Hyster S70XL Operating Manual
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Hyster S70XL Operating Manual

Hyster S70XL Operating Manual

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OPERATING MANUAL
SPACESAVER
S70XL, S80XL, S80XL BCS, S100XL,
S120XLS, S120XL (D004)
S135XL, S155XL, S155XLS, S135XL
, S155XL
2
2
(B024, C024)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
HYSTER COMPANY
PART NO. 897366

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Summary of Contents for Hyster S70XL

  • Page 1 OPERATING MANUAL SPACESAVER S70XL, S80XL, S80XL BCS, S100XL, S120XLS, S120XL (D004) S135XL, S155XL, S155XLS, S135XL , S155XL (B024, C024) DO NOT REMOVE THIS MANUAL FROM THIS UNIT HYSTER COMPANY PART NO. 897366...
  • 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

    THIS lift • NOTE: A comprehensive operator training program is truck. available from HYSTER COMPANY. For further details, understand the capabilities and limitations of the lift • contact your dealer for Hyster lift trucks.
  • 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 MAINTENANCE SCHEDULE ....HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING ......HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED .
  • Page 7 WARNING A WARNING label with this information must be on the lift truck.
  • Page 8 MODEL DESCRIPTION 1. OVERHEAD GUARD 5. MAST 2. COUNTERWEIGHT 6. FORKS 3. STEERING AXLE 7. CARRIAGE 4. DRIVE AXLE 8. LOAD BACKREST EXTENSION 9. SEAT BELT AND HIP RESTRAINT BRACKET S70 - -120XL S135- -155XL 12177 12443 FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS...

  • Page 9: Model Description

    Lift trucks with a three--speed manual transmission have the S70- -120XL (D004) series includes the S70XL, • two control levers on the left side of the steering wheel. S80XL, S80XL BCS, S100XL, S120XLS, and S120XL...

  • Page 10: Operator Protection Equipment

    Any change to the lift truck, the tires or its equipment stalled on your lift truck is required, contact your Hyster lift can change the lifting capacity. If the Nameplate does truck dealer.

  • Page 11: Safety Labels

    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.
  • Page 12 MODEL DESCRIPTION 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.
  • Page 13 MODEL DESCRIPTION NOTE: THIRD--FUNCTION CONTROL LEVER (17a) IS AVAILABLE ON ALL UNITS POWERSHIFT TRANSMISSION WITH 12189 POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL DIRECTION CONTROL LEVER FIGURE 4. CONTROLS AND INSTRUMENTS, S70--120XL...
  • Page 14 MODEL DESCRIPTION NOTE: THIRD--FUNCTION CONTROL LEVER (17a) IS AVAILABLE ON ALL UNITS 12402 POWERSHIFT WITHOUT MONOTROL PEDAL MANUAL TRANSMISSION 12189 12189 POWERSHIFT WITH MONOTROL PEDAL FIGURE 5. CONTROLS AND INSTRUMENTS, S135--155XL...

  • Page 15: Instruments And Controls

    MODEL DESCRIPTION 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.
  • Page 16 MODEL DESCRIPTION ITEM ITEM FUNCTION Fuel Gauge Indicates the amount of fuel in the gasoline or diesel fuel tank. Warning Light, The red light will be ON when the key switch is ON and the engine is not Alternator running. CAUTION Do not continue to operate the lift truck if the red light is ON at engine speeds above idle.
  • Page 17 MODEL DESCRIPTION ITEM ITEM FUNCTION Warning light, Powershift Transmission: The red light is ON when the key switch is in the Powershift START position. Transmission Manual Transmission: The red light is ON when the oil pressure in the clutch Oil Temperature system is too low for continued operation.
  • Page 18 MODEL DESCRIPTION TABLE 2. CONTROLS ITEM ITEM FUNCTION Cold 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.
  • Page 19 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 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.
  • Page 20 MODEL DESCRIPTION ITEM ITEM FUNCTION Range Lever The range lever is located to the left of the steering column. This lever controls (Manual the three speed ranges of the S135--155XL manual transmission. Transmission) (S135--155XL) Range Lever The range lever for the transmission is to the left of the steering column. The (Powershift range lever controls the two speed ranges of the powershift transmission.
  • Page 21 MODEL DESCRIPTION ITEM ITEM FUNCTION Control Lever for Auxiliary The control lever for auxiliary hydraulic functions is installed to the right of the Hydraulic Functions tilt control lever. This control lever actuates a control spool in the control valve for a single function attachment and two control spools for a two--function See TABLE 3.
  • Page 22 MODEL DESCRIPTION ITEM ITEM FUNCTION Control Lever and Switch for Three- -Function Operation: Optional Auxiliary Hydraulic The control lever will have a special knob with a button. The button permits the Functions lever to control three functions of an attachment. The button operates a function See TABLE 3.
  • Page 23 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 24 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 25: Operating Procedures

    OPERATING PROCEDURES OPERATING PROCEDURES GENERAL ple to work for a lift truck, the load on the forks must be bal- anced by the weight of the lift truck. The location of the cen- Know Your Lift Truck ter of gravity of both the truck and the load is also a factor. The fork lift truck is designed to pick up and move materials.
  • Page 26 OPERATING PROCEDURES CG Truck which the load is raised; the amount of forward and back- ward tilt; tire pressure; and the dynamic forces created when the truck is moving. These dynamic forces are caused CG Load by things like acceleration, braking, turning, and operating on uneven surfaces or on an incline.

  • Page 27: Capacity

    OPERATING PROCEDURES Capacity the Nameplate apply when transporting loads that are cen- tered on the centerline of the lift truck. Capacities listed un- (Weight and Load Center) der “Sideshifted” on the Nameplate apply if loads are trans- The capacity of the lift truck is shown on the Nameplate. ported that are not centered on the centerline of the lift The capacity is listed in terms of weight and load center.

  • Page 28: Starting Procedures

    OPERATING PROCEDURES Starting Procedures • Oil level in the engine and hydraulic tank. Do not start nor • Coolant level in the cooling system and condition of the operate the lift drive belts. truck, including any of its func- • Condition of the radiator. Clean if necessary. tions or attach- •...

  • Page 29: Diesel Engine

    OPERATING PROCEDURES 3. If equipped, put the direction control lever for the trans- 3. Turn the key to START to engage the starter. If the out- mission in the NEUTRAL (N) position. side temperature is 7°C (45°F) or below, crank the engine two revolutions to prime the fuel system.

  • Page 30: Checks With The Engine Running

    OPERATING PROCEDURES The operator must be aware that the lift truck can tip over. Checks With the There is a great risk that the operator or someone else can Engine Running be killed or injured if trapped or hit by the truck as it tips over.

  • Page 31: Operating Techniques

    OPERATING PROCEDURES Powershift transmission when the direction control There are a number of operations, if not performed lever is in NEUTRAL and the engine is running at idle carefully, that can cause the lift truck to tip. If you have speed.
  • Page 32 OPERATING PROCEDURES as simple and obvious as driving the family automobile. new operator for proper defensive driving and to expect the (e.g. Look where you are going, start and stop smoothly, unexpected. etc.) But a lift truck is a special machine designed to do a 2.
  • Page 33 OPERATING PROCEDURES 4. Do not drive a lift truck into an elevator unless authorized WARNING to do so. Approach the elevator slowly. After the elevator is properly leveled, the lift truck must be centered so that the This lift truck is designed and intended for handling elevator is balanced.

  • Page 34: Driving And Direction Changes

    OPERATING PROCEDURES Driving And Direction Changes third gear, increase the engine speed before changing to the lower gear. Also change to a lower gear before traveling The S70--120XL lift trucks have a single--speed powershift down a steep grade. transmission. The S135--155XL lift trucks can have either a To change directions, apply the brakes and depress the three--speed manual transmission and oil clutch or a two-- clutch pedal to stop the lift truck.

  • Page 35: Operator Presence System

    OPERATING PROCEDURES or the accelerator pedal while the inching/brake pedal is Lift trucks produced after November 1. 2005 are equipped released. with an Operator Presence System (OPS). The OPS fea- ture has an electrical switch in the seat which senses the CAUTION presence of the operator and a operator presence module which disengages the transmission.

  • Page 36: Steering (Turning)

    OPERATING PROCEDURES Steering (Turning) Inching is the movement of a lift truck that allows a slow travel speed while keeping the engine speed high for fast operation of the lift mechanism. WARNING TRAVEL FAST SLOWLY WHEN TURN- ING. Lift trucks can tip over even at very slow SLOW...
  • Page 37 OPERATING PROCEDURES ward tilt, off- -center loads and uneven ground will ag- gravate these conditions. WARNING IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR FEET, AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT.

  • Page 38: Load Handling, General

    OPERATING PROCEDURES steers with the left hand. The right hand is used to operate the lift, tilt, and attachment controls. However, such factors as weak floors, uneven terrain, spe- cial load handling attachments or loads having a high center When turning the lift truck from a wide aisle into a narrow of gravity can mean that the safe working load is less than aisle, start the turn as close to the opposite stock pile as tail the rated capacity.
  • Page 39 OPERATING PROCEDURES If the weight of the load is not centered between the forks, the load can fall from the forks when you turn a corner or hit a bump. An off--center load will increase the possibility of the truck tipping over to the side. Make sure the pins that keep the forks in position are en- gaged so that the forks cannot move.

  • Page 40: Load Handling, Lifting, Lowering, And Tilting

    Do not lift or hit anything that can fall on the operator or a or near the bystander. Remember, a lift truck equipped with a HYSTER overhead guard and load backrest extension provides rea- sonable protection to the operator from falling objects, but...
  • Page 41 OPERATING PROCEDURES WARNING The lift truck can tip over forward when the load is raised. Forward tipping is even more likely when tilting forward, braking when traveling forward or accelerating in reverse. A lift truck without an overhead guard provides no such pro- tection and other personnel have no overhead protection.

  • Page 42: Load Handling, How To Engage And Disengage A Load

    OPERATING PROCEDURES load that is raised. The lift truck can tip forward if the mast is tilted forward with a load in the raised position. Approach the load carefully. Make sure that the truck is per- pendicular to the load. Raise the forks to the proper height for engaging the load.
  • Page 43 OPERATING PROCEDURES not damaged. Lift the load a small distance from the floor to make sure the lift truck has the capacity to lift the load. Be Careful of Forks Beyond the Load 4. If the load is being removed from a stack, slowly move the lift truck away from the stack.
  • Page 44 OPERATING PROCEDURES 5. To put the load on a stack, align the lift truck with the IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE stack. Lift the load to eye level and then tilt the load forward OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO until it is level.

  • Page 45: Load Handling, Traveling

    OPERATING PROCEDURES floor under the object to be lifted. Tilt the mast fully back- ward to help keep the load on the forks. When the mast, carriage or load is in an elevated position the stability of the lift truck is reduced. This is also critical when the lift truck is not carrying a load.
  • Page 46 OPERATING PROCEDURES visibility available to the operator. If the lift truck must travel When operating an unloaded lift truck on a steep grade, in a direction where visibility is obstructed, a lookout helper keep the counterweight upgrade. may be required. 5.
  • Page 47 OPERATING PROCEDURES 6. Anytime the 7. Avoid bumps, holes, slick spots and loose materials that lift truck is mov- may cause the lift truck to swerve or tip. If unavoidable, ing keep arms, slow down. legs, etc., in- side the opera- tor’s compart- ment.
  • Page 48 OPERATING PROCEDURES equipment that are behind the load being lifted are not dam- 10. Do not pass another lift truck traveling in the same di- aged. rection at intersections, blind spots or at other dangerous locations. Serious accidents can be caused by masts and overhead guards hitting pipes and beams near the ceiling.

  • Page 49: Highway Trucks, Railroad Cars And Docks

    OPERATING PROCEDURES HIGHWAY TRUCKS, RAILROAD CARS AND 12. Under all DOCKS travel condi- tions, operate WARNING the lift truck at a speed that Maintain a will permit it safe distance to be brought from the edge to a stop in a of docks, safe manner.
  • Page 50 OPERATING PROCEDURES Before operating in a highway truck or railroad car, observe the following: DO NOT use a lift truck to move a railroad car. DO NOT use a lift truck to open or close the door on a railroad car unless the lift truck has an attachment that is specifically designed for opening and closing railcar doors and the operator is trained in its use.

  • Page 51: Attachments

    OPERATING PROCEDURES When entering a railroad car the operator can enter at an angle (if the dock plate or bridge is wide enough). This will reduce the turning required after entering. ATTACHMENTS If an attachment is installed on the lift truck, make sure the operating PARKING instructions are avail-...
  • Page 52 OPERATING PROCEDURES If the lift truck is equipped with an LPG fuel system and is removed and stored outside. parked more than momentarily, close the fuel valve at the tank. If the lift truck is going to be left over night or longer, Do not park the lift truck so that it limits access to fire aisles, the truck must be parked outside or the LPG tank must be stairways, and fire equipment.

  • Page 53: Maintenance

    MAINTENANCE SCHEDULE. Service Manuals are avail- The recommendation for the time intervals are for eight able from your dealer for Hyster lift trucks to help users hours of operation per day. The time intervals must be who do their own maintenance.

  • Page 54: How To Move A Disabled Lift Truck

    MAINTENANCE HOW TO MOVE A DISABLED LIFT TRUCK MUST 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 WARNING have a load center equal to half the width of the dis- Use extra caution when towing a lift truck if any of abled lift truck.

  • Page 55: How To Put A Lift Truck On Blocks

    MAINTENANCE Use a towing link made of steel that attaches to the tow NOTE: Some lift trucks have lifting eyes. These lift points pins in the counterweights of both lift trucks. can be used to raise the lift truck so that blocks can be installed.
  • Page 56 MAINTENANCE 2. Use a hydraulic jack to raise the steering tires. Make 3. Put the jack under the steering axle or frame to raise sure that the jack has a capacity of at least 2/3 of the total the lift truck. Put blocks under the frame to support the lift weight of the lift truck as shown on the Nameplate.

  • Page 57: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE 12183 GM V- -6 ENGINE SHOWN 23, 22 *S135- -155XL FIGURE 7. MAINTENANCE POINTS...
  • Page 58 MAINTENANCE ITEM ITEM PROCEDURE OR SPECIFICATION 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. TIRES Check Condition See Nameplate STEERING AXLE SPINDLES 2 Fittings Multipurpose Grease See NOTE 1 COOLANT HOSES Check Condition See Parts Manual...
  • Page 59 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. VALVE ADJUSTMENT Adjust as Required 0.45 mm (0.018 in) DIESEL, ALL UNITS Exhaust Valves (Cold) AIR FILTER Clean or Replace See Parts Manual...
  • Page 60 MAINTENANCE ITEM ITEM PROCEDURE OR SPECIFICATION 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. ENGINE OIL 4.7 litre (5.0 qt) --18 ° to 40 ° C (0 °...
  • Page 61 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. HOOD LATCH, SEAT Check Condition SAFETY LABELS Replace as Necessary See Parts Manual CHECK FOR LEAKS Check for Leaks FUEL, OIL, WATER...
  • Page 62 Engine Oil Check Condition STEERING AND STEERING Check Operation WHEEL POSITION LATCH CLUTCH, BRAKE, AND Adjust as Required Hyster Part No. 328388 INCHING/BRAKE PEDALS WHEEL NUTS Check Torque All Wheel Nuts DRIVE WHEELS 610 to 680 Nm (450 to 500 lbf ft)
  • Page 63 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 6 mo. 1 yr. 3 mo MAST, 4 Fittings Multipurpose Grease SIDE--SHIFT CARRIAGE See NOTE 1 ROLLERS MAST, As Required Multipurpose Grease SLIDING SURFACES AND See NOTE 1...
  • Page 64 14.2 litre (15.0 qt) SAE 80W--90, 85W--140 DIFFERENTIAL OIL S135--155XL (B024) See NOTE 5 POWERSHIFT 15.1 litre (16 qt) Hyster Part No. 336831 TRANSMISSION OIL Single Speed Powershift See NOTE 6 Change oil filter when S70--120XL transmission oil is changed.
  • Page 65 Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. POWERSHIFT 15.1 litre (16 qt) Hyster Part No. 336831 TRANSMISSION OIL Two--Speed Powershift See NOTE 6 Change oil filter when S135--155XL, XL transmission oil is S155XLS changed. OIL CLUTCH SYSTEM, OIL 9.4 liter (10 qt)
  • Page 66 MAINTENANCE ITEM ITEM PROCEDURE OR SPECIFICATION 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. HYDRAULIC SYSTEM 42 litre (11 gallon) --18 C (0 F) and Above ° °...
  • Page 67 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. DRIVE SHAFT AND 2 Fittings Multipurpose Grease UNIVERSAL JOINTS See NOTE 1 S135--155XL, XL S155XLS ENGINE OIL FILTER See NOTE 6...
  • Page 68 MAINTENANCE ITEM ITEM PROCEDURE OR SPECIFICATION 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. PCV VALVE See Parts Manual GM V--6 FUEL FILTER See Parts Manual GASOLINE FUEL FILTER See Parts Manual FUEL FILTER, LPG...
  • Page 69 MAINTENANCE ITEM PROCEDURE OR SPECIFICATION ITEM 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. TEST LPG/GAS REGULATOR PRESSURE Drain Oil If Necessary INSPECT LOW PRESSURE REGULATOR FOR OIL BUILDUP AND LEAKS CHECK AIR INDUCTION SYSTEM FOR LEAKS...
  • Page 70 MAINTENANCE ITEM ITEM PROCEDURE OR SPECIFICATION 8 Hr./ 1000 2000 Daily Hr./ Hr./ Hr./ Hr./ Hr./ QUANTITY 6 wks. 2 mo. 3 mo 6 mo. 1 yr. INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS INSPECT CATALYST INLET AND OUTLET Check Indicator Light OXYGEN SENSOR GM V6 EPA Compliant Engine...

  • Page 71: How To Make The Checks With The Engine Stopped

    MAINTENANCE HOW TO MAKE THE CHECKS WITH THE CAUTION ENGINE STOPPED Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Put the lift truck on a level surface. Lower the carriage and Never operate the pump without oil in the hydraulic forks, stop the engine and apply the parking brake.
  • Page 72 MAINTENANCE S135- -155XL S70- -120XL 11618 11725 NOTE: BREATHER IS ON TOP OF 4. BREATHER, HYDRAULIC TANK 1. BATTERY HYDRAULIC TANK AND 5. BREATHER, ENGINE 2. RESERVOIR, BRAKE FLUID 6. FILL CAP, HYDRAULIC OIL UNDER THE TOP OF 3. DIPSTICK, HYDRAULIC OIL 7.
  • Page 73 MAINTENANCE GASOLINE/LPG 12185 12186 4. AUXILIARY COOLANT DIESEL RESERVOIR 5. PCV VALVE (GM V--6) 6. BATTERY 1. DIPSTICK FOR ENGINE OIL 2. ENGINE OIL FILL CAP 7. FILL CAP, FUEL 8. COLD START AID, DIESEL 3. AIR FILTER FIGURE 9. ENGINE MAINTENANCE POINTS...

  • Page 74: Engine Oil

    MAINTENANCE Engine Oil (See FIGURE 9.) cause burns. DO NOT remove the cover for the radia- tor when the engine is running. After the engine has stopped, wait one minute before Make sure the coolant level is between the FULL and the checking the oil level.
  • Page 75 MAINTENANCE 1. CANISTER 2. O--RING 3. FILTER ELEMENT 12205 4. BAFFLE 5. CLAMP 6. END COVER 11619 FIGURE 11. AIR FILTER FIGURE 10. AUXILIARY COOLANT RESERVOIR...

  • Page 76: Air Filter

    MAINTENANCE Air Filter (See FIGURE 11.) Fuel System WARNING WARNING Compressed air can move particles so that they cause All fuels are very flammable and can burn or cause an injury to the user or to other personnel. Make sure that explosion.

  • Page 77: Battery

    MAINTENANCE Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flame away from the battery area. Do not make sparks from the battery connections. Disconnect the battery ground cable when doing maintenance. Keep the battery and cable terminals clean. Check the electrolyte level (unless maintenance--free battery).

  • Page 78: Tires And Wheels

    MAINTENANCE Tires And Wheels (See FIGURE 13.) Check the tires for damage. Check the tread and remove any objects that will cause damage. Check for bent or damaged rims. Check for loose or missing hardware. Re- move any wire, strapping or other material that is wrapped around the axle.

  • Page 79: Forks

    MAINTENANCE Forks Forks, Removal And Installation A fork can be removed from the carriage for replacement The identification of a fork is determined by how the fork is of the fork or other maintenance. connected to the carriage. The S70- -155XL series of lift trucks normally have hook forks.
  • Page 80 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 14. FORK LOCK PIN ASSEMBLY...
  • Page 81 MAINTENANCE WARNING 1. CARRIAGE BARS Do not try to install a fork without a lifting device. 2. HOOK FORK 3. BLOCKS Each hook fork for these lift trucks can weigh 66 kg to 183 kg (145 to 402 lb). Hook Fork (Installation). Move the fork and carriage so that the top hook on the fork can engage the upper car- riage bar.

  • Page 82: Inspection Of Forks, Mast, And Lift Chains

    MAINTENANCE Inspection Of Forks, Mast, and Lift Chains 1. Inspect the welds on the mast and carriage for cracks. Make sure that the capscrews and nuts are tight. (See FIGURE 16. and FIGURE 17.) 2. Inspect the channels for wear in the areas where the WARNING rollers travel.
  • Page 83 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 84: Safety Labels

    MAINTENANCE 7. Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains. 8. Inspect the lift chains for cracks or broken links and pins. (See FIGURE 17.) 9. Inspect the chain anchors and pins for cracks and dam- age.

  • Page 85: Operator Restraint System

    MAINTENANCE Operator Restraint System (See FIGURE 19.) The seat belt, hip restraint brackets, seat and mounting, hood, latches and floor plates are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly and is in good condition.

  • Page 86: Hood And Seat Latches

    MAINTENANCE When the ELR style seat belt is properly buckled across • With the hood closed and in the locked position, pull the operator, the belt will permit slight operator reposition- the seat belt with a sudden jerk. Make sure the seat ing without activating the locking mechanism.
  • Page 87 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 S70- -120XL SHOWN GASOLINE AND DIESEL ARRANGEMENT LPG ARRANGEMENT 11858 FIGURE 19.

  • Page 88: How To Make The Checks With The Engine Running

    MAINTENANCE HOW TO MAKE THE CHECKS WITH THE If engines are operated in confined spaces ENGINE RUNNING maintain adequate ventilation or vent exhaust to the outside. Do not exceed applicable air contaminant limits. WARNING Follow the inspection and maintenance Exhaust from internal combustion engines contains schedule and procedures in this manual.

  • Page 89: Gauges, Lights, Horn And Fuses

    MAINTENANCE Gauges, Lights, Horn And Fuses Start the engine. Check the gauges and lights for correct operation as described in TABLE 1. Check the operation of the horn. If any of the lights or gauges do not operate correctly, check the fuses. The fuses are under the instru- GAGES LIGHT HORN...
  • Page 90 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 21. ENGINE COMPARTMENT FUSES AND RELAYS, GM 4.3L ENGINE (S135--155XL, S135--155XL AND S135XLS [C024] TRUCKS ONLY)
  • Page 91 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 22. ENGINE COMPARTMENT FUSES AND RELAYS, PERKINS 1104C--44 (RE) DIESEL ENGINE (S135--155XL, S135--155XL AND S135XLS [C024] TRUCKS ONLY)

  • Page 92: Oil Level, Powershift Transmission

    MAINTENANCE Oil Level, Powershift Transmission when the transmission is at operating temperature. (See FIGURE 23.) Oil Level, Oil Clutch System, S135- -155XL (B024) (See FIGURE 23.) Apply the parking brake. Check the oil level in the power- shift transmission when the oil is warm and the engine is Put the direction control lever in the NEUTRAL (N) posi- running at idle speed.

  • Page 93: Control Levers And Pedals

    MAINTENANCE S135-- 155XL 11638 1. DIPSTICK FOR POWERSHIFT TRANSMISSION OIL S70-- 120XL OR OIL CLUTCH SYSTEM OIL 2. DIPSTICK FOR POWERSHIFT TRANSMISSION 11703 3. FLOOR PLATE FIGURE 23. TRANSMISSION DIPSTICK LOCATIONS Control Levers and Pedals TABLE 3. Check that the pedals operate as described in TABLE 2.

  • Page 94: Lift System Operation

    MAINTENANCE Lift System Operation height at least once. The mast components must raise and lower smoothly in the correct sequence. WARNING 3. The inner weldments and the carriage must lower Lower the lift mechanism completely. Never allow completely. anyone under a raised carriage. Do not put any part 4.

  • Page 95: Service Brakes

    MAINTENANCE switch in the starting circuit is closed so that the engine Parking Brake 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 96: How To Add Fuel To The Lift Truck

    MAINTENANCE HOW TO ADD FUEL TO THE LIFT TRUCK Do not store LPG tanks near heat or open flame. Do not park the lift truck near heat or ignition sources. For complete instructions on the storage of LPG WARNING fuels, refer to ANSI/NFPA 58 & 505. Stop the engine.
  • Page 97 MAINTENANCE 3. See FIGURE 24. Turn the tank fuel valve clockwise 1. Before the LPG tank is installed on the lift truck, until the valve is completely closed. check the operation of the fuel gauge. Look at the fuel gauge and move the tank. If the gauge needle 4.
  • Page 98 MAINTENANCE Use the following procedure to fill the LPG tank: WARNING Read and follow all the refueling precautions and in- structions under Liquified Petroleum Gas (LPG). NOTE: The following instructions are general procedures. There is a variation in equipment for filling LPG tanks. The Use only local authorities that have jurisdiction have specific rules this hole...

  • Page 99: Gasoline Or Diesel Fuel

    MAINTENANCE 5. Open the vent valve on the liquid level indicator. 12. Stop the pump. 13. Close liquid outlet valve and by--pass return valve 6. Open the tank fuel valve. on the storage tank. 7. Open the valve on the end of the supply hose. Gasoline Or Diesel Fuel 8.

  • Page 100: Wheels And Tires

    MAINTENANCE WHEELS AND TIRES HOW TO CHANGE A SOLID RUBBER TIRE UNIT S70--80XL, S135--155XL When new solid rubber tires (press--on) must be installed, put the lift truck on blocks and remove the wheel. The cor- S100--120XL 25.4 mm (1.0 in) rect tools, equipment and a press ring must be used for 1.

  • Page 101: Install The Wheels

    MAINTENANCE INSTALL THE WHEELS OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE CAUTION Check all wheel nuts after 2 to 5 hours of operation: A new or rebuilt engine must be operated under special when new lift trucks begin operation and on all lift conditions during the first 50 hours.
  • Page 102 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 con- tains and/or emits chemicals known to the State of California to cause cancer, birth de- fects, or other reproductive harm.

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