alignment pin extends through the cor- Read and follow all the refuelling precautions and in-

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rect hole in the rim of the LPG tank. See FIGURE 23. structions under Liquefied Petroleum Gas (LPG).
The hose or the fittings can be damaged if the LPG
tank is not installed in the correct position. A dam- NOTE: The following instructions are general procedures.

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aged hose or fitting can release LPG fuel and cause There is a variation in equipment for filling LPG tanks.
an explosion and fire hazard. The local authorities that have jurisdiction have specific
rules and regulations for filling LPG tanks. Make sure

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b. Install the LPG tank in its bracket so that the align- these rules and regulations are available and understood.
ment pin is in the correct hole as shown in

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FIGURE 23. Close the latch on the tank bracket. a. Check the LPG tank to make sure it needs filling.
During the fill operation, the LPG tank must be in a

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c. Connect the quick disconnect fitting to the fuel position so that the liquid level indicator will always
valve on the LPG tank. Use your hand to tighten be in the vapor space above the liquid level. See
the fitting. FIGURE 23.
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MAINTENANCE

b. Open the liquid outlet valve and by--pass return j. Close the fuel valve on the LPG tank.
valve on the storage tank.
k. Disconnect the supply hose.
c. Start the pump.
l. Stop the pump.
d. Connect the supply hose to the quick disconnect fit-
ting on the LPG tank. If the LPG tank has an auxil- m. Close the liquid outlet valve and the by--pass return
iary fill fitting, connect the supply hose to this fitting. valve on the storage tank.

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Make sure the correct adapter is used to connect

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the supply hose to the auxiliary fill fitting. TIRES AND WHEELS
e. Open the vent valve on the liquid level indicator.
WARNING

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f. Open the fuel valve on the LPG tank. The type of tire and tire pressure (pneumatic tires)

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are shown on the nameplate. Make sure the name-
g. Open the valve on the end of the supply hose.
plate is correct for the type of tires on the lift truck.
h. Watch for a discharge from the vent valve on the
Some models of lift trucks can be equipped with pneu-

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liquid level indicator. When a cloud of visible vapor
matic tires or solid rubber tires that look like pneumatic
appears, the LPG tank is full. Do not fill the LPG
tires. These variations in the tires also cause a variation in
tank more than the maximum level indicated by the

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liquid level indicator. Immediately close the valve at the types of wheels and the disassembly and assembly
procedures. See FIGURE 24. The procedures for solid
the end of the supply hose.

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rubber tires that look like pneumatic tires are described
i. Close the vent valve on the LPG tank. later in this section.

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 MAINTENANCE

Remove The Wheels From The Lift Truck

2
1
WARNING
Wheels must be changed and tires repaired by
2 3 trained personnel only.
4 Always wear safety glasses.
1

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Completely remove the air pressure from the tire be-

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fore it is removed from the lift truck. If dual wheels
1. WHEEL RIM
2. SIDE RING are installed, remove the air pressure from both tires.
3. WEDGE BAND Air pressure in the tires can cause the tire and rim to

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4. LOCK RING explode causing serious injury or death.

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NOTE: If solid rubber tires are installed, the 1. Raise the lift truck as described in How To Put a Lift
four--piece wheel assemblies must be used. Truck On Blocks in this manual.
12437

2. Remove the air from the tire. Remove the valve core to

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FIGURE 24. TYPES OF WHEELS
make sure that all of the air is out of the inner tube. Push
a wire through the valve stem to make sure that the valve

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stem does not have a restriction. If dual tires are installed,
remove the air pressure from both tires.

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SEE WARNINGS

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STEP 1. Loosen the tire bead from the side ring STEP 3. Turn the tire over. Separate the tire from

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and/or lock ring. the wheel rim.

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STEP 2. Put the tire tool into the slot between the side STEP 4. Remove the wheel rim from the tire.
ring and/or lock ring and the wheel rim. Remove the Remove the inner tube and flap.

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side ring and/or lock ring. 12455

FIGURE 25. REMOVE THE TIRE FROM THE WHEEL

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 MAINTENANCE

3. Remove the wheel nuts and remove the wheel from the Keep tire tools in firm contact with the wheel. If the
lift truck. Be careful not to damage the studs when remov- tool slips, it can move with enough force to cause se-
ing the wheels. Lift truck wheels are heavy. rious injury.
Pneumatic Tires, Remove The Tire From The Wheel Pneumatic Tires, Install The Tire On The Wheel
(See FIGURE 25.) (See FIGURE 26.)
NOTE: When disassembling the wheels, see FIGURE 24.
NOTE: When assembling the wheels, see FIGURE 24.

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There are two types of wheels used on this series of lift
There are two types of wheels used on this series of lift
trucks.

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trucks.
WARNING
Completely remove the air pressure from the tire be-

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fore it is removed from the lift truck. If dual wheels

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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.

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1. Clean and inspect all parts of the wheel. If the wheel

WARNING has rust or corrosion, remove loose rust and corrosion
Failure to follow the procedures can cause the wheel and paint the parts.
assembly to explode and cause injury or death.
Clean and inspect all parts of the wheel before in- 2. Install a new inner tube and flap in the tire. Inner tubes
stalling the tire. DO NOT use any damaged or re- and flaps that have been used in earlier service can
paired wheel parts. Wheels that have been repaired cause tire failure. (Some inner tubes also require a

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can explode when air pressure is added to the tire or backup washer on the valve stem.)

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during operation. Make sure that all parts of the
wheel are the correct parts for the wheel assembly.
Do not mix parts between different types or manufac- WARNING

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turers of wheels. Do not mix type of tires, type of tire Do not lubricate the tire bead with anti--freeze or pe-
tread or wheel assemblies of different manufacturers troleum based liquid. Vapors from these liquids can

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on any one lift truck. cause an explosion when air pressure is added or
when the tire is in use.
Do not use a steel hammer on the wheel. Use a rub-

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ber, lead, plastic or brass hammer to put parts to-
gether. Make sure that the side ring is in the correct 3. Apply a rubber lubricant or a soap solution to the tire
position. The ends of the side ring must not touch. bead and tube.

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The clearance at the ends of the side ring must be 2.5

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to 6.5 mm (0.1 to 0.25 in) after air pressure is added 4. Make sure that the rim is the correct size for the tire.
to the tire. If the clearance is wrong, the wrong part Lubricate the parts of the rim that engage the bead and
has been used. flap.

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 MAINTENANCE

SEE WARNINGS

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STEP 1. Install the inner tube and the flap in the tire.

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STEP 3. Turn over the rim and tire. Put a block under
the rim so that the rim is 8 to 10 cm (3 to 4 inches)

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above the floor. If used, install the wedge band. Install
the side ring and/or the lock ring.

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STEP 2. Install the wheel rim in the tire. Make sure the
stem of the inner tube is aligned with the slot in the rim.

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12455

FIGURE 26. INSTALL THE TIRE ON THE WHEEL

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MAINTENANCE

Add Air To The Tires (See FIGURE 27.)

WARNING
Add air pressure to the tires only in a safety cage. In-
spect the safety cage for damage before use. When
air pressure is added to the tire, use a chuck that fas-
tens onto the valve stem of the inner tube. Make sure

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there is enough air hose to permit the operator to

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stand away from the safety cage when air pressure is
added to the tire.

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Do not sit or stand by the safety cage. Do not use a
hammer to try and correct the position of the side

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ring and/or lock ring when the tire has air pressure
greater than 20 kPa (3 psi).

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FIGURE 27. ADD AIR TO THE TIRES
1. Put the tire in a safety cage.

2. Add 20 kPa (3 psi) of air pressure to the tire.

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5. Check that all wheel parts are correctly installed. If in-
3. Check that all wheel parts are correctly installed. Hit stallation is not correct, remove all of the air pressure

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the side ring and/or lock ring lightly to make sure that it is from the tire. Remove the valve core to make sure all of
in the seat. the air pressure has been removed and make adjust-

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ments. The clearance at the ends of the side ring and/or
4. If installation is correct, add air pressure to the tire. The lock ring will be 13 to 25 mm (0.5 to 1.0 in) when the tire
correct pressure is shown on the nameplate. has the correct air pressure.
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 MAINTENANCE

Solid Rubber Tires, Remove The Tire From The Clean and inspect all parts of the wheel before in-
Wheel (See FIGURE 28.) stalling the tire. DO NOT use any damaged or re-
NOTE: When disassembling the wheels, see FIGURE 24. paired wheel parts. Make sure that all parts of the
There are two types of wheels used on this series of lift wheel are the correct parts for the wheel assembly.
trucks. Do not mix parts between different types or manufac-
turers of wheels. Do not mix type of tires, type of tire
WARNING tread or wheel assemblies of different manufacturers

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Keep tire tools in firm contact with the wheel. If the on any one lift truck.

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tool slips, it can move with enough force to cause se- Do not use a steel hammer on the wheel. Use a rub-
rious injury. ber, lead, plastic or brass hammer to put parts to-

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Solid Rubber Tires, Install The Tire On The Wheel gether. Make sure that the side ring is in the correct
(See FIGURE 29.) position. The ends of the side ring must not touch.

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NOTE: See Figure 24 when assembling the wheels. The clearance at the ends of the side ring and/or lock
There are two types of wheels used on this series of lift ring will be 13 to 25 mm (0.5 to 1.0 in) when the tire
trucks. The four--piece wheel must be used with solid rub- parts have been installed correctly. If the clearance is

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ber tires. Some solid rubber tires will not allow the wedge wrong, the wrong part has been used.
band to be installed. If necessary, install the side ring and Keep tire tools in firm contact with the wheel. If the
the lock ring only.

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tool slips, it can move with enough force to cause se-
rious injury.
WARNING

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Failure to follow these procedures will cause damage
to the tire and wheel assembly and can cause injury

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or death. of
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MAINTENANCE

SEE WARNINGS STEP 3. Turn the tire

over. Put a support
STEP1. Put the wheel under the wheel rim.
rim on the bed of the Make sure the wheel rim
press. Put the cage in is at least 150 to 200 mm
position on the tire. Use (6 to 8 inches) from the

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the press to push the bed of the press.

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tire away from the side
flange.

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STEP 2. Put the tire tool STEP 4. Put the cage in
into the slot between the position on the tire. Use

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lock ring and the wheel the press to push the tire
rim. Remove the lock from the wheel rim.
ring and side flange.

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FIGURE 28. REMOVE THE TIRE FROM THE WHEEL
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 MAINTENANCE

SEE WARNINGS STEP 3. Remove the cage

and put the flange seat (if
STEP 1. Lubricate the
used), the side flange and the
wheel rim and the inner
lock ring in position on the
surface of the tire with
wheel rim. Install the cage on
tire lubricant or soap.
the tire. Use the press to push
the tire onto the wheel rim so

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that the side flange and lock

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ring can be installed.
CAUTION
Too much lubricant can

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cause the tire to slide and
move around the wheel

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rim.

STEP 2. Put the wheel STEP 4. While the cage is

rim on the bed of the

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holding the tire on the wheel
press. Put the tire over rim, install the lock ring. Use
the wheel rim. Put the a tire tool to make sure the
cage in position on the

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lock ring is in the correct
tire. Use the press to position.

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install the tire on the
wheel rim.

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12602

FIGURE 29. INSTALL THE TIRE ON THE WHEEL

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MAINTENANCE

Install the Wheels (See FIGURE 30.)

1. WHEEL RIM
2. HUB
1. Install the wheel on the hub. When dual wheels are
3. WHEEL STUD
used, install the inner wheel so that it is tight against the 4. WHEEL NUT
brake drum. Install the outer wheel. Be careful not to 5. FLANGE
damage the threads on the studs. 6. LUBRICATE

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2. Lubricate the studs and nuts as shown in FIGURE 30. X= NO LUBRICANT

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Do not get any oil on the outer surfaces of the wheel or
the flange of the nut.

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3. Start with the wheel nut at the top and tighten the nuts
to 68 to 136 Nm (50 to 100 lbf ft) in the sequence shown.

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Check to make sure that the wheel(s) is tight against the
hub, then tighten the nuts to 640 to 680 Nm (470 to 500
lbf ft).

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WARNING

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Check all wheel nuts after 2 to 5 hours of operation
when new trucks are put into operation or when

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wheels have been removed and installed. Tighten the
nuts in a cross pattern to the correct torque value

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12437
shown in the MAINTENANCE SCHEDULE table. When
the nuts stay tight for eight hours, the interval for FIGURE 30. INSTALL THE WHEELS
checking the torque can be extended to 150 hours.
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 MAINTENANCE

HOW TO PUT INTERNAL COMBUSTION For safety and increased usable floor area, remove the
ENGINE (I.C.E.) TRUCKS IN STORAGE forks and tag them with the truck serial number.
Prior to operating a truck each month, make a visual in-
Experience has taught that complications can arise as a spection for leaks or signs of deterioration. Take correc-
result of improper handling of trucks during periods of tive action immediately. Also, check the fluid level in the
storage. radiator, hydraulic tank and brake master cylinder.

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The main areas of concern are engines, hydraulic compo- All hydraulic cylinders must be cycled several times each

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nents and truck batteries. month to keep the seals active and to coat the interior
walls with oil. Actuate each cylinder, in both directions, un-
I.C.E. powered trucks can best be protected by being op- til it reaches the stops.

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erated for a short period of time each month.
To protect the tilt cylinder rods, park your trucks with the

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mast tilted fully backward (cylinders retracted).
Before placing any truck in storage, you must choose an
area which is clean, dry and free from airborne contami- When parked with the power off, actuate each control
nates.

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handle to relieve hydraulic pressure.

Trucks powered by I.C.E. must be started and run at 700 CAUTION

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RPM until normal operating temperature is reached. This Mast are to be stored fully lowered to protect cylinder
will coat the internal engine components with a film of oil rods.

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and rid the engine of built--up condensation.
Coat any exposed portion of all cylinder rods with fresh,
high grade SAE 30 or 40 weight engine oil.

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CAUTION
Do not shut down an engine before it reaches operat- Install blocks, front and rear, at the drive wheels when
ing temperature. Engine damage can occur. parked -- DO NOT USE THE HAND BRAKE.
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MAINTENANCE

HOW TO PUT BATTERIES IN STORAGE b. Neutralize and clean the battery. Clean with a solu-
tion of 16 ounces of baking soda to one (1) gallon
Batteries are to be placed on a wooden pallet and stored of water.
in a dry, moderately cool area.
c. Store in a cool dry location.
Lead acid batteries will slowly “self--discharge” over a pe-
riod of time due to their chemical make--up. If the self--dis- d. Check each cell in the battery at least once every
charge is left uncontrolled, excessive sulfation can occur 30 days and boost charge when specific gravity

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which is difficult to reduce and can damage the plates. A falls below 1.240.

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discharged battery with a specific gravity of 1.100 will
e. Protect batteries from ambient contamination.
freeze at --7.8°C (+18°F). A fully charged battery with a

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specific gravity of 1.280 will freeze at --66°C (--87°F). If a greasy film forms on the top of a battery, this is acid
and must be neutralized with the solution described
This “self--discharge” is due to a chemical reaction; there-

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fore, that chemical reaction can be accelerated by heat above.
resulting in more rapid “self--discharge”. The rate of dis- When a truck is to be placed in service after storage, it
charge can amount to an average of about 0.001 point

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must be given the 150 hour inspection shown in the Rec-
drop in specific gravity per day. ommended Schedule of Maintenance.
The following procedure can be followed when placing a

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battery is storage or when not in operation for more than OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE

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30 days:
a. Give an equalizing charge prior to placing new bat- A new or rebuilt engine must be operated under special

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teries in storage. Used batteries are to be fully conditions during the first 50 hours. These special condi-
charged then allowed to balance for approximately tions prevent damage to the engine until the new parts
three more hours. can wear and adjust to fit each other.
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 MAINTENANCE

1. Make sure the fluid levels of oil and coolant are correct. tion. High engine speeds with a light load can cause dam-
age to the cylinders in the engine.
2. Start and run the engine at approximately one--half
throttle for 30 minutes for the first operation. Check the
CHANGES TO THE OVERHEAD GUARD
gauges and indicators for the correct operation during this
first operating period. Check for leaks. WARNING
Do not operate the lift truck without the overhead

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guard correctly fastened to the lift truck.

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3. If the work conditions are slow and the loads are less
than 50% of the truck capacity, a simulated work condition Do not make changes to the overhead guard by weld-
must be used during the first four hours of operation. Op- ing. Changes that are made by welding, or by drilling

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erate the lift truck with a minimum load of 75% capacity. holes that are too big in the wrong location, can re-
Operate the engine through cycles from idle to full throttle duce the strength of the overhead guard. See the in-

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and back to idle. Avoid long periods of high engine structions for “Changes To The Overhead Guard” in
speeds with a light load during the first 50 hours of opera- the PERIODIC MAINTENANCE section.

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 110
MAINTENANCE

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NOTES

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MAINTENANCE

111

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 NO MATTER HOW YOU SAY IT . . .
La Prudence Paye

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La Seguridad Paga

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Betriebssicherheit Macht Sich Bezahlt
Passaa Oll Huolellinen
Veiligheid Voor Alles

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Säkerhet Först

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Essere Sicuro Paga
Seguranca Paga
Sikkerhet Først

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Pinter Be Awas

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WARNING

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California Proposition 65 -- This product contains and/
or emits chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm. 10/02 (10/99)( 3/99) (11/98) (5/97)(9/93) (2/91)(10/89) Printed in U.S.A.
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 History
5/97 - ARW
Updated Operating Manual to include GM V8--366 engine and LPG fuel system. Reformatted Main-
tenance section to more closely follow the revised formats of newer manuals.
11//98 - Lloyd
Revised to add Autoshift.
3/3/99 - Kevin Johnston
s
Added missing Fire Hazard Materials Updates and I.C.E. Storage Updates. Also updated copywrite informa-
ne
tion. Added “Changes to the Overhead Guard”, “Serial Number Data” and “Support Information” sections.
Changed Maintenance Section Layout to match UK version. Addeed “Maintenance Procedures” and “Every 8
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Hours or Daily” section headers. Standardization of formatting also conducted throughout.
10/99 - Jack
Ai
Corrected autoshift details on pages 15, and 24. Added bypass unit on page 28. Added OSHA
statement on page 1. Deleted reference to Operator Seat alarm buzzer on page 23 per Alan Reece
review comments. Corrected formatting errors throughout. Changed illustration on page 85 to show
autoshift fuses. an
ic REVISED: 14
er REISSUED: 96
11/03/99 TOTAL: 110
6/5/00 - Greg Vogel
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Added change to the Operating Procedure (page 50, #7) regarding the use of the side--shift function when pick-
ing up containers. Change was done per Richard Shaber’s instructions.
10/02 - Rich Bundy of
Updated to include shutdown procedure for turbocharged engines.
ty
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D019/E007 Operating Manual -- U.S .
op
H8.00--12.00XL (H165--280XL) [E007]
Pr
H13.00-- 16.00XL (H300-- 360XL) (H330-- 360XL-- EC) [D019]
PART NO. 897342 10/02 (9/99) (5/99) (11/98) (5/97)(9/93)(2/91)(10/89)
DO NOT PUBLISH THIS PAGE
REFERENCE ONLY
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2
 Writer’s Notes
2/20/97 - ARW
Updated Operating Manual to include GM V8--366 engine and LPG fuel system. Reformatted Main-
tenance section to more closely follow the revised formats of newer manuals.
10/28/98 - Lloyd
Created this Writer’s Notes page since none existed. Revising to add Autoshift. Reformatted to cur-
rent format. Changed all Warnings and Cautions symbols to current format. Changed all “N.m (lbf ft”)
and “N.m (lbf in)” torques to “Nm (lbf ft) torque” and “Nm (lbf in) torque” as applicable according to
s
current practice. Added Model Code designations.
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11/9/98 - Lloyd
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Finished. To Chris for routing/printing.
11/11/98 - Lloyd
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Made Chris and Theo’s changes. Back to Chris for routing/printing.
10/11/99 - Jack
an
Corrected autoshift details on pages 15, and 24. Added bypass unit on page 28. Added OSHA
statement on page 1. Deleted reference to Operator Seat alarm buzzer on page 23 per Alan Reece
review comments. Corrected formatting errors throughout. Changed illustration on page 85 to show
autoshift fuses.
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D019/E007 Operating Manual -- U.S .
of
H8.00--12.00XL (H165--280XL)
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PART NO. 897342
H13.00--16.00XL (H300--360XL) er
9/99 (5/99) (11/98) (5/97)(9/93)(2/91)(10/89)
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DO NOT PUBLISH THIS PAGE
REFERENCE ONLY