D456-Operating Manual

OPERATING MANUAL
S1.0 - S1.2 - S1.4 - S1.6 - S2.0 (D456)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4140244 7/23

Spacer
LIFT TRUCK MODEL SERIAL NUMBER

TRACTION MOTOR SERIAL NUMBER
HYDRAULIC PUMP MOTOR SERIAL NUMBER
STEERING GEAR MOTOR SERIAL NUMBER
LIFT HEIGHT GROUP NUMBER
DRIVE TIRE SIZE COMPOSITION
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2023. All Rights Reserved.
HYSTER , FORTIS, MONOTROL, and YARDMASTER are Registered Trademarks of Hyster-Yale Group, Inc. HSS, DURAMATCH, UNISOURCE, and
are Trademarks in the United States and certain other jurisdictions.
INTRODUCTION
INTRODUCTION
GENERAL CONDITIONS The operator and the maintenance technician must be thor-
oughly acquainted with the contents of this “Operating and
This Operating and maintenance manual contains orig- maintenance manual”.
inal instruction.
All operators must read the manual carefully and, if doubts
A self-propelled industrial truck is understood to be any arise before operating the truck, should contact the HYS-
vehicle equipped with wheels (except for those running on TER service network for further explanations.
rails) designed to transport, tow, push, lift, stack or set on
shelving any type of load and operated by an operator who THE TRUCK MAINTENANCE MANUAL MUST
moves on foot together with the truck or on the machine, ALWAYS BE AVAILABLE TO THE OPERA-
on a seat or on a specific platform. TOR FOR CONSULTATION.
The person in charge, acting on behalf of the company The employer, through the personnel in charge at his com-
that owns the truck, must observe the general safety pany, must ensure that these regulations are observed.
conditions detailed below in order to comply with
safety standards. The operator must not allow the truck to be used by unskil-
led personnel and must remove the starting key when leav-
Compliance with the instructions provided in this manual is ing the truck unattended in order to prevent it being used
mandatory for the safe use of this truck. Failure to comply by others.
with the operating conditions constitutes “incorrect use” by
the operator and as such relieves HYSTER of all responsi- Keys must be given only to qualified personnel.
bility with regard to compliance with all essential safety
requirements.
©HYSTER COMPANY 2023 4140244 - ENGLISH-UK 1

INTRODUCTION
The person in charge, acting on behalf of the company,
must: IT IS FORBIDDEN TO CARRY OUT REPAIRS
OR MAJOR MAINTENANCE OPERATIONS.
• Ensure that the operators are in a good psychologi-
cal and physical condition;
Any repairs or major maintenance carried out by the user
• Ensure that the operators know how to use the truck
or in an unauthorised workshop may result in failures that
and are aware of the contents of this operating and
could cause personal injury or damage to property.
maintenance manual.
In these cases the manufacturer will be released from all
The operator and the maintenance technician must carry
liability in relation to the general safety regulations.
out the routine maintenance operations indicated in this
manual in the dedicated chapter. The repairer or maintenance technician (other than HYS-
TER) will assume all liability in relation to the safety regula-
The operator and maintenance technician must ask the
tions for the entire machine and the technical file, held by
person in charge at the company to contact the HYSTER
the manufacturer (HYSTER), will no longer be considered
technical service centre regarding the supplementary main-
to be representative of the machine as a whole.
tenance operations indicated in this manual.
Any repairs or major maintenance carried out by the
The operator must not use the truck if any kind of operating
user or in an unauthorised workshop during the guar-
fault is detected.
antee period will automatically make the warranty void.
2
INTRODUCTION
The use of special equipment that has not been made and INFORMATION ABOUT DISPOSAL
installed by HYSTER may modify the conditions under
which the machine may be used. BATTERY DISPOSAL
It is mandatory to submit the installation of equipment NOTE: Do not dispose of exhausted batteries with nor-
directly to HYSTER, for any acceptance. Failure to meet mal solid waste. They are composed of noxious mate-
this requirement will relieve HYSTER of all liability, as rial. They must be collected, disposed of and/or
already specified in the case of major maintenance. recycled as prescribed by legislation in force in indi-
vidual countries.
The special equipment installed directly by HYSTER will be
provided with the necessary documentation for compliance LUBRICANT OILS DISPOSAL
with safety standards. NOTE: Used oil must be specially collected. It must not
The instructions for use and maintenance of the truck with be disposed of into normal drainage system pipes.
special equipment will be attached to this document. Special companies can be employed to dispose of or
recycle industrial oils according to the laws in force in
individual countries.
RECYCLE
3
INTRODUCTION
TRUCK SCRAPPING ELECTRICAL SYSTEM
The truck is composed of metal and plastic components, • Connections: Copper cores and PVC insulation
which can be recycled. • Motors: Steel, copper and aluminium
• Electronic controller and electronic board: Aluminium,
The materials used for the truck components are listed copper, ceramic and plastic
below:
NOTE: This controller has both mechanical parts and
CHASSIS high-density electronic parts (Printed circuit boards
• Frame: Steel and integrated circuits).
• Wheels: Polyurethane, rubber If not properly handled during waste processing, this
• Finishing: Plastic material may become a relevant source of pollution.
HYDRAULIC SYSTEM The disposal and recycling of this controller has to fol-
• Reservoir: Plastic low the local laws in force in individual countries.
• Pump unit: Steel and aluminium
• Flexible pipes: Rubber, steel and plastic
• Cylinders: Steel and cast iron, rubber (seals)
• Valves: Steel and aluminium
4
INTRODUCTION
DOCUMENTS Manufacturer
The truck is supplied complete with accompanying docu-

ments in order to ensure its identification and to provide
correct instructions for operation and maintenance.
On receiving the truck, be sure to check that the purchase
documents are correct and that the following documents
are present:
• EC Declaration of Conformity (1) HYSTER EUROPE
• UKCA Declaration of Conformity (1) Centennial House
• Use and maintenance manual Frimley Business Park
Frimley, Surrey GU16 7SG
If any of these documents are missing, it is essential to United Kingdom
inform the dealer from whom the truck was purchased.
Use of the truck is prohibited if any of the accompanying SERVICE NETWORK ADDRESSES
documents are missing. To comply with general warranty conditions, all service and
(1)
The following Declarations of Conformity are a Facsimile. repair operations must be carried out by qualified techni-
The Declarations of Conformity are not present on trucks shipped to China and Ukraine. cians that are part of the HYSTER authorized service cen-
The Declarations of Conformity will change based on the truck destination country.
tre network.
To find your nearest HYSTER authorized service centre,
see the website at:
www.hyster.com
5
6
EC DECLARATION OF CONFORMITY
INTRODUCTION
WE HYSTER EUROPE
CENTENNIAL HOUSE
FRIMLEY BUSINESS PARK
FRIMLEY, SURRY GU16 7SG
UNITED KINGDOM
DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT ELECTRIC POWERED
TYPE
SERIAL NUMBER(S)
YEAR OF CONSTRUCTION
IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC.
OTHER APPLICABLE DIRECTIVES:

2014/30/EU - EMC EMISSIONS.
COMPLIANCE WITH THIS DIRECTIVE IS ESTABLISHED BY MEETING THE TECHNICAL

REQUIREMENTS OF STANDARD EN12895:YYYY+A1:YYYY
FOR THE PURPOSE OF REGULATION (EU) 2019/1020 ON MARKET SURVEILLANCE AND

COMPLIANCE OF PRODUCTS THE ECONOMIC OPERATOR IS: HYSTER-YALE ITALIA SPA,
VIA CONFALONIERI 2 – 20060 MASATE (MI) ITALY
TECHNICAL FILE CONTROLLED BY: NAME AND JOB TITLE

HYSTER-YALE ITALIA SPA
VIA CONFALONIERI 2 - 20060 MASATE
(MI) ITALY
NAME AND JOB TITLE PLANT MANAGER - MASATE
PLACE Day of week, MM/DD/YYYY
Note that some products have options for equipment that are subject to Radio
Equipment Directive 2014/53/EU. Where applicable, product/option meets the
requirements outlined in this Directive.
UK DECLARATION OF CONFORMITY
WE HYSTER EUROPE
CENTENNIAL HOUSE
FRIMLEY BUSINESS PARK
FRIMLEY, SURRY GU16 7SG
UNITED KINGDOM
DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT ELECTRIC POWERED
TYPE
SERIAL NUMBER(S)
YEAR OF CONSTRUCTION
IS IN CONFORMITY WITH THE SUPPLY OF MACHINERY (SAFETY) REGULATIONS 2008.
OTHER APPLICABLE DIRECTIVES:
EMC REGULATIONS 2016
COMPLIANCE WITH THIS REGULATION IS ESTABLISHED BY MEETING THE TECHNICAL

REQUIREMENTS OF STANDARD EN 12895:YYYY+A1:YYYY
TECHNICAL FILE CONTROLLED BY: NAME AND JOB TITLE

HYSTER-YALE UK Limited
88 Charlestown Road, Portadown Co
Armagh, BT63 5PP
Northern Ireland
NAME AND JOB TITLE PLANT MANAGER - MASATE
PLACE Day of week, MM/DD/YYYY

7
INTRODUCTION
Contents
Contents
INTRODUCTION .......................................................... 1 TRUCK COMPONENTS POSITIONING .................... 51
GENERAL CONDITIONS ........................................... 1 INSTRUCTIONS FOR USING THE CONTROLS AND
INFORMATION ABOUT DISPOSAL .......................... 3 INSTRUMENTS ....................................................... 57
TRUCK SCRAPPING ................................................. 4 PRELIMINARY CHECKS ........................................... 80
DOCUMENTS ............................................................ 5 GENERAL STABILITY PRINCIPLES ......................... 81
SERVICE NETWORK ADDRESSES ......................... 5 OPERATING TECHNIQUES ...................................... 85
Warning ....................................................................... 9 CONSIDERATIONS CONCERNING LOADS ............ 91
GENERAL RISKS / TRANSPORTING THE TRUCK .. 10 DRIVING RULES ........................................................ 98
RISKS AS A RESULT OF INCORRECT USE ............ 10 STORAGE AND RESTARTING OPERATIONS ......... 107
GENERAL GUIDELINES ............................................ 12 MAINTENANCE / BATTERY ....................................... 109
TRUCK HARNESSING FOR HOISTING ................... 13 MAINTENANCE GENERAL PRINCIPLES ................. 109
AFTER TRANSPORTATION ...................................... 15 SCHEDULED MAINTENANCE TABLES ................... 111
DESCRIPTION / OPERATING INSTRUCTIONS ......... 17 LUBRICANTS ............................................................. 129
CONSTRUCTIONS STANDARDS ............................. 17 CLEANING ................................................................. 130
MODEL DESCRIPTION ............................................. 17 BATTERY INTRODUCTION ...................................... 131
TRUCK CHANGES .................................................... 19 RECHARGING LEAD-ACID BATTERY ..................... 133
IDENTIFICATION DATA ............................................ 20 LI-ION BATTERY ....................................................... 135
WARNING AND INFORMATION LABELS ................. 22 REPLACING THE BATTERY ..................................... 142
TECHNICAL DATA ..................................................... 25
8
Warning
WARNING
SAFETY WARNINGS AND MARKINGS: The safety regu- These symbols are used to draw attention to the pres-
lations and important explanations are marked by the ence of a risk: failure to comply with safety regulations
following symbols. and all relative instructions may be hazardous for peo-
ple and property.
DANGER
A general risk is defined as the possibility of major
Indicates an imminently hazardous situation which, if
hazard situations ensuing, such as: Overturning, Fall-
not avoided, will result in death or serious injury. This
ing load, Crushing, Explosion, Electrocution.
signal word is to be limited to the most extreme situa-
tions. The operators, maintenance engineers and anyone
working near the truck are exposed to these risks.
WARNING
Indicates a potentially hazardous situation which, if not WARNING
avoided, could result in death or serious injury. This lift truck may be equipped with devices that can
emit non-ionising radiation, such as radio transmitters
CAUTION or RFID card readers. Users may be exposed to radio
Indicates a potentially hazardous situation which, if not frequency radiation. Users with implanted medical
avoided, may result in minor injury and/or damage to devices should consult their medical professional
the equipment. before using lift trucks equipped with devices that can
emit such radiation.
NOTE: It is given before warnings and explanations.
9
GENERAL RISKS / TRANSPORTING THE TRUCK

RISKS AS A RESULT OF INCORRECT USE RESTRICTIONS ON USE
In order to operate in safe conditions, the following instruc- The operator must prevent the truck from being used by
tions must be followed and dangerous situations must be unauthorised personnel by removing the key from the
handled with caution. control panel when leaving the truck unattended.
OPERATOR DEFINITION When remaining in the vicinity of the truck with the key
inserted, the driver must make sure that no unauthorised
The operator is defined to be any person who is persons gain access to the controls.
trained and responsible for moving the truck and
TRUCK KNOWING
handling the load.
The operator can be transported on the truck or The operator must be fully acquainted with the truck he is
drive the truck from the ground or remotely (by using, carefully study the operating instructions and work
cable, radio, etc.) only with loads that do not exceed the load capacity indica-
ted on the nameplate.
The truck may only be driven by trained and author- LOAD KNOWING
ised personnel.
The operator must be fully aware of the nature and the
stacking condition of the load that is being transported.
The operator has the right to refuse to transport loads he
considers to be hazardous to the transit environment or
loads that are incorrectly stacked.
10
ENVIRONMENT MAINTENANCE
The operator must be fully aware of the presence, within The operator and the maintenance engineer must know the
the transit area, of pollutants that are dangerous to humans maintenance schedule and how to perform routine mainte-
or that may cause explosions out of incompatibility with the nance meticulously.
truck, or that may trigger a reaction with the load carried.
If routine maintenance operations are assigned to opera-
The presence of holes, bumps or obstacles along the route tors from outside companies, they must ensure that the
may pose a risk for the operator or for the truck. schedule is followed strictly and that work is performed
scrupulously.
Handling and transit areas must be suitably paved, flat and
cleared of any obstacles. Extraordinary maintenance must always be carried out
by authorised HYSTER service centres.
The operator has the right to refuse to transit through areas
or along routes that may be dangerous to persons or the CLOTHING
truck.
The truck operator must use clothing that reduces risks to a
The operator has the right to refuse to transport loads that minimum. It is recommended to wear safety footwear,
he considers to be dangerous to the transit areas. gloves, and close-fitting jackets and trousers.
It is recommended not to wear watches or metal jewellery
so as to avoid short-circuiting near to the battery.
Use suitable safety equipment in aggressive environments.
Carefully read the operating instructions.
11
GENERAL GUIDELINES
For the transportation of industrial trucks by road or rail, be
sure to verify acceptable dimensions for freight, bearing in
mind both maximum profile dimensions and permissible
weight.
If the dimensions of the truck are higher than this limit, the
truck must be disassembled by removing the parts that
exceed the permissible dimensions.
Use the tools and equipment listed in the procedure given
For this operation please contact HYSTER technical in below.
support.
Do not improvise any kind of manoeuvre that is not offi-
To transport the truck without a proper container it is nec- cially approved by authorised and specialised personnel.
essary to fasten the truck firmly to the transport vehicle.
While parking the truck, the operator must not leave it in
In case of exposure to weather the truck must be protected conditions that could cause damage to people or things.
against atmospheric agents.
CAUTION
To load and unload the truck from the carrier use
appropriate hoisting systems with suitable load
capacities and in good condition. To know the weight
of the truck, refer to the identification data plate.
12
TRUCK HARNESSING FOR HOISTING PHASE 1:
UNLOADING THE TRUCK: EQUIPMENT AND TOOLS Pick up the pallet using the lift truck, raise it and carry it to
a safe place, provided with a bridge crane, away from the
transit areas of other vehicles and pedestrians.
Forklift truck Bridge crane Lifting Chain

PROCEDURE
CAUTION
Before starting work, ensure that you are wearing suit-
able protective clothing.
13
PHASE 2:
• Remove the packaging.
• Fix the pendants directly to the bridge crane (A).
• Fit the hooks of the pendants in the holes (B), prear-
ranged for lifting the lift truck.
CAUTION
Ensure that the bridge crane is positioned vertically
above the truck to be lifted.
• Slowly raise and carefully position the truck on the
ground.
To load and unload the truck, in the absence of the pallet,
refer directly to phase 2, or use a lifting platform with a suit-
able load capacity if there is the possibility to set the truck
into operation.
14
AFTER TRANSPORTATION Upon receipt of the machine, on trucks equipped with bat-
tery lateral extraction and release lever, the ‘A’ lever will be
Following transportation, the truck must be prepared for in a lowered position (Fig. 1), also in case of machines
use in order to ensure its correct operation. transported without the battery installed, to allow a com-
If the truck has been dismantled for transport requirements, plete closing of the cover.
request technical assistance from HYSTER to reassemble On these last types, before installing the battery, it is nec-
it. essary to restore the functionality of the coupling/uncou-
pling system.
To do this pull the lever ‘B’ completely up, holding it up
while lifting also the lever ‘A’ and then lower the lever ‘B’
until it goes into the engagement position (Fig. 2).
15
Figure 1 Figure 2 Now proceed to make the checks listed below:
• Inspect the truck to make certain there is no damage
and there are no parts missing.
• Connect the truck plug with the battery socket.
• Set the truck into operation.
• Check the battery charge level (Indicator).
• Make a general inspection of the controls and instru-
mentation.
WARNING
Any damage or incorrect operation of the truck must
be reported immediately to the HYSTER service centre.
Never start the truck if it is damaged or defective.
Trucks may only operate when they are in good condi-
tion.
NOTE: If the truck needs to be repaired, place a clearly
visible sign saying “OUT OF ORDER - DO NOT USE”
Closed position: Open position: on the truck and remove the key from the control
Battery locked Battery unlocked panel.
16
DESCRIPTION / OPERATING INSTRUCTIONS

CONSTRUCTIONS STANDARDS MODEL DESCRIPTION
The truck described in this manual is constructed in The machines in this series are electric forklift trucks with
accordance with the standards indicated in the EC Declara- driving on the ground , and horizontal and vertical load
tion of Conformity. handling. The steering system is mechanical or in option
electrical.
See the "EC Declaration of Conformity".
The models with INITIAL LIFT option are equipped with the
function "Initial Lift", that allows the truck to get over small
obstacles and slopes, by lifting the load arms.
The transport of double stacked pallets (one on the load
arms, the other on the forks) is allowed only on models with
DOUBLE-DECK option.
The models with STRADDLE LEGS option are equipped
with FEM forks and width-adjustable legs (see technical
sheet). Only skilled technicians authorized by the truck
manufacturer are allowed to adjust the distance between
the legs. TO PERFORM THESE OPERATIONS, PLEASE
CONTACT THE HYSTER SERVICE CENTRE.
This model allows to fork closed pallets laying on the
ground.
17
WARNING
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 it must be
ensured that:
• It is allowed by the national regulations of the coun-
try in which the truck is used.
• An approved safety platform is attached to the forks.
The supplier of the platform is responsible that all
applicable regulations are met. He has to deliver all
necessary instructions for a safe operation.
18
TRUCK CHANGES The user must:

• Make sure that any change or alteration is designed,
WARNING tested and carried out by an engineer specialized in
NO MODIFICATIONS MAY BE MADE TO THE TRUCK industrial trucks and their safety;
WITHOUT PRIOR AUTHORIZATION. • Keep a permanent record of drawings, tests and equip-
No changes which could alter load bearing, stability and ment relevant to the changes or alterations which have
safety of the truck must be carried out without HYSTER been carried out;
written approval. • Approve and make appropriate changes to the capacity
plate, decals, labels and the use and maintenance man-
This refers to changes in brakes, steering system and visi- ual;
bility. It is also forbidden to install removable equipment. • Put a permanent and visible decal on the truck detailing
When the manufacturer approves a change, the capacity the way in which the truck has been modified, the date
rating plate, the adhesive decals, the labels and the use on which this change introduced, the name and address
and maintenance manual must be updated accordingly. of the company which carried out the modification.
The user can modify a motorized industrial truck, only if the The EC Declaration of Conformity issued with the vehi-
manufacturer of the truck has closed down and there are cle will be invalidated by any substantial modifications.
no successors. The party carrying out the modifications becomes the man-
ufacturer, and is required to issue a new EC Declaration of
Conformity.
This also applies to any modifications made to the acces-
sories (i.e any replaceable parts).
19
IDENTIFICATION DATA NOTE: THE IDENTIFICATION DATA PLATE WILL

CHANGE BASED ON THE TRUCK DESTINATIONS
NOTE: The plates and decals positioned on the truck COUNTRY.
have a warning and information function; it is forbid-
den to remove them, paint over them or to render them The fields listed below are not completed for these models.
illegible. • Maximum force of traction (N)
If a plate or decal is found to be illegible it should be • Towing force (N)
replaced by means of an supplementary maintenance
• Application time (h)
operation.
IDENTIFICATION DATA PLATE (1)
(1)
Facsimile in English.
20
CAPACITY DATA PLATE (1) DOUBLE-DECK INFORMATION LABEL

The information label below is in addition to the capacity
plate only on models with initial lift option and double-deck
option.
(1)
The load capacity data plates gives the liftable load values
at varying heights up to the maximum with different distan-
ces from the load centre of gravity on the forks.For a centre NOTE: Double stacked pallets (one on the load arms,
of gravity less than 600 mm, the load capacities are the the other on the forks) can only be carried if the DOU-
same as for the centre of gravity at 600 mm. BLE-DECK option is available.
DANGER
Only work with loads that do not exceed the load
capacity indicated on the plate.
21
The information label shows: WARNING AND INFORMATION LABELS
• that the heavier load should always be carried on the
load arms, in order to not jeopardize the truck’s stability
(QB <= QA) Warranty. (1)
• that the total load must never exceed the value “Q”
given in the technical sheet (QA + QB <= Q)
• that travelling with forks raised at a maximum height of Warns that no-one can climb the forks
1600mm off the ground is allowed only if the double- whether loaded or not.
deck option is available, in double-deck mode.
Shearing hazard.
Indicated the functions of the buttons on

the tiller.

the tiller for models with initial lift option.
22
Indicates that the lift truck is suitable to

work in cold rooms. (2)

the tiller for models with the supplemen-
tary hydraulic function. (2) Indicates the type of battery that it is
possible to charge. (3)
It indicates the battery lever percentage

indicated by the LED while charging
through the battery charger on board. (3)
green led = 100%
Indicates the sling points for hoisting the
yellow led = 80%
truck.
red led = 10%
Indicates the fuses installed on the It indicates the truck voltage potential.
machine for models with electrical steer-
ing option.
Indicates the presence of a LI-ION bat-

Indicates the fuses installed on the tery on the truck. (2)
machine.
23
Warns persons on the ground to keep
out from under the forks. Telemetry decal: indicates the point in
Warns persons on the ground not to which it is necessary to pass the card to
climb onto the truck. activate the truck. (2) (4)
Warns persons on the ground to keep

clear of moving parts - danger of shear-
ing or crushing. CAUTION
The warning and information decals must never be
removed, painted over or made undecipherable.
Telemetry adhesive decal. (2) (4) Should a decal be undecipherable it must be replaced.
(1)
(2)
Option.
(3)
Only for configuration with on-board charger.
(4)
Only for level 2-3 telemetry configuration.
24
TECHNICAL DATA
The dimensions diagram and the specification sheet con-
tain the truck data.
Knowledge of weight, dimensions, movement areas, are
essential for enabling the operator to avoid the general
risks for misuse.
NOTE: ALL VALUES ARE NOMINAL AND SUBJECT TO
TOLERANCES.
FOR MORE INFORMATION, PLEASE CONTACT YOUR
SUPPLIER.
HYSTER PRODUCTS ARE SUBJECT TO CHANGE
WITHOUT NOTICE.
THE TRUCKS ILLUSTRATED MAY FEATURE
OPTIONAL EQUIPMENT.
THE VALUES MAY VARY DEPENDING ON THE DIF-
FERENT CONFIGURATIONS.
25
OVERALL DISPLACEMENT DIAGRAMS
STANDARD MODELS
26
STANDARD MODELS
27
SPECIFICATION SHEET VDI 2198: Pedestrian stacker (Updated 04/2021)
Distinguishing mark
1.1 Manufacturer (abbreviation) Hyster Hyster Hyster Hyster Hyster
1.2 Manufacturer's type designition S1.0 S1.2 S1.4 S1.6 S2.0
1.3 Drive: electric (battery or mains), diesel, petrol, fuel gas Electric (battery) Electric (battery) Electric (battery) Electric (battery) Electric (battery)
1.4 Operator type: hand, pedestrian, standing, seated, order-picker Pedestrian Pedestrian Pedestrian Pedestrian Pedestrian
1.5 Rated capacity/Rated load Q (t) 1.0 1.2 1.4 1.6 2.0
1.6 Load centre distance c (mm) 600 600 600 600 600
1.8 Load distance, centre of drive axle to fork (1) x (mm) 648 649 649 649 649
1.9 Wheelbase y (mm) 1204 1259 1259 1331 1331
Weight
2.1 Service weight (2) kg 956 1005 1038 1145 1151
2.2 Axle loading, laden front/rear kg 676 / 1280 708 / 1497 741 / 1697 805 / 1940 846 / 2305
2.3 Axle loading, unladen front/rear kg 642 / 314 663 / 342 688 / 350 748 / 397 771 / 380
Tyres, chassis
Topthane / Topthane / Topthane / Topthane / Topthane /
3.1 Tyres: polyurethane, topthane, NDIIThane, front/rear
Polyurethane Polyurethane Polyurethane Polyurethane Polyurethane
3.2 Tyre size, front ø (mm x mm) 230 x 70 230 x 70 230 x 70 230 x 70 230 x 70
3.3 Tyre size, rear ø (mm x mm) 85 x 100 85 x 100 85 x 70 85 x 70 85 x 70
3.4 Additional wheels (dimensions) ø (mm x mm) 150 x 54 150 x 54 150 x 54 150 x 54 150 x 54
3.5 Wheels, number front/rear (x = driven wheels) 1x + 1 / 2 1x + 1 / 2 1x + 1 / 4 1x + 1 / 4 1x + 1 / 4
3.6 Tread, front b 10 (mm) 510 510 510 510 510
3.7 Tread, rear b 11 (mm) 400 400 400 400 400
28
Dimensions
4.2 Height of mast, lowered h1 (mm) 2100 2100 2100 2100 2100
4.3 Free lift h2 (mm) 100 100 100 100 100
4.4 Lift h3 (mm) 3200 3200 3200 3200 3000
4.5 Height, mast extended h4 (mm) 3728 3728 3728 3728 3572
4.9 Height drawbar in driving position min./max. h14 (mm) 867 / 1223 867 / 1223 867 / 1223 867 / 1223 867 / 1223
4.15 Height, lowered h13 (mm) 90 90 90 90 90
4.19 Overall length (3) l1 (mm) 1878 1933 1933 2005 2005
4.20 Length to face of forks (3) l2 (mm) 728 783 783 855 855
4.21 Overall width b1 (mm) 790 790 790 790 790
4.22 Fork dimensions (4) s/e/l (mm) 55 / 185 / 1150 55 / 185 / 1150 55 / 185 / 1150 55 / 185 / 1150 65 / 185 / 1150
4.25 Distance between fork-arms (5) b5 (mm) 570 570 570 570 570
4.31 Ground clearance, laden, below mast m1 (mm) 42 42 42 42 42
4.32 Ground clearance, centre of wheelbase m2 (mm) 32 32 32 27 32
4.33 Load dimension b 12 x l 6 crossways b 12 x l 6 1000 x 1200 1000 x 1200 1000 x 1200 1000 x 1200 1000 x 1200
4.34.1 Aisle width for pallets 1000mm x 1200mm crossways A st (mm) 2307 2359 2359 2428 2428
4.34.2 Aisle width for pallets 800mm x 1200mm lengthwise A st (mm) 2293 2345 2345 2414 2414
4.35 Turning radius (Pedestrian) W a2 (mm) 1411 1464 1464 1533 1533
29
Performance data
5.1 Travel speed, laden/unladen km/h 6/6 6/6 6/6 6/6 6/6
5.1.1 Travel speed, laden/unladen, backwards km/h 6/6 6/6 6/6 6/6 6/6
5.2 Lift speed, laden/unladen m/s 0.15 / 0.23 0.17 / 0.28 0.16 / 0.28 0.14 / 0.28 0.10 / 0.19
5.3 Lowering speed, laden/unladen m/s 0.37 / 0.35 0.40 / 0.35 0.40 / 0.35 0.40 / 0.35 0.24 / 0.17
5.7 Gradeability, laden/unladen % 5.2 / 12.6 4.3 / 11.9 3.7 / 11.5 3.1 / 10.2 2.9 / 11.5
5.8 Max. gradeability, laden/unladen % 12.5 / 25.1 10.9 / 24.4 9.6 / 24.5 8.3 / 22.8 7.0 / 22.6
5.10 Service brake Electro magnetic Electro magnetic Electro magnetic Electro magnetic Electro magnetic
Electric - engine
6.1 Drive motor S2 60 minute rating kW 1.2 1.2 1.2 1.2 1.2
6.2 Lift motor, S3 15% rating kW 2.2 (7) 3 (8) 3 (8) 3 (8) 3 (8)
6.3 Battery according to DIN 43531/35/36 A,B,C, no no B B B B
6.4 Battery voltage/nominal capacity K5 (V)/(Ah) 24V / 200Ah (9) 24V / 250Ah (10) 24V / 250Ah (11) 24V / 375Ah (12) 24V / 375Ah (12)
6.5 Battery weight (6) kg 185 212 212 288 288
Energy consumption according to VDI cycle (mechanic
6.6 kWh/h 0.68 / 0.85 0.78 / 1.0 0.89 / 1.13 0.99 / 1.13 0.99 / 1.13
steering/electric steering)
Drive/lift mechanism
8.1 Type of drive unit AC Controller AC Controller AC Controller AC Controller AC Controller
Addition data
Sound pressure level at the driver’s position (mechanic
10.7 dB (A) 67.6 / 64 67.6 / 64 67.6 / 64 67.6 / 64 67.6 / 64
steering/electric steering)
30
(1) (7)
With 3 stage mast -43 mm. These values may vary of +/-5%.
(2) (8)
With forks 1400/1600 mm +14 kg. Value referred to S3 12%.
(3) (9)
With 3 stage mast +43mm, with 3 stage mast with load backrest +43mm, with 2 stage mast with load backrest Available battery 24V / 210Ah (212 kg); 24V / 200Ah BS (185 Kg) the battery is not Din B; 24V / 200Ah Li-Ion (154
+27mm. kg); 24V / 200Ah Li-Ion (211 kg); with BS200Ah the wheelbase is decreased y= -62 mm.
(4) (10)
With 2 stage mast and b5=570mm the s dimension increases 5mm for first 250mm at toe. Available battery 24V / 210Ah (212 kg); 24V / 315Ah (288 kg); 24V / 375Ah (288 kg); 24V / 200Ah Li-Ion (211 kg);
24V / 300Ah Li-Ion (277 kg); with 315/375Ah the wheelbase is increased y=+72 mm.
(5)
Available battery 24V / 315Ah (288 kg).
(11)
Available battery 24V / 315Ah (288 kg); 24V / 300Ah Li-Ion (277 kg).
(6)
Load section lowered +72mm.
(12)
With battery 200Ah BS -60 mm.
31
MODELS WITH INITIAL LIFT
32
MODELS WITH INITIAL LIFT
33
Distinguishing mark
1.1 Manufacturer (abbreviation) Hyster Hyster Hyster
S1.2 S1.4 S1.6
1.2 Manufacturer's type designition
with initial lift option with initial lift option with initial lift option
1.3 Drive: electric (battery or mains), diesel, petrol, fuel gas Electric (battery) Electric (battery) Electric (battery)
1.4 Operator type: hand, pedestrian, standing, seated, order-picker Pedestrian Pedestrian Pedestrian
1.5 Rated capacity/Rated load Q (t) 1.2 1.4 1.6
1.6 Load centre distance c (mm) 600 600 600
1.8 Load distance, centre of drive axle to fork (1) x (mm) 644 644 644
1.9 Wheelbase y (mm) 1350 1350 1422
Weight
2.1 Service weight (2) kg 1111 1111 1187
2.2 Axle loading, laden front/rear kg 832 / 1479 760 / 1751 920 / 1867
2.3 Axle loading, unladen front/rear kg 735 / 376 715 / 396 790 / 397
Tyres, chassis
Topthane / Topthane / Topthane /
Polyurethane Polyurethane Polyurethane
3.2 Tyre size, front ø (mm x mm) 230 x 70 230 x 70 230 x 70
3.3 Tyre size, rear ø (mm x mm) 85 x 95 85 x 75 85 x 75
3.4 Additional wheels (dimensions) ø (mm x mm) 150 x 54 150 x 54 150 x 54
3.5 Wheels, number front/rear (x = driven wheels) 1x + 1 / 2 1x + 1 / 4 1x + 1 / 4
3.6 Tread, front b 10 (mm) 510 510 510
3.7 Tread, rear b 11 (mm) 385 385 385
34
Dimensions
4.2 Height of mast, lowered h1 (mm) 1900 1900 1900
4.3 Free lift h2 (mm) 100 100 100
4.4 Lift h3 (mm) 2800 2800 2800
4.5 Height, mast extended h4 (mm) 3328 3328 3328
4.6 Initial lift h5 (mm) 120 120 120
4.9 Height drawbar in driving position min./max. h14 (mm) 867 / 1223 867 / 1223 867 / 1223
4.15 Height, lowered h13 (mm) 90 90 90
4.19 Overall length (3) l1 (mm) 2028 (12) 2028 2100
4.20 Length to face of forks (3) l2 (mm) 878 (12) 878 950
4.21 Overall width b1 (mm) 790 790 790
4.22 Fork dimensions s/e/l (mm) 55 / 185 / 1150 (4) 55 / 185 / 1150 (4) 55 / 185 / 1150 (4)
4.24 Fork-carriage width b3 (mm) - - -
4.25 Distance between fork-arms b5 (mm) 570 570 570
4.26 Distance between wheel arms/loading surfaces b4 (mm) - - -
4.31 Ground clearance, laden, below mast m1 (mm) 44 44 44
4.32 Ground clearance, centre of wheelbase m2 (mm) 20 20 20
4.33 Load dimension b 12 x l 6 crossways b 12 x l 6 1000 x 1200 1000 x 1200 1000 x 1200
4.34.1 Aisle width for pallets 1000mm x 1200mm crossways A st (mm) 2449 (12) 2449 2518
4.34.2 Aisle width for pallets 800mm x 1200mm lengthwise A st (mm) 2436 (12) 2436 2505
4.35 Turning radius (Pedestrian) W a2 (mm) 1551 (6) (12) 1551 (6) 1620 (6)
35
Performance data
5.1 Travel speed, laden/unladen km/h 6/6 6/6 6/6
5.1.1 Travel speed, laden/unladen, backwards km/h 6/6 6/6 6/6
5.2 Lift speed, laden/unladen m/s 0.16 / 0.27 0.15 / 0.27 0.15 / 0.27
5.3 Lowering speed, laden/unladen m/s 0.40 / 0.25 0.40 / 0.25 0.40 / 0.25
5.7 Gradeability, laden/unladen % 4.1 / 10.6 3.6 / 10.6 3.0 / 9.8
5.8 Max. gradeability, laden/unladen % 11.0 / 22.5 9.3 / 22.5 8.2 / 21.9
5.10 Service brake Electro Magnetic Electro Magnetic Electro Magnetic
Electric - engine
6.1 Drive motor S2 60 minute rating kW 1.2 1.2 1.2
6.2 Lift motor, S3 15% rating (8) kW 3 3 3
6.3 Battery according to DIN 43531/35/36 A,B,C, no B B B
6.4 Battery voltage/nominal capacity K5 (V)/(Ah) 24V / 250Ah (9) 24V / 250Ah (10) 24V / 375Ah (11)
6.5 Battery weight (7) kg 212 212 288
Energy consumption according to VDI cycle (mechanic steering/electric
6.6 kWh/h 0.78 / 1.0 0.89 / 1.13 0.99 / 1.13
steering)
8.1 Type of drive unit AC Controller AC Controller AC Controller
Addition data
Sound pressure level at the driver’s position (mechanic steering/electric
10.7 dB (A) 67.6 / 64 67.6 / 64 67.6 / 64
steering)
36
(1) (7)
(2) (8)
(3) (9)
(4) (10)
(5)
(11)
(6)
(12)
37
MODELS WITH STRADDLE LEGS
38
MODELS WITH STRADDLE LEGS
39
Distinguishing mark
1.1 Manufacturer (abbreviation) Hyster
S1.6
1.2 Manufacturer's type designition
with straddle legs option
1.3 Drive: electric (battery or mains), diesel, petrol, fuel gas Electric (battery)
1.4 Operator type: hand, pedestrian, standing, seated, order-picker Pedestrian
1.5 Rated capacity/Rated load Q (t) 1.6
1.6 Load centre distance c (mm) 600
1.8 Load distance, centre of drive axle to fork (1) x (mm) 646
1.9 Wheelbase y (mm) 1408
Weight
2.1 Service weight (2) kg 1431
2.2 Axle loading, laden front/rear kg 950 / 2081
2.3 Axle loading, unladen front/rear kg 893 / 538
Tyres, chassis
Topthane /
Polyurethane
3.2 Tyre size, front ø (mm x mm) 230 x 70
3.3 Tyre size, rear ø (mm x mm) 85 x 70
3.4 Additional wheels (dimensions) ø (mm x mm) 125 x 60
3.5 Wheels, number front/rear (x = driven wheels) 1x + 1 / 4
3.6 Tread, front b 10 (mm) 522
3.7 Tread, rear b 11 (mm) 968 / 1168 / 1368
40
Dimensions
4.2 Height of mast, lowered h1 (mm) 2100
4.3 Free lift h2 (mm) 100
4.4 Lift h3 (mm) 3200
4.5 Height, mast extended h4 (mm) 3728
4.6 Initial lift h5 (mm) -
4.9 Height drawbar in driving position min./max. h14 (mm) 867 / 1223
4.15 Height, lowered h13 (mm) 55
4.19 Overall length (3) l1 (mm) 2086
4.20 Length to face of forks (3) l2 (mm) 935
4.21 Overall width b1 (mm) 794 / 1095 - 1295 1495
4.22 Fork dimensions s/e/l (mm) 35 / 120 / 1150
4.24 Fork-carriage width b3 (mm) 800 / 1000 / 1200
4.25 Distance between fork-arms b5 (mm) -
4.26 Distance between wheel arms/loading surfaces b4 (mm) 841 - 1041 - 1241
4.31 Ground clearance, laden, below mast m1 (mm) 42
4.32 Ground clearance, centre of wheelbase m2 (mm) 26
4.33 Load dimension b 12 x l 6 crossways b 12 x l 6 1000 x 1200
4.34.1 Aisle width for pallets 1000mm x 1200mm crossways A st (mm) 2504
4.34.2 Aisle width for pallets 800mm x 1200mm lengthwise A st (mm) 2490
4.35 Turning radius (Pedestrian) W a2 (mm) 1607
41
Performance data
5.1 Travel speed, laden/unladen km/h 6/6
5.1.1 Travel speed, laden/unladen, backwards km/h 6/6
5.2 Lift speed, laden/unladen m/s 0.14 / 0.28
5.3 Lowering speed, laden/unladen m/s 0.40 / 0.35
5.7 Gradeability, laden/unladen % 3.1 / 8.9
5.8 Max. gradeability, laden/unladen % 7.4 / 17.8
5.10 Service brake Electro magnetic
Electric - engine
6.1 Drive motor S2 60 minute rating kW 1.2
6.2 Lift motor, S3 15% rating (8) kW 3
6.3 Battery according to DIN 43531/35/36 A,B,C, no B
6.4 Battery voltage/nominal capacity K5 (V)/(Ah) 24V / 375Ah (5)
6.5 Battery weight (7) kg 288
6.6 Energy consumption according to VDI cycle (mechanic steering/electric steering) kWh/h 0.99 / 1.13
8.1 Type of drive unit AC Controller
Addition data
10.7 Sound pressure level at the driver’s position (mechanic steering/electric steering) dB (A) 67.6 / 64
42
(1) (7)
(2) (8)
(3) (9)
(4) (10)
(5)
(11)
(6)
(12)
43
MAST TABLE
Lift height Free lift Height, mast lowered Height, mast extended Weight (3)
Models / Mast type
h3 (mm) h2 (mm) (1) (2) kg
h1 (mm) h4 (mm)
2800 100 (4) (5) 3328 329
1900
3000 100 2000 (4) (5) 3528 343
3200 100 2100 3728 356
S1.0 - S1.2 - S1.4 - S1.6 3400 100 2200 3928 369
B583
2 stage NFL 3600 100 2300 4128 382
3800 100 2400 4328 395
4000 (6) 100 (6) 2500 (6) 4528 (6) 409 (6)
4200 (6) 100 (6) 2600 (6) 4728 (6) 422 (6)
2740 1418 1850 (4) (5) 3268 341
2940 1518 (4) (5) 3468 354

1950
3140 1618 2050 3668 367
S1.0 - S1.2 - S1.4 - S1.6 3340 1718 2150 3868 380
B582
2 stage FFL 3540 1818 2250 4068 393
3740 1918 2350 4268 406
3940 (6) 2018 (6) 2450 (6) 4468 (6) 419 (6)
4140 (6) 2118 (6) 2550 (6) 4668 (6) 432 (6)
(1) (2)
With free lift of 100 mm for NFL mast. With load backrest (h=1000) for carriage h4 +562mm (2 stage), +524mm (3 stage), +518mm (Mast 2 ton.).
44
Lift height Free lift Height, mast lowered Height, mast extended Weight (3)
Models / Mast type
h3 (mm) h2 (mm) (1) (2) kg
h1 (mm) h4 (mm)
4040 1318 (4) 4606 462
1850
4340 1418 1950 (4) 4906 481
4620 1518 2050 5186 499
S1.2 - S1.4 - S1.6
With straddle legs option 4900 1618 2150 5466 518
B584 5180 (7) 1718 (7) 2250 (7) 5746 (7) 537 (7)
3 stage FFL
5460 (7) 1818 (7) 2350 (7) 6026 (7) 556 (7)
(8) (8) (8) (8)
5740 1918 2450 6306 575 (8)
6020 (8) 2018 (8) 2550 (8) 6586 (8) 594 (8)
2600 100 (4) 3172 327
1900
2800 100 (4) 3372 340
2000
3000 100 2100 3572 353
S2.0 3200 100 2200 3772 366
B583-20
2 stage NFL (2 ton.) 3400 100 2300 3972 379
3600 100 2400 4172 393
3800 100 2500 4372 406
4000 100 2600 4572 419
(3) (6)
All weights are: mast structures (weldment, cylinders, chain, pulley) + oil. EXCLUDED: forks, accessories. Only for S1.2 - S1.4 - S1.6 models.
(4) (7)
For S1.2 - S1.4 - S1.6 - S2.0 models, not available with vertical extraction. Only for S1.4 - S1.6 - S1.6 models with straddle legs option.
(5) (8)
For S1.0 model, only available with 150Ah battery. Only for S1.6 model.
45
FORKS TABLE (MAST 2 STAGE)
Distance Length to
Fork length Turning Overall Load dis-
Wheelbase between face of forks Load dimensions Aisle width
(1) radius length tance (1)
fork-arms (2)
Models
l y Wa b5 l2 l1 x l6 b12 Pallet Ast
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) position (mm)
1000 1000 crossways 2222
1000 1204 1411 570 / 680 728 1728 648
1000 800 lengthwise 2144
S1.0
1000 1200 crossways 2307
1150 1204 1411 570 / 680 728 1878 648
1000 1000 crossways 2275
1000 1259 1464 570 / 680 783 1783 649
1000 1200 crossways 2359
1150 1259 1464 570 / 680 783 1933 649
S1.2 1200 800 lengthwise 2345
S1.4
(250Ah) 1000 1400 crossways 2680
1400 1459 1764 570 / 680 783 2183 849
1000 1600 crossways 2778
1600 1459 1764 570 / 680 783 2383 849
1000 1200 crossways 2428
S2.0 1150 1331 1533 570 / 680 855 2005 649
(1) (3)
Less 27mm with a load backrest fitted. Values referred to b3. Not all versions shown in tables are available as standard option.
(2)
Add 27mm with a load backrest fitted.
46
Distance Length to
fork-arms (2)
Models
1000 1000 crossways 2344
1000 1331 1533 570 / 680 728 1728 649
1000 1200 crossways 2428
1150 1331 1533 570 / 680 855 2005 649
S1.4 1200 800 lengthwise 2414
(375Ah)
S1.6 1000 1400 crossways 2745
1400 1531 1829 570 / 680 728 2128 849
1000 1600 crossways 2843
1600 1531 1829 570 / 680 728 2328 849
S1.2 1000 1200 crossways 2449
S1.4
(250Ah) 1150 1350 1551 570 / 680 878 2028 644
With initial 1200 800 lengthwise 2436
lift option
(1) (3)
(2)
47
Distance Length to
fork-arms (2)
Models
S1.4 1000 1200 crossways 2518
(375Ah)
S1.6 1150 1422 1620 570 / 680 950 2100 644
lift option
800 / 1000 / 1000 800 crossways 2393

800 1208 1510 728 1528 446
1200 (3) 800 800 lengthwise 2244
S1.6
With strad- 800 / 1000 / 1000 1000 crossways 2420
950 1408 1607 728 1678 646
dle legs 1200 (3) 1000 800 lengthwise 2341
option
800 / 1000 / 1000 1200 crossways 2504
1150 1408 1607 935 2085 646
1200 (3) 1200 800 lengthwise 2490
(1) (3)
(2)
48
FORKS TABLE (MAST 3 STAGE)
Distance Length to
fork-arms (2)
Models
1000 1000 crossways 2301
1000 1259 1464 570 / 680 826 1826 606
1000 1200 crossways 2382
1150 1259 1464 570 / 680 826 1976 606
S1.2 1200 800 lengthwise 2380
S1.4
(250Ah) 1000 1400 crossways 2690
1400 1459 1764 570 / 680 826 2226 806
1000 1600 crossways 2787
1600 1459 1764 570 / 680 826 2426 806
1000 1000 crossways 2370
1000 1331 1533 570 / 680 898 1898 606
1000 1200 crossways 2451
1150 1331 1533 570 / 680 898 2048 606
S1.4 1200 800 lengthwise 2449
(375Ah)
S1.6 1000 1400 crossways 2755
1400 1531 1829 570 / 680 898 2298 806
1000 1600 crossways 2852
1600 1531 1829 570 / 680 898 2498 806
49
Distance Length to
fork-arms (2)
Models
S1.2 1000 1200 crossways 2472
S1.4
(250Ah) 1150 1350 1551 570 / 680 921 2171 601
lift option
S1.4 1000 1200 crossways 2541
(375Ah)
S1.6 1150 1422 1620 570 / 680 993 2143 601
lift option
800 / 1000 / 1000 800 crossways 2429

800 1208 1510 978 1778 403
1200 (3) 800 800 lengthwise 2274
S1.6
With strad- 800 / 1000 / 1000 1000 crossways 2445
950 1408 1607 978 1928 603
dle legs 1200 (3) 1000 800 lengthwise 2371
option
800 / 1000 / 1000 1200 crossways 2526
1150 1408 1607 978 2128 603
1200 (3) 1200 800 lengthwise 2526
(1) (3)
(2)
50
TRUCK COMPONENTS POSITIONING

The figures below indicate the terminology used to
describe the main components of this truck and their loca-
tion.
1. PROTECTION NET
2. GLOVE COMPARTMENT
3. STEERING TILLER
4. COMMAND AND CONTROL PANEL
5. OPERATOR'S MANUAL COMPARTMENT
6. MOTOR COMPARTMENT COVER
7. BATTERY COMPARTMENT COVER
8. ADHESIVE TAPE ROLL HOLDER
9. CHASSIS
10. BEVERAGE HOLDER
11. MAIN LIFTING CYLINDERS
12. MAST
51
13. CASTOR WHEEL
14. LOAD WHEELS
15. FORKS
16. FREE LIFTING CYLINDER
17. LIFTING CHAIN
52
18. DIAGNOSIS CONNECTOR (1)
19. TRUCK PLUG / BATTERY SOCKET
20. DRIVE MOTOR
21. STEERING MOTOR
22. HYDRAULIC CONTROL UNIT
23. ELECTRICAL BOX
24. BATTERY
25. QUICK EXTRACTION HANDLE (2)
(1)
Use allowed only to specialized personnel.
(2)
Not available for S1.0 model.
53
OPTIONS
26. LEXAN PROTECTION SCREEN
27. TELEMETRY DISPLAY
28. A4 FORMAT BOOKSTAND
29. TELEMETRY CARD READER
30. ON-BOARD BATTERY CHARGER
31. BUZZER ACOUSTIC SIGNAL
32. FEM FORKS (1)
33. SAFETY FASTENERS (1) (2)
34. LI-ION BATTERY
35. PEDESTRIAN AWARENESS LIGHT
36. BOTTLE HOLDER
(1)
Only for models with straddle legs.
(2)
Not compatible with the Load backrest.
54
37. MULTIPURPOSE BAR (3) 39. MULTIPURPOSE CLAMP (4)
38. ROLL HOLDER 40. MULTPURPOSE BAR
(3) (4)
One side. One or two sides.
55
41. LOAD BACKREST (5) ACCESSORIES
42. EXTENTION BATTERY CABLE
43. ROLLERS BATTERY STAND (1) (2)
(5)
Not compatible with the Lateral safety fasteners for forks. (1)
Model for battery 210 / 250Ah.
(2)
Model for battery 315 / 375Ah.
56
INSTRUCTIONS FOR USING THE CONTROLS

AND INSTRUMENTS
The following diagrams and instructions show the type of
control or instrument, their position and the way to use
them.
STEERING TILLER (POS. 3)
CAUTION
As always it must be gripped in the right gripping posi-
tions in order to reduce the possibility of involuntary
finger crushing.
SERVICE BRAKING
The steering tiller in position “1” enables the truck to be
• Move the steering tiller to position “2” to brake.
driven.
• It causes a deceleration due to braking of the electric
Operate the driving tiller to steer. braking of the drive motor with subsequent engagement
of the electromagnetic brake.
PARKING BRAKE
• The parking brake (electromagnetic brake) is automati-
cally engaged by releasing the drive throttles that return
on their neutral position or by releasing the steering tiller
that returns to the vertical position "2".
57
FORKS LIFTING BUTTON (POS. B)
Press this button to lift the forks.
The forks lifting and lowering speed controlled by buttons
on side “1” is electronically set by the manufacturer to be
lower than the speed controlled by buttons on side “2”.
The forks lifting and lowering speed (for both buttons on
side “1” and “2”) can be adjusted according to the opera-
tor’s needs.
In order to change the forks lifting and lowering speed,
please contact the HYSTER service centre.
Buttons on side “2” are proportional. Higher pressure will
A. FORKS LOWERING BUTTON
increase the forks lifting and lowering speed.
B. FORKS LIFTING BUTTON
C. HORN BUTTON
D. BELLY SWITCH (REVERSING BUTTON)
E. DRIVE COMMAND THROTTLES
F. TURTLE BUTTON
FORKS LOWERING BUTTON (POS. A)
Press this button to lower the forks.
58
HORN BUTTON (POS. C) DRIVE COMMAND THROTTLES (POS. E)
Press this button to operate the horn. The operation of the throttles permits travelling both in the
operator side direction (FORWARD TRAVEL) and in the
BELLY SWITCH - REVERSING BUTTON (POS. D)
fork side direction (REVERSE TRAVEL).
It is a device located at the tiller end to reverse the direc-
The truck speed increases proportionally according to the
tion of travel when it is hit. It works during the truck travel
angle of rotation of the throttles.
on the operator side.
If bumped, the truck reverses and stops immediately in Reversing the travel causes a progressive deceleration of
"ENGAGED BRAKE" position. the truck to a stop due to the traction engine electrical brak-
ing (reverse braking).
After reversing, if held down, the truck continues the travel
for a maximum of 5 seconds at low speed. On releasing the butterfly controls, they return to their neu-
To reset the truck functions it is necessary to move the tral position, causing a progressive deceleration, due to the
transfer throttles or the driving tiller. traction engine electrical braking, with subsequent engag-
ing of the electromechanical brake (release braking).
59
• Turning the throttles counter-clockwise, the truck moves TURTLE BUTTON (POS. F)
in the operator direction.
By pressing this button and operating the transfer control
• Turning the throttles clockwise, the truck moves in the
throttles, the truck moves forwards or backwards at
fork direction.
reduced speed, regardless of the tiller position.
On releasing the TURTLE button with the steering tiller in
pos.1, the truck stops.
On releasing the TURTLE button with the steering tiller in
pos.2, the truck keeps on moving at reduced speed.
To reset the drive speed, release the throttles in the neutral

position.
60
STEERING TILLER FOR MODELS WITH INITIAL LIFT (1) LOAD ARMS LOWERING BUTTON (POS. G)
Press this button to lower the load arms.
LOAD ARMS LIFTING BUTTON (POS. H)
Press this button to lift the load arms.
A drive speed reduction will occur when the forks are
raised above the height given in the table “Forks height off
the ground”. (2)
The load arms lifting is inhibited when the forks are raised
above the height given in the table “Forks height off the
G. LOAD ARMS LOWERING BUTTON ground”. (2)
H. LOAD ARMS LIFTING BUTTON Only for models with initial lift option without double-
deck option: with load arms lifted, the forks lifting will stop
once they reach the height given in the table “Forks height
off the ground” (2) and the load arms will lower motion-con-
trolled (it is always possible to stop the load arms lowering
motion by releasing the forks lifting button).
Once the load arms have completely lowered, it is possible
to lift the forks again.
1. FORKS
2. LOAD ARMS
61
Only for models with initial lift option and double-deck FORKS HEIGHT OFF THE GROUND
option: with load arms lifted, the forks lifting will stop once
Forks height off the ground Forks height off the ground
they reach the height given in the table “Forks height off Lift
(models with INITIAL LIFT (models with INITIAL LIFT
Mast height
the ground”. (2) type h3
option, without double-deck option and DOUBLE-DECK
option) (3) option) (3)
It is necessary to lower the load arms using the dedicated (mm)
(mm) (mm)
push button.
2800 1250 1530
When the load arms are completely lowered, it is possible 3000 1250 1530
to lift the forks. B583
3200 1250 1530
3400 1250 1530
2 stage
If the truck is switched off while lowering the load arms, an NFL
3600 1250 1530
3800 1250 1530
alarm will occur preventing traction and forks lifting/lower-
4000 1250 1530
ing. 4200 1250 1530
2740 1523 1633
To restore these functions, when the truck is restarted, it is 2940 1623 1733
necessary to lift and lower the load arms completely. If the B582
3140 1723 1833
3340 1823 1933
alarm does not disappear, please contact the HYSTER 2 stage
3540 1923 2033
service centre. FFL
3740 2023 2133
3940 2123 2233
(1)
Option.
4140 2223 2333
(2)
This value may vary according to the truck configuration: see column “Forks height off the ground”. 4040 1438 1658
(3)
The values are subject to tolerance of 5%. 4340 1538 1758
4620 1638 1858
B584
4900 1738 1958
3 stage
5180 1838 2058
FFL
5460 1938 2158
5740 2038 2258
6020 2138 2358
62
STEERING TILLER FOR MODELS WITH SUPPLEMEN- SUPPLEMENTARY HYDRAULIC FUNCTION BUTTONS
TARY HYDRAULIC FUNCTION (1) (POS. I - J)
Press one of these buttons to activate the supplementary
hydraulic function.
SUPPLEMENTARY HYDRAULIC FUNCTION CONSENT
BUTTON (POS. K)
If present, it is necessary to press one of this buttons at the
same time, in order to allow the operation of the buttons I
and J.
(1)
Option.
(2)
For models with double auxiliary hydraulic function.
I. SUPPLEMENTARY HYDRAULIC FUNCTION BUT-

TONS
J. SUPPLEMENTARY HYDRAULIC FUNCTION BUT-
TONS (1) (2)
K. SUPPLEMENTARY HYDRAULIC FUNCTION CON-
SENT BUTTON (1)
63
COMMAND AND CONTROL PANEL (POS. 4) B) MDI DISPLAY
When switching on the truck, it shows in sequence:
• “Total Hr”, for approx. 3 sec.
• “XXXXX” (Total working hours), for about 3 sec. (The
hours are counted with the tiller in position “1”)
• “BDI XXX%” (Battery discharge indicator).
Standard panel Optional panel
A) IGNITION SWITCH
The ignition switch has two positions:
Lowering the tiller in driving position 2, or pressing the
• Position “0” (off): the entire electrical circuit
TURTLE button, it is possible to view the hours of work in
is isolated
traction (“Trac Hr”).
• Position “1” (on): the entire electrical circuit
is powered up
Do not operate any truck functions until the truck has com-
pleted its start-up cycle.
64
After about 3 sec. the battery charge level percentage is
displayed again (“BDI XXX%”). The battery charge status
is displayed continuously; it is only stopped when there is
an alarm in progress.
• The GREEN LED is always on steady and indicates that
the truck is switched on.
• The AMBER LED indicates a low battery charge; if the
battery charge is below a set threshold (<=20%) the
LED is on steady.
• The RED LED indicates an alarm or a maintenance
request. When an alarm is in progress, the LED will be
blinking. The device will display the alarm code CAN.
(Example: XXXX02)
At the end of the alarm status, the device displays again
the battery charge level percentage (“BDI XXX%”).
On reaching the number of hours after which routine main-
tenance is required, the RED LED lights up fixed.
65
C) EMERGENCY STOP BUTTON D) KEYPAD
By pressing it, the battery supply is disconnected and all USER LOG ON:
the electric controls are disabled (button down: electrical
• Enter one of the user passwords previously activated in
system disconnected).
the Supervisor Menu (Default factory password: 55555).
To restore, turn the button in the direction indicated by the A wrongly entered digit can be erased by pressing the
arrows on the button; it will return to the up position (but- ‘O’ button.
ton up: electrical system connected). • Press the ‘I’ button. The GREEN led ON solid confirms
the entry is accepted.
Pressing it, it also acts as an emergency brake (the electro-
The truck is activated.
magnetic brake engages).
The RED led blinking once warns of an invalid code.
If a user presses the ‘I’ button before entering all 5 pass-
word digits, the RED led will blink once and the digits
entered will be erased.
The RED led then turns back on solid; waiting for a
password.
66
TRUCK PLUG / BATTERY SOCKET (POS. 19)
QUICK EXTRACTION HANDLE (POS. 25)
The truck plug and battery socket is the connection point
between the truck electric installation and the battery. The
plug is fixed to the truck and is connected to the truck elec-
trical system; the socket is connected to the battery and is
extractable.
The battery socket must be disconnected from the truck
USER LOG OFF (This options are available): and connected to the battery charger for recharging opera-
tions.
• Press the ‘O’ button for at least 2 seconds.
The truck is stopped. The RED led will be ON solid and Lead-Acid batteries: The battery socket must be discon-
the keypad will be waiting for a password. nected from the truck and connected to the battery charger
• Turn the truck emergency switch off. for recharging operations.
• Leave the truck inactive for longer than what is set in To remove the socket use the dedicated quick extraction
MENU 6. handle. (1) To access it, it is necessary to open the battery
compartment cover.
NOTE: MENU 6 (Auto Switch-off Function) access is
enabled only for skilled technicians authorized by the Lithium batteries:Refer to battery operating manual.
truck manufacturer. (1)
Not available for model S1.0.
67
NOTE: If necessary, by taking out the socket, the truck BUZZER ACOUSTIC SIGNAL (POS. 31)
would be completely disconnected from the mains.
Depending on the setting, this buzzer automatically turns
Use this procedure in the event of a short-circuit or
on with an audible signal during the movement (it can be
malfunctioning of the operating controls.
activated only for forward drive, only for reserve or both), or
By disconnecting the battery supply, all the operating con- when the tiller is in position "1".
trols are disabled.
68
TELEMETRY: WIRELESS MANAGEMENT SYSTEM Service card
(POS. 27 - 29) The functions of the service card are:
USER GUIDE • The service card permits to unlock the truck after a serv-
ice lock.
These trucks can be equipped with a wireless fleet man-
For example, in case the operator does not successfully
agement system (Telemetry option).
carry out a point on the checklist, causing the truck to be
If the trucks are equipped with RF-ID reader or a control out of service, this card will have to be scanned to put
display, this device needs to be activated in order to enable the truck in service again.
truck functioning. If the following decal is present on the • When the service card is inserted the truck does not turn
truck, it is required to scan a RF-ID card. off after a period of time in which it remains without
operator or inactive.
The system accepts two levels of RF-ID cards:
Furthermore it will also not be necessary to scroll the
Operator card control list to turn on the truck.
This card allows limited access to the use of the truck. If • The service card should be used when programming the
the truck is equipped with the operator presence detection truck CANbus devices. It prevents the truck from switch-
function, this card level will switch off the device after a set ing off during a programming cycle.
time in which the truck will remain with no operator or inac-
If the display is fitted on the truck, the monitoring system
tive and truck functions will be disabled.
will require filling out a checklist.
For the checklist refer to the "Checklist" paragraph. (1)
(1)
If equipped.
69
ACTIVATION (WAKE UP) RF-ID CARD SCANNING (1)
Release emergency switch and turn the ignition key to the If a display is installed on the truck, follow the instructions
ON position to proceed with the activation. If the ignition on the screen.
key is in the ON position, it is necessary to bring it back to
OFF and then back ON. CARD READER (3)
These trucks will have the following decal: (2) 1. Check the presence of this decal
2. Swipe the ID card on the sticker:
• 1 long buzzes - card accepted
• 3 short buzzes - card rejected
• 2 short buzzes - truck in service lock
(1)
If equipped.
(2)
To use the truck: (3)

Option.
1. Set the ignition key to OFF and then back to ON.

2. Swipe the ID card.
3. When the acoustic signal is heard, operate the truck
normally.
70
CHECKLIST (1) Service level RF-ID card:

1. If a display is installed on the truck, it is necessary to • Key switch set to ON and then to OFF.
follow a checklist: follow the instructions on the screen. • NOTE: If the key switch is not turned from ON to
2. Complete the pre-starting checklist. OFF, the service card will remain connected indefi-
nitely.
• The truck is switchend on.
• Complete the after-starting checklist, following the INFORMATION ON THE BUZZER
instructions shown on the screen. During activation, with the card reader:
• Use the buttons at the bottom of the display to answer
the questions on the checklist. • Activation: long buzz
• At this point it is possible to use the truck. • Accepted card scanning, truck ready to be turned on:
one long buzz.
SWITCHING OFF • Denied RF-ID card scanning: 3 short buzzes.
The switch-off will take place after one of the following con- • Card with service lock scanning: 2 short buzzes.
ditions: During the switching off:
Operator level RF-ID card: • Less than 30 seconds: a short buzz every 5 seconds.
• Expired truck activation time • Less than 10 seconds: a short buzz every second.
• Key switch set to OFF (1)
If equipped.
• Unattended truck (not available on all models)
• Inoperative truck
• No movement or lifting detected for a prolonged period
of time.
71
ON-BOARD BATTERY CHARGER (POS. 30) If the socket is not earthed to the ground, do not use it
before a suitable socket has been installed by a qualified
It is a device installed on the truck with AC plug near the
technician. The customer must make sure that the electri-
battery, which allows to recharge it connecting the plug to a
cal system to which the battery charger will be connected is
proper power socket. To identify the type of battery which
suitable and properly protected, if in doubt, contact the
can be recharged, refer to the instructions on the decals
Hyster service centre.
applied in the battery compartment.
Do not open the battery charger as it does not contain
parts that can be repaired and/or replaced by the user.
Only authorized personnel can perform operations that
require opening the device.
Inside there are electrical/electronic components that can
cause electric shock even if the device is not connected to
the power socket. At power on, the battery charger runs a
Do not charge other types of rechargeable or non- test on the battery voltage to decide whether or not to start
rechargeable batteries as they may explode causing dam- the charging process.
age to objects and/or persons. Before using the battery it is
necessary to check the condition of the insulation sheath of If the battery is not connected to the battery charger, the
the connection cable to the mains. yellow LED will flash. If the test was successful, after a few
seconds the battery charging will start with the red LED on.
If it is damaged, contact the HYSTER service centre to get
it replaced. Check the compatibility of the mains plug sup- During the charging process the operator must not discon-
plied to the battery charger with the power socket: it is not nect the battery from the charger. Before disconnecting the
permitted to use adapters. The battery charger must be battery from the charger disconnect the charger from the
connected to a power socket that is properly grounded. mains.
72
During the charging process, its progress is signalled by a Battery charger visual indicators:
LED indicator light, inside the battery compartment (A).
Indication Meaning
Red LED Battery charger configured to recharge
with flashing light (twice) batteries
Red LED
First phase of normal charge (10%)
with fixed light
Yellow LED
Second phase of normal charge (80%)
with fixed light
Green LED End of charging or holding phase
with fixed light (100%)
ANOMALIES
Yellow LED
BATTERY NOT CONNECTED
with flashing light
Red LED SAFETY TIMER EXCEEDED INTER-
with flashing light NAL SHORT CIRCUIT
Green light indicates the charging stop or the last phase in TEMPERATURE ERROR: charging has
been interrupted because the tempera-
buffer mode. After charging, put the battery charger cable Red and green LED ture has exceeded the maximum limit.
in the battery compartment. with fixed light Charging will resume when the tempera-
ture drops below the limit imposed by
Do not close the battery cover under any circumstances the temperature sensor.
without repositioning the battery charger cable.
73
FEM FORKS (POS. 32) (1) FORKS REMOVING (1)

FEM FORKS DISTANCE ADJUSTMENT (1) To remove the forks, proceed as follows:
To adjust the distance between the forks, proceed as fol- • Unlock the fork by pulling up the lever "A".
lows: • Move the fork sideways by the groove "B", at the bottom
of the fork holder plate.
• Unlock the fork by pulling up the lever "A". • Raise the tip of the fork until the fork uncouples from the
• Move the fork sideways and position it. bottom of the fork holder plate.
• Lock the fork by pushing down the lever "A". • Raise the fork to uncouple it from the top of the fork
Repeat the steps described above for the other fork. holder plate as well.
Repeat the steps described above for the other fork.
(1)
(1)
74
FORKS FITTING (1) WARNING

To refit the forks, proceed as follows: The operation of FEM FORKS DISTANCE ADJUST-
MENT, REMOVING and FITTING must be carried out
• Make sure the lever "A" is raised. with the truck stationary and the battery connector dis-
• Place the fork by the groove "B". connected. It is recommended to wear safety footwear,
• Couple the fork, first at the top of the fork holder plate gloves, and suitable clothing.
and then at the bottom.
• Move the fork sideways and position it. Fasteners fixed to the forks carriage, or the load backrest
• Lock the fork by pushing down the lever "A". when mounted, have the function of forks lateral safety fas-
teners.
Repeat the steps described above for the other fork.
(1)
75
SAFETY FASTENERS (POS. 33) (1) ROLL HOLDER (POS. 38)

They have the function of forks lateral safety fastener. To insert the roll/roller, in order to avoid the mast cross-
member interference, proceed as follows:
PEDESTRIAN AWARENESS LIGHT (POS. 35)
• Loosen the screws "A".
The Pedestrian Awareness Light (2) warns of the approach- • rotate the multipurpose clamp "B" outwards of the truck.
ing of the lift truck. It will turn on automatically when the • Insert the roll/roller.
truck moves. Two types of configuration are available: the • Rotate the multipurpose clamp "B" back in the original
light may turn on only in one direction or in both directions position.
of travel. • tighten the screws "A".
LOAD BACKREST (POS. 41)
The truck can be equipped with a load backrest to increase
to the stability of the load on the forks.
The adoption of the load backrest must be evaluated in
function of the application, the type of the load and its
dimensions.
(1)
(2)
Option.
WARNING
Only for models with straddle legs: The truck cannot
be used if the side safety retainers or the load backrest
are not correctly in place.
76
FORKS EMERGENCY LOWERING Procedure:
• Turn the ignition switch (A) to position “0”
WARNING
• Press the emergency button (B).
• Do not walk or stand under the forks when they are • Remove the motor compartment cover (C and D)
raised. unscrewing the screws (E) in order to access the emer-
• During forks emergency lowering, never allow peo- gency taps.
ple to stand around anywhere near the truck.
• Forks emergency lowering is not allowed within the
shelving.
• Report any faults immediately to the HYSTER serv-
ice centre.
• Mark the defective truck and take it out of service.
• Do not return the truck to service until you have rec-
tified the faults.
77
• On models with supplementary hydraulic function (1), you Standard models and models with straddle legs option
need to remove the cover (F) to access the supplemen- To lower the forks, open the emergency tap of the propor-
tary valve block (G), unscrewing the screws (H). tional valve (I).
In order to open this tap, unscrew the outer knurled ring nut
anticlockwise.
A limit stop will occur; the tap is fully open after 4 and 1/4
turns.
Keys are not required for loosening the tap, except for the
first length.
(1)
Option.
78
Models with initial lift option Models with supplementary hydraulic function (1)
To lower the forks, open the emergency tap of the valves In order to lower the forks, open first the emergency tap of
ON/OFF (J/K), then open the emergency tap of the propor- the ON/OFF valves (L) located on the supplementary valve
tional valve (I). To open the emergency tap of the valves block, then the emergency tap of the proportional valve (I).
ON/OFF (J), the screw must be screwed. In order to open the emergency tap of the ON/OFF valves ,
To open the emergency tap of the valves ON/OFF (K), the it is necessary to unscrew the screw. In order to open the
screw must be unscrewed. emergency tap of the proportional valve , unscrew the
To open the emergency tap of the proportional valve, outer knurled ring nut anticlockwise. A limit stop will occur;
unscrew the outer knurled ring nut anticlockwise. A limit the tap is fully open after 4 and 1/4 turns. Keys are not
stop will occur; the tap is fully open after 4 and 1/4 turns required for loosening the tap, except for the first length.
Keys are not required for loosening the tap, except for the
first length.
(1)
Option.
79
PRELIMINARY CHECKS CHECKS WITH THE TRUCK TURNED ON

• Check the correct operation of the brakes using the dif-
WARNING ferent braking methods.
Before daily use of the lift truck check the condition of • Check the correct operation of the valves.
the following parts as described in the "Maintenance" • Check the conditions of the castor wheel support bear-
chapter. ings.
CHECKS WITH THE TRUCK TURNED OFF • Check the correct operation of the steering tiller.
• Check the correct operation of the horn button.
• Check for oil leaks from the drive unit and the hydraulic • Check the correct operation of the BELLY switch.
system. • Check the correct operation of the TURTLE button.
• Check the conditions and wear of the wheels. • Check the battery charge level (Battery charge indica-
• Check the fork conditions. tor).
• Check the linkage conditions (if it is present).
• Check the integrity of the battery socket and plug. WARNING
• Check for liquid leakage from the battery. Any damage or incorrect operation of the truck must
• Check the conditions of the warning and information be reported immediately to the HYSTER service centre.
plates and decals. Never start the truck if it is damaged or defective.
NOTE: If the truck needs to be repaired, place a clearly Trucks may only operate when they are in good condi-
visible sign saying “OUT OF ORDER - DO NOT USE” tion.
on the truck and remove the key from the control
panel.
80
GENERAL STABILITY PRINCIPLES

TRUCK KNOWING
Fork lift trucks are designed for loading and transporting
materials. In their standard version, these vehicles have a
fork lift mechanism, which is used to pick up the load.
The lift mechanism raises the load to facilitate transporta-
tion and storage operations.
In order to understand the operation of the truck, it is
essential to have some familiarity with a few basic con-
cepts regarding the forces and dynamics of trucks with and
without a load.
1. Truck centre of gravity
2. Common centre of gravity
3. Load centre of gravity
4. Load
5. Drive wheel axle
6. Load wheels axle
81
LOAD CENTRE OF GRAVITY When empty, the centre of gravity of the truck is normally
situated in the area between the mast and the battery.
The "load centre" (or "centre of gravity of the load") is the
When the truck is loaded, the truck and the load together
point where the object is balanced in all directions.
have a new common centre of gravity.
In practical terms, the centre of gravity of a uniform object
is the centre of the body (e.g.: the centre of gravity of a The lift truck remains stable when the centre of gravity of
cubic and uniform load of wood is at the centre of the the load and of the truck are both positioned between the
cube). drive wheel axle and the load wheel axle. The area
between these two axles is defined as the "area of stabil-
For loads made up of non-uniform objects, the centre of
ity".
gravity is located in an area between the full (heavy) zones
and the empty zones. COMMON CENTRE OF GRAVITY
The "common centre of gravity" is defined to be the centre
of gravity for the truck configuration with the load on board.
The truck must remain stable in both a longitudinal and
transversal direction.
82
LONGITUDINAL STABILITY AREA Example of the variation of longitudinal stability:
WARNING
• The maximum gradient of the truck is given in the
specification sheet. Never exceed the stated limits.
"The longitudinal area of stability" is defined as the zone • Never drive the truck transversely at the slopes.
between the drive axle and the load wheel axle. • In case of rises and descents drive the truck with
the forks facing the top of the rise, either with or
without load, and with lowered lifting system at a
minimum height, which enables the translation.
83
TRANSVERSE STABILITY AREA CENTER OF GRAVITY IN RELATION TO THE LOAD
POSITION
"The transverse area of stability" is defined as the zone NOTE: Truck stability is reduced, during the phases of
between the front and rear track widths. putting down and picking up, with the load in a high
position. it should be remembered that excessive
stacking (e.g. 2 or more stacked containers) raises the
common centre of gravity, which has the effect of
reducing the stability of the truck.
84
OPERATING TECHNIQUES DANGER

NOTE: When using the truck there are some opera- If the truck should tip over try and keep body parts as
tions that, in spite of all the safety precautions, may far as possible from the point of impact with the
cause it to overturn unless performed with care. ground.
• Turning too fast. NOTE: Carefully read the GENERAL CONDITIONS,

• Driving and turning on a slope. RISKS and the GENERAL STABILITY PRINCIPLES
• Driving with raised loads. chapters and the instructions described below.
• Driving with a side-positioned load. BASIC PRINCIPLE
• Driving on a slope with a load facing downwards.
• Loads out of size. Because of the specific skills required, it is advisable that
• Driving with swinging loads. each individual operator follow a special training course,
• When transporting liquids, the centre of gravity inside even if he has already obtained a licence entitling him to
one of the containers loaded may change; this can drive lift trucks in general.
cause the truck to tip up as a result of the force of iner- The following pages contain a list of some of the basic reg-
tia, for example when switching on, braking or on bends. ulations and manoeuvres that should be employed when
• Ramps or steps. using the truck.
• Loading operations on a lorry, for example if the lorry
engine is switched on while the forks are still raised
above the loading area, if the ramp is not in the right
position or if a truck wheel is beyond the edge/limit.
• Driving over rough ground.
85
AUTHORISED AND TRAINED PERSONNEL WORK ENVIRONMENT
This means that only operators who have followed a spe- The truck may only be used in suitable areas and nor-
cific training course, aimed at providing total comprehen- mal environmental conditions. Do not operate the
sion of the truck functions, should be allowed to operate industrial truck outdoor in the event of adverse
the truck. weather conditions or in hazardous areas.
The instructor should therefore be an expert truck user and
Acceptable environmental conditions:
should work alongside beginners for a period of time, until
they are judged to be sufficiently proficient. Temperature: 5°C to 40°C
A thorough basic training in driving techniques and load Altitude: up to 2000m
handling is absolutely essential to enable the operator to Relative humidity: 30 to 95 % (without condensation)
handle dangerous and unexpected situations effectively. Lighting minimum required: 40 lux.
If the truck works for long periods of time at altitudes above

1000m it is necessary to take into account that the engine
cooling will be less efficient than the working conditions at
sea level.
NOTE: In environments with critical conditions of tem-
perature, humidity or aggressive agents (salinity, dust,
etc.), contact your dealer.
A model specifically manufactured to work in

cold rooms (-30°) exists.
86
The cold store application for a pedestrian controlled or on- Condition for cold store application:
board truck is considered to be inside-out into/from the cold
Truck
store room. application
Cold store
Cold store room temperature can be from 0°C to -30°C. Oil type
Aeroshell
Fluid 41
Climate condition for charging phase has intended to be at
In/Out cold store room
min +5°C temperature. Application
-30°C
Charging and maintenance schedules must be carried out
Cold store environment
in normal ambient temperatures above freezing and the temperature
-30°C
truck must be completely dry before commencing another
Time in cold store room
in-out operation phase. Up to 4 hrs
in working mode
Warm air blowers should be made available in the charg- Standard environment
>10°C
ing/maintenance area to assist in the drying process if nec- temperature
essary. Time out cold store room
15 min
in working mode
Truck should not remain in cold store during extended
intervals of non-use more than five minutes, for operator
breaks, or battery charge cycles.
For cold store application a cold store oil for the hydraulic
system is considered.
87
IMPROPER LIFTING
WARNING
DO NOT ALLOW THE TRUCK TO ENTER AREAS This truck has been designed and constructed for the han-
WHERE FLAMMABLE GASES, VAPOURS OR POW- dling of materials.
DERS ARE GENERATED. THE TRUCK IS NOT EQUIP-
PED WITH ANTI-EXPLOSION PROTECTION. WARNING
The truck is not suited to lifting or carrying persons on
Take the utmost care when transporting dangerous materi-
the forks.
als: flammable liquids, acids, etc. must be transported in
appropriate closed containers. LIFTS
Where possible, avoid routes with holes, bumps and obsta- Never enter lifts without first having obtained permission
cles; if this proves to be impossible, calculate whether each from the person in charge.
individual obstacle can be negotiated and always drive the
NOTE: Check the load bearing capacity of the lift (it
truck with extreme caution. Take steps to ensure that all
must be able to sustain the weight of the truck + opera-
holes, bumps and obstacles are removed wherever possi-
tor + load if present).
ble.
• Approach the lift slowly.
WARNING • Only activate the lift after the truck is correctly centred
INCORRECT USE ON UNSUITABLE FLOORING MAY and perfectly level, so that the lift is well balanced.
CAUSE DANGEROUS SITUATIONS AND REDUCE THE • Make sure that the forks or other parts of the truck do
WORKING LIFE OF THE TRUCK. not protrude beyond the lift perimeter.
Contact the service network for advice concerning the
flooring, or the most suitable type of truck for a particular
type of flooring.
88
ROUTE PERSONS
NOTE: Never enter railway wagons or trailers without • Never carry passengers on the truck.
first checking that their wheels are braked or locked • Prevent persons from standing under the fork lift
with chocks. Check the grip and condition of the floor- mechanism or within its range of action.
ing. Check the width, the load capacity and the reliabil- • Never start the truck if there is someone positioned
ity of loading platforms. between the truck and a fixed structure.
• Study the route. DRIVING
• Check that the manoeuvring clearance zone is free.
• Pay attention and do not exceed the established speed
• Pay attention to obstacles and the surrounding space,
limits.
especially the headroom.
• Pay attention to and observe road signs.
• Points of hazard along corridors or pathways must be
• Do not overtake and use the horn in narrow lanes, on a
made safe and appropriately signposted, with road signs
bend, at crossings and in all cases of poor visibility.
and any additional signs that may be required.
• Do not travel alongside other trucks.
• Observe the rules of priority.
WARNING
• Slow down at crossroads, pedestrian crossings, on
Do not use the truck on routes outdoors when there is
ramps and gangways and on wet or slippery surfaces.
a risk of storms with lightning strikes. The truck does
• Both when laden or unladen, never drive around with the
not have a grounding system.
lifting forks raised.
TOWING OR PUSHING
Travelling with forks raised at a maximum height of
The truck must not be used to push or tow loads or per- 1600mm off the ground is allowed only if the double-
sons. deck option is available, in double-deck mode.
89
STOPS
• Before parking, lower the load completely.
• If you leave the truck, switch it off.
• If the truck is to remain out of sight of the operator, he
must remove the key in order to prevent unauthorised
personnel from using the truck.
• Do not park on slopes; if unavoidable, place chocks
under the wheels. During halts, even for brief periods,
do not stop the truck on a gradient unless absolutely
unavoidable.
In the absence of electrical power supply, the steering
REMOVAL IN BREAKDOWN EVENT wheel is not operational and the electromagnetic brake is
Before removing the truck in the event of a breakdown: engaged, therefore to move this type of lift truck when it is
broken-down it is necessary to lift it.
• Fully lower forks, if raised. Use the manual lowering
valve, if required. Make sure that the means used for lifting has adequate
• Remove load from truck to be towed. capacity and that the slinging equipment is of suitable
capacity and in good condition.
To know the weight of the out-of-service lift truck, refer to
the summary identification data plate. If present, the load
must be removed from the broken-down lift truck before
proceeding with the lifting operations.
90
Secure the hooks of the pendants / the band, in the dedica- CONSIDERATIONS CONCERNING LOADS
ted slots prearranged for lifting the lift truck (for the proce-
dure refer to the "Transporting the truck" chapter). Avoid loading materials that may fall.
Raise the broken-down truck just enough to move it out of You should bear in mind that the truck, even when it is
the work area. equipped with a load backrest, offers a reasonable degree
of protection for the operator against objects falling, but it
CAUTION cannot protect against all possible risks.
The operations mentioned above must be carried out Only move stable loads with weights that can be supported
wearing protective gloves and suitable clothing. by the truck (see the summary identification data plate on
the truck).
Pick up the load so that its weight is well distributed and
balanced on the forks.
Even if a load no greater than that indicated on the load
capacity data plate affixed on the truck weighs entirely on
the tip of a fork, this could constitute a tipping hazard.
The load must not excessively overreach the tip of the
forks.
91
PICKING UP THE LOAD FROM THE GROUND
• Position the truck in line with the load to be lifted.
• Move slowly when moving the forks into position under
the load and make sure that the load is correctly centred
on the forks.
• After fitting the forks in the pallet, slightly lift the load just
enough to move it.
The entering speed, the presence or absence of weight on
the pallet and the floor conditions can influence the maneu-
ver of entering or exiting the pallet from the side of the
lower crossbar.
PUTTING DOWN THE LOAD ON THE GROUND
• Put the load on the ground.
• Lower the forks.
• Move slowly to remove the forks from the pallet.
92
PICKING UP THE LOAD FROM THE GROUND IN DOU- NOTE: The total load must never exceed the value “Q”
BLE-DECK MODE given in the technical sheet.
(see the "DOUBLE-DECK INFORMATION LABEL" para-
graph)
• Move slowly when moving the forks into position under
the first load and make sure that the load is correctly NOTE: During all the operations of picking up/putting
centred on the forks. down the load, use the machine at the lowest speed
• After fitting the forks in the pallet, lift the load in order to allowed by the operation. Always make sure that the
have enough space to pick up the second pallet on the space in the aisle is sufficient, during operations of
load arms. picking up/putting down goods, to prevent the opera-
• Move slowly when moving the load arms into position tor from coming into contact with other persons work-
under the second load and make sure that the load is ing in the same aisle.
correctly centred on the load arms.
• After fitting the load arms in the pallet, lift the load. WARNING
The lift unit is lowered by gravity.
PUTTING DOWN THE LOAD ON THE GROUND IN DOU-
If the lowering command does not actually lower the
BLE-DECK MODE
lift unit (laden or unladen), take immediate action, plac-
• Put the first load on the ground. ing adequate guarding to ensure that no one stands
• Lower the load arms. below or near the raised load, transferring the load if
• Move slowly to remove the load arms from the pallet. possible using other vehicles and calling the HYSTER
• Put the second load on the ground. service centre for assistance.
• Lower the forks.
NOTE: In order to not jeopardize the truck’s stability,
the heavier load should always be carried underneath.
93
PICKING UP THE LOAD FROM A STACK OF CONTAIN-
ERS OR SHELVING
• Move slowly when moving with the forks into position
under the load and make sure that the load is correctly
centred on the forks.
• After fitting the forks in the pallet, slightly lift the load just
enough to move it.
• move the load until it comes out from the stack or shelv-
ing.
• Slowly lower the load until almost to the ground for the
transfer.
94
PUTTING DOWN THE LOAD ON A STACK OF CON-
CAUTION
TAINERS OR SHELVING
Lower slowly, without sudden movements or halts, so
that the load does not fall and cause large stresses in • Position the truck in line with the stack or shelf.
the structure (chassis, forks). • Lift the load to a greater height than the resting surface.
Transfer always with the load positioned low. • Move slowly when moving with the forks into the center
of the load resting point.
WARNING • Lower the load until it is securely placed over the stack
Proceed with the utmost caution and without sudden or shelving.
movements when lifting a load on top of a stack of • Lower the forks, taking care not to drag them on the
containers. When the load is lifted, the common centre underneath load or on the shelf. If when disengaging the
of gravity of the truck and of the load is higher and forks from the pallet, the forks rest on the load under-
more projecting than usual. This may cause the risk of neath or on the shelf, there is a risk that they may slope
overturning the truck. upwards with the risk of destabilizing the pallet.
95
LOAD HANDLING
CAUTION
Never raise the load to a height lower than the target
WARNING
surface and then bump up to the required height.
Only work with loads that do not exceed the load
This kind of manoeuvre makes the load more unstable
capacity indicated on the plate.
and increases the risk of overturning.
Take care not to damage any nearby loads. This information concerns the maximum weight that may
be lifted to the respective height and centre of gravity.
NOTE: Always make sure that the space in the aisle is
Other factors, such as unstable or uneven ground, loads
sufficient, during operations of picking up/putting
with high centres of gravity, should also be taken into con-
down goods, to prevent the operator from coming into
sideration as they reduce stability; to ensure safe working
contact with other persons working in the same aisle.
conditions, the real loadbearing capacity should always be
taken as less than the maximum permissible capacity.
WARNING
Never move your hands, arms or head near to moving LOAD STABILITY
parts.
The operator must prevent anyone, even himself, from WARNING
moving hands, arms or head close to moving parts.
• Only work with stable loads.
Do not lean against the truck while it is engaged in
• Never load unstable elements.
manoeuvres. Do not climb onto the forks or allow any-
• Do not handle a load, composed of a number of sep-
one else to do so.
arate parts, when any one of them is precariously
balanced and in danger of falling.
• It is not permitted to carry swinging loads.
96
LOAD POSITIONING
Make sure that the weight of the load is equally distributed
and balanced on the forks, so that the load will not overturn
when negotiating a bend.
WARNING
A load that is placed in an unbalanced position on the
forks will increase the risk of overturning.
CENTRED LOAD
NON-CENTRED LOAD
97
DRIVING RULES
NOTE: Carefully read the GENERAL CONDITIONS,
RISKS and the GENERAL STABILITY PRINCIPLES
chapters and the instructions described below, before
driving the truck.
VISIBILITY
In order to define the concept of visibility, it is necessary to
indicate the terminology used for the direction of movement
(See the pictures).
This truck can be driven only with the operator on the
ground.
Generally, the truck forward movement direction provides
the operator with the best visibility.
A. FORWARD
B. BACKWARD
98
WARNING
If the truck has to travel in conditions of poor visibility,
it is recommended that the operator be assisted by
specialised and authorised personnel.
A. SIDE SHIFT
B. PICK UP / PUT DOWN
Keep the "BACKWARD" driving position for the load pick-

ing up/putting down operations.
CHANGING DIRECTION
The direction of the truck is changed by turning the steering
tiller (or, if present, the steering wheel).
WARNING
Keep the "FORWARD" driving position for the truck or load
Drive slowly when negotiating bends. When the truck
movement.
is cornering it tends to increase in speed, due to inertia
and the centrifugal force.
99
The truck can overturn even when moving at low speed, The space required by the truck to turn is called the
depending on where the centre of gravity of the load is manoeuvring clearance.
located. If a dangerous bend is approached at a relatively
high speed, the truck could overturn. WARNING
While driving in fork direction side take great care with
The truck is less stable when the forks are raised, even
the manoeuvring clearance. Always make sure that the
without a load.
space required to negotiate the bend is free of obsta-
Most operators fully understand the need to be careful cles. Serious accidents can occur if insufficient
when handling a load, but some do not realise that the manoeuvring clearance is allowed when negotiating a
truck can overturn even when there is no load being car- bend.
ried.
It is in fact easier to overturn a truck when it is travelling
unloaded and with raised forks.
Loads not centred on the forks and uneven road surfaces
increase the risk of overturning. These trucks are designed
to operate in relatively narrow spaces; when negotiating a
bend, the operator must take into account the movements
the truck will make when changing direction.
The geometry of the truck is such that it can pivot on a
point mid way between the wheels, which means that if a
tight 90° bend is to be negotiated, the entire length of the (1)
Run out.
truck (including the dimension attributable to the load) will
be needed to make the turn.
100
PEDESTRIANS
DANGER
To eliminate the risk of overturning, never turn on a Use the horn to warn others of your presence and of the
gradient. potential danger that this may cause to exposed persons
such as pedestrian and persons on the truck’s route.
SPEED
Slow down near crossroads, on ramps and at blind bends
The speed at which the truck is driven must take into
in order to reduce the risk of hitting people.
account the presence of people in the truck working area,
visibility, floor conditions and the load. PRUDENCE
Pay special attention when driving on wet and slippery sur- Always drive the truck with extreme caution in order to
faces. In any case, the truck must travel at a speed which avoid skidding, jumping, etc.
allows its immediate stop in safety conditions.
Avoid creating dangerous situations by engaging in com-
petitions, acrobatics or misusing the truck in any other way.
101
ASCENTS AND DESCENTS
WARNING
Proceed slowly on ramps or slopes. The ascents and Always bear in mind the maximum gradient that the
descents must be travelled, either laden and unladen, with truck can travel (see the dedicated "SPECIFICATION
the forks pointing upstream. When laden lift the forks just SHEET" paragraph).
enough to allow the movement of the pallet/load without
OVERTAKING
dragging it on the ground.
When unladen lift the forks just enough to allow not drag- Never overtake other trucks near junctions, blind
ging them on the ground. corners or other dangerous points.
DESCENT ASCENT
102
OBSTACLES ON THE GROUND KERBS AND VERGES
Avoid holes, bumps, puddles, and any scattered objects
that may cause skidding or overturning. Always choose the
DANGER
easiest route for the truck. Always observe safety distances from the edge of haz-
ardous routes, e.g. platforms, verges, ramps, etc.
MANOEUVRING SPACE Always pay attention to the clearance while driving in
Pay attention to the manoeuvring space, with special the fork direction side.
regard to the forks and to the manoeuvring clearance. Remember that if you steer so as to move away from the
The operator should remember that the forks may protrude end of a loading platform, while driving in the fork direction
beyond the load, which means they may collide against or side, the truck will move towards the end of the platform.
lift other material accidentally.
NARROW PASSAGES
Narrow passages must be appropriately signposted.
Before entering a narrow passage, the driver must check
that there are no persons or other trucks in the passage.
In this case, or if there are insufficient measures to protect
people or prevent collisions with other trucks, it is forbidden
for the driver to enter the passage.
(1)
Run out.
103
CONNECTION RAMPS TRANSFER ON ROAD-GOING TRAILERS AND RAIL-
WAY WAGONS
Before proceeding along connection ramps, the operator
must make sure that the ramp has been correctly mounted Before beginning work inside a trailer or a railway wagon,
and secured and that it is of an appropriate capacity. On the operator must be trained to work in these particular
connecting ramps, proceed only at reduced speed and with conditions and must observe the following instructions:
great caution.
• Never use the truck to open or close the doors of the
The operator must make sure that the vehicle on which the wagons;
loading and unloading operations take place does not • Check that the trailer brakes have been applied and that
move and that it can support the weight of the truck, the blocks have been positioned on both rear wheel units
load and the operator. (unless a specific locking mechanism is installed);
• Fixed supports may be required to sustain the front and
BRAKING DISTANCE
rear parts of the trailer, in order to prevent movement
In all driving situations the truck must be driven at a speed when loading and unloading material;
that will allow it to stop safely in all situations, even in the • Make sure that the railway wagon brakes have been
event of unexpected obstacles. applied and that the wheels are correctly locked for load-
ing and unloading operations, in order to prevent move-
Remember that braking distances increase when the truck
ment caused by the truck entering and leaving the
is loaded and on smooth or wet floors.
wagon;
• Check the solidity of the manoeuvring surface and that
the deck board is capable of supporting the weight of the
truck, the load and the operator.
104
DRIVING IN CONTAINERS TRUCK PARKING
The operator must make sure that the container on which NOTE: THE OPERATOR MUST NEVER LEAVE THE
the loading and unloading operations take place does not LIFT TRUCK IN A CONDITION SUCH THAT IT COULD
move and that it can support the weight of the truck, the CAUSE DAMAGE OR INJURY.
load and the operator.
In order to park the truck, proceed as follows:
TRUCK STOPPING
• Stop the truck.
The truck should always be stopped as gradually as possi- • Lower the forks completely.
ble. Sharp braking and skidding can cause the load to fall. • Switch off the truck.
• Remove the key from the dashboard.
With the truck stationary, the parking brake located on the
drive wheel will be applied automatically.
If the truck is parked on a slope, place chocks under the
wheels on the downhill side so that the truck is unable to
move.
105
CAUTION
Never park the truck in a position where it may
obstruct access to emergency exits, stairs or fire-fight-
ing equipment.
Never park the truck in a cold room, even if it is a vehi-
cle model specifically manufactured to work in cold
rooms.
106
STORAGE AND RESTARTING OPERATIONS 7. Protect the battery terminals with an anti-corrosion product (pure Vaseline).
Important: recharge the battery every month and top up with distilled water if
8.
STORING FOR A SHORT PERIOD OF INACTIVITY necessary.
9. Check that the filler caps are on tight.
Short term storage is intended as storage for a period from
Position blocks under the chassis in order to keep it raised from the ground.
1 to 6 months. This will prevent the weight of the truck from deforming the wheels and rollers
10.
The procedure detailed below is suitable for environmental over time. Take care when raising the truck to position the blocks and make
sure that it is in a stable position.
conditions with temperatures above 0°C.
Protect the truck with a sheet or other protective material. In humid conditions,
In order to allow for different local conditions this procedure 11. a cover is not sufficient to protect the truck from rusting; if the environment is
humid or saline, it is preferable to store in a closed environment.
must be adjusted. Unforeseen variations in climatic condi-
tions during the period of inactivity should also be taken For Lithium batteries refer to battery operating manual.
into account.
In order to store the truck for a short period of time, pro- STORING FOR A LONG PERIOD OF INACTIVITY
ceed as follows: Storage periods exceeding 6 months.
1. Position the truck in a dry and dust-free place. In order to store the truck for a long period of time, proceed
Switch off the truck using the key and make sure that all the instruments are as follows:
2.
turned off.
Carry out all suggested operations for a short storage period (as described in
3. Perform a thorough general cleaning operation. 1.
the "SHORT TERM STORAGE" paragraph).
Keep the lifting system completely lowered; grease the guideways and lubri- Remove the battery from the truck and place it in a position which is raised
4.
cate only the exposed part of the cylinder rods. from the ground and has been approved for this purpose. Make sure that local
Check that the battery is charged and that the electrolyte level is correct. If 2. legislation is complied with. Long storage periods can damage batteries. If
5. possible, it is advisable to use the batteries removed trucks in storage in other
not, recharge the battery and top up with distilled water.
trucks performing normal duties. Batteries deteriorate when not used.
Disconnect the cables from the battery. Protect the terminal clamps with insu-
6. 3. Treat the chassis and the external surfaces with a protective spray.
lating tape.
For Lithium batteries refer to battery operating manual.
107
RESTARTING AFTER A SHORT PERIOD OF INACTIV- RESTARTING AFTER A LONG PERIOD OF INACTIVITY
ITY
When restarting the truck, the following procedure is rec-
When restarting the truck, the following procedure is recommended:
ommended:
Carry out all suggested operations for restarting after a short period of inactiv-
1. ity (see the "RESTARTING THE TRUCK AFTER A SHORT PERIOD OF
1. Remove the blocks and rest the truck on the ground.
INACTIVITY" paragraph).
Reconnect the cable clamps to the battery terminals, clean them and smear
2. Refit the battery; connect the cable clamps to the battery terminals, clean
the terminals with Vaseline.
2. them and smear the terminals with Vaseline. Check the battery charge and the
3. Check the battery charge and the electrolyte level. electrolyte level.
4. Check the level and condition of the hydraulic system oil.
5. Grease all the parts that require greasing.
Check all the truck functions and especially the braking system. NOTE: If there are any malfunctions, switch off the
6. Perform a few trial braking operations without a load and check that the brak- truck and contact the HYSTER service centre.
ing action is continuous.

NOTE: If there are any malfunctions, switch off the
truck and contact the HYSTER service centre.
108
MAINTENANCE / BATTERY
MAINTENANCE GENERAL PRINCIPLES Particular environmental conditions (e.g. dusty environ-
ments or cold stores) may call for a reduction in the inter-
This section includes the Maintenance schedule and vals indicated in the maintenance schedule.
detailed instructions for inspection and maintenance opera-
tions. Failing to follow the recommend maintenance schedules
The maintenance schedule indicates the recommended will reduce the operating efficiency and working life of the
time intervals between routine inspection, maintenance and truck.
replacement operations. These intervals are those envis- The operator or maintenance staff must carry out periodic
aged for normal work cycles. inspections, formulating his opinions or evaluations only on
the basis of safety criteria, without being influenced by
business or economic factors.
He must have sufficient knowledge and experience to be
able to verify the condition of the truck.
HYSTER dealers can provide specialised personnel and
suitable equipment for the performance of these mainte-
nance operations.
It is advisable to ask the HYSTER service network annually
to carry out a check to ensure that the truck meets safety
By normal work cycle one intends eight hour shifts on a standards.
daily basis in relatively clean environments and on suitable
floor surfaces.
109
NOTE: THE REPLACEMENT OF PARTS MUST BE
ENTRUSTED ONLY TO SPECIALIST SERVICE TECHNI-
CIANS APPROVED BY THE TRUCK MANUFACTURER.
TO CARRY OUT ALL REPLACEMENTS, PLEASE CON-
TACT THE HYSTER SERVICE CENTRE.
CAUTION
• Do not use a truck if it requires repairs.
• Any damage or incorrect operation of the truck must
be reported immediately to the Hyster service cen-
tre. OUT OF ORDER
• If the truck needs to be repaired, place a clearly visi- DO NOT USE
ble sign saying “OUT OF ORDER - DO NOT USE” on
the truck and remove the key from the control panel.
• Trucks may only operate when they are in good con-
dition.
• Never carry out repairs or fine tuning operations on
the truck without the required authorisation and the
necessary technical training. Incorrectly executed
repairs or fine tuning operations may lead to dan-
gerous working conditions.
110
CAUTION SCHEDULED MAINTENANCE TABLES

If checks, maintenance or cleaning operations are car- ■ = Checks and maintenance to be performed by the operator or the
ried out immediately after the truck is stopped, some person assigned to truck maintenance.
components of the motor or of the hydraulic system TO CARRY OUT THESE CHECKS AND MAINTENANCE
could be hot. OPERATIONS, PLEASE REFER TO THE INSTRUCTIONS
GIVEN IN THE PARAGRAPHS.
It is recommended to wear safety footwear, gloves, and
● = Checks and maintenance operations that should only be per-
suitable clothing.
formed by a technician authorised by the truck manufacturer.
TO CARRY OUT THESE CHECKS AND MAINTENANCE
OPERATIONS, PLEASE CONTACT THE HYSTER SERVICE
CENTRE.
X = Replacement of parts that should only be performed by a skilled
technician authorised by the truck manufacturer.
TO CARRY OUT THESE REPLACEMENTS, PLEASE CON-
TACT THE HYSTER SERVICE CENTRE.
NOTE: If traffic is obstructed because of a truck break-
down, move the truck as indicated in dedicated para- CAUTION
graph, “Removal in the event of truck breakdown”.
BEFORE CARRYING OUT ALL THE MAINTENANCE
OPERATIONS DESCRIBED IN THIS CHAPTER ENSURE
THAT THE TRUCK IS ON A FLAT SURFACE, WITH NO
LOAD (1) AND THAT THE BATTERY IS DISCONNEC-
TED. (1)
(1)
Except for the checks that require the use of the load or which require that the machine is in operation.
111
CHASSIS
MAINTENANCE INTERVALS
Every Every Every Every
OPERATION DESCRIPTION
8 hours 1000 hours 2000 hours 3000 hours
1 day 1 year 2 years 3 years
CHECK THE SCREWS AND BOLTS ●
VISUALLY CHECK THE MAIN WELDS ●
GENERAL CLEANING ●
112
BRAKING SYSTEM
CHECK SERVICE BRAKING ACTION ■ ●
CHECK EMERGENCY BRAKING ACTION ■ ●
CHECK REVERSE BRAKING ACTION ■ ●
CHECK RELEASE BRAKING ACTION ■ ●
ELECTROMAGNETIC PARKING BRAKE COIL EFFICIENCY CHECK ●
ELECTROMAGNETIC PARKING BRAKE LINER WEAR CHECK (1) ●
(1)
Replace if necessary.
WARNING
Carry out the checks listed below with the forks raised just Never allow people to stand around anywhere near the
enough to allow the transfer on a section of flat and dry truck when testing the braking action.
road, free from obstacles and sufficiently long to allow the Never carry out tests where damage could be caused
truck to stop in case of brakes failure. by a lengthy braking action.
113
CHECK SERVICE BRAKING ACTION Type of braking Tool Braking method Braking intensity
Traction motor
Move the steering tiller into position “2”. electrical braking
SERVICE with subsequent
CHECK EMERGENCY BRAKING ACTION BRAKING
Steering tiller
engagement of the
4
electromagnetic
Drive the truck forward and press the emergency button. brake
Braking with elec-
CHECK REVERSE BRAKING ACTION EMERGENCY
Emergency switch tromagnetic brake 3
BRAKING
engagement
Drive the truck forward and reverse the travel using the
REVERSE Transfer command Drive motor electric
transfer control throttles. BRAKING throttle braking
2
CHECK RELEASE BRAKING ACTION Traction motor

electrical braking
Drive the truck forward and release the control throttles in RELEASE Transfer command with subsequent
1
BRAKING throttle engagement of the
rest position. electromagnetic
brake
The highest value corresponds to the less stop space and

vice versa.
NOTE: In the event of irregular operation, contact the
HYSTER service centre.
114
HYDRAULIC SYSTEM
CHECK FOR OIL LEAKS ■ ●
CHECK FOR SMOOTH OPERATION OF VALVES ■ ●
CHECK OIL LEVEL IN TANK ●
CHECK THE CONDITION AND TENSION OF THE HOSES (2) ●
TANK OIL CHANGE X
OIL FILTER CLEANING (1) X
(1)
Replace if necessary. CHECK FOR OIL LEAKS
(2)
Replace in the following situations:
• A shift of the connection on the pipe; Check if there are evident oil leaks in the hydraulic system.
• The presence of damage, cuts or abrasions on the surface layer;
• Hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• The presence of cracks, damages or strong corrosion on the connector; CHECK FOR SMOOTH OPERATION OF VALVES
• The presence of leaks along the pipe or at the coupling joint;
• The presence of permanent creases, compression, flattening or twists in the pipe;
• The presence of blisters, softening, wear of the external coat. Lift and lower the forks, with or without the load: they must
move up and down smoothly and with no jerks.
WARNING NOTE: In the event of oil leakage or irregular operation
During the following tests, never allow anyone to climb of the valves, contact the HYSTER service centre.
onto the forks, never insert any part of the body
between the lifting mechanisms.
115
MOTORS
CHECK MOTOR INSULATION ●
CHECK CABLE CONNECTIONS ●
CHECK FIXING NUT CONDITION ●
BEARING NOISE CHECK ●
116
REDUCTION UNIT
CHECK FOR OIL LEAKS ■ ●
CHANGE OIL IN REDUCTION UNIT (1)
CHECK REDUCTION UNIT OUTER GEAR TEETH WEAR (STEERING WHEEL CROWN AND PIN-
ION) ●
REDUCTION UNIT NOISE CHECK ●
(1)
Not necessary to replace, very long life oil. NOTE: In the event of oil leakage, contact the HYSTER
CHECK FOR OIL LEAKS service centre.
Check if on the floor under the truck or on the drive wheel

there are traces of oil.
117
WHEELS & TYRES
CHECK CONDITION AND WEAR OF DRIVE WHEEL (1) ■ ●
CHECK CONDITION AND WEAR OF LOAD WHEELS (1) ■ ●
CHECK CONDITION AND WEAR OF CASTOR WHEEL (1) ■ ●
CHECK CONDITION OF CASTOR WHEEL SWIVEL SUPPORT BEARINGS (1) ■ ●
CHECK CONDITION OF CASTOR WHEEL BEARINGS (1) ●
CHECK CONDITION OF LOAD WHEEL BEARINGS (1) ●
CHECK DRIVE WHEEL FIXING NUTS ●
CHECK CASTOR WHEEL-CHASSIS SWIVEL SUPPORT FIXING NUTS ●
(1)
The diameters of the wheels must be no less than the fol-
CHECK THE CONDITION AND WEAR OF DRIVE lowing measurements:
WHEEL, LOAD WHEELS, CASTOR WHEEL
• Drive wheel: 210 mm
It is important that there are no strands or any other mate- • Load wheels: 76 mm
rial wrapped between the rim and the drive unit hub, • Castor wheel: 134 mm
between the load wheels and the support (levers/frame), • Castor wheel for models with straddle legs option: 113
between the rim and the castor wheels supports, and that mm
there are no objects stuck in, flattening or big cuts in the
tread.
118
The consumption of the load wheels must take place CHECK CONDITION OF CASTOR WHEEL SWIVEL SUP-
evenly for both of them. PORT BEARINGS
NOTE: Should replacement be necessary, contact the If at the start or stop the truck tends to fluctuate greatly, the
HYSTER service centre. cause may be excessive clearance of the swivelling sup-
port bearing.
During the lift truck turning, the support rotation must not
block.
NOTE: Should any of these cases arise, contact the
119
MAST
CHECK THE SCREWS AND BOLTS ●
CHECK THE SCREWS OF THE FORK SUPPORT DEVICE LIMIT STOP BLOCK (2) ●
CHECK CONDITONS OF CHAIN TENSIONER (1) ●
CHECK LIFT CHAINS STRETCH ●
CHECK WEAR ON LINKS AND PINS OF LIFT CHAINS (1) ●
CHECK CONDITIONS OF CHAIN PULLEYS AND PIPES (1) ●
CHECK CONDITIONS OF BEARINGS SLIDE GUIDES ●
CLEANING OF BEARINGS SLIDE GUIDES ●
CHECK CONDITIONS OF MAST BEARINGS (1) ●
CHECK CLEARANCE OF MAST ADJUSTMENT DOWELS ●
(1) (2)
Replace if necessary. Only for models with initial lift option.
120
FORKS
CHECK CONDITONS OF FORKS (1) ■ ●
(1)
Replace if necessary. NOTE: In the event of trouble, contact the HYSTER
CHECK CONDITIONS OF FORKS service centre.
Check the integrity and wear of the forks.

Check that there is no visible damage such as cracked,
deformed or very worn forks.
121
LINKAGE, LEVERS
CHECK CONDITIONS OF THE LINKAGE (1) ■ ●
(1)
Only for models with initial lift option. NOTE: In the event of trouble, contact the HYSTER
CHECK CONDITIONS OF THE LINKAGE service centre.
Check that the linkage and levers for visible damage such
as cracks or bends.
When lifting the load arms, with load arms completely low-
ered, check that the tips lift at the same time.
122
GREASING POINTS
LUBRICATE LIFTING CHAINS ●
LUBRICATION WITH GREASE OF FORK SUPPORT DEVICE BEARINGS SLIDE GUIDES AND
MAST ●
LUBRICATION WITH GREASE OF LEVERS (1) ●
LUBRICATION WITH GREASE OF REDUCTION UNIT OUTER GEAR (STEERING WHEEL CROWN
AND PINION) (2)
●
NOTE: Trucks working in cold stores must

(1)
Only for models with initial lift option.
(2)
Only for models with electric steering option.
be lubricated every 500 hours, or even more
frequently in the case of particularly inten-
sive use.
123
STEERING TILLER
STEERING TILLER OPERATION CHECK ■ ●
CHECK THE STEERING TILLER EFFICIENCY ●
STEERING TILLER OPERATION CHECK NOTE: In the event of irregular operation, contact the
Check that the steering tiller turns freely and does not
present an excessive clearance.
124
CONTROLS AND INSTRUMENTATION
BELLY SWITCH OPERATION CHECK (REVERSING BUTTON) ■ ●
HORN BUTTON OPERATION CHECK ■ ●
TURTLE BUTTON OPERATION CHECK ■ ●
BELLY SWITCH OPERATION CHECK (REVERSING HORN BUTTON OPERATION CHECK

BUTTON)
Check that the horn operates correctly when the button is
Check the integrity and correct operation: the truck must pressed.
stop and reverse the travel (see the dedicated "BELLY
TURTLE BUTTON OPERATION CHECK
SWITCH - REVERSING BUTTON" paragraph).
Check the integrity and correct operation: the truck travels
at low speed.
125
ELECTRICAL SYSTEM
BATTERY PLUG/SOCKET INTEGRITY CHECK ■ ●
CHECK CONDITIONS OF ELECTRICAL POWER CONNECTIONS ●
CHECK CONDITIONS OF ELECTRONIC CONTROLLERS AUXILIARY CONNECTIONS ●
CHECK ELECTRICAL WIRING CONDITION ●
SENSORS OPERATION CHECK (1) ●
GENERAL CLEANING OF ELECTRIC PANEL ●
(1)
Only for models with initial lift option. NOTE: In the event of irregular operation, contact the
BATTERY PLUG/SOCKET INTEGRITY CHECK HYSTER service centre.
Check the integrity of the battery socket and plug.

The plug must be securely attached to the truck and the
handle for quick removal must be securely attached to the
socket.
126
LEAD-ACID BATTERY
CHECK BATTERY CHARGE LEVEL ■ ●
CHECK CONDITION OF CABLE CONNECTIONS ●
CHECK FOR LIQUID LEAKS ■ ●
CHECK ELECTROLYTE DENSITY ●
CHECK ELECTROLYTE LEVEL ●
CHECK BATTERY INSULATION ●
CHECK BATTERY CHARGE LEVEL CHECK FOR LIQUID LEAKS

Check the battery charge level through the battery dis- Check if there are evident liquid leaks.
charge indicator (see dedicated "DISPLAY" paragraph).
NOTE: In the event of liquid leaks, contact the HYSTER
service centre.
127
PLATES AND DECALS
CHECK CONDITIONS OF VISIBLE WARNING AND INFORMATION PLATES AND DECALS (1) ■
GENERAL CLEANING OF VISIBLE WARNING AND INFORMATION PLATES AND DECALS ■
CHECK CONDITIONS OF ALL WARNING AND INFORMATION PLATES AND DECALS (1) ●
GENERAL CLEANING OF ALL WARNING AND INFORMATION PLATES AND DECALS ●
(1)
CHECK CONDITIONS AND CLEANING OF VISIBLE

WARNING AND INFORMATION PLATES AND DECALS
Check that the visible warning and information plates and
adhesive decals are still positioned on the lift truck and that
they are clearly legible.
NOTE: Should replacement be necessary, contact the
128
LUBRICANTS
Application Standard Cold store
OIL for lubrication of the SHELL SHELL
HYDRAULIC CIRCUIT TELLUS S2 VX 46 AEROSHELL FLUID 41
GREASE for lubrication of
LIFTING CHAINS
GREASE for lubrication of SHELL
REDUCTION UNIT ADVANCE TEFLON CHAIN
OUTER GEAR (STEER-
ING WHEEL CROWN
AND PINION)
GREASE for lubrication of
FORK SUPPORT
SHELL
DEVICE BEARINGS
ALVANIA EP0
SLIDING GUIDES AND
MAST
GREASE for lubrication of SHELL AEROSHELL
LEVERS ALBIDA GREASE EP2 GREASE 6
Insulation of BATTERY
Pure Vaseline
TERMINALS
(1)
(2)
Only for models with initial lift option.
(3)
Only for models with double-deck option.
(4)
Only for models with supplementary hydraulic function.
(5)
Only for models with double auxiliary hydraulic function.
129
CLEANING CLEANING OF ENGINES, BRAKING SYSTEM AND

ELECTRIC PANEL
CLEANING OF CASING, PLASTIC COVERS, PLATES,
DECALS AND PAINTED PARTS Use only dry air at low pressure and a clean dry brush.
Use only dry air, cloths moistened with water, or cleaning CAUTION
products. Do not use wet rags, water jets, vapour, solvents or
flammable products that may damage the truck or that
CAUTION may be dangerous for the operator.
Do not use jets of water or steam, a solvent or explo-
sive, oxidizing, flammable, toxic, corrosive and harm- CLEANING OF HYDRAULIC SYSTEM, REDUCTION
ful/irritant product which can damage the truck, plates, GEAR AND BEARING SLIDING GUIDES
decals or that can be dangerous for the operator. Use degreasing products.
CAUTION
Do not use water jets, vapours, solvents or flammable
products that may damage the truck or that can be
dangerous for the operator.
BATTERY CLEANING
Follow the directions on the instruction manual of
the battery.
130
BATTERY INTRODUCTION
NOTE: THE BATTERY ON BOARD THE TRUCK IS THE
ONLY POWER SOURCE THAT MAY BE USED. NO
OTHER POWER SOURCE CONNECTED BY CABLES
TO THE TRUCK MAY BE USED.
WARNING
Failure to follow the instructions in this chapter and
the information of the battery and charger instruction
manuals, can cause serious damage to persons or
property in relation to the danger level of the batteries.
The aim of this chapter is to provide the operator with the
instructions needed to perform the battery checking and WARNING
recharging operations in safe conditions. It is recommended to wear safety footwear, gloves,
safety glasses and suitable clothing when working
The following instructions are general, since the user is with the batteries.
free to use different batteries and battery chargers from The container is acid resistant and must be kept in a
those initially supplied by HYSTER. vertical position (or as close to vertical as possible): it
must never be turned upside down in order to avoid
electrolyte spillage.
The acid present in the solution can cause serious
injury.
131
CHOICE OF BATTERY
WARNING
The battery used in this truck is a "TRACTION BATTERY". It is recommended to use batteries compatible with the
truck, for dimensions, weight and capacity.
The truck is normally supplied by the manufacturer com-
plete with traction battery. • Do not use batteries that are too small for the com-
partment where they are housed (even if the
If it is not, the purchaser must follow the indications given
capacity is the same).
in the specification sheet included in this operation and
• Do not make alterations to the battery compart-
maintenance manual.
ments in order to house batteries that are too large.
The choice of battery must fall within the range of the spec- • Do not use batteries of lower weight (even if the
ifications indicated in the specification sheet depending on capacity is the same); this can dangerously affect
the more or less demanding duties the truck will be the stability of the truck.
required to perform. • The weight of the battery must fall within the range
between the battery min. and max. weight stated on
the summary table of the machine identification data
plate.
• Do not use batteries with different capacities from
those specified on the specification sheet.
132
RECHARGING LEAD-ACID BATTERY BATTERY CHARGER
BATTERY CHARGE STATUS The battery charger should be chosen according to the
technical characteristics of the battery:
The battery has to be completely charged before being
used, please refer to battery supplier manual for specific • Number of elements in the battery
information for charging usage and stocking. • Nominal capacity.
• Type: lead-acid (with flat plates or tubes)
RECHARGING ENVIRONMENT • Available power supply: voltage, frequency
• Time available to perform charging
WARNING
The battery should be recharged in a special well venti- NOTE: Call a technician from the manufacturer if you
lated room separated from the working environment have any doubts regarding compatibility with the bat-
because the batteries generate flammable gases that tery.
may cause explosions if they come into contact with RECHARGING METHODS
flames or sparks.
In the case of forced ventilation, flues also used for the The recharge method depends on the type of battery.
extraction of combustion products may not be used. NOTE: Follow the instructions on the instruction man-
ual of the battery and recharging methods.
133
RECHARGING PROCEDURE NOTE: The battery compartment cover must be kept
open at all times during recharging operations in order
WARNING to allow gases generated by chemical reactions inside
Follow the instructions on the instruction manual of the battery elements to disperse.
the battery and battery charger for the recharging pro-
NOTE: The battery socket and truck plug must only be
cedure.
separated when the truck is switched off. The battery
It is good practice to allow a battery to cool down after
socket and charger plug must only be connected and
taking it out of service and before starting to recharge.
separated when the charger is switched off.
The element caps are provided with vents. Before
recharging the battery, make sure the holes are not
obstructed.
• Switch off the truck.
• Open the battery compartment.
• Check that the voltage and the polarity are correct so as
to avoid causing serious damage to the battery and the
battery charger.
• Disconnect the battery socket from the truck plug and
connect it to the battery charger plug.
• Disconnect the battery socket from the battery charger
and connect it to the truck plug when the charging is
completed.
• Re-close the battery compartment.
134
LI-ION BATTERY NOTE: The following images are examples only. The
position and design of the various components may
MAIN COMPONENTS AND LABELS vary depending on battery brand and model.
1. Activation backlight button and battery status leds
2. Diagnostic connector
3. Truck interface CAN port
4. Easy charge port (1)
5. Cap (3)
6. Rating plate (2)
7. Safety label (2)
8. Easy charge port label (2)
9. First charge warning tag (2)
10. Li-Ion identification label (2)
11. Version without easy charge port CAUTION
(1)
Option.
The battery MUST BE FULLY CHARGED upon receipt
(2)
Not illustrated.
from the factory before placing the truck in storage or
(3)
If present. selling to a customer. Failure to charge the battery may
result in a battery failure which may not be considered
NOTE: Refer to the battery operating manual for any a warrantable failure.
safety advice and hazard related to the Li-Ion battery.
NOTE: Unsuitable Lithium-ion batteries that have not
been approved by HYSTER for the truck can be hazard-
ous. Only HYSTER approved batteries should be used.
135
BATTERY SPECIFICATION WARNING AND ALARMS FOR LI-ION BATTERY
Please refer to Battery Operating manual for full battery CODE
ALARM
DESCRIPTION
WARNING
DESCRIPTION
specification details. 0 BATTERY LOW
72 CAN BUS KO BMS
OPERATING INSTRUCTIONS 73
81
BMS TRUCK INHIBIT
WARNING INHIBIT
BMS SHUTDOWN (only fault
Full operating instructions can be found in the battery oper- 83
log)
ating manual. Please see truck specific operations below: 84
129A02
BMS MISMATCH
CAN BUS KO BMS
SETTINGS FOR LI-ION BATTERY BMS TRUCK INHIBIT

130A02 BMS SHUTDOWN (only fault
log)
Truck can be supplied with both Lead-Acid and Li-Ion bat- BMS MISMATCH
tery type. It’s allowed to switch between the two types of 184-33 CHARGING
batteries. Based on truck model, it could be required 196-01 CHARGING
parameter change in order to enable feature. 197-01 CAN BUS KO BMS

198-01 BMS TRUCK INHIBIT
NOTE: Only technicians authorised by the truck manu- 204 BATTERY LOW
facturer are allowed to perform this operation. Contact 226-33 BMS TRUCK INHIBIT
243-33 CAN BUS KO BMS
the HYSTER service centre. 252-01 BMS MISMATCH
252-33 BMS MISMATCH
136
ALARM WARNING ALARM /
CODE EXPLANATION EFFECT
DESCRIPTION DESCRIPTION WARNING DESCRIPTION
BMS SHUTDOWN (only fault If HYSTER LI-ION BATT Traction is reduced based on
253-01
log) parameter is ON this alarm BMS* SPEED RED parameter
BATTERY LOW
BMS SHUTDOWN (only fault occurs when BMS* enables and pump lift function is inhibi-
253-33
log) the limited operation bit ted
254-01 WARNING INHIBIT Communication between Main
254-33 WARNING INHIBIT BMS ALERT Truck and Li-ion battery is A soft stop will occur
BMS ALERT (1) BMS ALERT missing.
BMS MSM 30107 BMS MISMATCH Inhibit operation bit is true --> 15 sec and then traction and
BMS ALRM
no action on the truck pump are stopped
BMS NOK 30108 CAN BUS KO BMS
Set fault because BMS mes-
BMS Over-T (1) BMS Over-T Check BMS connection and
BMS CANBUS KO sage doesn’t received within
BMS TI 30109 BMS TRUCK INHIBIT CAN impedance.
tolerance time interval.
If HYSTER LI-ION BATT
CO55-0 BMS CANBUS KO Traction and pump are stop-
BMS MISMATCH parameter is OFF but message
ped
CO66-0 BMS TRUCK INHIBIT from BMS* are received
CHARGE BTRY Li-Ion battery is working at an
high avarage temperature. Message is dispalyed at every
WARNING INHIBIT BMS Over-T
This behaiviour could com- keyon
BMS ALRM
primes battery lifecycle.
NA BMS SHUTDOWN (only fault
BMS* disables internal battery
log) BMS SHUTDOWN Truck supply is disconnected
contactor
CHARGING
CHARGE STATUS
(1)
Yellow LED blinking.
137
ALARM /
WARNING DESCRIPTION
EXPLANATION EFFECT If one of below alarms/warnings occurs:
after 15 sec of inhibit operation
BMS TRUCK INHIBIT this alarm occurs and no more
Traction and pump are stop-
ped
• CAN BUS KO BMS
truck operations
If HYSTER LI-ION BATT
• BMS TRUCK INHIBIT
15 sec and then traction and
CAN BUS KO BMS parameter is ON but no com-
pump are stopped • BMS ALRM
munication from BMS*
If HYSTER LI-ION BATT Traction is reduced based on • BMS SHUTDOWN
CHARGE BTRY
parameter is ON this alarm
occurs when BMS* enables
BMS* SPEED RED parameter
and pump lift function is inhibi-
• BMS MISMATCH
the limited operation bit ted • WARNING INHIBIT
Battery is in recharging plug- Traction and pump are stop-
CHARGE STATUS
ged to status charger ped • BATT ALARM
CHARGING
Battery is in recharging plug- Traction and pump are stop- • BMS ALERT
ged to status charger ped
Inhibit operation bit is true --> 15 sec and then traction and
WARNING INHIBIT
no action on the truck pump are stopped Based on severity of fault, Li-Ion battery could be automati-
cally switched OFF and then ON. If Li-Ion battery is auto-
Alarm/Warning codes may vary depending on the truck matically switched OFF too many times then a manually
model. recover is needed to switch battery ON pushing backligh-
ted button (Pos. 1 of Main components and labels) for at
least 2 secs.
PRE-SHIFT CHECKS
All pre-shift checks will remain the same as standard truck,
please refer to standard truck manual for more details.
138
OPERATING TEMPERATURES DISPLAY:
NOTE: It is important to ensure operating temperatures Battery capacity is showed as a segmented bar graph in
are kept within the battery temperature range, please 20% increments or as a percentage value (100-0%).
refer to battery operating manual for full details of bat- To prevent deep discharge of the lithium-ion battery, per-
tery operating temperatures. formance limitations are imposed once the charging state
of the battery drops to a certain level: if the charging state
LI-ION BATTERY - RATE OF DISCHARGE
(SOC**) falls below a critical low threshold, the speed of
MDI: the truck is automatically reduced and pump lift function is
disabled. Pump lower function will continue to work.
The truck multifunction battery indicator (MDI) shows the
If SOC** <= critical low threshold, a battery low warning is
available battery capacity as a percentage or as a segmen-
active (charging required).
ted bar graph in 10% increments, depending on truck
model.
CAUTION
For a bar graph model, a charging state below 10% is dis-
To prevent an internal battery failure, the battery shall
played as a blinking segment.
be charged before the charging state drops to 0%.
To prevent deep discharge of the lithium-ion battery, per-
If SOC** reaches the 0% value, the truck smoothly
formance limitations are imposed once the charging state
stops (imemdiately or in 15 sec, depending on the
of the battery drops to a certain level:
truck model). Then BMS* will switch-off the battery
if the charging state (SOC**) falls below a critical low
(imemdiately or after 5sec, depending on the truck
threshold, the speed of the truck is automatically reduced
model).
and pump lift function is disabled.
Pump lower function will continue to work.
If SOC** <= critical low threshold, a battery low warning is
active (charging required).
139
BATTERY RECHARGING MODE If Easy charge port is present (Main battery connector dis-
connection not required):
NOTE: Read carefully and follow the instructions given
in the operation manuals provided with the battery and • Take the truck to a recharge area.
the battery charger for the recharging procedure. • Switch off the truck using the ignition switch.
• Remove the cap (if provided) to access the ‘Easy
OPPORTUNITY CHARGE FUNCTION
Charge port’.
Truck equipped with Li-ion battery can take advantage of • Connect the battery charger to the battery by means of
opportunity charging function. the ‘Easy Charge port’.
Opportunity charging is a system that let the Li-Ion battery
NOTE: Make sure that the charger plug is fully
to be charged several times during the work cycle in order
engaged to the ‘Easy Charge port’.
to eliminate the requirement to change spent batteries dur-
ing a shift day. • Once you have finished charging, disconnect the battery
charger from the battery and insert again the cap (if pro-
This system allows operators to apply sufficient charge to
vided); if the cap is not inserted, traction and hydraulic
the battery during breaks of lift-truck downtime and verify
functions will be inhibited.
value of charge applied by increment of segmented bar
graph or by increment of SOC** percentage value on MDI If Easy charge port is not present:
or display.
• Take the truck to a recharge area.
To recharge the battery, follow the instructions below. • Switch off the truck.
• Connect the battery charger to the battery by means of
the main battery connector.
140
NOTE: Make sure that the charger plug is fully Li-Ion battery will be automatically deactivated if left idle for
engaged to the main battery connector. too long to preserve its energy: If battery is not working
with state of charge (SOC**)>SOC**)>=20% it will be deac-
• Once you have finished charging, disconnect the battery
tivated automatically in few days.
charger from the battery and insert again the Battery
If battery is not working with state of charge (SOC**)<20%
Truck connector to the Main Battery connector.
it will be deactivated automatically in few hrs. In order to
For both standard complete re-charging and opportunity switch on the battery the backlighted button shall be
charging ensure battery is active (backlighted button pushed.
active).
Ensure to recharge the battery only with the right battery
charger which must be from the same supplier as the bat-
tery. BATTERY INSTALLATION / REMOVAL AND REPLACE-
MENT
Usage of different chargers can cause no battery recharg-
ing or damaging. Mechanical battery replacing procedure is the same as the
Refer to charger operating manual for detailed info. standard one.
In order to allow battery work, Truck Interface CAN Port
If the battery loses capacity due to intensive use or repea-
(Pos. 3 of Main components and labels) should be connec-
ted partial recharges, recharge the battery completely until
ted to Main wire harness by dedicated embedded connec-
the battery charger indicates SOC** =100%.
tor or optional harness.
Refer to battery operating manual for detailed info.
* BMS = Battery Management System
The battery socket and charger plug must only be separa-
** SOC = State of charge
ted when the charger is switched off. Refer to charger
operating manual for detailed info how switching off the NOTE: Contact HYSTER for Spare Parts, warranty and
charger. service.
141
REPLACING THE BATTERY

BATTERY CHANGE PROCEDURE (1)
• Take the truck to the battery change area.
• Open the battery compartment cover (A).
• Disconnect the battery from the truck electrical system
via the handle (B).
separated when the truck is switched off.
• Remove the standard battery catch (C) or, if equipped, • Hook the battery using the dedicated holes (F).
remove the polypropylene battery catch (D). • Make sure that the hoist, or the bridge crane (E), is set
at right-angles to the battery.
NOTE: To lift the battery use a hoist or an overhead • Lift the battery to extract it from the truck compartment.
crane, and slinging equipment (bands, pendants), of • Lower the battery very carefully and place it in a safe
suitable capacity and in good condition. place.
To know the weight of the battery, refer to the identifi- • To insert the battery, hooking using the dedicated holes
cation data plate. (F).
(1)
Models with vertical extraction. Models S1.0; and S1.2 - S1.4 - S1.6 - S2.0 with h1 greater than 2020mm and for • Make sure that the hoist, or the bridge crane (E), is set
models with initial lift option. Not available for models with supplementary hydraulic function.
at right-angles to the battery.
• Lift the battery and position it at right-angles to the bat-
tery compartment.
• Lower the battery very carefully, then unhook it.
142
CAUTION
Pay attention to the hands when placing the battery in
its compartment in order to avoid injury. During this
step, be careful not to pinch the battery cable between
the battery and the truck chassis.
• Put back the battery catch (C / D).
• Connect the battery to the truck electrical system (B).
connected when the truck is switched off.
• Close the battery compartment cover (A).
WARNING
Do not use the truck with the battery compartment
open or without a cover; metal parts falling onto the
battery could cause dangerous short-circuits and cre-
ate an explosion hazard.
143
CAUTION
Do not try to extract the battery from the top.
• Open the battery compartment cover (A).
via the handle (B).
separated when the truck is switched off. NOTE: To lift the battery use a hoist or an overhead
• Remove the battery catch (C). crane, and slinging equipment (bands, pendants), of
suitable capacity and in good condition.
To know the weight of the battery, refer to the identifi-
(2)
Models with lateral extraction without rollers. Models S1.2 - S1.4 - S1.6 - S2.0 with h1 less than 2020mm. Not
available for models with supplementary hydraulic function.
cation data plate.
• Hook the battery using the dedicated holes (E). Be care-
ful that from the extraction side, the band passes outside
of the crossbar (F).
• Make sure that the hoist, or the bridge crane (D), is set
at rightangles to the battery.
144
• Slightly lift the battery and simultaneously push it very
carefully outward so that the band on the opposite side
of the extraction, touches the crossbar (F).
• Lower the battery until it rests on the base of the battery
compartment.
• Unhook it from the other side of the extraction, put the
band under the crossbar (F) and hook it again in its seat.
145
• Slightly lift the battery and simultaneously pull it very • Lower the battery until it rests on the base of the battery
carefully to the outside to fully extract it from the truck compartment.
compartment. • Unhook it from the other side of the extraction, put the
• Lower the battery and place it in a safe place. band inside the crossbar (F) and hook it again in its
seat.
• To insert the battery, hooking using the dedicated holes

(E).
• Make sure that the hoist, or the bridge crane, is set at
right-angles to the battery.
• Lift the battery and simultaneously push it very carefully
inside the compartment of the truck, just enough to
make sure that lowering it, it rests on the base of the
battery compartment.
146
• Slightly lift the battery and simultaneously push it com-
CAUTION
pletely inside the compartment, being very careful.
• Lower the battery completely, then release it.
• Put back the battery catch (C).
• Connect the battery to the truck electrical system (B).
connected when the truck is switched off.
• Close the battery compartment cover (A).
WARNING
Do not use the truck with the battery compartment
open or without a cover; metal parts falling onto the
147

• Position the truck so that the battery compartment is
aligned with the empty battery removal trolley (A).
• Open the battery compartment cover (B).
via the handle (C).
separated when the truck is switched off.
• Adjust the height of the battery removal trolley, by
means of the feet (D), so that it is on the same level as
the battery compartment.
• Adjust the height of the lateral stabilizers (E) so that they
rest on the floor. The stabilizers are also designed to
allow fixing to the floor.
These two steps are required only when using the battery
removal trolley for the first time.
(3)
Models with lateral extraction with rollers and release lever (Option). Standard for models with supplementary
hydraulic function, not available for model S1.0
148
• Fully pull the release lever (F) upward to unlock the bat-
tery.
NOTE: Take care when carrying out this operation, dur-
ing which the battery has a gap of about 70 mm
towards the outside of the battery compartment.
NOTE: The battery can be unlocked only when the bat-
tery socket and truck plug are disconnected.
• Remove the flat battery carefully from the truck battery
compartment and put it on the battery removal trolley.
• When the battery to be replaced is on the battery
removal trolley, lock it moving the safety catch (G).
149
• Use an adequate extension cord to connect the truck
plug with the battery charging socket.
• Turn on the truck and position it so that the battery com-
partment is aligned with the battery removal trolley with
the charged battery.
• Switch off the truck and disconnect the extension cord.
• Move the charged battery carefully from the battery
removal trolley to the truck battery compartment.
• Make sure that the additional lever (H) is always in the
hooking position.
CAUTION
150
• Push the engagement lever (F) downward to lock the socket and truck plug must only be connected when
battery. In the last section of stroke it is necessary to the truck is switched off.
apply a greater force.
• Close the battery compartment cover.
NOTE: Make sure the battery is properly locked, check-
ing that it does not protrude beyond the truck outline, WARNING
in order to prevent it from coming out from the battery Do not use the truck with the battery compartment
compartment when the trolley is travelling. open or without a cover; metal parts falling onto the
• Connect the battery socket with the truck plug.
NOTE: This operation is only allowed with the release
lever in the "low" position (battery locked). The battery
151
NOTES
152
Spacer
7/23 (12/22)(3/22)(5/21)(1/21)(6/20)(12/19)(10/19)(4/19)(2/19)(1/19)
OPERATING MANUAL
S1.0 - S1.2 - S1.4 - S1.6 - S2.0 (D456)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4140244 7/23

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OPERATING MANUAL

S1.0 - S1.2 - S1.4 - S1.6 - S2.0 (D456)

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4140244 7/23

LIFT TRUCK MODEL SERIAL NUMBER

HYDRAULIC PUMP MOTOR SERIAL NUMBER

STEERING GEAR MOTOR SERIAL NUMBER

LIFT HEIGHT GROUP NUMBER

DRIVE TIRE SIZE COMPOSITION

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2023. All Rights Reserved.

©HYSTER COMPANY 2023 4140244 - ENGLISH-UK 1

TRUCK SCRAPPING ELECTRICAL SYSTEM

The truck is supplied complete with accompanying docu-

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

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

OTHER APPLICABLE DIRECTIVES:

COMPLIANCE WITH THIS DIRECTIVE IS ESTABLISHED BY MEETING THE TECHNICAL

FOR THE PURPOSE OF REGULATION (EU) 2019/1020 ON MARKET SURVEILLANCE AND

TECHNICAL FILE CONTROLLED BY: NAME AND JOB TITLE

NAME AND JOB TITLE PLANT MANAGER - MASATE

PLACE Day of week, MM/DD/YYYY

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

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

OTHER APPLICABLE DIRECTIVES:

EMC REGULATIONS 2016

COMPLIANCE WITH THIS REGULATION IS ESTABLISHED BY MEETING THE TECHNICAL

TECHNICAL FILE CONTROLLED BY: NAME AND JOB TITLE

NAME AND JOB TITLE PLANT MANAGER - MASATE

PLACE Day of week, MM/DD/YYYY

GENERAL RISKS / TRANSPORTING THE TRUCK

TRUCK HARNESSING FOR HOISTING PHASE 1:

Forklift truck Bridge crane Lifting Chain

DESCRIPTION / OPERATING INSTRUCTIONS

TRUCK CHANGES The user must:

IDENTIFICATION DATA NOTE: THE IDENTIFICATION DATA PLATE WILL

CAPACITY DATA PLATE (1) DOUBLE-DECK INFORMATION LABEL

Indicated the functions of the buttons on

Indicated the functions of the buttons on

Indicates that the lift truck is suitable to

Indicated the functions of the buttons on

It indicates the battery lever percentage

Indicates the presence of a LI-ION bat-

Warns persons on the ground to keep

MODELS WITH INITIAL LIFT

MODELS WITH INITIAL LIFT

MODELS WITH STRADDLE LEGS

MODELS WITH STRADDLE LEGS

2940 1518 (4) (5) 3468 354

800 / 1000 / 1000 800 crossways 2393

800 / 1000 / 1000 800 crossways 2429

TRUCK COMPONENTS POSITIONING

INSTRUCTIONS FOR USING THE CONTROLS

To reset the drive speed, release the throttles in the neutral

I. SUPPLEMENTARY HYDRAULIC FUNCTION BUT-

Standard panel Optional panel

To use the truck: (3)

1. Set the ignition key to OFF and then back to ON.