Hyster Fortis S40FT User manual

OPERATING MANUAL
FORTIS®
S40FT, S50FT, S55FTS, S60FT, S70FT (F187)
H40FT, H50FT, H60FT, H70FT (L177)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 1580499 10/16
Property of American Airlines

LIFT TRUCK MODEL
ENGINE MODEL
TRANSMISSION TYPE
MAST LIFT HEIGHT
CARRIAGE TYPE
DRIVE TIRE SIZE
SERIAL NUMBER
SERIAL NUMBER
SERIAL NUMBER
GROUP NUMBER
GROUP NUMBER
STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2016. All rights reserved.
HYSTER, , FORTENS, and MONOTROL are Registered Trademarks of Hyster-Yale Group, Inc. DURAMATCH, UNISOURCE, and are Trademarks
in the United States and certain other jurisdictions.
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Property of American Airlines

Foreword
To OWNERS, USERS, and OPERATORS:
The safe and efficient operation of a lift truck requires
skill and alertness on the part of the operator. To develop
the skill required the operator must:
•Receive training in the proper operation of THIS lift truck.
•Understand any potential hazards that may exist in the
work place where the lift truck is intended to be used.
•Understand the capabilities and limitations of the lift
truck.
•Become familiar with the construction of the lift truck and
see that it is maintained in good condition.
•Read and properly understand the warnings, instruc-
tions, and operating procedures in this manual.
In addition, a qualified person, experienced in lift truck
operation, must guide a new operator through several driv-
ing and load handling operations before the new operator
attempts to operate the lift truck alone.
It is the responsibility of the employer to make sure that the
operator can see, hear, and has the physical and mental
ability to operate the equipment safely.
Various laws and regulations require the employer to train
lift truck operators. These laws and regulations include:
•Occupational Safety and Health Act (USA)
•Canada Material Handling Regulations
NOTE: A comprehensive operator training program is avail-
able from Hyster Company. For further details, contact
your dealer for Hyster lift trucks.
This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
nance of a basic lift truck. Optional equipment is sometimes
installed that can change some operating characteristics
described in this manual. Make sure the necessary instruc-
tions are available and understood before operating the lift
truck.
Foreword
©HYSTER COMPANY 2016 1580499 - ENGLISH-US 1
Property of American Airlines

Some of the components and systems described in this
Operating Manual will NOT be installed on your unit. If you
have a question about any item described, contact your
dealer for Hyster lift trucks.
Additional information that describes safe operation and
use of lift trucks is available from the following sources:
•Employment safety and health standards or regulations
(Examples: "Occupational Safety and Health Standards
(USA)", "Canada Material Handling Regulations".
•Safety codes and standards (Example: Industrial Truck
Standards Development Foundation, ANSI/ITSDF
B56.1, Safety Standard for Low Lift and High Lift
Trucks).
•Publications from government safety agencies, govern-
ment insurers, private insurers and private organizations
(Example: Accident Prevention Manual for Industrial
Operations, from the National Safety Council).
•Guide for Users of Industrial Lift Trucks (Hyster Part No.
852930) describes lift truck safety, good maintenance
practices, and training programs and is available from
your dealer for Hyster lift trucks.
•Lift Truck/Pedestrian Accidents, Causes and Prevention.
Hyster Company (LIFTPED/B 12/2003).
NOTE: Hyster lift trucks are not intended for use on public
roads.
NOTE: The following symbols and words indicate safety
information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury and property
damage.
On the lift truck, the WARNING symbol and word are on
orange background. The CAUTION symbol and word
are on yellow background.
Foreword
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Contents
Foreword ...................................................................... 1
TO OWNERS, USERS, AND OPERATORS: ............. 1
Warning ........................................................................ 7
Model Description ....................................................... 10
GENERAL ................................................................... 11
OPERATOR PROTECTION EQUIPMENT ................. 14
NAMEPLATE .............................................................. 15
SAFETY LABELS ....................................................... 16
DISPLAY SWITCH CLUSTER .................................... 21
Display Switch Cluster – Right-Side Display Inputs .. 21
Display Switch Cluster – LCD Screen and Warning
and Indicator Lights .............................................. 28
OPERATOR CONTROLS ........................................... 37
OPERATOR CONTROLS – JOYSTICK FEATURES . 57
Operating Procedures ................................................ 63
GENERAL ................................................................... 63
Know Your Lift Truck ................................................ 63
Stability and Center of Gravity .................................. 65
Capacity (Weight and Load Center) ......................... 66
Impact Sensor ........................................................... 67
INSPECTION BEFORE OPERATION ........................ 68
Checks With the Engine Stopped ............................. 68
Mounting and Dismounting ....................................... 69
Operator Passwords ................................................. 69
Starting Procedures .................................................. 71
Starting Procedures, Trucks With Key Switch .......... 71
Starting Procedures, Trucks With Keyless Start
Option ................................................................... 73
Checks With the Engine Running ............................. 74
Load Weighing Sensor ............................................. 75
Set Load Weight to Zero ........................................... 76
Engine Shutdown ...................................................... 76
OPERATING TECHNIQUES ...................................... 77
Basic Operating Procedures ..................................... 78
Driving and Direction Changes ................................. 83
General ................................................................... 85
Normal Operations .................................................. 85
Standard Operator Presence System ..................... 86
Optional Operator Presence System ...................... 87
Basic Powershift and Powershift 1 Speed
Transmissions .................................................. 87
DuraMatch .............................................................. 88
Inching ...................................................................... 90
Steering (Turning) ..................................................... 91
Load Handling, General ............................................ 92
Load Handling, Lifting, Lowering, and Tilting ............ 93
Contents
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Load Handling, How to Engage and Disengage a
Load ...................................................................... 96
Load Handling, Traveling .......................................... 99
Load Handling, Emergency Load Lowering .............. 103
HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ....... 105
ATTACHMENTS ......................................................... 106
Disconnecting Attachment Hydraulic Quick-
Disconnect Hoses ................................................. 107
Connecting Attachment Hydraulic Quick-Disconnect
Hoses .................................................................... 108
STOPPING ................................................................. 108
PARKING .................................................................... 109
Maintenance ................................................................ 110
GENERAL ................................................................... 110
Serial Number Data .................................................. 111
HOW TO MOVE A DISABLED LIFT TRUCK .............. 111
How to Tow the Lift Truck ......................................... 111
HOW TO PUT A LIFT TRUCK ON BLOCKS .............. 112
How to Raise the Drive Tires .................................... 112
How to Raise the Steering Tires ............................... 113
HOW TO CLEAN A LIFT TRUCK ............................... 113
Maintenance Schedule ............................................... 114
Maintenance Procedures Every 8 Hours or Daily .... 150
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED ................................................................. 150
Tires and Wheels ...................................................... 150
Safety Labels ............................................................ 152
Mast, Carriage, Header Hoses, Lift Chains, and
Attachment ............................................................ 152
Operator Restraint System ....................................... 154
Automatic Locking Retractor (ALR) ........................ 157
Emergency Locking Retractor (ELR) ...................... 158
Hood and Seat Latches ............................................ 158
Engine Compartment ................................................ 160
Paper Application ...................................................... 160
Fuel, Oil, and Coolant Leaks, Check ........................ 162
Hydraulic Hoses ........................................................ 162
Coolant Hoses .......................................................... 162
Steering Column Gas Cylinder ................................. 163
Transmission ............................................................ 163
Hydraulic System Oil ................................................ 164
Engine Oil ................................................................. 164
Air Filter .................................................................... 169
Forks ......................................................................... 169
Forks, Remove ......................................................... 169
Forks, Inspect ........................................................... 172
Forks, Install ............................................................. 172
Forks, Adjust ............................................................. 173
HOW TO MAKE CHECKS WITH THE ENGINE
RUNNING ................................................................. 175
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Indicator Lights, Horn, Fuses, and Relays ................ 175
Service Brakes .......................................................... 177
Brake Fluid Level .................................................... 177
Operation, Check .................................................... 177
Parking Brake ........................................................... 178
Engine Oil Pressure .................................................. 179
Cooling System ......................................................... 179
Steering System ....................................................... 181
Control Levers and Pedals ....................................... 181
Lift System Operation ............................................... 181
HOW TO ADD FUEL TO THE LIFT TRUCK .............. 182
Liquefied Petroleum Gas (LPG) ................................ 183
LPG Tank, Remove ................................................ 184
LPG Tank, Fill ......................................................... 186
LPG Tank, Install .................................................... 187
Gasoline or Diesel Fuel ............................................ 188
WHEELS AND TIRES ................................................. 188
General ..................................................................... 188
How to Change a Solid Rubber Tire (S Series) ........ 188
Remove and Install the Tire on the Wheel ................ 189
PNEUMATIC TIRE WITH TUBE, REPAIR ................. 191
Remove Wheels From Lift Truck .............................. 191
Remove Tire From Wheel ......................................... 191
Tire Removal, Two-Piece Wheel ............................ 193
Tire Removal, Three- and Four-Piece Wheels ....... 194
Install Wheel in Tire .................................................. 195
Tire Installation, Three- or Four-Piece Wheel ......... 196
Tire Installation, Two-Piece Wheel ......................... 197
Add Air to Pneumatic Tires With Tube ...................... 198
Install the Wheels ..................................................... 199
PNEUMATIC TUBELESS TIRE, REPAIR .................. 199
Remove Tire From Lift Truck .................................... 199
Remove Tire From Wheel ......................................... 200
Install Tire on Wheel ................................................. 202
Add Air to Pneumatic Tubeless Tire ......................... 205
Install the Wheels ..................................................... 206
SOLID RUBBER TIRES ON PNEUMATIC WHEELS,
CHANGE .................................................................. 206
Remove Tire From Wheel ......................................... 206
Install Tire on Wheel ................................................. 208
DUAL DRIVE WHEELS, INSTALL ............................. 210
JUMP-STARTING THE LIFT TRUCK ......................... 211
Jump-Starting Using a Battery Charger .................... 211
Jump-Starting Using Another Lift Truck .................... 211
JUMP-STARTING THE LIFT TRUCK ......................... 212
Jump-Starting Using a Battery Charger .................... 212
Jump-Starting Using Another Lift Truck .................... 212
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE .................................................... 213
CHANGES TO THE OVERHEAD GUARD ................. 213
Contents
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HOW TO PUT INTERNAL COMBUSTION ENGINE
(ICE) TRUCKS IN STORAGE .................................. 213
Short-Term Storage .................................................. 214
Long-Term Storage ................................................... 215
While the Lift Truck is in Storage .............................. 215
How to Put Batteries in Storage ................................ 215
Putting a Stored Lift Truck Back Into Service ........... 216
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT ............................................................ 217
Loading ..................................................................... 218
Unloading .................................................................. 219
PREPARATION FOR USE ......................................... 219
Preparation After Transport ...................................... 219
Contents
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KNOW THE EQUIPMENT:
•ALWAYS use 3 points of contact when getting on and off
the truck.
•KNOW operating, inspection, and maintenance instruc-
tions in Operating Manual.
• DO NOT operate or repair truck unless trained and
authorized.
•INSPECT truck before use.
• DO NOT operate if truck needs repair. Tag truck and
remove key. Repair truck before use. Always use Hyster
Approved parts when making repairs. Replacement
parts must meet or exceed the specifications of the origi-
nal equipment manufacturer.
•USE auxiliary equipment (attachments) for intended pur-
pose only.
•VERIFY truck is equipped with overhead guard and load
backrest adequate for the load.
LOOK WHERE YOU ARE GOING:
•IF YOU CAN'T SEE, DON'T GO.
•TRAVEL in reverse if load blocks forward vision.
•MAKE SURE tail swing area is clear.
•SOUND horn at intersections or where vision is blocked.
•WATCH clearances, especially overhead.
KNOW YOUR LOADS:
•HANDLE only stable loads within specified weight and
load center. See Nameplate on truck.
•DO NOT handle loose loads higher than load backrest.
•SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
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USE COMMON SENSE:
•DO NOT use truck to lift people unless there is no other
practical option. Then, use only a securely attached spe-
cial work platform. Follow instructions in this Operating
Manual.
•OBEY traffic rules. Yield right-of-way to pedestrians.
•BE in complete control at all times.
•ALLOW NO ONE under or near lift mechanism or load.
•OPERATE truck only from operator's seat.
•KEEP arms, legs, and head inside operator's compart-
ment.
•DO NOT move truck if anyone is between truck and sta-
tionary object.
•BEFORE DISMOUNTING, neutralize travel control,
lower carriage, and set brake.
•WHEN PARKING, also shut off power, close LPG fuel
valve, block wheels on inclines.
KNOW THE AREA:
•NEVER enter a trailer or railroad car unless its wheels
are blocked.
•CONFIRM floor strength.
•FILL fuel tank or charge battery only in designated area.
•TURN OFF engine when fueling.
•AVOID sparks or open flame. Provide ventilation.
•DO NOT start if fuel is leaking.
•KEEP vent caps clear when charging battery.
•DISCONNECT battery during servicing.
•CHECK dockboard width, capacity, and security.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
8
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PROTECT YOURSELF FASTEN YOUR SEAT BELT!
•AVOID bumps, holes, and loose materials.
•AVOID sudden starts or stops.
•NEVER turn on or angle across an incline.
•TRAVEL on inclines with load uphill or when unloaded
with lift mechanism downhill.
•TILT mast slowly and smoothly. LIFT or LOWER with
upright vertical or tilted slightly back. Use minimum tilt
when stacking elevated loads.
•TRAVEL with carriage as low as possible and tilted
back.
•SLOW DOWN before turning, especially without load.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
CAUSE THE LIFT TRUCK TO TIP.
DO NOT JUMP off if the truck tips over. HOLD steering
wheel firmly. BRACE your feet. LEAN FORWARD and
AWAY from point of impact.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
9
Property of American Airlines

Model Description
COMPONENTS FOR H40-70FT TRUCKS ARE IN SAME
LOCATIONS.
1. OVERHEAD GUARD
2. TAIL, BRAKE, AND REVERSE LIGHTS
3. SEAT
4. COUNTERWEIGHT
5. STEERING AXLE
6. SEAT BELT AND HIP RESTRAINT
7. DRIVE AXLE
8. CARRIAGE
9. FORKS
10. LOAD BACKREST EXTENSION
11. PARKING BRAKE
12. STEERING WHEEL
13. MAST
14. OPERATING MANUAL (BEHIND SEAT)
Figure 1. Model View Showing Major Components of S40-70FT, S55FTS Series
Model Description
10
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Model Description
General
This Operating Manual is for the following models of lift
trucks:
S40FT, S50FT, S55FTS, S60FT, and S70FT (F187)
H40FT, H50FT, H60FT, and H70FT (L177)
These lift trucks are available with the following engines:
•Mazda 2.0L engine which uses gasoline or LPG fuel
•Mazda 2.2L engine which uses gasoline or LPG fuel
•GM 2.4L engine which uses gasoline or LPG fuel
•Yanmar 2.6L engine which uses diesel fuel
•Yanmar 3.3L engine which uses diesel fuel
Prior to January, 2011, these lift truck models can be
equipped with a Basic Powershift (iron case), Powershift 1
Speed (aluminum case gear drive) or DuraMatch transmis-
sion (see Table 1). After January 2011, these truck models
will be equipped with a Powershift 1 Speed (aluminum case
chain drive) or DuraMatch transmission (see Table 1) and
can be equipped with three types of controls:
•A MONOTROL® pedal that controls both the forward
and reverse operation of the powershift transmission and
the speed of the engine.
•A Direction Control Lever on the left side of the Display
Switch Cluster that controls the forward, neutral, and
reverse operation of the powershift transmission. A sep-
arate accelerator pedal controls the engine speed.
•A directional control switch integrated into the armrest on
units equipped with E-hydraulics controls both forward
and reverse operation of the transmission. A separate
accelerator pedal controls engine speed.
The S40-70FT lift trucks are equipped with solid rubber
tires. The H40-70FT lift trucks are equipped with pneumatic
tires or solid pneumatic-shaped tires. See Wheels and
Tires in the Maintenance Section for a description of
these tires.
If your lift truck is an S40-70FT, S55FTS (F187) with man-
ual hydraulics and manufactured prior to March, 2009, it is
not equipped an emergency lowering valve. If manufac-
tured after March, 2009, it is equipped with an emergency
lowering valve.
Model Description
11
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If your lift truck is an H40-70FT (L177) with manual hydraul-
ics and manufactured prior to March, 2009, is it not equip-
ped with an emergency lowering valve. If manufactured
after March, 2009, it is equipped with an emergency lower-
ing valve.
If your lift truck is equipped with electronic hydraulics, it has
an emergency lowering valve.
This emergency lowering valve (see Figure 15) allows the
operator or service technician to lower the lift truck's mast
assembly if the electrical signal to the main control valve is
disrupted. See the section Load Handling, Emergency
Load Lowering in the Operating Procedures section.
Model Description
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Table 1. Transmissions
Operational
Feature
Basic Powershift or
Powershift 1 Speed Transmission DuraMatch Transmission
Electronic Inching Yes Yes
Electronic Control of
Direction Changes
Yes Yes
Auto Deceleration – Yes
Controlled Power Reversal – Yes
Roll Reduction Feature – Yes
Roll Back Feature – Yes
Reduced Drive Tire Slippage – Yes
Model Description
13
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1. BASIC POWERSHIFT TRANSMISSION
2. DURAMATCH TRANSMISSION
3. POWERSHIFT 1 SPEED TRANSMISSION
Figure 2. Transmission Labels
Operator Protection Equipment
The LOAD BACKREST EXTENSION is installed to keep
loose parts of the load from falling back toward the opera-
tor. It must be high enough, with vertical openings small
enough, to prevent the parts of the load from falling back-
wards. If a load backrest extension that is different from the
one installed on your lift truck is required, contact your Hys-
ter lift truck dealer.
The OVERHEAD GUARD is intended to offer reasonable
protection to the operator from falling objects, but cannot
protect against every possible impact. Therefore, it must
not be considered a substitute for good judgment and care
when handling loads. Do not remove the overhead guard.
NOTE: The seat belt can be either black or red.
The SEAT BELT AND HIP RESTRAINT provide additional
means to help the operator keep the head and torso sub-
stantially within the confines of the lift truck frame and over-
head guard if a tipover occurs. This restraint system is
intended to reduce the risk of the head and torso being
trapped between the lift truck and the ground, but it cannot
protect the operator against all possible injury in a tipover.
The hip restraint will help the operator resist side move-
ment. It is not a substitute for the seat belt. Always fasten
the seat belt.
This lift truck may be equipped with an optional operator
presence system which will not allow the truck to travel
unless the seat belt is fastened. When equipped, the seat
belt interlock includes sequencing/logic for the seat pres-
sure switch and seat belt switch. The weight of the operator
must be detected prior to the seat belt switch being
engaged to enable operations.
Model Description
14
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Nameplate
WARNING
DO NOT add to or modify the lift truck. Any modifica-
tion that affects the safe operation of the truck cannot
be undertaken without the written authorization of Hys-
ter Company.
Any change to the lift truck, the tires, or its equipment
can change the lifting capacity. The lift truck must be
rated as equipped and the Nameplate must show the
new capacity rating.
The capacity is specified in kilograms (kg) and pounds (lb).
The capacity is the maximum load that the lift truck can
handle for the load condition shown on the Nameplate.
The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities with
the load height reduced or with optional load centers, may
also be shown on the Nameplate.
The lift truck serial number code is on the Nameplate. The
serial number code is also stamped on the right-hand side
of the lift truck frame, under the floorplate.
When a lift truck is shipped incomplete from the factory, the
Nameplate is covered by an INCOMPLETE label as shown
in Figure 3. If the equipment on the truck is changed, the
Nameplate is covered by a NOTICE label as shown in Fig-
ure 3. If your lift truck has either of these labels, do not
operate the lift truck. Contact your dealer for lift trucks to
obtain a complete and correct Nameplate.
Model Description
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A. NAMEPLATE
B. NOTICE LABEL
C. INCOMPLETE LABEL
Figure 3. Nameplate and Labels
Safety Labels
Safety labels are installed on the lift truck to provide infor-
mation about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 4.
All possible label configurations that can be on the lift
trucks covered in this Operating Manual are not shown in
Figure 4. See the Parts Manual for label part numbers and
a complete listing of all labels that are available for the lift
trucks covered in this Operating Manual.
Model Description
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LABELS FOR H40-70FT TRUCKS ARE IN SAME LOCATIONS.
Figure 4. Warning and Safety Labels (Sheet 1 of 3)
Model Description
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SEE THE PARTS MANUAL FOR THE PART NUMBER.
Figure 4. Warning and Safety Labels (Sheet 2 of 3)
Model Description
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