HOIST LIFTRUCK

OPERATING MANUAL

Model: F250 Hydrostatic

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

REV.11.06.08
LIFTRUCK MODEL_____________________ SERIAL NUMBER_______________________
ENGINE MODEL_______________________ SERIAL NUMBER_______________________
TRANSMISSION MODEL________________ SERIAL NUMBER_______________________

SPECIAL EQUIPMENT OR ATTACHMENTS

1
FOREWORD that it is maintained in good
condition.
To OWNERS, USERS, and • Read and understand the warnings
and operating procedures in this
OPERATORS:
manual.

The safe and efficient operation of In addition a qualified person,

a lift truck requires skill and alertness
on the part of the operator. To develop
the skill required the operator must:
• Receive training in the proper
operation on THIS lift truck.
• Understand the capabilities and
limitations of the lift truck.
• Become familiar with the
construction of the lift truck and see
experienced in lift truck operation, must
guide a new operator through several
driving and load handling operations
before the new operator attempts to
operate the lift truck alone.
It is the responsibility of the employer to
make sure that the operator can see,
hear, and has the physical and mental
ability to operate the equipment safely.

1
Various laws and regulations require the
employer to train lift truck operators.
The laws and regulations include:
Occupational Safety and Health Act
(USA)
Canada Material Handling Regulations
NOTE: A comprehensive operator
training program is available from you’re
your HOIST LIFTRUCK Dealer.
This OPERATING MANUAL contains
information necessary for the operation
of a basic fork lift truck. Optional
equipment is sometimes installed that
2
can change some operating
characteristics described in this manual.
Make sure the necessary instructions
are available and understood before
operating the lift truck.
Some of the components and systems
described in this OPERATING MANUAL
will NOT be installed on your unit. If
you have a question about any item
described, contact your Hoist Liftruck
Dealer.
Additional information that describes
the safe operation and use of lift trucks
is available from the following sources
• Employment safety and health Operations, from the National Safety
standards or regulations (Examples: Council).
“Occupational Safety and Health
Standards (USA)”, “Canada Material
Handling Regulations”.

• Safety codes and standards

(Example: American National NOTE: Hoist Liftrucks are not intended
Standard, ANSI B56.1, Safety for public roads.
Standard For Low Lift And High Lift
Trucks.

• Publications from government safety

agencies, government insurers,
private insurers and private
organizations (Example: Accident
Prevention Manual for Industrial

3
NOTE: The following symbols and
words indicate safety information in this CAUTION
manual:
Indicates a condition that can cause
WARNING property damage!

Indicates a condition that can cause

injury!

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 CONTENTS
FOREWORD…………………………………………………………1
CONTENTS.…………………………………………………………2
MODEL DESCRIPTION………………………….………………8
OPERATOR PROTECTION EQUIPMENT….….9
NAME PLATE ……………………………………..…9
SAFETY LABELS…………………………………….10
INSTRUMENTS AND CONTROLS………………12
OPERATING PROCEDURES….………………….26
Know Your Lift Truck………………..26
Stability and Center of Gravity…..27
CAPACITY (Weight and Load Center)…….…30
INSPECTION BEFORE OPERATION………….32
Checks with Engine OFF…………...32
Starting Procedures………………….33
The SRO Circuit……………………….35
Checks with the Engine Running..36
OPERATING TECHNIQUES……………………..39
Basic Operating Procedures……….39
Driving And Direction Change……44
Steering (Turning)……………………45
Load Handling, General…………….48
Load Handling, Lifting, Lowering,
5
And Tilting……………….……………51
Load Handling, How To Engage
And Disengage A Load……………55
Load Handling, Traveling…………..61
HIGHWAY TRUCKS, RAILROAD CARS
AND DOCKS…………………………………….66
ATTACHMENTS…………………………………..…69
STOPPING…………………………………………….69
PARKING………………………………………………70
GENERAL………………………………………………71
HOW TO MOVE A DISABLED LIFT TRUCK..73
How To Tow The Lift Truck……….74
How To Put A
Lift Truck On Blocks………….….75
How To Raise
the Drive Tires……………….…….77
How to Raise
the SteeringTires………………….78
MAINTENANCE SCHEDULE………………………………….79
HOW TO MAKE CHECKS WITH THE
ENGINE STOPPED………………………..….85
Hydraulic System…….…………..85
Engine Oil……………………….…………..…86
 Air Filter………………………………………... 87 HOW TO ADD FUEL TO THE LIFT TRUCK……………101
Drive Belts…….……………..……………..…..88 Liquified Petroleum Gas (LPG)…………………….102
Cooling System…….…………………………..88 Install the LPG Tank.……………….…………………104
Fuel System…….……….………………………89 Procedure To Fill the LPG Tank..………..……….105
UPRIGHT, FORKS, AND LIFT CHAIN….…………………91 Gasoline or Diesel Fuels.…………………………….107
FORKS-GENERAL……………………………………………..91 OPERATING PROCEEDURES FOR A NEW OR
FORKS-ADJUSTMENTS……….……………………………..91 REBUILT ENGINE…………………………………………108
Hook Forks…….…………..…………………………91 TIRES / WHEELS…………………………..………………….109
Pin Forks……..…………………….………..……….91 Solid Rubber Tires(Press On)………………………...111
Forks Removal……….………….…………………..92 Remove and Install the tire from the
Inspecting Mast, Forks and Lift Wheel…………………………………………111
Chains……………………………………………93 OVERHEAD GUARD.……………………………………..…..112
TIRES AND WHEELS…………..………………………………94 ADDENDUM……………………………………………………..113
OPERATOR RESTRAINT SYSTEM…………………..…….95
How to Make Checks with the Engine
Running …………………………………………96
GAUGES, HORN AND FUSES……….………………….……97
OIL LEVEL, POWERSHIFT TRANSMISION.…..…….….97
CONTROL LEVERS AND PEDALS..…………..…..……….98
LIFT SYSTEM OPERATION ………………………………….98
SERVICE BRAKES……………………….…………………….100
PARKING BRAKE……………………….……………………..100
STEERING SYSTEM…………………………………..………101

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 1

2
9

6 5 7
 FKS SERIES
Model Description
General 1) OVERHEAD GUARD
2) MAST
This Operating Manual is for the 3) CARRIAGE
following models of lift trucks. 4) FORKS
5) DRIVE AXLE
6) STEERING AXLE
7) COUNTWEIGHT
8) SEAT BELT AND HIP RESTRANT
9) OPERATOR’S COMPARTMENT

Refer to Hoist Liftruck’s Service Manual

for specifications on your Hoist Liftruck.

8
OPERATOR PROTECTION EQUIPMENT
The OVERHEAD GUARD is intended to
offer reasonable protection to the
operator from falling objects, but can
not protect against every possible
impact. Therefore, it must not be
considered a substitute for good
judgment and care when handling
loads. Do not remove the overhead
guard.
The SEAT BELT provides additional
means to help the operator keep the
head and torso substantially within the
confines of the lift truck frame and over
head guard if a tipover occurs. Always
9
fasten the seat belt. Hip restraints
always operate in the down position.
NAME PLATE
The rated capacity for the lift truck, as it
is equipped, must be shown on the
name plate. If the lift truck name plate
already has a rating for special load
handling equipment, it will be shown. If
the lift truck name plate does not show
the rated capacity, or if the lift truck
equipment does not match that shown
on the name plate , the lift truck must
not be operated until the capacity is
known.
 WARNING SAFETY LABELS

Safety labels are installed on the lift

DO NOT add to or modify the lift truck to give information about possible
truck. Any change to the lift truck, hazards. It is important that all safety
the tires or its equipment can labels are installed on the lift truck and
change the lifting capacity. The lift can be read.
truck must be rated as equipped
and the name plate must show the
new capacity rating.

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SAFETY LABELS

TIP-OVER WARNING

NO RIDERS

NO ONE ON OR
UNDER FORKS

MAST WARNING
CRUSH POINTS

MOVING FAN 11
WARNING
 Controls & Indicators

Key Switch: Is used to start the engine

and power the trucks electrical system.
By turning the key clockwise will start
the engine. Once the engine has started
the key switch will return to the run
position “ON”. To shut down the engine
and trucks electrical system, turn the key
switch counter clock wise to the “OFF”
Key Switch
position.
Cab Fan: The rocker type switch is
used to turn on the fan in the operator’s
compartment. To turn on the fan push on
the rocker type switch. To turn off the
fan push on the rocker type switch.
Parking Brake Working Lights: The rocker type
switch is used to turn on the outside
working lights. To turn on the lights
Cab Fan Working Lights push on the rocker type switch. To turn
off the lights push on the rocker type
switch.
 Controls & Indicators

Steering Wheel Horn Button: Is used to sound the

horn, to sound the horn push on the
horn button.
Steering Wheel: To steer the truck in
Engine idle any direction place both hand on the
speed steering wheel. To turn right while
traveling in either direction, turn the
steering wheel clockwise. To turn left
while traveling in either direction, turn
the steering wheel counter clockwise.
Engine Idle Speed: Is control by a
rocker type switch, OFF position is the
low idle and ON is the high idle.
Horn Button
 Controls & Indicators

Engine Maintenance: Indicator will

Engine Stop illuminate to inform the operator the
Engine engine needs maintenance.
Engine Oil
Maintanence Engine Stop: Indicator will illuminate
to inform the operator the engine stop
due to a fuel, mechanical or electrical
issue with the engine.
Transmission Engine Oil: Indicator will illuminate
Oil to inform the operator of a low engine
Engine oil condition.
Diagnostic Water in Fuel ! : Indicator will illuminate when the
engine is in the diagnostic mode.
Water in fuel: Indicator will
illuminate when there is water
detected in the fuel system.
Transmission Oil: Indicator will
illuminate to inform the operator of a
low transmission oil condition.
 Controls & Indicators

Air Filter: Indicator will illuminate

when the filter needs cleaning or
replacing.
Brake Pressure: Indicator will
illuminate to warn the operator the
brake pressure low. This must be
Brake Pressure corrected before using the truck.

Air
Filter
 Operating
The hydraulic functions lift/lower, tilt and side shift are controlled
by a series labeled control levers located on the operator’s
compartment. To lift a load to the desired height pull back on the
lift/lower lever. To lower the load, push forward on the lift/lower
lever. To tilt the load back, pull back on the tilt lever. To tilt the
load forward, push forward on the tilt lever. To side shift the load
left, push forward on the side shift lever. To shift right, pull back on
the side shift lever.
Operating
This truck is equipped with a clamp attachment. The
clamp and rotate function is controlled by two hydraulic
levers in the operator’s compartment. To rotate the clamp
clockwise pull back on the labeled rotate lever. To rotate
the clamp counter-clockwise push forward on the rotate
lever. To close the clamp pull back on the labeled clamp
lever. To open the clamp push forward on the clamp lever.
 Controls

Forward

Neutral
2nd Brake Pedal

1st Brake Pedal

Reverse

This truck is equipped with a hydrostatic

transmission. The forward, reverse and neutral is controlled by a spring applied rocket type pedal
located on the floor of the operator`s compartment. The direction of the truck is controlled by the
operator`s foot. To move the truck forward the operator must rock the pedal forward “toward the load”.
To move the truck in reverse the operator must rock the pedal back “toward the operator”. To put the
truck in to neutral remove the foot from the rocker pedal and the spring applied will return the pedal to
neutral.
This truck is equipped with two brake pedals located on the floor in the operator’s compartment. The
brakes are applied by the operator’s foot. To stop the truck the operator must remove the left foot off
the rocker directional control pedal and push down on the 1st brake pedal. The right foot can also be
used to stop the truck by using the 2nd brake pedal.
 Multi Function Combination Indicators and Gauges
6
1

7
2

8
3

9
NA

10
5

The purpose of this gauge is to monitor various functions informing the operator of the vehicle’s operating
condition.
 Multi Function Combination Indicators and Gauges
11
13

12
14
 Multi Function Combination Indicators and Gauges

Descriptions of the indicators and gauge readings:

1. Engine oil pressure indicator will illuminate “RED” when there is low or no engine oil pressure.
2. Transmission oil temperature indicator will illuminate “yellow” when the transmission has reached its
maximum temperature.
3. Parking Brake indicator will illuminate “RED” when the parking brake is engaged.
4. This indicator is not used.
5. This arrow key is used to switch between the water temperature “11” and fuel level “12” bar graph
display. Pushing the arrow key will display fuel level or water temperature.
6. Fuel level indicator will illuminate “RED” when there is low diesel or gasoline.
7. Engine water temperature indicator will illuminate “yellow” when the engine water temperature is in the
over heating condition.
8. Battery indicator will illuminate “RED” when there is a problem with the electrical charging system.
9. Maintenance indicator will illuminate “yellow” at 250hrs this will let the operator know it is time to
have the truck “PM”.
10. Triangle/ Dot key is use to display meter hours or standard time in the display box “14” by pushing the
key will switch between meter hours and time. To adjust the time, push the arrow key setting the hour,
minutes and seconds to the desired settings.
OPERATING PROCEDURES In order to understand how the
forklift truck can pick up a load, you
GENERAL must first know some basic things
about the lift truck.
Know Your Lift Truck

The forklift truck is designed to pick

up and move materials. The basic
lift truck has a lift mechanism and
forks on the front to engage the
load. The lift mechanism lifts the
load so that it can be moved and
stacked.

The lift truck is based on the

principle of two weights balanced on
opposite sides of a pivot (fulcrum).

1
26
This is the same principal used for a
see-saw. In order for this principle
to work for a lift truck, the load on
the forks must be balanced by the
weight of the lift truck. The location
of the center of gravity of both the
truck and the load is also a factor.
Stability and Center Of Gravity
The center of gravity (CG) of any
object is the single point about which
the object is balanced in all
directions.

This basic principle is used for

picking up a load. The ability of the
lift truck to handle a load is
discussed in terms of center of
gravity and both forward and side
stability.

27
 CG Truck
Every object has a CG. When the lift
truck picks up a load, the truck and
load have a new combined CG.

The stability of the lift is determined

by the location of its CG, or if the
truck is loaded, the combined CG.
The lift truck has moving parts and
therefore has a CG that moves. The
CG moves forward and back as the
mast is tilted forward and back. The
CG moves up and down as the mast
moves up and down.
The center of gravity, and therefore
the stability, of the loaded lift truck is
affected by a number of factors,
such as size, weight, shape, and
position of the load: the height to
which the load is raised, the amount
of forward and

28

backward tilt, and the dynamic
forces created when the truck is
moving. These dynamic forces are
caused by
29
things like acceleration, braking,
turning, and operating on uneven
surfaces or on an incline. These
factors must be considered when
traveling with an unloaded truck, as
well, because an unloaded truck
will tip over to the side easier
than a loaded truck with its load in
the lowered position.
In order for the lift truck to be stable
(not tip over forward or to the side)
the CG must stay within the area of
the lift the truck represented by a
triangle drawn between the drive
wheels and the pivot of the steering
axle.
If the CG moves forward of the drive
axle, the lift truck will tip forward. If
the CG moves outside of the line
represented by the lines drawn
30
between the drive wheels and the
steering axle pivot, the lift truck will
tip to that side.
Capacity
(Weight and Load Center)
The capacity of the forklift truck is
shown on the name plate . The
capacity is listed in terms of weight
and load center. The weight is
specified in kilograms or pounds.
The load center is specified in
millimeters or inches. The capacity
is the maximum load that the lift
truck can handle. This load must
weigh less than the maximum weight
for a load center shown on the name HOIST NAME PLATE
plate.

The load center of a load is

determined by the location of its
center of gravity. The load center is
measured from the front face of the
forks, or the load face of an
attachment, to the center of gravity
of the load. It is also assumed that
the location of the center of gravity
in the vertical direction is no greater
than the specified horizontal
dimension.

31
The operator must know whether or • Fuel level (if the lift truck has a
not a load is within the capacity of diesel engine, drain water from
the lift truck before the load is the primary filter).
handled.
• Oil level in the engine and
INSPECTION BEFORE OPERATION hydraulic tank.

Checks with the engine off • Coolant level in the cooling

Inspect the lift truck before use as system Reservoir.
described in the Hoist Liftruck
Service Manual. • Condition of the drive belts.

Before using the lift truck, make the • Condition of forks, carriage,
following checks: chains, mast and overhead
guard.

32
• Condition of the radiator. Clean if Report damage or faulty
necessary. operation immediately. Do not
operate a damaged or defective
• Leaks from the engine, lift truck. A lift truck will only
transmission, hydraulic system do its job when it is in proper
and fuel system. working order. If repairs are
required, install a tag in the
• Condition of wheels and tires. operator’s area stating “DO NOT
OPERATE” and remove the key
• Operator Restraint system and from the key switch.
Seat belt latches properly.
STARTING PROCEDURES
• Hood is securely latched.
Do not start nor operate the lift
truck, including any of its functions
WARNING or attachments, from any place other

33
than the designated operator’s 2. Make sure the parking brake is
position. applied or push on the brake
pedal.
GASOLINE OR LPG ENGINE
3. Place the directional control lever
1. If the lift truck uses LPG fuel, for the transmission in the
open the fuel valve on the LPG NEUTRAL (N) position.
tank.
4. Turn the key to START position
WARNING to engage the starter.

LPG is very flammable. An odor WARNING

of LPG fuel can indicate a leak in
the fuel system. DO NOT start
the engine until the fuel leak is
repaired.
Do not engage the starter for
more than 30 seconds at a time.
If the engine does not start,turn
the key switch to OFF.

34
Wait 60 seconds before DIESEL ENGINE
engaging the starter again. 1. Make sure the parking brake is
applied or push on the brake pedal.
If the engine does not start after
four attempts, get help from 2. Place the direction control lever
authorized service personnel. for the transmission in the
NEUTRAL (N) position.
5. When the engine is running,
check the gauges and indicator 3. For Cold starts active the glow
lights for correct operation. See plugs for up to 15 seconds.
the instruments And Controls
section for a description of the CAUTION
correct operation. Use only approved starting aids.
Use of non-approved starting
aids can result in engine
damage and void engine
warranty.

35
1. If the engine does not start after
four attempts, get help from
authorized service personnel.
5. When the engine is running, check
the gauges and indicator lights for
the correct operation. See the
Instruments and Controls section for
a description of the correct
operation.
36
CHECKS WITH THE ENGINE
RUNNING
WARNING
FASTEN SEAT BELT
If the lift truck tips over:
Do not jump – Stay on truck
- Hold on firmly to steering
wheel – brace feet – lean
forward and away from impact.
The seat belt is installed to help
the operator stay on the truck if
the truck tips over. IT CAN
ONLY HELP IF IT IS FASTENED.
The operator must be aware that the
lift truck can tip-over. There is a
great risk that the operator or
someone else can be killed or injured
if trapped or hit by the truck as it
tips over. The risk of injury can be
37
reduced if the operator stays on the
truck. If the truck tips over do not
jump off.
The SEAT BELT AND HIP RESTRAINT
provide a means to help the operator
keep the head and torso
substantially within the confines of
the truck frame and overhead guard
if a tip-over occurs. The protection
system is intended to reduce the risk
of the head and torso being trapped
between the truck and the ground,
but it can not protect the operator
against all possible injury in a tip-
over.

Make sure that the area around the
lift truck is clear before starting the
engine or making any operational
checks. Be careful when making the
checks. If the lift truck is stationary
during a check, apply the parking
brake and put in NEUTRAL.
Proceed carefully.
Check the operation of the following
• Check the operation of the horn,
gauges and indicator lights.
38
• Check the oil level in the
transmission. This should be
checked with the direction control
lever in the neutral position,
parking brake on and the engine
at idle speed.
• Operate the LIFT, TILT and
auxiliary functions to check for
correct operations.
• Check the operation of the
steering system.
• Check the operation of the
direction control lever and
accelerator pedal.
 There are a number of
• Check the operation of the operations, if not performed
service brakes and parking brake. carefully, that can cause the lift
truck to tip. If you have not read
the WARNING page in the front
of this Operating Manual, do so
NOW. As you study the
OPERATING TECHNIQUES following information about
how to properly operate a lift
WARNING truck, remember the
WARNINGS.
* Before operating the lift truck
FASTEN YOUR SEAT BELT. Basic Operating Procedures

Many people make the mistake of

thinking that operating a lift truck is
the same as driving an automobile.

39
This is not true. It is true that some
lift truck operating procedures are as
simple and obvious as driving the
family automobile. (E.g. Look where
you are going, start and stop
smoothly, etc.) But a lift truck is a
special machine designed to do a
much different job than an
automobile. Because of the close
areas in which a lift truck operates
and its other operating
characteristics (like rear wheel The following discussion lists basic
steering and tail swing), every procedures applicable to lift truck
operator must receive additional operation.
training, even if they have a license
to drive an automobile. 1. AUTHORIZED AND TRAINED
OPERATOR ONLY. This means

40
the operator must be trained to driving and to expect the
drive the lift truck and it means unexpected.
that the operator must
thoroughly understand the 2. Operate the lift truck only in
procedures for lift truck areas that have been approved
operation. It also means that a for lift truck operation.
qualified person experienced in
lift truck operation must guide
the operator through several
driving and load handling
operations before the operator
attempts to operate the lift truck
alone. A basic education in
proper driving and load handling
techniques is absolutely
necessary to prepare the new
operator for proper defensive

41
Certain areas contain hazardous anyone to ride on the forks or
flammable gases, liquid, dust, fibers anywhere else on the lift truck.
or other materials. Lift trucks that
are operated in these areas must
have special fire safety approval.

These areas must be designated to

show the type of lift truck approval
required for operation in the area.
Changes to special equipment or
poor maintenance can make the lift
truck lose its special approval.
3. NO RIDERS. A lift truck is built
for only one person—the
operator. It is dangerous for
WARNING
This lift truck is designed and
intended for handling materials.
A lift truck is not designed to lift
people and may not meet the
requirements of ANSI A92.6 for
lifting people. Do not use a lift
truck to lift people unless it has

42
been determined that there is
no other practical option
(scaffolds, elevated work
platforms, aerial baskets, etc.)
to perform the needed work.
If a lift truck is used to elevate a
worker, a safety platform must
be attached to the forks and
carriage. The platform must be
specially built to meet or exceed
the requirements of ANSI B56.1.
It must have a solid floor with a
surface to prevent the feet of
the worker from slipping, hand
rail, toe board and a screen or
shield at least 2 meters (7 feet)
43
high between the people on the
platform and the lift mechanism.
Before anyone is allowed on the
platform, lift and lower the mast
slowly with the platform in place
to make sure the mast functions
properly. Apply the parking
brake. Do not travel with
people on the platform. The
operator must remain at the
controls. Watch for overhead
obstructions.
4. Do not drive a lift truck into an
elevator unless authorized to do
so. Approach the elevator slowly.
 After the elevator is properly
leveled, the lift truck must be
centered so that the elevator is
balanced.
When the lift truck is in the proper
position in the elevator, set the
brakes, put the controls in
NEUTRAL and shut off the power.
It is advisable that all other
personnel leave the elevator before
the lift truck enters or leaves.
44
5. Drive carefully, observe traffic
rules and be in full control of the
lift truck at all times.
Be completely familiar with all the
driving and load-handling techniques
contained in this OPERATING
MANUAL.
Driving and Direction Changes
Hoist Internal Combustion lift trucks
are equipped with a three-speed
automatic transmission.
Move the direction control lever
toward the front of the lift truck to
go FORWARD. Move the lever
toward the rear of the lift truck to go
in REVERSE. The direction control
lever also has range selection to
control the speed of the lift truck.
Twist the direction control lever
toward the front of the lift truck to
increase speed. Turn the direction
control lever towards the back of the
truck to decrease speed.
WARNING
The drive train can be damaged
if the lift truck is traveling when
the controls are changed to the
opposite direction.
Steering (Turning)

The operator of the lift truck can

select the opposite direction only
when the lift truck comes to a full
stop.

45
 WARNING
TRAVEL SLOWLY WHEN
TURNING. The lift truck can tip
over even at very slow speeds.
The combination of speed and
sharpness of a turn can cause a
tipover. A lift truck is less stable
when the forks are elevated,
with or without a load. Most
operators can understand the
need to be careful when
handling loads. But some
operators do not realize that a
tipover can occur with an empty
lift truck because similar
dynamic forces are present. In
fact, the lift truck will actually
46
tip over easier when empty,
than when loaded with the load
lowered. Rearward tilt, off-
center loads and uneven ground
will aggravate these conditions.
WARNING
IF THE LIFT TRUCK TIPS OVER,
DO NOT JUMP OFF! HOLD
FIRMLY TO STEERING WHEEL,
BRACE YOUR FEET, AND LEAN
FORWARD AND AWAY FROM
THE POINT OF IMPACT.
Because lift trucks are designed to
work in a relatively small space, they
can turn sharper than some other WARNING
vehicles.
Failure to observe the tail swing
Most lift trucks are steered by the area when making a turn can
rear wheels and the rear of the lift injure or kill someone.
truck can move to the side very fast
during a turn. This movement is
called “tail swing”.
An operator must
be aware of tail
swing and always
check to make
sure the tail swing
area is clear before
turning.

47
Do not turn on an incline. To reduce enter the narrow aisle going straight
the possibility of a tipover, a lift truck ahead.
must not be driven across an incline.

When possible, keep both hands on

the steering wheel. During most
loading or unloading operations, the
operator steers with the left hand.
The right hand is used to operate
the lift, tilt, and attachment controls.

When turning the lift truck from a Load Handling, General

wide aisle into a narrow aisle, start
the turn as close to the opposite 1. Handle only loads within the
stockpile as tail swing will permit. rated capacity as shown on
This action permits the lift truck to the name plate.

48
 This rating represents the such conditions exist, the operator
maximum load that can be lifted. must reduce the load so that the lift
truck will remain stable.

2. Handle only stable loads. A load

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

WARNING

However, such factors as weak Do not handle a load if any part

floors, uneven terrain, special load the load is likely to fall.
handling attachments or loads
having a high center of gravity can
mean that the safe working load is
less than the rated capacity. When

49
 Make sure the pins that keep the
3. Position each fork the same forks in position are engaged so that
distance from the center of the the forks cannot move.
carriage. This action will help center
the load on the carriage. Set the
forks as far apart as possible for
maximum support of the load.
Center the weight of the load
between the forks. If the weight of
the load is not centered between the
forks, the load can fall from the forks
when you turn a corner or hit a
bump. An off-center load will
increase the possibility of the truck 4. Check the condition of the driving
tipping over to the side. surface. Make sure the floor will
support the weight of the lift truck
and the load.

50
Load Handling, Lifting,
Lowering, And Tilting

Separate levers control the LIFT and

TILT functions. See the Controls and
Instruments section for the correct
operation.

The speed of the hydraulic functions

is controlled by the position of the
control levers. The farther the hand
lever is moved from the NEUTRAL
position, the faster the speed of the Do not lift or hit anything that can
hydraulic function. fall on the operator or a bystander.
Remember, a lift truck equipped with
a HOIST® overhead guard provides

51
reasonable protection to the
operator from falling objects, but can
not protect against every possible
impact.

A lift truck without an overhead WARNING

guard provides no such protection
and other personnel have no
overhead protection. Avoid hitting
objects such as stacked material that
could become dislodged and fall.
Keep yourself and all others
clear of the lift mechanism.
Never allow anyone under or on
the forks.

The operator must exercise care

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

52

WARNING
NEVER put hands, arms, head or
legs through the mast or near
the carriage or lift chains. This
warning applies not only to the
operator but also a helper. A
helper must not be near the load
or lift mechanism while the
operator is attempting to handle
a load. The lift mechanism has
moving parts with close
clearances that can cause
serious injury.
53
Lift and lower with the mast vertical
or tilted slightly backward from
vertical. Tilt elevated loads forward
only when directly over the
unloading place. If the lift
mechanism is raised to pick up or
deposit a load, keep the tilt angle in
either direction to a minimum.
Backward and forward tilt are
helpful, but they affect side and
forward stability. Do not tilt in either
direction more than necessary when
handling a load that is raised. The
lift truck can tip forward if the mast
is tilted forward with a load in the
raised position.
 WARNING
The lift truck can tip over
forward when the load is raised.
Forward tipping is even more
likely when tilting forward,
braking when traveling forward
or accelerating in reverse.
IF THE LIFT TRUCK TIPS OVER,
DO NOT JUMP OFF! HOLD
FIRMLY TO STEERING WHEEL,
BRACE YOUR FEET, AND LEAN
AWAY FROM POINT OF IMPACT.

54
Load Handling, How To Engage Approach the load carefully. Make
And Disengage A Load sure that the truck is perpendicular
to the load. Raise the forks to the
proper height for engaging the load.
1. Avoid fast starts. Sudden 2. Move forward slowly until the
movement can cause the lift forks are in position under the
truck to tip. People can be hurt load. The forks must support at
or killed and material can be least two-thirds (2/3) of the
damaged. length of the load.

55

Make sure that the load is centered
between the forks. Make sure that
the forks do not extend past the load
so that loads or equipment that are
behind the load being lifted are not
damaged. Lift the load a small
distance from the floor to make sure
the lift truck has the capacity to lift
the load.
56
If the forks are longer than the load,
move the forks under the load so
that the tips of the forks do not
extend beyond the load. Lift the
load from the surface. Move
backward a few inches, then lower
the load onto the surface and inch
forward to engage the load against
the carriage. Tilt the mast backward
just far enough to lift the load from
the surface.
3. When a load is put on the floor,
tilt the mast forward to a vertical
position and lower the load. Tilt
the mast forward to permit
smooth removal of the forks.
Carefully move the lift truck
backward to remove the forks
from under the load.
57
4. If the load is being removed
from a stack, slowly move the lift
truck away from the stack. When
the load is clear of the stack,
lower the load for traveling.
Always travel with the load as
low as possible and tilted
backward. Lowering speed is
controlled by the position of the
control lever. Lower slowly and
smoothly. Slowly return the
control lever to the neutral
position so that the load is not
dropped or that the lift truck is
not tipped over due to the rapid
stop of the load.
 placed and “jog” the load up
into position. This operation
uses added energy,
particularly with and electric
lift truck. Be careful not to
damage or move adjacent
loads.

2. To put the load on a stack,

align the lift truck with the
stack. Lift the load to eye
level and then tilt the load
forward until it is level. Raise
the load higher than the point
where it will be placed. Do
not raise the load to a point
below where the load is to be

58
 WARNING
Move carefully and smoothly
when the load is raised over a
stack. When the load is
elevated the center of gravity of
the lift truck and the load is
much higher. The lift truck can
tip over when the load is raised. Move forward slowly. When the load
is in position for lowering on a stack,
IF THE LIFT TRUCK TIPS OVER tilt the mast to a vertical position
EITHER TO THE SIDE OR and lower the load. Lower the forks
FORWARD, DO NOT JUMP OFF! just enough to remove them from
HOLD FIRMLY TO STEERING under the load. Do not lower the
WHEEL, BRACE YOUR FEET, AND forks so that they will drag on the
LEAN FORWARD AND AWAY
FROM THE POINT OF IMPACT.

59
surface under the load. Tilt the mast
forward just enough to permit
smooth removal of the forks from
under the load. Carefully move the
lift truck backward to remove the
forks from under the load. Lower
the forks when traveling.

3. When lifting round objects,

use a block behind the object. NOTE: Not every load can be lifted
Tilt the mast forward so that using only the forks of a lift truck.
the forks can slide along the Some loads will require a special
floor under the object to be attachment.
lifted. Tilt the mast fully
backward to help keep the
load on the forks.

60
Load Handling, Traveling
1. When traveling with the load
lowered, keep the load against
the carriage and the mast tilted
fully backward. This will help
keep the load on the forks and
give good forward and side
stability.
When the mast, carriage or load is in
an elevated position the stability of
the lift truck is reduced. This is also
critical when the lift truck is not
carrying a load. The ability of the lift
truck to resist side tipping can be

2. Travel with the lift mechanism

raised only enough to clear the
ground or obstacles.

less on a lift truck without a load

than it is on a lift truck with a load in
the lowered (travel) position.

61
Therefore, a lift truck without a load
is more likely to tip sideways,
especially in a turn, than a lift truck
with a load carried in the lowered
position.
3. For better visibility with large
loads, travel with the load trailing (in
reverse), but always keep a proper
lookout in the direction of travel.
Normally, direction of travel is
determined by the best visibility
available to the operator. If the lift
truck must travel in a direction
where visibility is obstructed, a
lookout helper may be required.
62
WARNING
Some lift trucks have mirrors for
viewing along the side to
observe the tail swing area.
These mirrors are an aid to the
driver, but are NOT driving
mirrors and must NOT be used
as such when operating reverse.
Always look in the direction of
travel to avoid
damage to something or injury
to someone.
4. When traveling up or down a 5. Watch out for pedestrians at all
grade with a heavily loaded lift times. Do not drive up to anyone
truck, keep the load upgrade to standing in front of an object.
maintain control.

When operating an unloaded lift Use extra care at cross – aisles,

truck on a steep grade, keep the doorways and other locations where
counterweight upgrade. pedestrians can step into the path
of travel of the lift truck. Slow down
when approaching blind intersections

63
 7. Avoid bumps, holes, slick spots
or turns and sound the horn. This and loose materials that may
alarm is to warn pedestrians that cause the lift truck to swerve or
there is a vehicle in the area and to tip. If unavoidable, slow down.
be alert to possible danger.

6. Anytime the lift truck is moving

keep arms, legs, etc, inside the
operator’s compartment. Arms
and legs outside the machine can
be injured when passing
obstructions. Arms and legs Different models of lift trucks are
outside the machine can be designed to operate under different
injured when passing conditions. Lift trucks with solid
obstructions. rubber tries are designed to operate
on relatively smooth, firm surfaces.

64
Lift trucks with pneumatic style tires
can adapt to more uneven ground.
Always make sure you choose the
smoothest route for your lift truck.
8. Watch clearances, especially
forks, mast, overhead guard and
tail swing. A lift truck is designed
to perform a wide variety of
functions within limited space.
Make sure that the forks do not
extend past the load so that
loads or equipment that are
behind the load being lifted are
not damaged.
65
Serious accidents can be caused by
masts and overhead guards hitting
pipes and beams near the ceiling.
9. Do not indulge in stunt driving or
horseplay.
10. Do not pass another lift truck
traveling in the same directions
at intersections, blind spots or at
other dangerous locations.
11. Stay away from the edge of the HIGHWAY TRUCKS, RAILROAD
road. Keep the wheels of the lift CARS AND DOCKS
truck, particularly the steer
wheels, on the roadway. If the WARNING
wheels are allowed to run off the
edge of the travel surface onto Maintain a safe distance from
soft ground, the lift truck can tip the edge of docks, ramps,
over. platforms and other similar
working surfaces. Watch the
12. Under all travel conditions; “tail swing”.
operate the lift truck at a speed
that will permit it to be brought
to a stop in a safe manner.

66
 to open or close the door on a
WARNING railroad car unless the lift

IF THE LIFT TRUCK FALLS OFF

THE DOCK, DO NOT JUMP OFF!
HOLD FIRMLY TO STEERING
WHEEL, BRACE YOUR FEET, AND
LEAN FORWARD AND AWAY
FROM THE POINT OF IMPACT!

Before operating in a highway truck

or railroad car, observe the
following:
DO NOT use a lift truck to move a
railroad car. DO NOT use a lift truck
truck has an attachment that is
specifically designed for opening and
closing railcar doors and the
operator is trained in its use.

67
Check to make sure that the brakes
on the highway truck are set and
that wheel blocks have been placed
on both sides of the rear wheels
(unless a dock locking mechanism is
engaged). Fixed jacks may be
necessary to support the front and
rear of a semi-trailer to prevent it
from moving or tipping during
loading or unloading.
Make sure that the railroad car
brakes are set and the wheels are
blocked while loading or unloading.
Do this so that the railroad car will
not move due to the movement of
68
the lift truck in and out of the
railroad car.
Check the condition of the driving
surface. Make sure the floor will
support the weight of the lift truck
and the load.
Make sure the dockboard is secured,
in good condition and of the proper
capacity.
When entering a railroad car the
operator can enter at an angle (if the
dock plate or bridge is wide enough).
This will reduce the turning required
after entering.
ATTACHMENTS STOPPING

If an attachment is installed on the Stop the truck as gradually as

lift truck, make sure the operating possible. Hard braking and wheel
instructions are available and sliding can cause the load to fall off
understood before operating the of the forks and damage the load or
attachment. hurt someone.

WARNING

Make sure the DATA PLATE is

correct if an attachment has
been installed.

69
PARKING
The operator must never leave a lift
truck in a condition so that it can
cause damage and injury. When
parking the lift truck, do the
following operations:
1. Stop the lift truck and apply the
parking brake
2. Fully lower the forks or carriage.
Tilt the mast forward until the
tips of the forks touch the
ground.
70
3. Put the direction control lever in
NEUTRAL.
4. Turn the engine OFF.
5. If the lift truck must be left on an
incline, put blocks on the down
hill side of the wheels so that the
lift truck can not move.
Do not park the lift truck so that it
limits access to fire aisles, stairways,
and fire equipment.
GENERAL
This section contains MAINTENANCE
SCHEDULE and the instructions for
maintenance and inspection.
The service intervals are given in
both operating hours recorded on
the lift truck hour meter, and
calendar time. Use the interval that
occurs first. The recommendation
for the time intervals is for eight
hours of operation per day. The
time intervals must be decreased
from the recommendations in the
MAINTENANCE SCHEDULE for the
following conditions:
71
a. If the lift truck is used more than
eight hours per day.
b. If the lift truck must work in dirty
operating conditions.
Your Hoist Liftruck Dealer has the
equipment and trained service
personnel to do a complete program
of inspection, lubrication and
maintenance. Regular inspection,
lubrication, and maintenance will
help your lift truck give more
efficient performance and operate
for a longer period of time.
Some users have service personnel
and equipment to do the inspection,
lubrication, and maintenance shown
in the Hoist Liftruck Technical
Manual. Technical Manuals are
available from your dealer for Hoist
lift trucks to help users who do their
own maintenance.
WARNING
Do not make repairs or
adjustments unless you have
both authorization and training.
Repairs and adjustments that
are not correct can make a
dangerous operating condition.
WARNING
Do not operate a lift truck that
needs repairs. Report the need
for repairs immediately. If
repair is necessary, put a “DO
NOT OPERATE” tag in the
operator’s area. Remove the
key from the key switch.
Do not make repairs or adjustments
unless specifically authorized to do
so. Repairs and adjustments must be
done by trained service people.
Put the lift truck on a level surface.
Lower the carriage and forks, apply

72
the parking brake and turn the key
switch to OFF. Open the access
panels and check for leaks and
conditions that are not normal. Clean
any oil or other spills. Make sure that
lint, dust, paper, and other materials
are removed from the
compartments.
HOW TO MOVE A DISABLED LIFT
TRUCK
WARNING
Use extra caution when towing
a lift truck if any of the following
conditions exist:
• Brakes do not operate
correctly.
• Steering does not operate
correctly.
• Tires are damaged.
• Traction conditions are
bad.
• The lift truck must be
moved on a steep grade.
If the engine cannot run, there
is no power assist available for
the steering and service brakes.
This can make the control of the
Liftruck difficult. If there is no
electrical power, there is no

73
steering. DO NOT tow the lift
truck if there is no power. Poor
traction can cause the disabled
lift truck or towing vehicle to
slide. Steep grades will require
additional brake force to stop
the lift truck.
Never carry a disabled lift truck
unless the lift truck MUST be
moved and cannot be towed.
The lift truck used to carry the
disabled lift truck MUST have a
capacity equal to or greater than
the weight of the disabled lift
truck. The capacity must be for a
load center equal to half the
74
width of the disabled lift truck.
See the DATA PLATE of the
disabled lift truck for
approximate total weight. The
forks must extend the full width
of the disabled lift truck. Center
the weight of the disabled lift
truck on the forks and be careful
not to damage the under side of
the lift truck.
How to tow The Lift Truck
1. The towed lift truck must have an
operator.
2. Tow the lift truck slowly.

3. Raise the carriage and forks
approximately 30 cm (12 inches)
from the surface. Install a chain
to prevent the carriage and mast
channels from moving.
4. If another lift truck is used to tow
the disabled lift truck, that lift
truck must have an equal or
larger capacity than the disabled
lift truck. Install approximately
½ of a capacity load on the forks
of the lift truck that is being used
to tow the disabled lift truck.
This ½ capacity load will increase
75
the traction of the lift truck.
Keep the load as low as possible.
5. Use a towing link made of steel
that attaches to the tow pins in
the counterweights of both lift
trucks.
How to Put A Lift Truck on
Blocks
WARNING
The lift truck must be put on
blocks for some types of
maintenance and repair. The
removal of the following
assemblies will cause large
changes in the center of gravity:
mast, drive axle, batteries, and
the counterweight. When the
lift truck is put on blocks put
additional blocks in the
following positions to maintain
stability:
1. Before removing the mast and
drive axle, put blocks under the
counterweight so that the lift truck
can not fall backward.
76
2. Put blocks under the mast
assembly so that the lift truck can
not tip forward.
The surface must be solid, even, and
level when the lift truck is put on
blocks. Make sure that any blocks
used to support the lift truck.
Lift trucks are solid, one-piece
units.
NOTE: Some lift trucks have lifting
eyes. These points can be used to
raise the lift truck so that blocks can
be installed.
How to Put A Lift Truck on Blocks

How to Raise the Drive Tires

1. Put blocks on each side (front

and back) of the steering tires to
prevent movement of the lift
truck.

2. Put the mast in a vertical

position. Put a block under each
outer mast channel.

3. Tilt the mast fully forward until

the drive tires are raised from the
surface.

77
4. Put additional blocks under the
frame behind the drive tires.
5. If the hydraulic system will not
operate, use a hydraulic jack
under the side of the frame near
the front. Make sure that the
jack has a capacity equal to at
least half the weight of the lift
truck. See the DATA PLATE.
How to Raise the Steering Tires
2. Use a hydraulic jack to raise the
steering tires. Make sure that the
jack has a capacity of at least 2/3
of the total weight of the lift truck
as shown on the name plate.
3. Put the jack under the steering
axle or frame to raise the lift
truck. Put blocks under the
frame to support the lift truck.

1. Apply the parking brake. Put

blocks on both sides (front and
back) of the drive tires to prevent
movement of the lift truck.

78
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

1 Hydraulic Oil X C
Filters

2 Hydraulic Oil X C AW 32, Some trucks use a water

based fluid check your specification
sheet .
3 Engine Oil X C 10W30 SJ for GM Engine
15W 40 SF/SG for Perkins

4 Transmission Oil X C 30W NJ

5 Transmission Oil X C
Filter

X = CHECK C = CHANGE L = LUBRICATE

79
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

6 Fuel Tank and X Check for leaks

Lines

7 Fuel Filter X C For Gas or Diesel engines

8 Cooling System X C Change Coolant 50/50 mix

9 Tires X For cuts or debris

10 Radiator Hoses X C Check Hoses, Change Hoses

X = CHECK C = CHANGE L = LUBRICATE

80
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

11 Battery Electrolyte X Check condition and level

12 Drive Belts X C Check Daily change @ 2000 hrs.

13 Drive Axle X C Change Oil

80W90 GL-5

14 Brake Service X Check and adjust as needed

15 Parking Brake X Check and adjust as needed

X = CHECK C = CHANGE L = LUBRICATE

81
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

16 Tune Up C Replace Spark Plugs Check

Ignition wires Replace Cap and
Rotor set timing.
17 Steer Wheel X Check and repack
Bearing

18 Torque Drive x Torque to 450 Ft. Lbs. After the

Wheels first 10hrs. Weekly there after.

19 Seat Belt and Seat X Check for proper operation

Rails

20 Mast hinge X Check Torque 585 Ft-Lbs.

bearing screws

X = CHECK C = CHANGE L = LUBRICATE

82
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

21 Drive Shaft and X, L Check and grease

U-Joints

22 Steer Axle X, L Check and grease

23 Tilt Cylinders X, L Check for wear and alignment and

grease bushings

24 Upright Carriage X, L Check for wear

Attachment

25 Lift Chains X Check for cracks or stretching

X = CHECK C = CHANGE L = LUBRICATE

83
 MAINTENANCE

Item Description Daily 200 400 1000 2000 Procedure or Quantity

Number 8 Hours Hours Hours Hours Hours

26 Air Filter X C Different environments will

require replacement sooner than
others.
27 Sheet Metals and X Check for tightness and ease of
Doors operation

28 Horn, Gauges, X Check for proper operation

Lights, Alarm
29 Steering X Check for ease of operation

30 Forks X Check for Wear

31 Pedals, Levers, X Check for ease of operation

Linkages, Cables,
Hinges

X = CHECK C = CHANGE L = LUBRICATE

84
HOW TO MAKE CHECKS WITH
THE ENGINE STOPPED
Hydraulic System
WARNING
At operating temperature the
hydraulic oil is HOT. Do not permit
the oil to contact the skin and
cause a burn.
CAUTION
Do not permit dirt to enter the
hydraulic system when the oil level
is checked or the filter is changed.
85
Never operate the pump without oil
in the hydraulic system. The
operation of the hydraulic pump
without oil WILL damage the
pump.
Check the hydraulic oil level when the
oil is at operating temperature, the
carriage is lowered and the engine is
stopped. Add hydraulic oil only as
needed. If more hydraulic oil is added
than the “FULL” level, the hydraulic oil
will leak from the breather during
operation.

Inspect the hydraulic system for leaks
and damaged or loose components.
HYDRAULIC OIL FILL
86
ENGINE OIL DIPSTICK
Engine Oil
Keep the oil at the correct level as
indicated on the dipstick. Use the
correct oil as shown in the Maintenance
Schedule. After the engine has stopped,
wait one minute before checking the oil
level.
Air Filter
Clean or replace the air filter as
necessary. Use compressed air to clean
the filter element. Air pressure must be
less than 210 kPa (30 psi). Apply the air
from the inside to the outside of the
element.
AIR FILTER HOUSING
87
To inspect the element, put a bright
light inside and look for holes or other
damage. If the element is damaged,
replace it with a new element. Clean
the inside of the canister when changing
filters.

Drive Belts
Check the drive belts for cracks, wear
or damage.
Cooling System
WARNING
DO NOT remove the radiator cap
from the radiator when the engine
is hot. When the radiator cap is
removed, the pressure is released
from the system. If the system is
88
hot, the steam and boiling coolant
can cause burns. DO NOT remove
the cover of the radiator when the
engine is running.
Make sure the coolant level is between
the “FULL” and the “ADD” mark on the
auxiliary coolant reservoir. The coolant
will expand as it is heated and the level
in the auxiliary coolant reservoir will
increase. If coolant is added, use
correct mixture of water and ethylene
glycol. See the Maintenance Schedule
FUEL SYSTEM
WARNING
All fuels are very flammable and
can burn or cause an explosion. DO
NOT use an open flame to check
the fuel level or to check for leaks
in the fuel system. If there is a
leak in the fuel system , extra care
must be used during the repair. Do
not operate the lift truck until the
leak is repaired.
Check the fuel system for leaks and the
condition of parts. When the fuel is
added to the lift truck, see the section,
89
How To Add Fuel To The Lift Truck
procedures in this OPERATING MANUAL
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 (Baking soda) to make
the acid neutral. Acid in the eyes
must be flushed with water
immediately. Batteries generate
explosive fumes. Keep the vents in
the caps clean. Keep sparks or
open flame away from the battery
area. Do not
make sparks from the battery 1. Always connect the positive boost
connections. Disconnect the cable to the positive terminal of the
battery ground cable when doing discharged battery and the negative
maintenance. to the negative.

Keep the battery and cable terminals
clean. Check the electrolyte level
(unless maintenance-free). Keep the
electrolyte level above separators and
plates. Use distilled water. Do not fill
the battery past the bottom of the
internal filler neck.
2. Always connect the cable that is the
ground cable last.
3. Always connect the boost cables to
the discharged battery before
connecting them to the boost
battery.

If the battery becomes discharged and

requires a boost from another charged
battery, follow these procedures
carefully.

90
Upright, Forks, and Lift Chains
Forks – General
The identification of a fork is determined
by how it is connected to the carriage
Forks – Adjustment
Hook forks are connected to the
carriage by hooks and lock pins. These
lock pins are installed through the top
carriage bar and fit into slots in the top
of the forks. Adjust the forks as far
apart as possible for maximum support
of the load. Hook forks will slide along
the carriage bars to adjust for the load
91
being handled. Raise the lock pins to
slide the forks. Make sure the lock pins
are locked in the forks after adjustment
is made.
Pin forks are connected to the carriage
by a round shaft. Adjust the forks as far
apart as possible for maximum support
of the load. These forks are adjusted by
removing the lock pins from the top of
the carriage, sliding the fork to the
correct position for your load, and
reinstalling the lock pins. Some forks are
adjusted hydraulically and are controlled
by one or more levers to the right of the
lift and tilt levers. (These forks do not
have lock pins.)

Forks – Removal
WARNING
Do not try to remove a fork without
a lifting device. The forks can
weigh up to 500 lbs. each.
Remove the keeper plates on each side
of the carriage that retain the fork-
mounting pin. Lower the forks onto
blocks to remove tension from the fork
pin. Slide the pin out either side of the
carriage. Move the carriage away from
the forks, or use a lifting device to move
the forks away from the carriage. On
92
forks with hydraulic cylinders attached
to them be sure to remove the
mounting pins before removing the
forks.
Forks – Installation
If reinstalling with lifting device, align
fork into carriage and slide pin into fork.
Install keeper plates. If reinstalling,
align forks on block and drive truck up
to forks. Slide pin in end of carriage and
forks. Install keeper plates.
Inspecting Mast, Forks and Lift adding shims. Always Replace
Chains damaged forks.

Never repair damaged forks by

WARNING
NEVER work under a raised
carriage or forks. Lower the
carriage or use blocks and chains
on the mast weldments and
carriage so that they can not move.
Make sure the moving parts are
attached to a part that does not
move.
Do not try to correct fork tip
alignment by bending the forks or
heating or welding. Forks are
made of special steel using special
procedures. Always Replace
damaged forks.
1. Inspect the welds on the mast and
carriage for cracks. Make sure that
the nuts and bolts are tight.
2. Inspect the channel for excessive
wear in the areas of roller contact.
Check the rollers for wear or
damage.

93
3. Inspect the forks for cracks and
wear. Check that the fork tips are
aligned within 13 mm (0.5 in) of
each other.
4. Replace any damaged or broken
parts that are used to keep the forks
locked in position.
5. Inspect the lift chains for the correct
lubrication.
6. Inspect the lift chains for cracks or
broken links and pins.
7. Inspect the chain anchors and pins
for cracks and damage
94
8. Make sure the lift chains are
adjusted so that they have equal
tension. If the chains need repair or
adjustment, it must be done by
authorized personnel.
Tires and Wheels
Inspect the tires for wire, rocks, glass,
pieces of metal, holes, cuts and other
damage. Remove any object that will
cause damage. Check for loose or
missing hardware. Remove any wire
strapping or other material that is
wrapped around the axle.
Make sure the wheel nuts are tight.
Tighten the wheel nuts in a cross
pattern to the correct torque value
shown in the MAINTENANCE SCHEDULE
table.
CAUTION
Operator Restraint System
The seat belt, hip restraint brackets,
hood Latch, seat frame and mounting,
are all part of the operator restraint
system. HIP
RESTRAINT

When the wheels have been

installed, check all wheel nuts after
10 hours of operation. Tighten the
nuts in a cross pattern to the
correct torque value shown in the
MAINTENANCE SCHEDULE table.
When the nuts stay tight for 10
hours, the interval for checking the
torque can be extended to weekly.

95
SEAT RAIL SEAT BELT
 Each item must be checked to make
sure it is attached securely, functions
correctly and is in good condition. If the
seat belt can not be pulled from the
retractor assembly, place a flat blade
screwdriver under the plastic housing.
Push the bar to release the spool.
Straighten the belt so that it pulls out
and retracts smoothly.
Make sure the seat rails are not loose.
The seat rails must lock securely in
position, but move freely when
unlocked. The seat rails must be
securely attached to the mounting
surface.
96
HOW TO MAKE CHECKS WITH THE
ENGINE RUNNING
WARNING
FASTEN YOUR SEAT BELT! The seat
belt is installed to help the
operator stay on the truck if the lift
truck tips over. IT CAN ONLY HELP
IF IT IS FASTENED.
Make sure that area around the lift truck
is clear before moving the lift truck. Be
careful when making the checks. If the
lift truck is stationary during the check,
apply the parking brake and put the
transmission in NEUTRAL. Proceed
carefully.
Gauges, Horn and Fuses
Start the engine. Check the gauges and
lights for correct operation as described
in the Instruments and Controls Section
of this Operating Manual. Check the
operation of the horn. The fuses are
located under the gauge cluster
assembly.
97
Oil Level, Powershift Transmission
Apply the parking brake. Check the oil
level in the powershift transmission
when the engine is running at idle speed
and the directional control lever is in
NEUTRAL (N) position. Use the correct
oil as shown in the Maintenance
Schedule. Keep the oil level at the
“FULL” mark on the dipstick.
Control Levers and Pedals
Check that the levers for the mast and
attachment operate correctly. Check
that the brake operates correctly.
Lift System Operation
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 mechanism unless all parts of
98
the mast are completely lowered
and the key switch is OFF.
Before making any repairs, use
blocks and chains on the mast
weldments and carriage so that
they can not move. Make sure the
moving parts are attached to a part
that does not move.
Do not try to locate hydraulic leaks
by putting hands on pressurized
hydraulic components. Hydraulic
oil can be injected into the body by
pressure.
1. Check for leaks in the hydraulic
system. Check the condition of the
hydraulic hoses and tubes.
2. Slowly raise and lower the mast
several times without a load. The
mast components must raise and
lower smoothly in the correct
sequence. The carriage raised first,
then the inner weldment and
intermediate weldment (three-stage
masts only).
NOTE: Some parts of the mast move at
different speeds during raising and
lowering.
99
3. The inner weldment and the carriage
must lower completely.
4. Raise the mast one meter (three
feet), with a capacity load. The
inner weldments and carriage must
raise smoothly. Lower the mast. All
moving components must lower
smoothly.
5. With the load lowered, tilt the mast
backward and forward. The mast
must tilt smoothly and both tilt
cylinders must stop evenly.
6. Check that the controls for the
attachment operate the functions of
 the attachment. See the symbols by
each of the controls. Make sure all
of the hydraulic lines are connected
correctly and do not leak.
Service Brakes
Check the operation of the service
brakes. Push on the brake pedal. The
brake pedal must stop firmly and must
not move slowly down after the brakes
are applied. The service brakes must
apply equally to both drive wheels with
no noticeable pull to either side. The
service brakes are not automatically
adjusted and need periodic adjustment.
See maintenance schedule.
100
Parking Brake
Check the operation of the parking
brake. The parking brake, when in
good condition and correctly adjusted,
will hold a lift truck with a capacity load
on a 15% grade (a slope that increases
1.5 meters in 10 meters or 1.5 ft in 10
feet). The brake is adjusted with two
cable adjustment nuts and lock nuts
located under the dash below the
parking brake handle. Do not tighten
the adjustment so that the brakes are
applied when the hand lever is released.
 How to Add Fuel to the Lift Truck
Steering System
WARNING

WARNING Stop the engine. The operator

The lift truck has hydraulic power must be off the lift truck while fuel
steering. The steering can be is added.
difficult if the engine is not
running. No smoking.

Make sure the steering system operates All fuels for internal combustion
smoothly and gives good steering engines are very flammable.
control.
Fill the fuel tank only in a
designated area with good
ventilation. Have a fire
extinguisher available.

101
Never fill the fuel tank near an
open flame or near equipment that
can create sparks. Never check
fuel level or check for leaks with an
open flame.
Liquified Petroleum Gas (LPG)
WARNING
Close the fuel valve on the tank
when parking the lift truck more
than momentarily.
LPG is extremely flammable.
smoking.
Only trained and authorized
personnel are permitted to operate
filling equipment.
Fill LPG tanks outdoors. Stay at
least 15 meters (50 feet) from
buildings, motor vehicles, electrical
equipment or other ignition
sources. Stay at least 5 meters (15
feet) from LPG storage tanks.
During the transfer of LPG, metal
components can become very cold.
Always wear gloves when refilling
No or changing tanks to prevent
“freeze burns” to the skin.
102
Do not store LPG tanks near heat or
open flame. For complete 4. Turn the tank fuel valve clockwise
instructions on the storage of LPG until the valve is completely
fuels, refer to ANSI/NFPA 58 & closed.
505.
5. Run the engine until it stops,
1. Use the Following Procedure to then turn the key switch to the
Remove the LPG Tank: OFF position.

2. Removable LPG tanks can be 6. Disconnect the quick disconnect

removed and placed indoors only fitting.
if the lift truck is at least 8 meters
(25 feet) from any open flame or 7. Release the LPG tank latch and
ignition source. remove the tank from the
bracket.
3. Move the lift truck to the area
where tanks are changed.

103
 1
2
4
WARNING

Do not use an LPG tank that is

damaged. A damaged LPG tank
must be removed from service.
Frost on the surface of the tank,
the valves or fittings indicates
leakage. A strong odor of LPG fuel
can indicate a leak.

5
1. FUEL VALVE, TANK Install the LPG Tank:
2. FUEL LINE CONNECTOR 3
3. FUEL GAUGE 1. Before the LPG tank is installed on
4. PLUG the lift truck, check the operation of
5. RELIEF VALVE
the fuel gauge. Look at the fuel
NOTE: Some LPG tanks have an auxiliary fill fitting gauge and move the tank. If the
instead of a plug for item 4.

104
 gauge needle does not move, a new
tank must be installed.
2. Put the tank in the tank bracket.
Make sure that the tank is aligned
with the alignment pin.
3. Close the latch.
4. See LPG Tank picture on the
previous page. Connect the quick
disconnect fitting to the fuel valve on
the tank. Use your hand to tighten
the fitting. Do not open the fuel
valve until the quick disconnect
fitting is completely tightened. Turn
105
the fuel valve counterclockwise to
open the fuel valve.
5. Inspect the fuel system for leaks
when the fuel valve is open. Frost
on the surface of the tank, valves or
fittings or a strong odor indicates
leakage.
Use the Following Procedure to Fill
the LPG Tank:
WARNING
Read and follow all the refueling
precautions and instructions under
Liquified Petroleum Gas (LPG)

The following instructions are general
procedures. There is a variation in
equipment for filling LPG tanks. The
local authorities that have jurisdiction
have specific rules and regulations for
filling LPG tanks. Make sure these rules
and regulations are available and
understood.
1. Check the LPG tank to make sure it
needs filling. During the filling operation
the LPG tank must be in a position so
that the liquid level indicator will always
be in the vapor space above the liquid
level.
106
1. Open the liquid outlet valve and by-
pass return valve on the storage
tank.
2. Start the pump.
3. Connect the supply hose to the quick
disconnect fitting. If the LPG tank
has an auxiliary fill fitting, connect
the supply hose to this fitting. Make
sure the correct adapter is used to
connect the supply hose to the
auxiliary fill fitting.
4. Open the vent valve on liquid level
indicator.
5. Open the tank fuel valve.
6. Open the valve on the end of the
supply hose.
7. Watch for a discharge from the vent
valve on the liquid level indicator.
When a cloud of visible vapor
appears, the tank is full. Do not fill
the LPG tank more than the
maximum level indicated by the
liquid level indicator. Immediately
close the valve at the end of the
hose.
8. Close the vent valve.
107
9. Close the fuel valve on the tank.
10. Disconnect the supply hose.
11. Stop the pump.
12. Close liquid outlet valve and by-pass
return valve on the storage tank.
Gasoline or Diesel Fuels
1. Remove the fuel cap. Make sure the
fuel tank is filled with the correct fuel
for the type of engine in the lift
truck. Clean the fuel cap.
2. Replace the fuel cap.

WARNING
When the fuel is added, keep the
funnel or fuel nozzle in contact
with the metal of the fuel tank to
reduce the possibility of static or
electric sparks. Clean any spilled
fuel.
Operating Procedures for a New or
Rebuilt Engine
A new or rebuilt engine must be
operated under special conditions during
the first 50 hours. These special
conditions prevent damage to the
108
engine until the new parts can wear and
adjust to fit each other.
1. Make sure the fluid levels of oil and
coolant are correct.
2. Start and run the engine at
approximately one-half throttle for
30 minutes for the first operation.
Check the gauges and indicators for
the correct operation during the first
operating period. Check for leaks.
3. If the work conditions are slow and
the loads are less than 50% of the
truck capacity, a simulated work
condition must be used during the
4. first hours of operation. Operate the
lift truck with a minimum load of
75% capacity. Operate the engine
through cycles from idle to full
throttle and back to idle. Avoid long
periods of high engine speeds with a
light load during the first 50 hours of
operations. High engine speeds with
a light load can cause damage to the
cylinders in the engine.
109
TIRES / WHEELS
WARNING
The type of tire is shown on the
DATA PLATE . Make sure the DATA
PLATE is correct for the type of
tires on the lift truck.
General
The Titan Series uses solid rubber tires.
Solid rubber tires made from softer or
harder material can be installed as
optional equipment. The tread on the
solid rubber tires can be either smoother
or it can have lugs.
Solid Rubber Tires (Press-On) –
Remove the Wheels from the Lift
Truck
WARNING
Wheels must be changed and tires
repaired by trained personnel only.
Always wear safety glasses.
110
1. Raise the lift truck as described in
How to Put A Lift Truck on
Blocks in this manual. (see page
75)
2. For drive wheels, remove the wheel
nuts and remove the wheel from the
lift truck. Lift truck wheels are
heavy. A lifting device will be
required.
3. For steer wheels, remove bearing
cover. Remove the cotter pin and
spindle nut. Slide the wheel and
bearings off the spindle. Lift truck
wheels are heavy. A lifting device will
be required.
Solid Rubber Tires (Press-On) –
Remove and Install the Tire from
the Wheel
Remove and Install the Tire from
the Wheel
1. The correct tools, equipment and a
press ring must be used for each size
of wheel. Use a press to push the
wheel from the rim and tire.
NOTE: Make sure the tires are installed
on the wheels according the offset
dimensions. Each drive tire must have
the same offset. Each steer tire must
have the same offset. Also check the
DATA PLATE of the lift truck for the
111
correct tread width. The tread width is
measured from the outside of one wheel
to the inside of the other wheel.
1. When the drive wheels are installed
on the lift truck, tighten the wheel
nuts in a cross pattern to the torque
value in the MAINTENANCE
SCHEDULE.
2. The steering wheels are fastened to
the spindle of the steering axle with a
large castle nut. Make sure the inner
and outer bearings are correctly
lubricated with grease. Install the wheel
and inner bearing assembly on the
spindle. Install the outer bearing cone
and castle nut. Tighten the caste nut to
200 N.M. (150lbf ft) while the wheel is
rotated. Loosen the castle nut to less
than 27 N.M. (20-lb. ft). Thighten the
castle nut to 34 N.M. (25-lb. ft).
Tighten the castle nut to the first
position where the cotter pin can be
installed. Install the cotter pin.
CHANGES TO THE OVERHEAD
GUARD
or by drilling holes that are too big
in the wrong location, can reduce
the strength of the overhead guard
and should not be performed.
WARNING
Do not operate the lift truck
without the overhead guard
fastened correctly to the lift truck.

WARNING
Do not make changes to the
overhead guard by welding.
Changes that are made by welding,

112

ADDENDUM
The following additional information is provided
as specified in Machinery Directive 89/392 EEC
and should be held with the Operating Manual
and Periodic Maintenance Manual supplied in
the attached truck literature package. This
information will be incorporated in future
publication updates as CEN standards are
finalized.
OPERATING MANUAL:
Dimensional Details: Certain information is
shown on the truck DATA PLATE . For
additional dimensional details on this or any
specific truck, consult your dealer.
113
Noise Levels: Base sound pressure emissions
from vehicles remain unchanged. EEC test
methods, under development, may alter
published “Equivalent” (Leg.) values.
For guidance, levels will remain in the following
ranges:
75 to 90 dB(A) for I.C. engine models,
up to 3.2T,
60 to 80 dB(A) for Electric trucks.
Full Body Vibration Levels: These vary
depending on the exact truck configuration but
are in the range 0.7 to 1.2 m/s2. Note that CEN
vibration measurement standards are currently
incomplete.
Hazardous Atmospheres: Specific CEN
standards, still under development, apply to
trucks, which are intended to be operated in
Hazardous Atmospheres. Conversions should
be carried out only be certified contractors or 3) Electric units, with reference to traction
specialist companies. battery charging:
NOTE: Use only battery chargers
PERIODIC MAINTENANCE MANUAL: approved by the battery manufacturer or
dealer.
Note the following additional Warnings and
advisory notes:
HOW TO STORE A LIFT TRUCK
1) All units, with reference to starter batteries
and traction batteries: The following storage procedures are for
conditions and temperatures above 0. C. Adjust
CAUTION these procedures for local conditions and any
Disposal of batteries must meet local changes in conditions during storage. The
environmental regulation. preparations necessary for storage is also
2) All units, with reference to lubrication determined from the following conditions:
service: • Short-term storage is from 1 to 6 months.
Long-term storage is over 6 months.
CAUTION • Storage Location. A lift truck stored indoors
Disposal of lubricants and fluids must will not require as much external protection
meet local environmental regulation. as a lift truck stored outdoors.

114

Short-Term Storage
Do the following steps to prepare the lift truck for
storage from 1 to 6 months:
1. Check lubricant and fluid levels. Completely
fill the fuel tank. Make sure the coolant
mixture will protect cooling system and
engine to lowest temperature expected
during storage. Make sure all caps and
dipsticks are installed correctly.
2. Fully lower the forks or carriage. Tilt mast
forward until the tips of the forks touch the
ground. Apply a thin coat of engine oil to the
cylinder rods.
3. Check that all switches and accessories are
in the OFF position.
4. If the lift truck must be left on an incline, put
blocks on the down hillside of the wheels so
that the lift truck can not move – do not use
the parking brake.
115
5. Disconnect the battery cables from the
batteries. Apply a protective coat to the
cable connectors and battery terminals to
prevent corrosion.
6. Clean the lift truck and engine compartment
to prevent corrosion.
7. If the lift truck is not stored in a shelter put a
cover over the lift truck to prevent damage
from the weather. In wet conditions, a cover
will not prevent corrosion to a lift truck that is
in long – term storage outside of a dry
storage area.
Long-Term Storage
Do the following steps to prepare the lift truck for
storage for 6 month or longer:
1. Complete all short-term storage procedures.
2. Wrap or cover all exterior lights, radiator
grill, and air vents with a moisture barrier
cover. Use tape to hold the covers in
position.
3. Remove the batteries from the lift truck.
Store the batteries in an approved space.
Be sure to follow local regulations. Batteries
that are stored for long periods can become
damaged. A recommendation is that the
batteries be used in service if possible.
4. Spray exterior surfaces and frame with
preservative coating.
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT
WARNING
Stay a safe distance from the edge of:
Docks, ramps, plat forms and other
Similar working surfaces. Watch the
“tail swing”. Remember when traveling
in the forward direction and the steering
wheel is turned to move the lift truck away
from the edge of the dock the rear will swing
116
toward the edge. This can cause the lift
truck
to fall off the dock.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK,
DO NOT JUMP OFF! HOLD FIRMLY TO
STEERING WHEEL, BRACE YOUR FEET,
AND LEAN FORWARD AND AWAY FROM
THE POINT OF IMPACT.
Before the lift truck is moved on a transport,
check the selected route to make sure there is
enough clearance for the lift truck as loaded on
the transport vehicle. Bridges, overpasses,
powerlines, natural barriers can prevent
clearance. Removal of the mast can be
necessary.
If a trailer is the method of transportation, use
blocks in front and back of the trailer tyres to
prevent movement of the trailer when the lift
truck is loaded and unloaded. If a loading ramp
is used, make sure that the ramp is the correct
design and capacity.
If the lift truck is equipped with lifting eyes, use a
crane to load and unload the lift the truck from
the transport. If the truck is not equipped with
approved lifting eyes, do not lift the truck by
attaching a lifting device to any other part of the
lift truck for the purposes of loading or
unloading.
Loading
If components and attachments must be
removed for transport of the lift truck, see the
SERVICE MANUAL for removal procedures.
The operator must never leave a lift truck in a
condition so that it can cause damage and
injury. When the lift truck is loaded on the
transport, do the following operations:
117
1. Apply the parking brake.
2. If the mast is mounted on the lift truck, fully
lower the forks or carriage. Tilt the mast
forward until the tips of the forks touch the
surface.
3. Put the direction control lever for the
powershift transmission in NEUTRAL. If
the lift truck has a manual transmission,
leave the gears of the transmission
engaged. DO NOT leave a manual
transmission in NEUTRAL.
4. Turn the key switch to OFF to stop the
engine. Check that all switches and
accessories are turned off.
5. Put blocks in front and back of the lift truck
tyres to prevent any movement of the lift
truck. Make sure the blocks are attached to
the load surface.
If the lift truck is equipped with an LPG fuel
system and is parked more than momentarily,
close the fuel valve at the tank. If the lift truck is
going to be left overnight or longer, the truck
must be parked outside or the LPG tank must be
removed and stored outside.
WARNING
The straps or chains used to fasten the lift
truck to the transport must be directly
connected to the lift truck frame or to a
component (drive axle, tow pin) that is
solidly attached to the frame. Do not fasten a
strap or chain to the mast or any attachment
to hold the lift truck on the transport.
CAUTION
Make sure that any straps or chains used to
fasten the lift truck to the transport do not
contact any tubes, hoses, hydraulic
cylinders, or other parts of the truck that are
easily damaged.
118
If the lift truck is transported in severe weather
or any other condition that can damage the lift
truck, cover the lift truck. Make sure the
protective cover that is designed for the
application and is securely fastened.
Unloading
If components normally attached to the lift truck
were removed for transport, see the Service
Manual for installation procedures.
1 If used, remove any protective cover.
2 Make sure the parking brake is applied.
3 Disconnect the straps or chains.
4 Remove the wheel blocks.
5 Check that all switches and accessories are
turned off.
6 Unload the lift truck.
PREPARATION FOR USE
After being transported or stored, the lift truck
must be prepared for use for proper operation.
All problems must be corrected before use of the
lift truck, see the SERVICE MANUAL for
procedures.
Preparation After Transport
1 Complete the unloading procedures.
2 Inspect the lift truck for damage and missing
components.
3 Follow the steps in the section CHECKS
WITH THE ENGINE STOPPED.
Preparation After Storage
1 Remove all tape, covers, and preservation
materials.
119
2 Check the lift truck for damage and missing
components. Repair damage and/or
replace missing components.
NOTE: If the lift truck has been stored longer
than one year, all lubricants and fluids must be
drained and replace. See this Periodic
Maintenance section for the procedures.
3 Clean the battery cables and terminals.
Check the battery voltage. If the voltage is
not correct, charge battery. Connect battery
cables to battery.
4 Do the procedures in the section EVERY 8
HOURS OR DAILY
Use only battery charger approved by the
battery manufacturer or dealer.
CAUTION
Batteries must be discarded according to NOTES:
local environmental regulations.

CAUTION
Lubricants and fluids must be discarded
according to local environmental
regulations.

120
NOTES: NOTES:

121