Hyster H1.5XT User manual

OPERATING MANUAL
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
H1.5-1.8XT, H2.0XTS
H2.0-3.5XT
(D475)(D466)

CONTENTS
Model Description ..................................................................... 1
General
Operator Protection Equipment
Nameplate
Location of Stamped Chassis No. and Serial No.
Pre-operation and Periodic Inspections
Handling of New Truck
Nameplate Installation
Main Components
Controls and Instrument Panel ................................................ 10
Controls (Powershift Transmission with Direction Control Lever)
Controls (Powershift Transmission with Monotrol Pedal)
Key Switch
Dash Display
Operator Mode (Operator setting functions)
Safety device
Levers
Pedals
Light Switch
Steering Wheel
ECO mode switch (Electronic controlled engine)
Fuel changeover switch (Dual fuel truck)
Return To Vertical (RTV)(Option)
Truck Structure and Stability .................................................... 40
Load and Truck Stability
Center of Gravity
Stability Range
Load Center and Capacity Table
Loading and Safety Operation .................................................. 42
Picking up Loads
De-stacking
Stacking
Before Starting Work
During Travel
During Work
Parking

How to Drive ............................................................................ 60
Before Driving Adjusting Seat
Starting Engine After Starting
Starting and Driving Stopping and Parking
After Operation
Before Operating with LPG
Changing Fuel for Dual Fuel Truck
Parking for LPG Truck
Replacement of LPG Container
Handling during Winter
Handling during Summer
Inspection ................................................................................ 71
Pre-operational Inspection Post Operation Inspection
Daily Storage Long Term Storage
Periodic Inspection and Servicing
Weekly Inspection (Every 50 Hours)
Monthly Inspection (Every 200 Hours)
Work Items .............................................................................. 98
Replacement of Engine Oil
Replacement of Engine Oil Filter
Draining of Sedimenter (Diesel)
Bleeding Air in Fuel system (Diesel)
Parking Brake Lever Adjustment
Checking Fuses
How to Start Engine when Battery Discharged
How to Use Coupler Pin
Changing Tires
Installation Procedures, Dual Drive Wheels of 2.0-3.5 ton trucks
Wash lift truck
Service Data ........................................................................... 111
List of Lubricants and Periodic Replacement Parts
List of Periodic Replacement of Safety Parts
Main Specications Table ...................................................... 116
Vechicle body dimensions
Specication sheet for I.C.E lift truck (METRIC)

Model Description 1
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1
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General
● This operator manual describes the following models of lift trucks.
Model of lift truck Rated capacety
kg
Load center
mm Engine
H1.5XT 1,500 500
GCT K21
Yanmar 4TNE92
H1.8XT 1,750 500
H2.0XTS 2,000 500
H2.0XT 2,000 500 GCT K21
GCT K25
Yanmar 4TNE92
Yanmar 4TNE98
H2.5XT 2,500 500
H3.0XT 3,000 500 GCT K25
Yanmar 4TNE98
H3.5XT 3,500 500

Model Description 1
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2
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● This manual describes instructions for proper handling of the Hyster fork lift truck
as well as daily lubrication and maintenance check methods. To ensure safe
and highly efcient work through correct operation and servicing, please read
this manual thoroughly before using the truck.
● This manual has been prepared for the standard model. Please contact a Hyster
designated service center for details on options, special specications and any
other unclear points.
This manual is subject to change with changes in the truck specications.
● The following marks are used in this manual to show important items related to
safety, etc. Read this points carefully in addition to the text.
DANGER Indicates items to be observed to prevent high-risk accidents
that could lead to fatalities or personal injuries.
WARNING Indicates items to be observed to prevent accidents that
could lead to fatalities or personal injuries.
CAUTION Indicates items to be observed to prevent personal injuries
or damage to the truck or surroundings.
ADVICE Items that should be followed to prevent accidents and trouble,
and to allow the lift truck to be used safely for a long time.
Make sure that this operator manual is included when transferring ownership of the
lift truck.

Model Description 1
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3
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Operator Protection Equipment
The LOAD BACKREST EXTENSION is installed to keep loose parts of the load from
falling back toward the operator. It must be high enough, with openings small enough
to prevent the parts of the load from falling backwards. Do not remove the load
backrest extension. If a load backrest extension that is different from the one installed
on your truck is required, contact your 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.
Nameplate
The capacity for the lift truck, as it is equipped, must be shown on the Nameplate.
See page 41. If the Nameplate for the lift truck already has a rating for special load
handling equipment, it will be shown. If the Nameplate for the lift truck does not show
the capacity, or if the lift truck equipment does not match that shown on the Nameplate,
do not operate the lift truck.
When a lift truck is shipped incomplete from the factory, the Nameplate is not complete.
If your lift truck does not have a Nameplate or has an incomplete Nameplate, do not
operate the lift truck. Contact your dealer to obtain a complete Nameplate.
DO NOT add to or modify the lift truck. A 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.
WARNING

Model Description 1
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4
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Pre-operation and Periodic Inspections
It is important to carry out the periodic inspections to secure the safety of the lift truck
during use and to provide economically feasible operation.
Pre-operation inspection ..............This daily inspection must be carried out
before starting work with the lift truck.
Post operation inspection ............This inspection is carried out when the daily
operation and work have been completed.
Monthly inspection........................This is a spontaneous inspection that must
be carried out once within a period not ex-
ceeding one month.
Annual inspection..........................This is a spontaneous inspection that must
be carried out once within a period not ex-
ceeding one year.
Location of Stamped Chassis No. and Serial No.
The serial No. for this lift truck is stamped at the location shown in the gure. The
serial No. and model No. are stamped on the nameplate located on the upper part of
the operator’s seat side. Please inform your dealer of these numbers when making
inquiries regarding repairs, etc.
Serial No. stamped on right hand of
Frame

Model Description 1
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5
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Handling of New Truck
Before delivery, special care has been taken for the inspection, adjustment and trial
run of the new truck. However, a certain amount of time will be necessary to break
the lift truck in completely. Careful breaking in of the new truck will lead to a
long-term trouble-free operation. For the rst two weeks of use, take special care
to not apply excessive loads, and pay attention to the following points.
● Avoid high-speed operation, and keep the load to 70 to 80% of the rated
load.
● Pay attention to loosening of bolts, nuts and hydraulic line joints during
the break-in period. If any looseness is found, stop the lift truck and
retighten the loose part.
● Take time to train in the usage of each on the lift truck before starting full
scale operation. Even after becoming used to the handling, be careful
during the actual operation to prevent personal accidents or physical
accidents.
● Even if the lift truck has the same specications, each lift truck will have
its own characteristics in terms of brakes, accelerators and loading
devices. Always feel the lift truck out before starting use. Take special
care to get a feel of the brakes before starting.
CAUTION

Model Description 1
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6
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Nameplate Installation
Safety labels and other nameplates are attached to the positions shown below. Read
these labels before starting work, and make sure that the details are well understood
so that the lift truck can be operated safely and without accidents.
(ON BOTH SIDES)
(FOR LPG,ON LPG TANK BRACKET)
(ON HOOD)
(ON HOOD)
(ON BOTH SIDES)
(ON BOTH SIDES)
(ON BOTH SIDES)

Model Description 1
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7
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If the label is no longer readable, or if it has come off, always replace it with
a new one.
CAUTION
(ON BOTH SIDES)
(ON BATTERY)
FOR GASOLINE
FOR DSL
FOR LPG

Model Description 1
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8
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1. Load backrest
2. Fork carriage
3. Fork
4. Tilt cylinder
5. Fuel tank
6. Frame
7. Covers
8. Fuel port
9. Hood
10. Seat
11. Overhead guard
12. Front light
13. Turn signal light
Main Components
1.
2.
3.
4.
6. 5.
7.
8.
9.
10.
11.
13.
12.

Model Description 1
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9
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16. Rear combination light
17. Counterweight
18. Rear tire
19. Hydraulic oil tank
20. Front tire
21. Dash panel
22. Kick panel
23. Mast
24. Steering wheel
25. Rear-view mirror
16.
17.
18.
19. 20.
22.
21.
23.
24.25.

Controls and Instrument Panel 2
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10
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1. Direction control lever
2. Parking brake lever
3. Inching pedal
4. Brake pedal
5. Accelerator pedal
6.Third control lever for auxiliary
hydraulic function(s).
7. Tilt lever
8. Lift lever
9. Key switch
10. Turn signal lever/Light switch
11. Tilt column lever
12. Horn button
13. Steering wheel
14. ECO mode switch
(Electronic controlled LPG engine)
15. Fuel changeover switch(Dual fuel)
Controls
(Powershift Transmission with Direction Control Lever)
1.
2.
11.
3. 4. 5. 14. 15.
6.7.8.10.9.12.13.

Controls and Instrument Panel 2
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11
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Controls
(Powershift Transmission with Monotrol Pedal)
1.
2.
11.
3.
4.5.6.7. 8.10.
9. 12. 13.
1. Parking brake lever
2. Brake/inching pedal
3. Monotrol pedal
4.Third control lever for auxiliary
hydraulic function(s).
5. Tilt lever
6. Lift lever
7. Key switch
8. Turn signal lever/Light switch
9. Tilt column lever
10. Horn button
11. Steering wheel
12. ECO mode switch
(Electronic controlled LPG engine)
13. Fuel changeover switch(Dual fuel)
Controls
(Powershift Transmission with Monotrol Pedal)

Controls and Instrument Panel 2
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12
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Key Switch
The key switch is on the right side of the
steering column near the cowl. The key
switch has three positions:
“OFF” position: Deenergizes all electric
circuits except for the horn and lights.
“ON” position: Energizes all electric cir-
cuits except the starter circuit. The key
switch will be in this position during normal
operation.
“START” position: Energizes the starter
motor for starting the engine. A spring re-
turns the key to “ON” position when the
key is released.
NOTE:
1. The key switch has a function of anti-
restart, so if the engine does not start
even when the key is turned to “ST”,
return the key to “OFF” once, and
then try again after 5 to 10 seconds.
2. When you pull out the key, turn it to
“OFF”.
OFF position
ON position
Key switch
START position

Controls and Instrument Panel 2
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13
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Dash Display
All icons will be shown for 0.5 seconds when the key switch is set to “ON”. If the
icons do not exist even when the key switch is set to “ON”, the LCD may be failed
or there may be an error in the related equipment. If the icon does not exist even
after repair, inspect the lift truck immediately and perform adequate measures.
ADVICE
Fuel Gauge
(Gasoline/Dsl)
Seat Belt
(10 sec.)
Alarm Set Coolant Temp Mode Change Button
Real Time Clock, Travel Speed,
Load Weight Pass-Word Entry
Menu(Optional),Message
Hour Meter,Calender,
Error,and Message
Control Button Panel
Display Change
Button for
Bottom Figures
(Hour Meter area)
Display Change
Button for
Center Figures
(Clock Area)
Maintenance
RequiredWarning
ATF Temp
Engine Oil
Pressure
Battery
Charge
Glow Lamp
(Dsl Only)
Sedimenter
(Dsl Only)
START position

Controls and Instrument Panel 2
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14
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Message
This icon will be displayed simultaneously with any of the
following messages when an abnormality has occurred in the
forklift state or operation.
Message Description Release method
The operator has stood from the seat when the
key switch is at the "ON" position. In addition, in
case of seat belt warning option, the seat belt is
not fastened.
Sit on the seat.Fasten the
seat belt.
(Seat belt warning option)
When the key switch has been turned "ON"
position, the shift lever is at the forward position
or the reverse position.
Return the shift lever to the
neutral position.
The operator has stood from the seat without
pulling the parking brake lever.
Pull the parking brake
lever.
The key switch has been turned "ON" position
when the parking brake lever is not pulled and
the shift lever is at the forward position or the
reverse position.
Pull the parking brake lever
and return the shift lever to
the neutral position.
Low battery voltage warning. The key switch is at
"ON" position for ten minutes or more in the stop
of the engine.
Start the engine, or return the
key switch to "OFF" position.
Maintenance
● This icon indicates that the forklift is in abnormal condition.
● The icon will be displayed together with error code display
when an abnormality has occurred in the vehicle system or
engine control system.
If the icons exist during operation, stop the lift truck immediately and perform
adequate measures.
CAUTION

Controls and Instrument Panel 2
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15
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1. Hourmeter
The hour meter operates when the key
switch is in the “ON” position. Periodic
Maintenance recommendations are based
on these hours.
2. Coolant temperature gauge
This gauge indicates the temperature of the
engine cooling water. Start operation after
the engine has been warmed up and the bar
gauge starts raising. When the bar gauge
reaches around the middle bar, the water
temperature is optimum.
3. Fuel gauge (Gasoline&Diesel)
This gauge indicates the amount of remain-
ing fuel in the fuel tank.
Always replenish fuel before the gauge
reaches (if fuel level reaches the bottom bar,
warning buzzer beeps.) the bottom bar.
Make it a habit to replenish fuel before end-
ing operations.
Do not continue to operate the lift
truck when the gauge indicates
that the engine is too hot (full bars
indicated, and warning buzzer
beeping).
CAUTION
Normal Temp
Full Fuel
Caution Level
Over 110°C
Half Fuel of Tank
Warning Level
(blinking & beep)
Over 115°C
Low Fuel
(blinking & beep)

Controls and Instrument Panel 2
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16
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4. Glow plug icon (Diesel)
●
The icon indicates the operation of the glow plug.
●
When the engine switch is turned “ON”, the icon will be
lit for 3 seconds at the maximum, and the glow plug will
be rapidly heated to perform starting preparations.
After this, the switch will blink during glow operation until
the engine switch is turned “OFF”.
●
The operating time of the glow plug is automatically
controlled according to the temperature of engine
coolant. When the coolant temperature is low or on
a cold day, the operating time tends to be longer to
some extent.
5. Engine oil pressure warning icon
The icon is “ON” when the key switch is in the “ON” po-
sition and must go “OFF” when the engine is running.
6. Charge lamp
The icon will be “ON” when the key switch is “ON” and
the engine is not running. The lamp must go “OFF” when
the engine is running.
Stop the engine immediately if the icon is “ON” while
the engine is running.
CAUTION
Do not continue to operate the lift truck if the icon
is “ON” at engine speeds above idle.
CAUTION