Hyster S70XL User manual

OPERATING MANUAL
S70XL, S80XL, S80XL BCS, S100XL,
S120XLS, S120XL (D004)
S135XL, S155XL, S155XLS, S135XL2, S155XL2
(B024, C024)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
SPACESAVER
HYSTER COMPANY PART NO. 897366
Property of American Airlines

LIFT TRUCK MODEL SERIAL NUMBER
ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE SERIAL NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE GROUP NUMBER
DRIVE TIRE SIZE STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
Hyster,,Vista, MONOTROLand Yardmasterare registered trademarks of Hyster Company in certain
countries. ,Fortist, Fortenst, Pacesetter VSMt, DuraMatcht, Spectrumt, TouchPointt, TouchControlt,
EZXchanget,HSMt, ReachStackert, SitDrivet, StanDrivet, Multiquipt, and Unisourcetare trademarks of Hyster
Company in the united States and/or in certain countries where rights in unregistered trademarks are recognized. Hyster
Company products included in this document may be covered by U.S. Patenet No. 6,684,148 and other U.S. and foreign
patents pending. EHyster Company 2005. All rights reserved.
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FOREWORD
HYSTER COMPANY 2005 897366 -- ENGLISH 1
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 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 understand the warnings and operating
procedures in this manual.
In addition a qualified person, experienced in lift truck opera-
tion, must guide a new operator through several driving and
load handling operations before the new operator attempts
to operate the lift truck alone.
It is the responsibility of the employer to make sure that
the operator can see, hear, and has the physical and men-
tal 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
available from HYSTER COMPANY. For further details,
contact your dealer for Hyster lift trucks.
This OPERATING MANUAL contains information neces-
sary for the operation and maintenance of a basic fork lift
truck. Optional equipment is sometimes installed that can
change some operating characteristics described in this
manual. Make sure the necessary instructions are avail-
able and understood before operating the lift truck.
Some of the components and systems described in this
OPERATINGMANUALwillNOTbeinstalledonyourunit.
If you have a question about any item described, contact
your dealer for Hyster lift trucks.
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FOREWORD
2
Additional information that describes the 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, ITSDF B56.1,
Safety Standard For Low Lift And High Lift Trucks.
•publications from government safety agencies,
government insurers, private insurers and private
organizations (Example: Accident Prevention Manual
For Industrial Operations, from the National Safety
Council).
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 condition that can cause injury!
CAUTION
Indicates a condition that can cause property damage!
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CONTENTS
3
CONTENTS
FOREWORD 1..................................
CONTENTS 3...................................
MODEL DESCRIPTION 7.........................
GENERAL 7..................................
OPERATOR PROTECTION EQUIPMENT 8......
NAMEPLATE 8...............................
SAFETY LABELS 9............................
INSTRUMENTS AND CONTROLS 13.............
OPERATING PROCEDURES 23....................
GENERAL 23..................................
Know Your Lift Truck 23......................
Stability and Center Of Gravity 23..............
Capacity
(Weight and Load Center) 25..................
INSPECTION BEFORE OPERATION 25..........
Checks With the Engine Stopped 25...........
Starting Procedures 26.......................
Gasoline Or LPG Engine 26...................
Diesel Engine 27............................
Checks With the Engine Running 28...........
OPERATING TECHNIQUES 29..................
Basic Operating Procedures 29................
Driving And Direction Changes 32.............
Operator Presence System 33................
Inching 33..................................
Steering (Turning) 34........................
Load Handling, General 36...................
Load Handling, Lifting,
Lowering, And Tilting 38......................
Load Handling, How To Engage And Disengage A
Load 40....................................
Load Handling, Traveling 43..................
HIGHWAY TRUCKS, RAILROAD CARS AND
DOCKS 47....................................
ATTACHMENTS 49.............................
STOPPING 49.................................
PARKING 49..................................
MAINTENANCE 51...............................
GENERAL 51..................................
HOW TO MOVE A DISABLED LIFT TRUCK 52.....
HowToTowTheLiftTruck 52.................
How To Put A Lift Truck On Blocks 53..........
HowToRaiseTheDriveTires 53..............
How To Raise The Steering Tires 53...........
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CONTENTS
4
MAINTENANCE SCHEDULE 55....................
HOW TO MAKE THE CHECKS WITH THE
ENGINE STOPPED 69..........................
Hydraulic System Oil 69......................
Engine Oil 72...............................
Drive Belts 72...............................
Cooling System 72..........................
Air Filter 74.................................
Fuel System 74.............................
Primary Fuel Filter, Diesel Engine 74...........
Battery 75.................................
Tires And Wheels 76.........................
Forks 77...................................
Forks, Adjustment 77........................
Forks, Removal And Installation 77............
Inspection Of Forks, Mast, and Lift Chains 80....
Safety Labels 82............................
Operator Restraint System 83................
Automatic Locking Retractor (ALR) 83..........
Emergency Locking Retractor (ELR) 83.........
Hood And Seat Latches 84...................
HOW TO MAKE THE CHECKS WITH THE
ENGINE RUNNING 86..........................
Gauges, Lights, Horn And Fuses 87............
Oil Level, Powershift Transmission 90..........
Oil Level, Oil Clutch System 90................
Control Levers and Pedals 91.................
Lift System Operation 92.....................
Inching/Brake Pedal 92.......................
Service Brakes 93...........................
Parking Brake 93............................
Steering System 93..........................
HOW TO ADD FUEL TO THE LIFT TRUCK 94.....
Liquified Petroleum Gas (LPG) 94.............
Gasoline Or Diesel Fuel 97...................
WHEELS AND TIRES 98..........................
HOW TO CHANGE A SOLID RUBBER TIRE 98....
INSTALL THE WHEELS 99......................
Steering Wheels 99..........................
Drive Wheels 99.............................
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE 99...........................
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WARNING
5
AWARNING
label with this
information
must be on
the lift truck.
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MODEL DESCRIPTION
6
FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS
1. OVERHEAD GUARD
2. COUNTERWEIGHT
3. STEERING AXLE
4. DRIVE AXLE
S70 --120XL
S135--155XL
5. MAST
6. FORKS
7. CARRIAGE
8. LOAD BACKREST EXTENSION
9. SEAT BELT AND HIP RESTRAINT BRACKET
1244312177
11
22
55
6
6
88
7
7
443
3
9
9
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MODEL DESCRIPTION
7
MODEL DESCRIPTION
GENERAL
This Operating Manual is for the following models of lift
trucks:
•the S70--120XL (D004) series includes the S70XL,
S80XL, S80XL BCS, S100XL, S120XLS, and S120XL
•the S135--155XL (B024, C024) series includes the
S135XL, S135XL2, S155XL, S155XL2, and S155XLS.
The S70--120XL and the S135--155XL series of lift trucks
are available with a gasoline engine, an LPG fuel engine,
or a diesel engine.
The S70--120XL series of lift trucks has a single--speed
powershift transmission. The lift trucks can be equipped
with two kinds 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 near the left side of the steer-
ing wheel that controls the forward and reverse opera-
tion of the powershift transmission. A separate accel-
erator pedal controls the engine speed.
The S135--155XL series of lift trucks can have either a
three--speed manual transmission with an oil clutch (B024
models only) or a two--speed powershift transmission.
Lift trucks with a three--speed manual transmission have
two control levers on the left side of the steering wheel.
One lever controls the forward and reverse direction of the
lift truck and the other lever is used to select the speed
range. These lift trucks have a clutch pedal and an accel-
erator pedal.
The two--speed powershift transmission has a range lever
on the left side of the steering column to control the two
speed ranges. The two--speed powershift transmission
can be equipped with two kinds of controls for forward and
reverse and engine speed control:
•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 near the left side of the steer-
ing wheel that controls the forward and reverse opera-
tion of the powershift transmission. A separate accel-
erator pedal controls the engine speed.
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MODEL DESCRIPTION
8
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 openings small enough to
prevent the parts of the load from falling backwards. If a
load backrest extension that is different from the one in-
stalled on your lift truck is required, contact your Hyster lift
truck dealer.
The OVERHEAD GUARD is intended to offer reasonable
protection to the operator from falling objects, but can not
protect against every possible impact. Therefore, it must
not be considered a substitute for good judgment and care
when handling loads. Do not remove the overhead guard.
The SEAT BELT AND HIP RESTRAINT BRACKET pro-
vide additional means to help the operator keep the head
and torso substantially within the confines of the lift truck
frame and overhead guard if a tipover occurs. This re-
straint system is intended to reduce the risk of the head
and torso being trapped between the lift truck and the
ground, but it can not protect the operator against all pos-
sible injury in a tipover. The hip restraint bracket will help
the operator resist side movement if the seat belt is not
fastened. It is not a substitute for the seat belt. Always fas-
ten the seat belt.
NAMEPLATE
WARNING
Any change to the lift truck, the tires or its equipment
can change the lifting capacity. If the Nameplate does
not show the maximum capacity, or if the lift truck
equipment, including the battery for electric trucks,
does not match that shown on the Nameplate, the lift
truck must not be operated.
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 Name-
plate.
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 lift truck frame.
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MODEL DESCRIPTION
9
When a lift truck is shipped incomplete from the factory,
the nameplate is covered by a label as shown in
FIGURE 2. If your lift truck has this type of label, do not
operate the lift truck. Contact your dealer for HYSTER lift
trucks to obtain a complete nameplate.
SAFETY LABELS
Safety labels are installed on the lift truck to give informa-
tion about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
FIGURE 3.
FIGURE 2. NAMEPLATE AND LABEL
LABEL
NAME PLATE
TRUCK MODEL
Serial no.
Approx. weight
NOTICE TO USER
This unit was shipped incomplete from factory/
The U.S.A. Occupational Safety and Health Act of 1970 and other national
safety codes require the installation of a completed Nameplate showing unit
configuration and rated capacity. Completed Nameplates may be obtained
through your HYSTER dealer.
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MODEL DESCRIPTION
10
FIGURE 3. WARNING AND SAFETY LABELS
1. WARNING, OPERATION
2. OPERATING MANUAL
3. NAMEPLATE
4. IMPACT TEST
5. NO ONE ON OR UNDER FORKS
6. TIPOVER WARNING
7. FIRE SAFETY
8. FAN WARNING
9. NO RIDERS
10. FLAMMABLE LP--GAS
11. WARNING FOR PARKING BRAKE
12. MAST WARNING
13. OPERATOR PRESENCE SYSTEM
SEE THE PARTS MANUAL FOR THE
PART NUMBER AND LOCATION
1
7
9
5
6
8
3
11 4
10
2
12
13
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MODEL DESCRIPTION
11
12189
FIGURE 4. CONTROLS AND INSTRUMENTS, S70--120XL
POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL POWERSHIFT TRANSMISSION WITH
DIRECTION CONTROL LEVER
NOTE: THIRD--FUNCTION CONTROL LEVER (17a)
IS AVAILABLE ON ALL UNITS
6
1
22
1
3
3
45
7
88
9
9
10
10
11 11
12
15
15
16
16
17
17a
17a
18
1920
20
16 17
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MODEL DESCRIPTION
12
12189
MANUAL TRANSMISSION
POWERSHIFT WITHOUT MONOTROL PEDAL
POWERSHIFT WITH MONOTROL PEDAL 12189
12402
FIGURE 5. CONTROLS AND INSTRUMENTS, S135--155XL
NOTE: THIRD--FUNCTION CONTROL LEVER (17a)
IS AVAILABLE ON ALL UNITS
1
2
3
45
67
8
9
10
11
11
11 14
12
12
13
15
15
14
15
16
16
16
17
17a
17
17a
16
18
18
19
20
20
2122
17a
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MODEL DESCRIPTION
13
INSTRUMENTS AND CONTROLS
(See TABLE 1., TABLE 2., TABLE 3., FIGURE 4., and FIGURE 5.)
WARNING
If any of the instruments, levers, or pedals do not operate as described in the following tables, report the problem
immediately. DO NOT operate the lift truck until the problem is corrected.
TABLE 1. INSTRUMENTS
ITEM
NO. ITEM FUNCTION
1Hour Meter The hour meter operates when the key switch is in the ON position. Periodic
Maintenance recommendations are based on these hours.
2Coolant
Temperature
Gauge
Indicates engine coolant temperature when the key switch is in the ON
position. During normal operation, the needle will indicate in the green zone of
the gauge.
Do not continue to operate the lift truck when the gauge indicates that
the engine is too hot (needle in the red zone).
CAUTION
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MODEL DESCRIPTION
14
ITEM
NO. ITEM FUNCTION
3Fuel Gauge Indicates the amount of fuel in the gasoline or diesel fuel tank.
4Warning Light,
Alternator The red light will be ON when the key switch is ON and the engine is not running.
Do not continue to operate the lift truck if the red light is ON at engine
speeds above idle.
CAUTION
5Warning Light,
Engine Oil
Pressure
The red light is ON when the key switch is in the START position.
CAUTION
Stop the engine immediately if the light is ON when the engine is running.
6Warning Light,
“Check Engine” Lift trucks with electronic engine control (electronic spark timing and fuel
injection). This light will be ON when the key switch is ON and the engine is not
running. This light will illuminate when the ECM computer senses a fault in the
operation of the engine. If the engine will start, the operation of the engine will
not be correct until the fault is corrected. A trained service person must make
repairs and adjustments if this light is ON when the engine is running.
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MODEL DESCRIPTION
15
ITEM
NO. ITEM FUNCTION
7Warning light,
Powershift
Transmission
Oil Temperature
or
Oil Pressure for
Clutch, Manual
Transmission
(S135--155XL)
Powershift Transmission: The red light is ON when the key switch is in the
START position.
Manual Transmission: The red light is ON when the oil pressure in the clutch
system is too low for continued operation. The red light is ON when the key
switch is ON and the engine is not running.
Do not continue to operate the lift truck if the light is ON during
operation.
CAUTION
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MODEL DESCRIPTION
16
TABLE 2. CONTROLS
ITEM
NO. ITEM FUNCTION
8Cold Start Aid The cold start aid is used on lift trucks with a diesel engine. For S70--120XL lift
trucks, the control button is to the left of the steering column. On S135XL,
S155XL lift trucks, the control button is on the top of the instrument panel. The
keyswitchmustbeintheON position before the cold start aid can be
energized.
9
K
ey
Switch 12
3
The key switch has three positions:
No. 1 Position: OFF position. Deenergizes all electric circuits except for the
horn and headlights.
No. 2 Position: ON position. Energizes all electric circuits except the starter
circuit. The key switch will be in this position during normal operation.
No. 3 Position: START position. Energizes the starter motor for starting the
engine. A spring returns the key to position No. 2 (ON position) when the key is
released.
NOTE: There is a mechanical lockout that prevents the key switch from being
returned to the START position without first being returned to the OFF position.
10 Horn The horn button controls the operation of the horn.
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MODEL DESCRIPTION
17
ITEM
NO. ITEM FUNCTION
11 Parking Brake Lever The lift truck is equipped with a lever to apply the parking brake. Pull the lever
to the vertical position to apply the parking brake.
Lift trucks with a MONOTROL pedal: when the parking brake is applied, a
switch in the starting circuit is closed so that the engine can be started. The
switch also puts the transmission in NEUTRAL. Use your finger to release the
lock on the lever when the lever is moved to release the parking brake.
Correct adjustment is necessary to provide adequate braking and to keep
the parking brake lever in the engaged position. See the Maintenance
section for adjustment procedures.
Always apply the parking brake when leaving the lift truck.
WARNING
12 Direction Control Lever
S70--120XL S135--155XL
The direction control for the transmission is to the left of the steering column.
The direction control lever is used on lift trucks with a manual transmission and
those lift trucks with a powershift transmission without a MONOTROL pedal.
The direction control lever has three positions: FORWARD,NEUTRAL (N), and
REVERSE. Move the lever to one of the direction positions for travel.
NOTE: The direction control lever must be in the NEUTRAL (N) position before
the engine can be started.
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MODEL DESCRIPTION
18
ITEM
NO. ITEM FUNCTION
13 Range Lever
(Manual
Transmission)
(S135--155XL)
The range lever is located to the left of the steering column. This lever controls
the three speed ranges of the S135--155XL manual transmission.
14 Range Lever
(Powershift
Transmission)
(S135--155XL
Only)
The range lever for the transmission is to the left of the steering column. The
range lever controls the two speed ranges of the powershift transmission.
15 Lift/Lower
Control
Lever
The lift/lower control lever is the first lever to the right of the steering wheel. Pull
backward on the control lever to raise the carriage and forks. Push the control
lever forward to lower the carriage and forks.
16 Tilt
Control
Lever
The tilt control lever is on the right of the lift/lower control lever. Push the control
lever forward to tilt the upright and forks forward. Pull backward on the control
lever to tilt the upright and forks backward.
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