Hyster CHALLENGER H70XL Operating Manual
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Hyster CHALLENGER H70XL Operating Manual

Hyster CHALLENGER H70XL Operating Manual

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OPERATING MANUAL
CHALLENGER
H70XL, H80XL, H90XLS, H90XL, H100XL,
H110XL (G005)
H135XL, H135XL
, H155XL, H155XL
H155XLS
2
2,
(F006, G006)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
HYSTER COMPANY
PART NO. 897364

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  • Page 1 OPERATING MANUAL CHALLENGER H70XL, H80XL, H90XLS, H90XL, H100XL, H110XL (G005) H135XL, H135XL , H155XL, H155XL H155XLS (F006, G006) DO NOT REMOVE THIS MANUAL FROM THIS UNIT DO NOT REMOVE THIS MANUAL FROM THIS UNIT HYSTER COMPANY PART NO. 897364...
  • Page 2 EZXchanget, HSMt, ReachStackert, SitDrivet, StanDrivet, Multiquipt, and Unisourcet are 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...

  • Page 3: Foreword

    • truck. NOTE: A comprehensive operator training program is understand the capabilities and limitations of the lift available from HYSTER COMPANY. For further details, • truck. contact your dealer for Hyster lift trucks. become familiar with the construction of the lift truck •...
  • Page 4 For Industrial Operations, from the National Safety and use of lift trucks is available from the following Council). sources: NOTE: Hyster lift trucks are not intended for use on public roads. employment safety and health standards or regulations • (Examples: “Occupational Safety and Health Standards NOTE: The following symbols and words indicate safety (USA)”, “Canada Material Handling Regulations”.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS FOREWORD ........Driving And Direction Changes .
  • Page 6 CONTENTS Hydraulic System Oil ..... . Lift System Operation ..... Inching/Brake Pedal .
  • Page 7 CONTENTS Remove The Tire From The Wheel ..Install The Tire On The Wheel ....OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE .
  • Page 8 MODEL DESCRIPTION A WARNING label with this information must be on the lift truck.
  • Page 9 WARNING NOTES...
  • Page 10 MODEL DESCRIPTION 1. OVERHEAD GUARD 7. FORKS 2. COUNTERWEIGHT 8. CARRIAGE 3. STEERING AXLE 9. LOAD BACKREST 4. DRIVE AXLE EXTENSION 5. PARKING BRAKE 10. SEAT BELT AND 6. MAST HIP RESTRAINT BRACKET H70- -110XL (with LPG Tank) H135- -155XL 11781 11621 FIGURE 1.

  • Page 11: Model Description

    MODEL DESCRIPTION MODEL DESCRIPTION GENERAL mission. The single--speed powershift transmissions can be equipped with two kinds of controls: • a MONOTROL pedal that controls both the for- This Operating Manual is for the following models of lift ward and reverse operation of the powershift trans- trucks: mission and the speed of the engine.

  • Page 12: Operator Protection Equipment

    If the Nameplate does HYSTER lift trucks. not show the maximum capacity, or if the lift truck equipment, including the battery for electric trucks,...

  • Page 13: Safety Labels

    FIGURE 2. If your lift truck has this type of label, do not NAMEPLATE operate the lift truck. Contact your dealer for HYSTER lift trucks to obtain a complete nameplate. TRUCK MODEL SAFETY LABELS Serial no.
  • Page 14 MODEL DESCRIPTION 1. WARNING, OPERATION 2. CASE WITH 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.
  • Page 15 MODEL DESCRIPTION 9 10 POWERSHIFT WITHOUT MONOTROL PEDAL 11701 21 19 MANUAL TRANSMISSION 11701 POWERSHIFT WITH MONOTROL PEDAL 11701 FIGURE 4. INSTRUMENTS AND CONTROLS (H70--110XL, EARLIER PRODUCTION)
  • Page 16 MODEL DESCRIPTION 6, 8 12402 POWERSHIFT WITHOUT MONOTROL PEDAL 15 16 12402 MANUAL TRANSMISSION POWERSHIFT WITH MONOTROL PEDAL 12402 FIGURE 5. INSTRUMENTS AND CONTROLS (H70--110XL, LATER PRODUCTION)
  • Page 17 MODEL DESCRIPTION 12 13 6, 8 POWERSHIFT WITHOUT MONOTROL PEDAL 12402 MANUAL TRANSMISSION POWERSHIFT WITH MONOTROL PEDAL 12402 FIGURE 6. INSTRUMENTS AND CONTROLS (H70--110XL, WITH ELECTRONIC ENGINE CONTROL)
  • Page 18 MODEL DESCRIPTION POWERSHIFT WITH MONOTROL PEDAL 11639 9 10 11639 MANUAL TRANSMISSION POWERSHIFT WITHOUT MONOTROL PEDAL 11639 FIGURE 7. INSTRUMENTS AND CONTROLS (H135--155XL, [F006], EARLIER PRODUCTION)
  • Page 19 MODEL DESCRIPTION POWERSHIFT WITHOUT MONOTROL PEDAL 11639 MANUAL TRANSMISSION POWERSHIFT WITH MONOTROL PEDAL 11639 11639 FIGURE 8. INSTRUMENTS AND CONTROLS (H135--155XL [F006, G006], LATER PRODUCTION)
  • Page 20 MODEL DESCRIPTION POWERSHIFT WITHOUT MONOTROL PEDAL 12581 MANUAL TRANSMISSION POWERSHIFT WITH MONOTROL PEDAL 12581 12581 FIGURE 9. INSTRUMENTS AND CONTROLS (H135--155XL WITH ELECTRONIC ENGINE CONTROL)

  • Page 21: Instruments And Controls

    MODEL DESCRIPTION INSTRUMENTS AND CONTROLS (See TABLE 1., TABLE 2., TABLE 3., and FIGURE 4., FIGURE 5., FIGURE 6., FIGURE 7., FIGURE 8., FIGURE 9.) WARNING If any of the instruments, levers, or pedals do not operate as described in the following tables, report the problem immediately.
  • Page 22 MODEL DESCRIPTION ITEM ITEM FUNCTION Fuel Gauge Indicates the amount of fuel in the gasoline or diesel fuel tank. Warning Light, The light will be ON when the key switch is ON and the engine is not running. Alternator CAUTION Do not continue to operate the lift truck if the red light is ON at engine speeds above idle.
  • Page 23 MODEL DESCRIPTION ITEM ITEM FUNCTION Warning Light, This light will be ON when the key switch is ON and the engine is not running. “Check Engine” This light will illuminate when the ECM computer senses a fault in the operation of the engine.
  • Page 24 MODEL DESCRIPTION TABLE 2. CONTROLS ITEM ITEM FUNCTION Cold Start Aid The cold start aid is used on lift trucks with a diesel engine. The control button is on the instrument panel to the left of the steering column on H70--110XL units.
  • Page 25 MODEL DESCRIPTION ITEM ITEM FUNCTION Parking Brake Lever The lift truck is equipped with a hand lever to apply parking brake. Pull the lever to the upright position to apply the 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.
  • Page 26 MODEL DESCRIPTION ITEM ITEM FUNCTION The range lever is located to the left of the steering column. This lever controls Range Lever the three speed ranges of the H70--110XL manual transmission. (Manual Transmission) (H70--110XL ) Range Lever The range lever is to the left of the steering column. The lever controls the four (Manual speed ranges of the manual transmission.
  • Page 27 MODEL DESCRIPTION ITEM ITEM FUNCTION Tilt The tilt control lever is on the right of the lift/lower control lever. Push the control Control lever forward to tilt the upright and forks forward. Pull backward on the control Lever lever to tilt the upright and forks backward. The control lever for auxiliary hydraulic functions is installed to the right of the Control Lever for Auxiliary tilt control lever.
  • Page 28 MODEL DESCRIPTION ITEM ITEM FUNCTION MONOTROL 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 (Powershift REVERSE. Pushing on the left side of the pedal causes the lift truck to move in Transmission) FORWARD.
  • Page 29 MODEL DESCRIPTION ITEM ITEM FUNCTION Clutch Pedal The clutch pedal is located to the left of the brake pedal. This pedal, controlled (Manual by the operator’s left foot, controls clutch engagement for the transmission and Transmission) inching operations. Latch for Tilt Steering Column A latch located on the lower right side of the steering column allows the (Only on lift trucks equipped operator to select one of five different positions for the steering wheel.
  • Page 30 MODEL DESCRIPTION TABLE 3. AUXILIARY CONTROL LEVERS FUNCTION DIRECTION OF MOVEMENT The control levers will be arranged in the LOAD OR EQUIPMENT CONTROL LEVER following order from left to right. REACH Retract / Extend Backward/Forward SIDE SHIFT Right / Left Backward/Forward PUSH - - PULL Backward / Forward...

  • Page 31: Operating Procedures

    OPERATING PROCEDURES OPERATING PROCEDURES GENERAL This basic principle is used for picking up a load. The abil- ity of the lift truck to handle a load is discussed in terms of Know Your Lift Truck center of gravity and both forward and side stability. The fork lift truck is designed to pick up and move materi- Stability and Center Of Gravity als.

  • Page 32: Capacity (Weight And Load Center)

    OPERATING PROCEDURES In order for the lift truck to be stable (not tip over forward The lift truck has CG Load moving parts and or to the side) the CG must stay within the area of the lift the truck represented by a triangle drawn between the therefore has a CG that moves.

  • Page 33: Inspection Before Operation

    OPERATING PROCEDURES The operator must know whether or not a load is within the maximum capacity of the lift truck before the load is han- dled. INSPECTION BEFORE OPERATION Checks With the Engine Stopped Inspect the lift truck before use and every eight hours or daily as described in the MAINTENANCE section of this OPERATING MANUAL.

  • Page 34: Starting Procedures

    OPERATING PROCEDURES Gasoline Or LPG Engine • Condition of wheels and tires. • Seat belt latches properly. 1. If the lift truck uses LPG fuel, open the fuel valve on the LPG tank. • Seat is correctly fastened to its mounts. Hood is se- curely latched.

  • Page 35: Diesel Engine

    OPERATING PROCEDURES 6. When the engine is running, check the gauges and indi- the glow plugs in the engine are hot. Engage the starter cator lights for the correct operation. See the Instruments again. Push the button for the Cold Start Aid while the And Controls section in this OPERATING MANUAL for a starter is engaged.

  • Page 36: Checks With The Engine Running

    OPERATING PROCEDURES Checks With the Engine Running Make sure that the area around the lift truck is clear before starting the engine or making any operational checks. Be FASTEN YOUR SEAT BELT! The seat careful when making the checks. If the lift truck is station- belt is installed to help the operator ary during a check, apply the parking brake and put the stay on the truck if the lift truck tips...

  • Page 37: Operating Techniques

    OPERATING PROCEDURES OPERATING TECHNIQUES the locking mechanism will be activated and hold the oper- ator’s lower torso in the seat. WARNING Basic Operating Procedures Before operating the lift truck FASTEN Many people make the mistake of thinking that operating a YOUR SEAT BELT.
  • Page 38 OPERATING PROCEDURES that a qualified person experienced in lift truck operation 3. NO RIDERS. A lift truck is built for only one person ---- the operator. It is must guide the operator through several driving and load dangerous for anyone to ride on the handling operations before the operator attempts to oper- forks or anywhere else on the lift ate the lift truck alone.
  • Page 39 OPERATING PROCEDURES 4. Do not drive a lift truck into an elevator unless author- ized to do so. Approach the elevator slowly. After the ele- vator is properly leveled, 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- form must be attached to the forks and carriage.

  • Page 40: Driving And Direction Changes

    OPERATING PROCEDURES Driving And Direction Changes If the lift truck begins to move more slowly because of the load or a grade, select a lower speed range. (Do not select first gear when the lift truck is moving.) Depress the clutch The H70--110XL lift trucks can have a three--speed manual and select the lower speed range (lower gear).

  • Page 41: Operator Presence System

    OPERATING PROCEDURES truck has a direction control lever, move the lever toward Operator Presence System the front of the lift truck to travel FORWARD. Move the lever toward the rear of the lift truck to travel in REVERSE. WARNING The H135--155XL lift trucks also have a range selection lever to control the two speed ranges of the transmission.

  • Page 42: Inching

    OPERATING PROCEDURES WARNING The operators presence module will automatically shift the Inching requires coordinated movement of the inch- transmission to neutral within 1--2 seconds when the oper- ing/brake pedal and the accelerator or the MONOTROL ator leaves the seat of the lift truck. pedal.
  • Page 43 OPERATING PROCEDURES with the load lowered. Rearward tilt, off--center loads and WARNING uneven ground will aggravate these conditions. Failure to ob- serve the tail WARNING swing area when making a IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! turn can injure HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR “TAIL...

  • Page 44: Load Handling, General

    OPERATING PROCEDURES operator must reduce the load so that the lift truck will re- main stable. 2. Handle only stable loads. A load can have unstable items that can easily shift and fall on someone. WARNING Do not handle a load if any loose part of it is above the load Load Handling, General...

  • Page 45: Load Handling, Lifting, Lowering, And Tilting

    OPERATING PROCEDURES If the weight of the load is not centered between the forks, Load Handling, Lifting, Lowering, And Tilting the load can fall from the forks when you turn a corner or hit a bump. An off--center load will increase the possibility The LIFT and TILT functions are con- of the truck tipping over to the side.
  • Page 46 OPERATING PROCEDURES A lift truck with- WARNING out an over- head guard pro- Keep yourself and all others clear of the lift mechanism. vides no such Never allow anyone under or protection and on the forks. other personnel have no over- head protection.
  • Page 47 OPERATING PROCEDURES Lift and lower with the mast vertical or tilted slightly back- WARNING ward from vertical. Tilt elevated loads forward only when The lift truck can tip directly over the unloading place. over forward when If the lift mechanism is raised to pick up the load is raised.

  • Page 48: Load Handling

    OPERATING PROCEDURES Load Handling, that loads or equipment that are behind the load being How To Engage And Disengage A Load lifted are not damaged. Lift the load a small distance from the floor to make sure the lift truck has the capacity to lift 1.
  • Page 49 OPERATING PROCEDURES 5. To put the load on a stack, align the lift truck with the stack. Lift the load to eye level and then tilt the load forward until it is level. Raise the load higher than the point where it will be placed.

  • Page 50: Load Handling, Traveling

    OPERATING PROCEDURES Move forward slowly. When the load is in position for lowering on a stack, tilt the mast to a vertical position and lower the load. Lower the forks just enough to remove them from under the load. Do not lower the NOTE: Not every load can be lifted using only the forks of forks so that they will drag a lift truck.
  • Page 51 OPERATING PROCEDURES ered (travel) position. Therefore, a lift truck without a load 4. When traveling up or down a is more likely to tip sideways, especially in a turn, than a grade with a heavily loaded lift lift truck with a load carried in the lowered position. truck, keep the load upgrade to maintain control.
  • Page 52 OPERATING PROCEDURES faces. Lift trucks with pneumatic tires can adapt to more 6. Anytime the lift truck is moving uneven ground. Always make sure you choose the keep arms, legs, etc., inside the oper- smoothest route for your lift truck. ator’s compartment.

  • Page 53: Highway Trucks, Railroad Cars And Docks

    OPERATING PROCEDURES HIGHWAY TRUCKS, RAILROAD CARS AND 10. Do not pass another lift truck DOCKS traveling in the same direction at WARNING intersections, blind spots or at other Maintain a safe distance from dangerous loca- the edge of docks, ramps, tions.

  • Page 54: Attachments

    OPERATING PROCEDURES Check the condition of the driving surface. Make sure the floor will support the weight of the lift truck and the load. Check to make sure that the brakes on the highway truck Make sure the dockboard is secured, in good condition are set and that wheel and of the proper capacity.

  • Page 55: Stopping

    OPERATING PROCEDURES STOPPING 3. Put the direction control lever for the powershift trans- mission in NEUTRAL. If the lift truck has a manual trans- Stop the lift truck as mission, leave the gears of the transmission engaged. DO gradually as possi- NOT leave a manual transmission in NEUTRAL.
  • Page 56 OPERATING PROCEDURES NOTES...

  • Page 57: 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 recommendation for the time intervals are for eight who do their own maintenance.

  • Page 58: How To Move A Disabled Lift Truck

    MAINTENANCE HOW TO MOVE A DISABLED LIFT TRUCK have a capacity rating equal to or greater than the weight of the disabled lift truck. The capacity of the lift truck used to move a disabled lift truck must have a WARNING load center equal to half the width of the disabled lift Use extra caution when towing a lift truck if any of the...

  • Page 59: How To Put A Lift Truck On Blocks

    MAINTENANCE 5. Use a towing link made of steel that attaches to the tow The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to pins in the counterweights of both lift trucks. support the lift truck are solid, one piece units.

  • Page 60: 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 10.) weight of the lift truck as shown on the nameplate. 1.
  • Page 61 MAINTENANCE 11705G 28 29 31, 32 GM V- -6 ENGINE SHOWN FIGURE 11. MAINTENANCE POINTS FOR H70--110XL...
  • Page 62 MAINTENANCE 11641 29 30 GM V- -6 ENGINE SHOWN FIGURE 12. MAINTENANCE POINTS FOR H135--155XL, H135--155XL H155XLS...
  • Page 63 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. HYDRAULIC OIL 36 liter (38 qt) --18 ° C (0 ° F) and Above H70--110XL SAE 10W API CC or CC/SE/SF/SG...
  • Page 64 C (14 to 122 ° ° SAE 15W--40 API CG4/CH4 ACEA E3/E5 MIL--PRF--2104G POWERSHIFT 17 liter (18 qt) Hyster Part No. 336831 TRANSMISSION OIL H70--110XL POWERSHIFT 15.1 liter (16 qt) Hyster Part No. 336831 TRANSMISSION OIL H135--155XL, XL H155XLS X=Check...
  • Page 65 OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. OIL CLUTCH SYSTEM, 9.5 liter (10.0 qt) Hyster Part No. 336831 OIL LEVEL H70--110XL FUEL TANK 87 liter (23 gallon) 86 Octane — Gasoline H70--110XL Diesel No. 2 LPG —...
  • Page 66 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. COOLING SYSTEM (Gas/LPG) 19.9 liter (21.0 qt) 50% Water and H135--155XL, XL , H155XLS 50% Ethylene Glycol GM V--6 EPA Compliant Engine Boron Free Anti--Freeze...
  • Page 67 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. MAST, CARRIAGE, AND LIFT Check Condition CHAINS and Operation CHECK FOR LEAKS Check for Leaks FUEL, OIL, WATER See NOTE 1 HOOD AND SEAT LATCHES...
  • Page 68 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. DRIVE SHAFT, TRANSMISSION 2 Fittings MultiPurpose Grease H70--110XL See NOTE 2 DRIVE SHAFT, TRANSMISSION 2 Fittings MultiPurpose Grease H135--155XL, XL...
  • Page 69 6 mo. 1 yr. BRAKE FLUID 0.5 liter (1.1 pt) SAE J--1703 CLUTCH, BRAKE, AND Adjust as Required Hyster Part No. 328388 INCHING/BRAKE PEDALS ENGINE IDLE SPEED Adjust as Required 625 to 675 rpm GM V--6 ENGINE IDLE SPEED Adjust as Required...
  • Page 70 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. WHEEL NUTS Check Torque All Wheel Nuts STEER WHEELS 610 to 680 N.m (450 to 500 lbf ft) ENGINE OIL FILTER See Parts Manual...
  • Page 71 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. MAST As Required Multipurpose Grease Sliding Surfaces and Load See NOTE 2 Roller Surfaces MAST 4 Fittings Multipurpose Grease...
  • Page 72 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. PCV VALVE (GM V--6) See Parts Manual CRANKCASE BREATHER See Parts Manual GM V--6 See NOTE 6 CRANKCASE BREATHER See Parts Manual...
  • Page 73 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. VALVE ADJUSTMENT Adjust as Required 0.45 mm (0.018 in) Diesel, All Engines Exhaust (Cold) MANUAL TRANSMISSION, 14.7 liter (15.5 qt) SAE 80W--90, 85W--140...
  • Page 74 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. SPEED REDUCER AND 12.1 liter (12.8 qt) SAE 80W--90, 85W--140 DIFFERENTIAL OIL, See NOTE 7 TWO--SPEED POWERSHIFT TRANSMISSION H135--155XL, XL...
  • Page 75 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. OIL FILTER, POWERSHIFT See Parts Manual TRANSMISSION See NOTE 5 PRIMARY FUEL FILTER, See Parts Manual DIESEL Drain Water...
  • Page 76 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ Hr./ OR QUANTITY 6 wks 2 mo. 3 mo 6 mo. 1 yr. OXYGEN SENSOR Check Indicator GM V6 EPA Compliant Light Engine Drain Oil If INSPECT LOW PRESSURE Necessary REGULATOR FOR OIL...

  • Page 77: How To Make The Checks With The Engine Stopped

    MAINTENANCE HOW TO MAKE THE CHECKS WITH THE Engine Oil (See FIGURE 14.) ENGINE STOPPED Keep the oil at the correct level as indicated on the dip- Hydraulic System Oil (See FIGURE 13.) stick. Use the correct oil as shown in the Maintenance Schedule.
  • Page 78 MAINTENANCE H135- -155XL 11618 H70- -110XL 11725 4. BREATHER, HYDRAULIC TANK 1. BATTERY 5. BREATHER, ENGINE 2. RESERVOIR, BRAKE FLUID 6. FILL CAP, HYDRAULIC OIL 3. DIPSTICK, HYDRAULIC OIL 7. FILTER HEAD FIGURE 13. MAINTENANCE POINTS...
  • Page 79 MAINTENANCE DIESEL GASOLINE/LPG 1. DIPSTICK FOR ENGINE OIL 5. PCV VALVE (GM V--6) 2. ENGINE OIL FILL CAP 6. BATTERY 3. AIR FILTER 7. FILL CAP, FUEL 4. AUXILIARY COOLANT RESERVOIR 8. COLD START AID, DIESEL 12185 12186 FIGURE 14. ENGINE MAINTENANCE POINTS...

  • Page 80: Drive Belts

    MAINTENANCE Drive Belts Check the drive belts for wear or damage. Cooling System (See FIGURE 15.) WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is re- moved, the pressure is released from the system. 11619 FIGURE 15.

  • Page 81: Fuel System

    MAINTENANCE correct mixture of water and ethylene glycol. See the Check the fuel system for leaks and the condition of parts. MAINTENANCE SCHEDULE. When fuel is added to the lift truck, see the section, How To Add Fuel To The Lift Truck procedures in this OPER- ATING MANUAL.

  • Page 82: Battery

    MAINTENANCE 1. Open the valve on the bottom of the filter canister. Drain If the battery becomes discharged and requires a boost some fuel (and any water) into a cup until clean fuel flows battery to start the engine, follow these procedures care- from the filter.
  • Page 83 MAINTENANCE pressure to the tire. Follow the procedures under ADD AIR TO THE TIRES. When adding air to the tires, a remote air chuck must be used so that the person adding air can stand to the side and not in front of the tire. Keep the tires at the correct air pressure.

  • Page 84: Forks

    MAINTENANCE lift trucks as an option. The H135- -155XL series of lift CAUTION trucks normally have a pin fork. Check all wheel nuts after 2 to 5 hours of operation: Forks, Adjustment when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and Hook forks are connected to the carriage by hooks and installed.
  • Page 85 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 18. HOOK FORK LOCK PIN ASSEMBLY...
  • Page 86 MAINTENANCE 12565 1. CARRIAGE 2. FORK 3. FORK PIN 4. LOCK PIN 5. LOAD BACKREST EXTENSION FIGURE 19. PIN FORKS...

  • Page 87: Forks, Removal And Installation

    MAINTENANCE Pin forks are fastened to the carriage with large fork pins. A lock pin for each fork fits into the top carriage bar and a 1. CARRIAGE BARS slot in the fork. These lock pins hold the fork in position. 2.

  • Page 88: Inspection Of Forks, Mast And Lift Chains

    MAINTENANCE Inspection of Forks, Mast and Lift Chains riage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the car- (See FIGURE 21. and FIGURE 22.) riage so that both upper and lower hooks engage the car- riage.
  • Page 89 MAINTENANCE 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. LATCH DAMAGE 4. HEEL OF FORK (MUST BE 90% OF DIMENSION “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 90 MAINTENANCE 3. Inspect the load backrest extension for cracks and dam- 10. Make sure the lift chains are adjusted so that they age. have equal tension. Adjustment or repair of the lift chains must be done by authorized personnel. 4. Inspect the forks for cracks and wear. Check that the fork tips are aligned within 13 mm (0.5 in) of each other.

  • Page 91: Safety Labels

    MAINTENANCE Safety Labels install the labels are also in the PERIODIC MAINTE- NANCE section WARNING Operator Restraint System Safety labels are installed on the lift truck to give in- (See FIGURE 23.) formation about operation and possible hazards. It is important that all safety labels are installed on the lift The seat belt, hip restraint brackets, seat and mounting, truck and can be read.
  • Page 92 MAINTENANCE 1. LATCH STRIKER 2. HOOD LATCH 3. LATCH LEVER 4. SEAT 5. SEAT BELT LATCH 6. HIP RESTRAINT 7. SEAT RAIL 8. FLOOR PLATE 9. HOOD 10. GAS CYLINDER 11. HINGE H70- -110XL SHOWN GASOLINE AND DIESEL ARRANGEMENT LPG ARRANGEMENT 11858 FIGURE 23.

  • Page 93: Automatic Locking Retractor (Alr)

    MAINTENANCE Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to the mount surface. If the mounting surface is the hood, the hood must be fastened to the floor plate with the latch.

  • Page 94: How To Make The Checks With The Engine Running

    MAINTENANCE When the ELR style seat belt is properly buckled across pulled with a sudden jerk, replace the seat belt as- the operator, the belt will permit slight operator reposition- sembly. ing without activating the locking mechanism. If the truck •...

  • Page 95: Gauges, Lights, Horn And Fuses

    MAINTENANCE to the outside. Do not exceed applicable air On H135--155XL (G006) lift trucks only, there are addition- contaminant limits. al fuses and relays located in the engine compartment. See FIGURE 26. and FIGURE 27. Follow the inspection and maintenance sched- ule and procedures in this manual.
  • Page 96 MAINTENANCE 1. FUSE PANEL 2. MOUNTING BRACKET F1. 20 AMPS R1. STARTER RELAY F2. 5 AMPS R2. POWER RELAY F3. 15 AMPS R3. FUEL PUMP RELAY F4. 15 AMPS R4. SPARE F5. SPARE F6. SPARE HO190288 FIGURE 26. ENGINE COMPARTMENT FUSES AND RELAYS, GM 4.3L EPA COMPLIANT ENGINE (H135---155XL, H135---155XL AND H155XLS [G006] TRUCKS ONLY)
  • Page 97 MAINTENANCE 1. LIFT PUMP RELAY 2. LIFT PUMP FUSE (10A) 3. ALTERNATOR FUSE (60A) 4. GLOW PLUG FUSE (60A) 5. STARTER RELAY 6. GLOW PLUG RELAY HO190289 FIGURE 27. ENGINE COMPARTMENT FUSES AND RELAYS , PERKINS 1104C--44 (RE) DIESEL ENGINE (H135---155XL, H135---155XL AND H155XLS [G006] TRUCKS ONLY)

  • Page 98: Oil Level, Powershift Transmission

    MAINTENANCE Oil Level, Powershift Transmission Oil Level, Oil Clutch System, H70- -110XL (See FIGURE 28.) (See FIGURE 28.) NOTE: The oil clutch system for the H135--155XL (F006) Apply the parking brake. Check the oil level in the power- lift trucks do not have a dipstick because the oil clutch shift transmission when the engine is running at idle speed uses oil from the hydraulic system.

  • Page 99: Control Levers And Pedals

    MAINTENANCE H135- -155XL 11638 H70- -110XL 1. DIPSTICK FOR POWERSHIFT TRANSMISSION OIL OR OIL CLUTCH SYSTEM OIL 2. DIPSTICK FOR POWERSHIFT TRANSMISSION 11703 3. FLOOR PLATE FIGURE 28. POWERSHIFT TRANSMISSION OR OIL CLUTCH SYSTEM OIL Control Levers and Pedals TABLE 3. Check that the pedals operate as described in TABLE 2.

  • Page 100: Lift System Operation

    MAINTENANCE Lift System Operation NOTE: Some parts of the mast move at different speeds during raising and lowering. WARNING c. The inner weldments and the carriage must lower completely. Lower the lift mechanism completely. Never allow any- one under a raised carriage. Do not put any part of d.

  • Page 101: Service Brakes

    MAINTENANCE Parking Brake switch in the starting circuit is closed so that the engine can be started. Check the operation of the parking brake. The parking brake, when in good condition and correctly adjusted, will Service Brakes hold a lift truck with a capacity load on a 15% grade [1.5 metre rise in 10 metres (1.5 ft rise in 10 ft)].

  • Page 102: How To Add Fuel To The Lift Truck

    MAINTENANCE HOW TO ADD FUEL TO THE LIFT TRUCK Liquified Petroleum Gas (LPG) WARNING Close the fuel valve on the tank when parking the lift WARNING truck more than momentarily. Do not park the lift truck near heat or ignition sources. Stop the engine.
  • Page 103 MAINTENANCE Use the following procedure to remove the LPG tank: a. Removable LPG tanks can be replaced indoors only if the lift truck is a minimum of 8 metres (25 feet) from any open flame or ignition source. b. Move the lift truck to the area where LPG tanks are changed.
  • Page 104 MAINTENANCE aged hose or fitting can release LPG fuel and cause WARNING an explosion and fire hazard. Use only the LPG tank listed on the label on the tank d. Close the latch on the tank bracket. Turn the fuel bracket.

  • Page 105: Gasoline Or Diesel Fuel

    MAINTENANCE b. Open the liquid outlet valve and by--pass return j. Close the fuel valve on the LPG tank. valve on the storage tank. k. Disconnect the supply hose. c. Start the pump. l. Stop the pump. d. Connect the supply hose to the quick disconnect m.

  • Page 106: Wheels And Tires

    MAINTENANCE WHEELS AND TIRES Remove The Wheels From The Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. How To Repair A Pneumatic Tire Deflate tire completely before removing the wheel from the lift truck. If dual wheels are used, deflate both tires.

  • Page 107: Remove The Wheel From The Tire

    MAINTENANCE TWO- -PIECE WHEEL THREE- -PIECE WHEEL FOUR- -PIECE WHEEL 1. WHEEL RIM 3. LOCK RING 5. FLANGE SEAT 2. SIDE FLANGE 4. FLANGE SEAT 11637 9458 11637 FIGURE 30. TYPES OF WHEELS Remove The Wheel From The Tire ber tire is installed instead of a pneumatic tire. Changes to the parts of the rim can cause a failure of (See FIGURE 31.
  • Page 108 MAINTENANCE WARNING WARNING Wheels must be changed and tires repaired by trained Make sure all of the air pressure is removed from the personnel only. tire before a wheel is disassembled. Air pressure in the tires can cause the tire and rim parts to explode Deflate tire completely before removing the wheel causing serious injury or death.
  • Page 109 MAINTENANCE SEE WARNINGS STEP 1. Remove the nuts that fasten the wheel halves together. STEP 3. Remove the wheel halves from tire. Remove the inner tube and flap. 11939 STEP 2. Loosen the tire bead from the side flange. FIGURE 31. TIRE REMOVAL, TWO PIECE WHEEL...
  • Page 110 MAINTENANCE 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 STEP 4.

  • Page 111: Install The Wheel In The Tire

    MAINTENANCE Install The Wheel In The Tire ance at the ends of the lock ring must be 13 to 25 mm (0.5 to 1.0 in) after it is installed. If the clearance is (See FIGURE 33. and FIGURE 34.) wrong, the wrong part has been used. WARNING 1.
  • Page 112 MAINTENANCE STEP 1. Install the inner tube and the rubber flap in STEP 3. Turn over the rim and tire. Put blocks under the the tire.. rim so that the rim is 8 to 10 cm (3 to 4 in) above the floor.

  • Page 113: Add Air To The Tires

    MAINTENANCE Add Air To The Tires (See FIGURE 35.) 11939 WARNING Add air pressure to the tires only in a safety cage. In- spect the safety cage for damage before use. When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube.

  • Page 114: Install The Wheels

    MAINTENANCE Install The Wheels the tire. Remove the valve core to make sure all of the air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be 25 to 32 WARNING mm (1.0 to 1.25 in) when the tire has the correct air pres- Check all wheel nuts after 2 to 5 hours of operation - - sure.

  • Page 115: Installation Procedures, Dual Drive Wheels

    MAINTENANCE INSTALLATION PROCEDURES, DUAL DRIVE fasten the rim halves together are toward the brake drum when they are installed. WHEELS NOTE: Some lift trucks can have dual drive wheels. The following procedures describe the steps to install the dual sets of wheels. 1.

  • Page 116: Pneumatic Tubeless Tire, Repair

    MAINTENANCE PNEUMATIC TUBELESS TIRE, REPAIR Remove Tire From Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. Deflate tire completely before removing the wheel from the lift truck. If dual wheels are used, deflate both tires.

  • Page 117: Remove Tire From Wheel

    MAINTENANCE 1. Put the lift truck on blocks as described in HOW TO 1. If wheel rim is a three or four--piece rim, turn the valve PUT THE LIFT TRUCK ON BLOCKS at the beginning of 1/4 turn and remove valve from wheel. this section.
  • Page 118 MAINTENANCE 4. Remove the press and remove the loose flange locking 3. Remove the loose flange locking ring and the advance ring and the advance band (four--piece wheel only) from band (four--piece wheel only) using a tire tool. the tire and wheel assembly.

  • Page 119: Install Tire On Wheel

    MAINTENANCE Install Tire on Wheel WARNING Damage to the tire and wheel assembly and injury or death can occur if you do not do the following proce- dures: • Clean and inspect all parts of the wheel before 5. Push the TBS towards the inside of the tire to remove it. installing the tire.
  • Page 120 MAINTENANCE • DO NOT use any damaged or repaired wheel parts. • Make sure that all parts of the wheel are the cor- rect parts for that wheel assembly. • DO NOT mix parts between different types or manufacturers of wheels. •...
  • Page 121 MAINTENANCE If the TBS has two valve holes, lubricate the plastic plug and insert into valve hole that will not be used. BO190190 4. Apply lubricant to the rim. If a four--piece wheel is being used, lubricate the advance band. Slide the tire and TBS onto the wheel.
  • Page 122 MAINTENANCE 6. Raise the tire and position the base and threaded stem of the press through the hole in the center of the wheel. Insert in wheel assembly, the following parts: S Advance band (four--piece wheel only) 5. Place the wheel and tire assembly on a flat surface. S Loose flange Turn the valve a 1/4 turn to lock the collar under the edges of the rim valve slot.
  • Page 123 MAINTENANCE 7. Position the advance band. Ensure that it does not go in too far and damage the valve. Position the arms of the 8. Insert tire tool into the locking ring groove, and a vise oress onto the loose flange. grip on other end.

  • Page 124: Add Air To Pneumatic Tubeless Tire

    MAINTENANCE Add Air to Pneumatic Tubeless Tire WARNING Add air pressure to the tires only in a safety cage. FIGURE 37. Inspect the safety cage for damage be- fore use. When air pressure is added, use a chuck that fastens onto the valve stem. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire.

  • Page 125: Install The Wheels

    MAINTENANCE SOLID RUBBER TIRES WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. 1. Put the lift truck on blocks as described in How to Put the Lift Truck on Blocks, at the beginning of this section. FIGURE 37.
  • Page 126 MAINTENANCE STEP1. Put the STEP 3. Turn the tire wheel rim on over. Put a the bed of support un- the press. der the Put the cage wheel rim. in position on Make sure the tire. Use the wheel the press to rim is at push the tire least 150 to...

  • Page 127: Install The Tire On The Wheel

    MAINTENANCE Install The Tire On The Wheel • DO NOT mix type of tires, type of tire tread or (See FIGURE 39.) wheel assemblies of different manufacturers on any one lift truck. WARNING Do not use a steel hammer on the wheel. Use a rubber, Failure to follow these procedures will cause damage lead, plastic or brass hammer to put parts together.
  • Page 128 MAINTENANCE STEP 3. Remove the cage SEE WARNINGS and put the wedge STEP 1. Lubricate the band (if used),the wheel rim and side ring and the lock the inner sur- ring in position on the face of the tire wheel assembly. In- with tire lubri- stall the cage on the cant or soap.

  • Page 129: Operating Procedures For A New Or Rebuilt Engine

    MAINTENANCE OPERATING PROCEDURES FOR A NEW OR gauges and indicators for the correct operation during this first operating period. Check for leaks. REBUILT ENGINE 3. If the work conditions are slow and the loads are less A new or rebuilt engine must be operated under special than 50% of the truck capacity, a simulated work condition conditions during the first 50 hours.
  • Page 130 MAINTENANCE NOTES...
  • Page 131 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 Cali- fornia to cause cancer, birth defects, or other repro- ductive harm.

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