Hyster S40XM Operating Manual
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Hyster S40XM Operating Manual

Hyster S40XM Operating Manual

Lift trucks
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OPERATING MANUAL
CHALLENGER
H45XM, H50XM, H55XM, H60XM, H65XM
SPACESAVER
S40XM, S45XM, S50XM, S55XM, S55XMS, S60XM,
S65XM
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 1458874
HYSTER COMPANY

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  • Page 1 OPERATING MANUAL CHALLENGER H45XM, H50XM, H55XM, H60XM, H65XM SPACESAVER S40XM, S45XM, S50XM, S55XM, S55XMS, S60XM, S65XM DO NOT REMOVE THIS MANUAL FROM THIS UNIT PART NO. 1458874 HYSTER COMPANY...
  • Page 2 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 REGISTERED TRADEMARKS Hyster, , Challenger, SpaceSaver, Monotrol, RACKLOADER, SitDrive and StanDrive are trademarks of Hyster Company.

  • Page 3: Foreword

    NOTE: A comprehensive operator training program is avail- • Become familiar with the construction of the lift truck able from HYSTER COMPANY. For further details, contact and see that it is maintained in good condition. your dealer for Hyster lift trucks.
  • Page 4 Hyster lift trucks. sources: NOTE: Hyster lift trucks are not intended for use on public • Employment safety and health standards or roads.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS FOREWORD ........OPERATING TECHNIQUES ....Basic Operating Procedures .
  • Page 6 CONTENTS How To Raise the Steering Tires ... HOW TO MAKE CHECKS WITH THE ENGINE RUNNING ........MAINTENANCE SCHEDULE .
  • Page 7 CONTENTS WHEELS AND TIRES ..... . . Remove The Tire From The Wheel ..General .
  • Page 8 CONTENTS NOTES...
  • Page 9 WARNING A WARNING label with this information must be on the lift truck.
  • Page 10 WARNING NOTES...
  • Page 11 MODEL DESCRIPTION 1. OVERHEAD GUARD 2. TAIL LIGHT, BRAKE LIGHT, REVERSE LIGHT 3. SEAT 4. COUNTERWEIGHT 5. STEERING AXLE 6. SEAT BELT AND HIP RESTRAINT 7. DRIVE AXLE 8. FORKS 9. CARRIAGE 10. LOAD BACKREST EXTENSION 11. PARKING BRAKE 12. STEERING WHEEL 13.
  • Page 12 MODEL DESCRIPTION 1. OVERHEAD GUARD 2. TAIL LIGHT, BRAKE LIGHT, REVERSE LIGHT 3. SEAT 4. COUNTERWEIGHT 5. STEERING AXLE 6. SEAT BELT AND HIP RESTRAINT 7. DRIVE AXLE 8. FORKS 9. CARRIAGE 10. LOAD BACKREST EXTENSION 11. PARKING BRAKE 12. STEERING WHEEL 13.

  • Page 13: Model Description

    H45--65XM only a load backrest extension that is different from the one The single--speed powershift transmission can be installed on your lift truck is required, contact your Hyster equipped with two types of controls: lift truck dealer. • A MONOTROLR pedal that controls both the for-...

  • Page 14: Nameplate

    If the Nameplate does labels, do not operate the lift truck. Contact your dealer not show the maximum capacity, or if the lift truck for HYSTER lift trucks to obtain a complete correct Name- equipment, including the battery for electric trucks, plate.

  • Page 15: Safety Labels

    MODEL DESCRIPTION SAFETY LABELS WARNING DO NOT add to or modify the lift truck. Any change to the lift truck, the tires or its equipment can change Safety labels are installed on the lift truck to give informa- the lifting capacity. The lift truck must be rated as tion about possible hazards.
  • Page 16 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. 1304058R INCOMPLETE LABEL NOTICE LABEL...
  • Page 17 MODEL DESCRIPTION SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS FIGURE 4. WARNING AND SAFETY LABELS (1 of 2)
  • Page 18 MODEL DESCRIPTION 1. WARNING, OPERATION 2. DRIVE TRAIN PROTECTION CAUTION 3. OPTIONAL FIRE SAFETY RATING 4. CASE WITH OPERATING MANUAL 5. NAMEPLATE 6. WARNING FOR PARKING BRAKE 7. NO ONE ON OR UNDER FORKS 8. NO RIDERS 9. TIPOVER WARNING 10.
  • Page 19 MODEL DESCRIPTION * USED ONLY ON S40- -65XM MODEL TRUCKS FIGURE 5. INSTRUMENTS...

  • Page 20: Instruments And Controls

    MODEL DESCRIPTION INSTRUMENTS AND CONTROLS WARNING If any of the instruments, levers, or pedals do not operate as described in the following tables, report the prob- lem immediately. DO NOT operate the lift truck until the problem is corrected. TABLE 1. INSTRUMENTS (See FIGURE 5.) ITEM ITEM FUNCTION...
  • Page 21 MODEL DESCRIPTION ITEM ITEM FUNCTION The light is on when the turn indicator lever is in the left turn position. Left--Hand Turn Indicator Warning Light, The light will be ON when the key switch is ON and the engine is not running. Alternator The light must go OFF when the engine is running.
  • Page 22 MODEL DESCRIPTION ITEM ITEM FUNCTION Warning Light, The red light is ON when the key switch is in the START position and must go Brake Fluid OFF when the engine is running. If the light is ON when the engine is running, Level the brake fluid level in the reservoir is too low.
  • Page 23 MODEL DESCRIPTION ITEM ITEM FUNCTION The red light is ON when the key switch is in the START position and must go Water separator OFF when the engine is running. If the light is ON when the engine is running, Warning Light, the water separator must be drained.
  • Page 24 MODEL DESCRIPTION ITEM ITEM FUNCTION Indicator Light, The red light is ON when the key switch is in the START position and must go Low LPG Fuel OFF when the engine is running. If the light is ON when the engine is running, Level the fuel level in the tank is low.
  • Page 25 MODEL DESCRIPTION ITEM ITEM FUNCTION Voltmeter This gauge indicates the output of the alternator. During normal operation the gauge needle will be in the green area. CAUTION Do not continue to operate the lift truck when the gauge indicates in the yellow or red areas of the gauge.
  • Page 26 MODEL DESCRIPTION UNITS WITH DIRECTION CONTROL LEVER UNITS WITH MONOTROLR PEDAL FIGURE 6. CONTROLS...
  • Page 27 MODEL DESCRIPTION TABLE 2. CONTROLS (See FIGURE 6.) ITEM ITEM FUNCTION The steering wheel controls the position of the steer tires. Steering Wheel Latch for Tilt A latch located on the lower left side of the steering column allows the operator Steering Column to select different positions for the steering wheel.
  • Page 28 MODEL DESCRIPTION ITEM ITEM FUNCTION Parking Brake Lever The lift truck is equipped with a lever to apply the parking brake. Pull the lever to apply the parking brake. Use your thumb to release the button on the lever when the lever is moved to release the parking brake. On lift trucks with a MONOTROLR pedal, applying the parking brake puts the transmission in NEUTRAL.
  • Page 29 MODEL DESCRIPTION ITEM ITEM FUNCTION Switch The switch controls the operation of the rear drive lights. Push on the top of the switch to turn the lights ON. Switch The switch controls the operation of the front windshield wiper and windshield washer.
  • Page 30 WARNING The control lever with a detent must be installed when an attachment with a clamp is installed. See your dealer for Hyster lift trucks to get the correct control lever. Control Lever with a Detent - - Attachments with a clamp action: The lever is spring--loaded toward the operator.
  • Page 31 MODEL DESCRIPTION ITEM ITEM FUNCTION The key switch has three positions: Switch No. 1 Position: OFF position. Deenergizes all electric circuits except for the horn. 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.
  • Page 32 MODEL DESCRIPTION ITEM ITEM FUNCTION MONOTROLR The MONOTROL pedal controls the speed and direction of the lift truck. Pedal Pushing on the right side of the pedal causes the lift truck to move in REVERSE. Pushing on the left side of the pedal causes the lift truck to move in FORWARD.
  • Page 33 MODEL DESCRIPTION ITEM ITEM FUNCTION Fuel Selector This switch is used to change engine fuel between gasoline and LPG and is in Switch (Not Shown the engine compartment near the Vaporizer/Regulator assembly. The switch In FIGURE 6.) has three positions: No.
  • Page 34 MODEL DESCRIPTION TABLE 3. AUXILIARY CONTROL LEVERS (See FIGURE 6.) FUNCTION DIRECTION OF MOVEMENT The control levers will be arranged in The control levers will be arranged in LOAD OR EQUIPMENT CONTROL LEVER the following order from left to right. REACH Retract/Extend Backward/Forward...

  • Page 35: Operating Procedures

    OPERATING PROCEDURES OPERATING PROCEDURES GENERAL Follow the inspection and maintenance schedule and procedures in this manual. Do not alter exhaust, igni- tion or fuel systems. Know Your Lift Truck WARNING WARNING FIRE HAZARD EXHAUST GASES The hot engine surfaces and exhaust of internal com- bustion engine powered lift trucks can present fire Exhaust from internal combustion engines contains hazards when operating in areas containing flam-...
  • Page 36 OPERATING PROCEDURES Operate the lift truck only in areas that have been ap- the front to engage the load. The lift mechanism lifts the proved for lift truck operation. load so that it can be moved and stacked. In order to understand how the fork lift truck can pick up a OSHA regulations prohibit the use of lift trucks in load, you must first know some basic things about the lift areas containing hazardous concentrations of cer-...

  • Page 37: Stability And Center Of Gravity

    OPERATING PROCEDURES Stability And Center Of Gravity CG Load The center of gravity (CG) of any ob- ject is the single point about which the object is balanced in all directions. Every object has a CG. When the lift Combined CG truck picks up a load, the truck and load have a new combined CG.

  • Page 38: Capacity (Weight And Load Center)

    OPERATING PROCEDURES In order for the lift truck to be stable (not tip over forward center is specified in millimeters and inches. The capacity or to the side) the CG must stay within the area of the lift is the maximum load that the lift truck can handle for the truck represented by a triangle drawn between the drive load condition shown on the Nameplate.

  • Page 39: Inspection Before Operation

    OPERATING PROCEDURES INSPECTION BEFORE OPERATION • Coolant level in the cooling system and condition of the drive belts. WARNING • Condition of the engine compartment. Ensure all Report damage or faulty operation immediately. Do surfaces are free of oils, lubricants, fuel, and or- not operate a lift truck that needs repair.

  • Page 40: Starting Procedures

    OPERATING PROCEDURES switch to OFF. Wait 60 seconds before engaging the Starting Procedures starter again. 4. Turn the key to the START position to engage the Do not start nor operate the lift truck, starter. including any of its functions or attach- 5.

  • Page 41: Checks With The Engine Running

    OPERATING PROCEDURES 4. Turn the key to the START position to crank and start the engine. The indicator light will be ON while the starter Checks With The Engine Running is cranking and go OFF when the key is released. WARNING CAUTION FASTEN SEAT BELT...

  • Page 42: Operating Techniques

    OPERATING PROCEDURES tips over. The risk of injury can be reduced if the operator parking brake is applied and the engine is running stays on the truck. If the truck tips over do not jump off. at idle speed. • Operate the LIFT, TILT, and auxiliary functions to THE SEAT BELT AND HIP RESTRAINT bracket provides check for correct operation of the mast, carriage a means to help the operator keep the head and torso...

  • Page 43: Basic Operating Procedures

    OPERATING PROCEDURES Basic Operating Procedures means that a qualified person experienced in lift truck op- eration must guide the operator through several driving Many people make the mistake of thinking that operating and load handling operations before the operator attempts a lift truck is the same as driving an automobile.

  • Page 44: Driving And Direction Changes

    OPERATING PROCEDURES vator is properly levelled, the lift truck must be centered so that the elevator is balanced. If a lift truck is used to elevate a worker, a safety plat- When the lift truck is in the proper position in the elevator, form must be attached to the forks and carriage.

  • Page 45: Inching

    OPERATING PROCEDURES the transmission. If the lift truck has a MONOTROLR CAUTION pedal, push on the left side of the pedal to go FORWARD, The drive train can be damaged if the lift truck is trav- or the right side of the pedal to go in REVERSE. If the lift elling too fast when the controls are changed to the truck has a direction control lever, move the lever toward opposite direction of travel.

  • Page 46: Steering (Turning)

    OPERATING PROCEDURES Steering (Turning) FAST WARNING TRAVEL SLOWLY WHEN TURNING. Lift trucks can tip over even at very slow speeds. The combination of speed and the sharpness of SLOW a turn can cause a tipover. WARNING A lift truck is less stable Inching requires coordinated movement of the inch- when the forks are elevated, ing/brake pedal and the accelerator or the...
  • Page 47 OPERATING PROCEDURES Do not turn on an incline. To re- WARNING duce the possibility of a tipover, a Failure to observe the tail swing area when making a lift truck must not be driven turn can injure or kill someone. across an incline.

  • Page 48: Load Handling, General

    OPERATING PROCEDURES tail swing will permit. This action permits the lift truck to WARNING enter the narrow aisle going straight ahead. Do not handle a load if any loose part of it Load Handling, General is above the load backrest or any part of the load is likely to fall.

  • Page 49: Load Handling, Lifting, Lowering And Tilting

    OPERATING PROCEDURES that keep the forks in position are engaged so that the Do not lift or hit anything that can fall on the operator or a forks cannot move. bystander. Remember, a lift truck equipped with a HYS- TER overhead guard and load backrest extension pro- 4.
  • Page 50 OPERATING PROCEDURES The operator must exercise care while working near such objects. Whether the lift truck is loaded or empty, do not travel with the load or carriage in a raised position. WARNING Keep yourself and all others clear of the lift mechanism. Nev- er allow anyone under or on the forks.

  • Page 51: Load Handling, How To Engage And Disengage A Load

    OPERATING PROCEDURES IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR FEET, AND LEAN AWAY FROM POINT OF IMPACT. 2. Move forward slowly until the forks are in position under the load. The forks must support at least two--thirds (@P3) of the length of the load.
  • Page 52 OPERATING PROCEDURES If the forks are longer than the load, move the forks under the load so that the tips of the forks do not extend beyond the load. Lift the load from the surface. Move backward a few inches, then lower the load onto the surface and inch forward to engage the load against the carriage.
  • Page 53 OPERATING PROCEDURES WARNING Move carefully and smoothly when the load is raised over a stack. When the load is elevated the center of gravity of the lift truck and the load is much higher. The lift truck can tip over when the load is raised. 5.

  • Page 54: Load Handling, Travelling

    OPERATING PROCEDURES 6. When lifting round objects, use a block behind the ob- ject. Tilt the mast forward so that the forks can slide along the floor under the object to be lifted. Tilt the mast fully backward to help keep the load on the forks. Move forward slowly.
  • Page 55 OPERATING PROCEDURES verse. Always look in the direction of travel to avoid damage to something or injury to someone. 3. For better visibility with large loads, travel with the load trailing, but always keep a proper lookout in the direction of travel.
  • Page 56 OPERATING PROCEDURES 6. Any time the lift truck is moving keep arms, legs, etc., inside the operator’s compartment. Arms and legs outside the machine can be injured when passing obstruc- tions. When operating an unloaded lift truck on a steep grade, keep the counterweight upgrade.
  • Page 57 OPERATING PROCEDURES ground. Always make sure you pick the smoothest route 9. Do not indulge in stunt for your lift truck. driving or horseplay. 8. Watch clearances, especially forks, mast, overhead guard and tail swing. A lift truck is designed to perform a wide variety of functions within limited space.

  • Page 58: Highway Trucks, Rail Cars And Docks

    OPERATING PROCEDURES HIGHWAY TRUCKS, RAIL CARS AND DOCKS 12. Under all travel condi- tions, operate the lift truck at WARNING a speed that will permit it to be brought to a stop in a safe Maintain a safe distance from manner.
  • Page 59 OPERATING PROCEDURES BRACE YOUR FEET, AND LEAN FORWARD AND S Check to make sure that the brakes on the highway AWAY FROM THE POINT OF IMPACT. truck are set and that wheel blocks have been placed on both sides of the rear wheels (unless a Before operating in a highway truck or rail car, observe dock locking mechanism is engaged).

  • Page 60: Attachments

    OPERATING PROCEDURES ATTACHMENTS WARNING Make sure the Nameplate is correct if an attachment has been installed. PARKING If an attachment is installed on the lift truck, make sure the operating instructions are available and understood The operator must never leave a lift truck in a condition so before operating the attachment.
  • Page 61 OPERATING PROCEDURES 6. Check engine compartment if operating in areas con- the tank. If the lift truck is going to be left over night or taining combustible material (See page 29, FIRE HAZ- longer, the truck must be parked outside or the LPG tank ARD) must be removed and stored outside.
  • Page 62 OPERATING PROCEDURES NOTES...

  • Page 63: Maintenance

    The MAINTENANCE SCHEDULE has time intervals for MAINTENANCE SCHEDULE. Service Manuals are avail- inspection, lubrication and maintenance for your lift truck. able from your dealer for Hyster lift trucks to help users The service intervals are given in both operating hours who do their own maintenance.

  • Page 64: Serial Number Data

    MAINTENANCE Serial Number Data Never lift and move a disabled lift truck unless the disabled lift truck MUST be moved and cannot be The serial number for the lift truck is on the Nameplate. It towed. A lift truck used to move a disabled lift truck is also on the front crossmember of the frame, on the MUST have a capacity rating equal to or greater than right--hand side.

  • Page 65: How To Put A Lift Truck On Blocks

    MAINTENANCE tow the disabled lift truck. This capacity load will in- The surface must be solid, even, and level when the crease the traction of the lift truck. Keep the load as low lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one piece as possible.

  • Page 66: How To Raise The Steering Tires

    MAINTENANCE How To Raise the Steering Tires 2. Use a hydraulic jack to raise the steering tires. Make sure that the jack has a capacity of at least 2/3 of the total (See FIGURE 7.) weight of the lift truck as shown on the Nameplate. 1.
  • Page 67 MAINTENANCE GM 3.0L ENGINE SHOWN. OTHERS ENGINES SIMILAR. 12788 25,26 22,23 FIGURE 8. MAINTENANCE AND LUBRICATION POINTS, S40--65XM...
  • Page 68 MAINTENANCE GM 3.0L ENGINE SHOWN. OTHERS ENGINES SIMILAR. 12788 25,26 22,23 FIGURE 9. MAINTENANCE AND LUBRICATION POINTS, H45--65XM...

  • Page 69: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 3 mo 6 mo 1 yr TIRES, TIRE PRESSURE See Nameplate MAST, CARRIAGE, Check condition See PARTS MANUAL LIFT CHAINS FORKS Check condition CHECK FOR LEAKS—...
  • Page 70 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 3 mo 6 mo 1 yr TRANSMISSION OIL Mobilfluid 424 H45--65XM 9.0 liter (10 qt) S40--65XM 8.5 liter (9.0 qt) ENGINE OIL --18 ° to 40 °...
  • Page 71 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 3 mo 6 mo 1 yr ENGINE OIL FILTER 1 -- See NOTE 2 See PARTS MANUAL FUEL FILTER, DIESEL Clean or replace See PARTS MANUAL See NOTE 3 WATER SEPARATOR, DIESEL Remove water...
  • Page 72 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo COOLING SYSTEM See NOTE 5 50% Water and GM 3.0L EPA Compliant 11.0 liter (11.7 qt) 50% Ethylene Glycol Engine Boron Free Anti--Freeze ENGINE COMPARTMENT...
  • Page 73 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo BATTERY ELECTROLYTE, Clean, Check level BATTERY CASE AND CABLES HYDRAULIC TANK BREATHER Clean or replace See PARTS MANUAL WHEEL NUTS (S40--65XM) Check torque DRIVE WHEELS 237 to 305 Nm...
  • Page 74 MAINTENANCE ITEM ITEM 8 hr/ 1000 2000 PROCEDURE OR SPECIFICATION 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo ENGINE SPEED (IDLE SPEED) Adjust as required Mazda M4--2.0G (IMPCO) 700 to 750 rpm Mazda M4--2.0G and 2.2G 775 to 825 rpm (Aisan Open Loop) Mazda M4--2.0G and 2.2G 775 to 825 rpm...
  • Page 75 MAINTENANCE ITEM ITEM 8 hr/ 1000 2000 PROCEDURE OR SPECIFICATION 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo ENGINE SPEED Adjust as required GOVERNED SPEED Mazda M4--2.0G (IMPCO) 2600 to 2700 rpm Mazda M4.20G and 2.2G 2700 to 2800 rpm (Aisan Open Loop) Mazda M4.20G and 2.2G 2700 to 2800 rpm...

  • Page 76: Mazda M4.20G And 2.2G

    Check and clean if required See NOTE 9 FUEL INJECTOR (Aisan) Check and clean if required See NOTE 9 PEDALS, LEVERS, SEAT Lubricate as Hyster Part No. 328388 RAILS, CABLES, HINGES, necessary LINKAGES, HOOD LATCH X=Check C=Change L=Lubricate CIL=Check indicator light during operation.

  • Page 77: Gm 3.0L

    MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo DIFFERENTIAL OIL SAE 80W--90, 85W--140 S40--65XM 3.8 liter (4.0 qt) H45--65XM 7.6 liter (8.0 qt) VALVE ADJUSTMENT Adjust as required Mazda M4--2.0G 0.30 mm (0.012 in) Cold Mazda M4--2.2G...
  • Page 78 MAINTENANCE ITEM ITEM 8 hr/ 1000 2000 PROCEDURE OR SPECIFICATION 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo TIMING Mazda M4--2.0G Gasoline 0° TDC (YELLOW Mark) Adjust as required 9° BTDC (RED Mark) Mazda M4--2.2G Gasoline 0° TDC (WHITE MARK) 9°...
  • Page 79 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo LPG REGULATOR (IMPCO) Drain tar FUEL FILTER, LPG (IMPCO) IDLE CIRCUIT/INJECTOR FILTER (Aisan) REGULATOR PRESSURE/ Check and adjust per DIAPHRAGM and O--RING specification if required.
  • Page 80 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 hr/ 1000 2000 1 day QUANTITY 6 wk 6 mo 1 yr 3 mo COOLANT HOSES Check condition See PARTS MANUAL SAFETY LABELS Replace as See PARTS MANUAL necessary SEAT BELT, HIP RESTRAINTS Check condition AND SEAT RAILS HOOD AND SEAT LATCHES...
  • Page 81 MAINTENANCE 250 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION 8 Hr./ 500 Hr./ ITEM 6 wks. Hr./ Hr./ QUANTITY Daily 3 mo. 6 mo. 1 yr. INSPECT ENGINE ELECTRICAL SYSTEM, CONNECTORS AND FCVS CONNECTION INSPECT ENGINE VACUUM AND FUEL LINES AND FITTINGS INSPECT LOCK OFF FOR LEAKS AND ENSURE LOCK...
  • Page 82 MAINTENANCE 250 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION 8 Hr./ 500 Hr./ ITEM 6 wks. Hr./ Hr./ QUANTITY Daily 3 mo. 6 mo. 1 yr. INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS INSPECT CATALYST INLET AND OUTLET OXYGEN SENSOR CONNECTOR GM 3.0L EPA Compliant Engine X=Check...

  • Page 83: Maintenance Procedures Every 8 Hours Or Daily

    MAINTENANCE MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY wheel parts to explode. The explosion of wheel parts WARNING can cause serious injury or death. Do not operate a lift truck that needs repairs. Report Remove all of the air from the tires before the tires the need for repairs immediately.
  • Page 84 MAINTENANCE 9447 1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD) 2. MAKE SMOOTH EDGES 11402 3. CHECK THE TIRE PRESSURE (PNEUMATIC TIRES) FIGURE 10. CHECK THE TIRES Check the tires for damage. Inspect the tread and remove WARNING any objects that will cause damage.

  • Page 85: Forks

    MAINTENANCE installed. Tighten the nuts in a cross pattern to the on the carriage bar. Make sure the lock pin is engaged in correct torque value shown in the MAINTENANCE the carriage bar to lock the fork in position after the width SCHEDULE.
  • Page 86 MAINTENANCE OLD STYLE LOCK PIN ASSEMBLY NEW STYLE LOCK PIN ASSEMBLY 1. FORK 5. WASHER 9. COTTER PIN 2. LOCK PIN 6. WEDGE 10. LOCK PIN ASSEMBLY 3. SPRING 7. KNOB 4. WASHER 8. LEVER FIGURE 12. FORK LOCK PIN ASSEMBLY A fork can be removed from the carriage for replacement fork removal notch on the carriage.

  • Page 87: Forks, Installation

    MAINTENANCE moves through the fork removal notch. See FIGURE 13. all parts of the mast are completely lowered and the Lower the carriage further so that the top hook of the fork engine is STOPPED. is disengaged from the top carriage bar. Move the car- Do not try to correct the alignment of the fork tips by riage away from the fork, or use a lifting device to move bending the forks or adding shims.
  • Page 88 MAINTENANCE 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. LATCH DAMAGE 4. HEEL OF FORK (MUST BE 90% OF DI- MENSION “X”) 5. CARRIAGE 6. LOAD BACKREST EXTENSION 7. MAXIMUM ANGLE 93° 8. FORK REMOVAL NOTCH FORK TIP ALIGNMENT LENGTH OF FORKS 3% DIMENSION 915 mm (36 in)

  • Page 89: Safety Labels

    MAINTENANCE 8. Inspect the lift chains for cracks or broken links and pins. See FIGURE 14. 9. Inspect the chain anchors and pins for cracks and dam- age. 10. Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.
  • Page 90 MAINTENANCE tem. Each item must be checked to make sure it is fas- er are not loose. The seat rails must lock tightly in posi- tened correctly, functions correctly and is in good condi- tion, but move freely when unlocked. The seat rails must tion.

  • Page 91: Steering Column Latch

    MAINTENANCE The end of the seat belt must fasten correctly in the latch. Make a visual check for leaks on and under the lift truck. Make sure the seat belt pulls from the retractor assembly If possible, find and repair the leak at the source. Leaks and retracts smoothly.

  • Page 92: Mazda M4--2.0G (Gas)

    MAINTENANCE GM 3.0L, GASOLINE AND LPG MAZDA M4- -2.0G, GASOLINE AND LPG 12622 4. RADIATOR CAP 8. FUEL FILTER 5. ENGINE OIL FILL 9. ENGINE OIL FILTER 1. DIPSTICK FOR ENGINE OIL 6. DRIVE BELTS 10. PCV VALVE 2. BATTERY 3.
  • Page 93 MAINTENANCE PERKINS 704- -26 (UB) 7. AIR FILTER 8. FUEL FILTER 9. ENGINE OIL FILTER 1. DIPSTICK FOR ENGINE OIL 4. RADIATOR CAP 10. GLOW PLUGS 2. BATTERY 5. ENGINE OIL FILL 3. AUXILIARY COOLANT RESERVOIR 6. DRIVE BELTS 11. FUEL INJECTORS FIGURE 17.

  • Page 94: Transmission Oil Temperature

    MAINTENANCE Transmission Oil Temperature (See FIGURE 18. ) NOTE: The engine will stop after a 30 second warning buzzer if transmission oil is over 121°C (250°F) on lift trucks with protection system. There is an indicator light on the instrument cluster for the transmission oil temperature.

  • Page 95: Hydraulic System Oil

    MAINTENANCE Hydraulic System Oil (See FIGURE 19.) indicated by the dipstick is most accurate when the oil temperature is 53 to 93°C (130 to 200°F). WARNING Check the hydraulic system for leaks and damaged or At operating temperature the hydraulic oil is HOT. Do loose components.

  • Page 96: Battery

    MAINTENANCE Battery (See FIGURE 16. And FIGURE 17.) a. Always connect the positive jumper cable to the positive terminal of the discharged battery and the negative jumper cable to the negative terminal. WARNING b. Always connect the jumper cable that is the ground The acid in the electrolyte can cause injury.

  • Page 97: How To Make Checks With The Engine

    MAINTENANCE HOW TO MAKE CHECKS WITH THE ENGINE WARNING RUNNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning sol- WARNING vents, always follow the recommendations of the FASTEN YOUR SEAT BELT! The seat belt is installed manufacturer.
  • Page 98 MAINTENANCE 1. TRANSMISSION SOLENOIDS (5 amp) 2. HORN (10 amp) 3. GLOW PLUG RELAY, DIESEL (30 amp) 4. LIGHTS (25 amp) 5. TURN SIGNALS/BRAKE LIGHTS (10 amp) 6. LIGHTS (30 amp) 7. INSTRUMENT CLUSTER (30 amp) 8. HEATER 9. FRONT WIPER 10.
  • Page 99 MAINTENANCE F1 20 AMPS F2 5 AMPS F3 15 AMPS F4 15 AMPS R1 STARTER RELAY R2 POWER RELAY R3 FUEL PUMP RELAY FIGURE 22. ENGINE COMPARTMENT FUSES AND RELAYS, GM 3.0L EPA COMPLIANT ENGINES (NEWER LIFT TRUCK MODELS)

  • Page 100: Gauges, Lights, Horn, Fuses And Relays

    MAINTENANCE Gauges, Lights, Horn, Fuses and Relays FUEL SYSTEM, AISAN CLOSED- -LOOP, 900 SRM 948 or LPG/GASOLINE FUEL SYSTEM GM 3.0L, 4.3L EPA Start the engine. Check the gauges and indicator lights for COMPLIANT ENGINES, 900 SRM 1088 for troubleshoot- correct operation as described in TABLE 1.

  • Page 101: Cooling System

    MAINTENANCE switch is in the START position and must go OFF when light is ON when the engine is running, the coolant and the engine is running. If the light is ON when the engine is engine are too hot. Stop the engine and check the coolant running, the engine oil pressure is low.

  • Page 102: Parking Brake

    MAINTENANCE There is an indicator light on the instrument cluster for the not move if it is parked on an incline. The parking brake, brake fluid. The red light is ON when the key switch is in when in good condition and correctly adjusted, will hold a the START position and must go OFF when the engine is lift truck with a capacity load on a 15% grade [a slope that running.

  • Page 103: Fuel System

    MAINTENANCE finger to release the lock on the lever when the parking brake is released. Lift trucks with a MONOTROLR pedal: when the park- ing brake is applied, a switch in the starting circuit is closed so that the engine can be started. The switch also 1.

  • Page 104: Fuel Filter, Diesel Engine

    MAINTENANCE Fuel Filter, Diesel Engine Remove Air From The Diesel Fuel System The fuel filter is replaced every 1000 hours or six months NOTE: The fuel injection pump will normally remove small of operation. amounts of air from the fuel system when the engine is started.

  • Page 105: Cooling System

    MAINTENANCE If the mast cannot be lowered, use chains on the components must lower smoothly. mast weldments and carriage so that they can not 5. Lower the load to approximately 0.3 meter (one move. Make sure the moving parts are attached to a foot).

  • Page 106: How To Add Fuel To The Lift Truck

    MAINTENANCE shown in the MAINTENANCE SCHEDULE. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all person- nel. Wear protective goggles or a face shield to prevent injury to the eyes.

  • Page 107: Liquefied Petroleum Gas (Lpg)

    MAINTENANCE No smoking. an LPG tank: No smoking. Stop engine. All fuels for internal combustion engines are very Frost on the surface of the tank, the valves or fittings flammable. and the odor of LPG fuel indicates a leak. Inspect the Fill the fuel tank only in a designated area with good LPG system and repair a leak immediately.
  • Page 108 MAINTENANCE WARNING LPG tanks are heavy. The weight of an LPG tank can exceed the maximum recommended weight for safe lifting by an individual. Get assistance when lifting or lowering an LPG tank. Use correct lifting procedures. Fill LPG tanks outdoors. Stay at least 15 meters (50 feet) from buildings, motor vehicles, electrical equip- ment or other ignition sources.
  • Page 109 MAINTENANCE 6. Raise the LPG tank from its bracket so that the 5. Inspect the fuel system for leaks when the fuel quick disconnect fitting can be disconnected. Re- valve is open. Frost on the surface of the tank, move the LPG tank from the bracket. valves or fittings or a strong odor of LPG fuel indi- cates a leak.

  • Page 110: Gasoline Or Diesel Fuel

    MAINTENANCE 4. Connect the supply hose to the quick disconnect Gasoline or Diesel Fuel fitting on the LPG tank. If the LPG tank has an aux- iliary fill fitting, connect the supply hose to this fit- WARNING ting. Make sure the correct adapter is used to con- When fuel is added, keep the funnel or fuel nozzle in nect the supply hose to the auxiliary fill fitting.

  • Page 111: How To Change A Solid Rubber Tire

    MAINTENANCE How To Change A Solid Rubber Tire Remove And Install The Tire On The Wheel S40- -65XM Models 1. The correct tools, equipment and a press ring must be (See FIGURE 28.) used for each size of wheel. Use a press to push the wheel from the rim and tire.
  • Page 112 MAINTENANCE 3. The steering wheels are fastened to the spindle of the while the wheel is rotated. Loosen the castle nut until the steering axle with a large castle nut. Make sure the inner hub turns freely with no looseness. The torque must be less than 27 Nm (20 lbf ft).

  • Page 113: How To Repair A Pneumatic Tire H45--65Xm Models

    MAINTENANCE How To Repair A Pneumatic Tire trained personnel only. H45- -65XM Models Deflate tire completely before removing the wheel from the lift truck. If dual wheels are used, deflate WARNING both tires. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or A solid rubber tire that is the same shape as a pneu- death.

  • Page 114: Remove The Wheel From The Tire

    MAINTENANCE TWO- -PIECE WHEEL THREE- -PIECE WHEEL FOUR- -PIECE WHEEL 1. WHEEL RIM 3. LOCK RING 2. SIDE FLANGE 4. FLANGE SEAT 11637 FIGURE 29. TYPES OF WHEELS (H45--65XM) Remove The Wheel From The Tire tire before a wheel is disassembled. Air pressure in the tires can cause the tire and rim parts to explode (See FIGURE 30.
  • Page 115 MAINTENANCE SEE WARNINGS STEP 1. Remove the nuts that fasten the wheel rims together. 11939 STEP 3. Remove the wheel rims from tire. STEP 2. Loosen the tire bead from the wheel rim. Remove the inner tube and flap. FIGURE 30. TIRE REMOVAL, TWO--PIECE WHEEL...
  • Page 116 MAINTENANCE SEE WARNINGS STEP 3. Loosen the bead from the other side of the STEP 1. Loosen the tire bead from the side flange. wheel rim. Remove the valve stem from the wheel. STEP 2. Put the tire tool into the slot between the lock ring and wheel rim.

  • Page 117: Install The Wheel In The Tire

    MAINTENANCE Install The Wheel in the Tire gether. Make sure that the lock ring is in the correct position. The ends of the lock ring must not touch. (See FIGURE 32. or FIGURE 33.) The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in) after it is WARNING installed.
  • Page 118 MAINTENANCE SEE WARNINGS STEP 3. Turn over the rim and tire. Put blocks under the STEP 1. Install the inner tube and the rubber flap in rim so that the rim is 8 to 10 cm (3 to 4 in) the tire.

  • Page 119: Add Air To The Tires

    MAINTENANCE 5. Make sure the rim is the correct size for the tire. Lubri- cate the part of the wheel that contacts the bead and flap. 6. Install the three--piece or four--piece wheel in the tire as shown in FIGURE 32. Install the two--piece wheel in the tire as shown in FIGURE 33.

  • Page 120: Install The Wheels

    MAINTENANCE from the tire. Remove the valve core to make sure all of the air pressure has been removed and then make adjust- ments. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in) when the tire has the correct air pressure.

  • Page 121: Installation Procedures, Dual Drive Wheels

    MAINTENANCE INSTALLATION PROCEDURES, DUAL DRIVE WHEELS NOTE: Some lift trucks can have dual drive wheels. The following procedures describe the steps to install the dual sets of wheels. 1. See FIGURE 35. Install the inner wheel on the hub. Tighten the nuts as shown in the MAINTENANCE SCHEDULE.

  • Page 122: Remove The Tire From The Wheel

    MAINTENANCE Always wear safety glasses. to the tire and wheel assembly and can cause injury. • Clean and inspect all parts of the wheel before 1. Put the lift truck on blocks as described in “How To Put installing the tire. The Lift Truck On Blocks”...
  • Page 123 MAINTENANCE SEE WARNINGS STEP 3. Turn the tire over. Put a STEP1. Put the wheel support under rim on the bed the wheel rim. of the press. Make sure the Put the cage wheel rim is at in position on least 150 to the tire.
  • Page 124 MAINTENANCE SEE WARNINGS STEP 3. Remove the cage and put the flange CAUTION seat (if used), the side flange and the Too much lubricant can lock ring in position cause the tire to slide and on the wheel rim. In- move around the wheel rim.

  • Page 125: Operating Procedures For A New Or Rebuilt Engine

    MAINTENANCE OPERATING PROCEDURES FOR A NEW OR CHANGES TO THE OVERHEAD GUARD REBUILT ENGINE WARNING A new or rebuilt engine must be operated under special Do not operate the lift truck without the overhead conditions during the first 50 hours. These special condi- guard correctly fastened to the lift truck.

  • Page 126: How To Put Batteries In Storage

    MAINTENANCE Before placing any lift truck in storage, you must choose When parked with the power OFF, actuate each control an area which is clean, dry and free from airborne con- handle to relieve hydraulic pressure. taminates. Mast is to be stored fully lowered. Lift trucks powered by I.C.E.

  • Page 127: How To Store A Lift Truck

    MAINTENANCE charge can amount to an average of about 0.001 point When a lift truck is to be placed in service after storage, it drop in specific gravity per day. must be given the 250 hour inspection shown in the REC- OMMENDED SCHEDULE OF MAINTENANCE.
  • Page 128 MAINTENANCE 2. Fully lower the forks or carriage. Tilt mast FOR- 8. If the lift truck is not stored in a shelter, put a cover WARD until the tips of the forks touch the earth. over the lift truck to prevent damage from the Apply a thin coat of engine oil to the cylinder rods.

  • Page 129: How To Move A Lift Truck On Atransport

    MAINTENANCE HOW TO MOVE A LIFT TRUCK ON A the lift truck as loaded on the transport vehicle. Bridges, overpasses, powerlines, natural barriers can prevent TRANSPORT clearance. Removal of the mast can be necessary. WARNING If a trailer is the method of transportation, use blocks in Stay a safe distance from the front and back of the trailer tyres to prevent movement of edge of docks, ramps, platforms...

  • Page 130: Unloading

    MAINTENANCE 4. Turn the key switch to OFF to stop the engine. CAUTION Check that all switches and accessories are turned Make sure that any straps or chains used to fasten OFF. the lift truck to the transport do not contact any 5.

  • Page 131: Preparation For Use

    MAINTENANCE 3. Disconnect the straps or chains. 3. Follow the steps in the section CHECKS WITH THE ENGINE STOPPED. 4. Remove the wheel blocks. Preparation After Storage 5. Check that all switches and accessories are turned 1. Remove all tape, covers, and preservation materials. OFF.
  • Page 132 MAINTENANCE NOTES...
  • Page 133 NO MATTER HOW YOU SAY IT . . . La Prudence Paye La Seguridad Paga Betriebssicherheit Macht Sich Bezahlt Passaa Oll Huolellinen Veiligheid Voor Alles Säkerhet Först Essere Sicuro Paga Seguranca Paga Sikkerhet Først Pinter Be Awas WARNING California Proposition 65 - - This product contains and/ or emits chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
  • Page 134 OPERATING MANUAL CHALLENGER H45XM, H50XM, H55XM, H60XM, H65XM SPACESAVER S40XM, S45XM, S50XM, S55XM, S55XMS, S60XM, S65XM DO NOT REMOVE THIS MANUAL FROM THIS UNIT PART NO. 1458874 HYSTER COMPANY...

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