Hyster CHALLENGER H165XL Operating Manual
  1. Manuals
  2. Brands
  3. Hyster Manuals
  4. Forklifts
  5. CHALLENGER H165XL
  6. Operating manual
Hyster CHALLENGER H165XL Operating Manual

Hyster CHALLENGER H165XL Operating Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

OPERATING MANUAL
CHALLENGER
H165- -280XL [E007]
H300- -360XL [D019]
H330- -360XL- -EC [D019]
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
HYSTER COMPANY
PART NUMBER 897342

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CHALLENGER H165XL and is the answer not in the manual?

Questions and answers

Related Manuals for Hyster CHALLENGER H165XL

Summary of Contents for Hyster CHALLENGER H165XL

  • Page 1 OPERATING MANUAL CHALLENGER H165- -280XL [E007] H300- -360XL [D019] H330- -360XL- -EC [D019] DO NOT REMOVE THIS MANUAL FROM THIS UNIT HYSTER COMPANY PART NUMBER 897342...
  • 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

    Canada Material Handling Regulations NOTE: A comprehensive operator training program is avail- · understand the capabilities and limitations of the lift able from HYSTER COMPANY. For further details, contact truck. your dealer for HYSTER lift trucks. · This OPERATING MANUAL contains information neces-...
  • Page 4 897342 trucks. HYSTER Part No. · employment safety and health standards or regulations NOTE: HYSTER lift trucks are not intended for use on (Examples: “Occupational Safety and Health Stan- public roads. dards (USA)”, “Canada Material Handling Regulations”. NOTE: The following symbols and words indicate safety in- ·...

  • Page 5: Table Of Contents

    CONTENTS CONTENTS FOREWORD ........Checks With The Engine Running .
  • Page 6 CONTENTS HOW TO PUT A LIFT TRUCK Forks, Removal ......ON BLOCKS ....... Forks, Installation .
  • Page 7 CONTENTS Pneumatic Tires, Remove The Install the Wheels (See FIGURE 30.) ..Tire From The Wheel (See FIGURE 25.) ..HOW TO PUT INTERNAL COMBUSTION Pneumatic Tires, Install The ENGINE (I.C.E.) TRUCKS IN STORAGE .
  • Page 8 CONTENTS NOTES...

  • Page 9: Warning

    WARNING A WARNING label with this information must be on the lift truck.

  • Page 10: Warning

    WARNING NOTES...
  • Page 11 MODEL DESCRIPTION 1. OPERATOR COMPARTMENT AND CAB (OVERHEAD GUARD) H300- -360XL 2. CARRIAGE AND LOAD BACKREST 3. COUNTERWEIGHT 4. STEERING AXLE 5. DRIVE AXLE 6. MAST 7. HOOD 8. FORKS H165- -280XL 12438 FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS...

  • Page 12: Model Description

    MODEL DESCRIPTION MODEL DESCRIPTION GENERAL These lift trucks can be equipped with attachments such as fork positioners, a side--shift carriage or a container at- tachment. This Operating Manual covers the following models of lift trucks: OPERATOR PROTECTION EQUIPMENT (SEE FIGURE 1.) H165XL, H190XL, H210XL, H230XL, H250XL, H280XL The OVERHEAD GUARD or CAB is intended to offer rea- H300XL, H330XL, H360XL...

  • Page 13: Nameplate

    FIGURE 2. If your lift truck has this type of decal, do NAMEPLATE not operate the lift truck. Contact your HYSTER lift TRUCK MODEL Serial no. truck dealer to obtain a complete nameplate.
  • Page 14 MODEL DESCRIPTION SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS FIGURE 3. WARNING AND SAFETY LABELS (1 of 2)
  • Page 15 MODEL DESCRIPTION 1. WARNING, OPERATION MOVING MAST- 2. CASE WITH OPERATING MANUAL CRUSH POINTS 3. NAMEPLATE 4. NO RIDERS 5. OVERHEAD GUARD WARNING 6. WINDOW MATERIAL WARNING 7. NO ONE ON OR UNDER FORKS 8. TIPOVER WARNING 9. MAST WARNING 10.
  • Page 16 MODEL DESCRIPTION s1120 FIGURE 4. INSTRUMENTS...

  • Page 17: Instruments And Controls

    MODEL DESCRIPTION INSTRUMENTS AND CONTROLS WARNING If any of the instruments, levers, or pedals do not op- erate as described in the following tables, report the problem immediately. DO NOT operate the lift truck until the problem is corrected. TABLE 1. INSTRUMENTS (See FIGURE 4.) ITEM ITEM FUNCTION...
  • Page 18 MODEL DESCRIPTION ITEM ITEM FUNCTION The red light flashes when the transmission oil pressure is low or the oil is too Autoshift hot. The transmission shifts to Neutral (N) when the light comes on. This Transmission happens with the lever in any position. For emergency conditions, move the Warning Light key to the OFF position and then to the ON position to allow lift truck movement in first gear for 16 to 31 seconds (normally 30 seconds).
  • Page 19 MODEL DESCRIPTION ITEM ITEM FUNCTION This gauge indicates the amount of fuel in the fuel tank. Fuel Gauge (Diesel Only) The light will be ON when the key switch is ON and the engine is not running. Warning Light, The light must go OFF when the engine is running. Alternator CAUTION Do not continue to operate the lift truck if the red light is ON at engine...
  • Page 20 MODEL DESCRIPTION ITEM ITEM FUNCTION The red light is ON when the key switch is in the START position and must go Warning light, OFF when the engine is running. Transmission Oil Temperature CAUTION Do not continue to operate the lift truck if the red light is ON.
  • Page 21 MODEL DESCRIPTION s1119 FIGURE 5. SWITCHES...
  • Page 22 MODEL DESCRIPTION TABLE 2. SWITCHES (See FIGURE 5.) ITEM ITEM FUNCTION This knob controls the operation of the parking brake. Parking Brake Knob The square, yellow knob works as follows: With the knob pushed in, the (Some lift trucks have this type of knob.) parking brake is applied and the transmission with Monotrol control is in NEUTRAL.
  • Page 23 MODEL DESCRIPTION ITEM ITEM FUNCTION This light is illuminated when the parking brake is applied or when there is not Parking Brake enough air pressure to release the parking brake. Indicator Light Switch This switch controls the lights on the empty container attachment. Push on the front of the switch to turn the lights ON.
  • Page 24 MODEL DESCRIPTION ITEM ITEM FUNCTION This switch controls the front work lights or front drive lights, rear drive lights Light Switch and tail lights. Push on the front of the switch to turn the lights ON. Container Attachment The controls for the container attachment operate as follows: Controls Amber Lights (Top): The amber lights illuminate when the right and left ends of the attachment are set down on the container and the attachment is in position...
  • Page 25 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 and headlights. No. 2 Position: ON position. Energizes all electric circuits except the starter circuit. The key switch will be in this position during normal operation. No.
  • Page 26 MODEL DESCRIPTION ITEM ITEM FUNCTION Heat Control This knob controls the heater valve. When the knob is pushed to the left, the Knob heater valve is closed (no heat). When the knob is pushed to the right, the heater valve is open and hot water enters the heater (heat to the cab). This switch controls the fan for the heater and defroster system.
  • Page 27 MODEL DESCRIPTION 5 or FIGURE 6. CONTROLS...
  • Page 28 MODEL DESCRIPTION TABLE 3. CONTROLS (See FIGURE 6.) ITEM ITEM FUNCTION Autoshift If the lift truck does not have a Monotrol pedal, travel direction is controlled by the Autoshift lever. Move the Autoshift lever to the Forward (F) position to travel Control Lever in the forward direction.
  • Page 29 MODEL DESCRIPTION ITEM ITEM FUNCTION Steering Wheel The steering wheel controls the position of the steer tires. The lift/lower lever is the first control lever to the right of the steering wheel. Pull Lift/Lower back on the lever to raise the carriage and forks. Push the lever forward to Control lower the carriage and forks.
  • Page 30 MODEL DESCRIPTION ITEM ITEM FUNCTION Extend/Retract Push the lever forward to extend the attachment to the 40 foot position. Pull Control Lever back on the lever to retract the attachment to the 20 foot position. (Used with Empty Container Attach- ment) MONOTROL The MONOTROL pedal controls the speed and direction of the lift truck.
  • Page 31 MODEL DESCRIPTION ITEM ITEM FUNCTION By varying the position of the inching/brake pedal, the operator can move the Inching/Brake lift truck slowly while a high engine speed is used for lifting loads. Completely Pedal depressing the pedal disengages the transmission and applies the service brakes.
  • Page 32 MODEL DESCRIPTION TABLE 4. AUXILIARY CONTROL LEVERS 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 SIDE- -SHIFT Right/Left Backward/Forward...

  • Page 33: Operating Procedures

    OPERATING PROCEDURES OPERATING PROCEDURES GENERAL WARNING Know Your Lift Truck FIRE HAZARD The hot engine surfaces and exhaust of internal com- WARNING bustion engine powered lift trucks can present fire EXHAUST GASES hazards when operating in areas containing flam- Exhaust from internal combustion engines contains mable gases, vapors, liquids, dusts or fibers.
  • Page 34 OPERATING PROCEDURES 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- truck.

  • Page 35: Stability And Center Of Gravity

    OPERATING PROCEDURES Stability And Center Of Gravity The lift truck has CG Load moving parts and therefore has a CG The center of gravity (CG) of any ob- that moves. The ject is the single point about which CG moves forward the object is balanced in all direc- and back as the tions.

  • Page 36: Capacity (Weight And Load Center)

    OPERATING PROCEDURES to the side easier than a loaded truck with its load in the The load center is specified in millimeters or inches. The lowered position. capacity is the maximum load that the lift truck can han- dle. This load must weigh less than the maximum weight In order for the lift truck to be stable (not tip over forward for a load center shown on the nameplate.

  • Page 37: Inspection Before Operation

    OPERATING PROCEDURES INSPECTION BEFORE OPERATION · Condition of forks, carriage, chains, mast, attachments and operator compartment. Checks With The · Leaks from the engine, transmission, hydraulic system Engine Stopped and fuel system. · Condition of wheels and tires. Check air pressure in Inspect the lift truck before use and every eight hours or pneumatic tires.

  • Page 38: Starting Procedures, Lpg Engine

    OPERATING PROCEDURES 1. Make sure the parking brake is applied. 4. If the engine does not start after four attempts, get help from authorized service personnel. 2. On units without a monotrol pedal, put the autoshift 5. When the engine is running, check the gauges and in- control lever in the N (Neutral) position.

  • Page 39: Shutdown Procedures, Turbo Engines

    OPERATING PROCEDURES CAUTION Checks With The Do not engage the starter for more than 30 seconds Engine Running at a time. If the engine does not start, turn the key switch to OFF. Wait 60 seconds before engaging the starter again. WARNING 5.
  • Page 40 OPERATING PROCEDURES The operator must be aware that the lift truck can tip over. WARNING There is a great risk that the operator or someone else Exhaust from internal combustion engines contains can be killed or injured if trapped or hit by the lift truck as carbon monoxide and other harmful chemicals.

  • Page 41: Operating Techniques

    OPERATING PROCEDURES OPERATING TECHNIQUES Check the operation of the following functions as de- scribed in the Periodic Checks and Maintenance section. WARNING Before operating the lift truck · Check the operation of the horn, gauges and indicator FASTEN YOUR SEAT BELT. lights.
  • Page 42 OPERATING PROCEDURES training, even if they have a license to drive an automo- driving and load handling techniques is absolutely neces- bile. sary to prepare the new operator for proper defensive driving and to expect the unexpected. The following discussion lists basic 2.
  • Page 43 OPERATING PROCEDURES and may not meet the requirements 3. NO RIDERS. A lift truck is built of ANSI A92.6 for lifting people. Do for only one person ---- the opera- not use a lift truck to lift people un- tor. It is dangerous for anyone to less it has been determined that ride on the forks or anywhere else there is no other practical option...

  • Page 44: Driving And Direction Changes

    OPERATING PROCEDURES 4. Do not drive a lift truck into an elevator unless author- Driving And Direction Changes ized to do so. Approach the elevator slowly. After the ele- The transmission can have either an Autoshift Control Le- vator is properly leveled, the ver with direction change function or an Autoshift Control Lever without the direction change function.

  • Page 45: Inching

    OPERATING PROCEDURES is moving rapidly, slow to a walking speed before chang- The inching/brake pedal (left--hand pedal) allows the di- ing the direction of travel. rection clutch in the transmission to slip and also applies the service brakes. When the inching/brake pedal is par- WARNING tially applied, the clutch in the transmission is partially dis- Do not start to move the lift truck until the air pres-...

  • Page 46: Steering (Turning)

    OPERATING PROCEDURES namic forces are present. In fact, the lift truck will ac- WARNING tually tip to the side easier when empty, than when Inching requires coordinated movement of the inch- loaded with the load lowered. Rearward tilt, off- -cen- ing/brake pedal and the accelerator.

  • Page 47: Load Handling, General

    OPERATING PROCEDURES steers with the left hand. The right hand is used to oper- ate the lift, tilt, and attachment controls. “TAIL SWING” When turning the lift truck from a wide aisle into a narrow WARNING aisle, start the turn as close to the opposite stock pile as Failure to observe the tail swing area when making a tail swing will permit.
  • Page 48 OPERATING PROCEDURES However, such factors as weak floors, uneven terrain, or mum support of the load. Center the weight of the load loads having a high center of gravity can mean that the between the forks. safe working load is less than the rated capacity. When such conditions exist, the operator must reduce the load so that the lift truck will remain stable.

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

    OPERATING PROCEDURES Load Handling, Lifting, Lowering And Tilting Remember, a lift truck equipped with a HYSTER over- head guard provides reasonable protection to the operator The LIFT and TILT functions are controlled by separate from falling objects, but cannot protect against every pos- levers.
  • Page 50 OPERATING PROCEDURES This warning applies not only to WARNING the operator but also a helper. A MOVING MAST- The lift truck can tip over forward when the load is helper must not be near the load or CRUSH POINTS raised. Forward tipping is even more likely when tilt- lift mechanism while the operator ing forward, braking when traveling forward or accel- is attempting to handle a load.

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

    OPERATING PROCEDURES Approach the load carefully. Make sure that the truck is perpendicular to the load. Raise the forks to the proper height for engaging the load. 2. Move forward slowly until the forks are in posi- tion under the load. The IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! forks must support at HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR...
  • Page 52 OPERATING PROCEDURES mast backward just far enough to lift the load from the surface. Be Careful of Forks 4. If the load is being removed from a stack, slowly move Beyond the Load the lift truck away from the stack. When the load is clear of the stack, lower the load for traveling.
  • Page 53 OPERATING PROCEDURES the control lever. Lower slowly and smoothly. Slowly re- turn the control lever to the neutral position so that the load is not dropped or that the lift truck is not tipped over due to the rapid stop of the load. WARNING Move carefully and smoothly when the load is raised over a stack.

  • Page 54: Load Handling, How To Handle Empty Containers

    OPERATING PROCEDURES forward just enough to permit smooth removal of the forks Tilt the mast fully backward to help keep the load on the from under the load. Carefully move the lift truck back- forks. ward to remove the forks from under the load. Lower the forks when traveling.
  • Page 55 OPERATING PROCEDURES 2. Before using the container attachment, inspect the at- HOW TO PICK UP A CONTAINER tachment for damage and make sure all of the controls 1. When the engine is shut--off the lock pins extend. The operate as specified in Table 3. green lights on the control panel for the attachment will be illuminated when the lock pins are extended.
  • Page 56 OPERATING PROCEDURES The amber lights on the control panel will come on when sure the indicator flags for the lock pins are in the en- both ends of the attachment are in contact with the con- gaged position. See FIGURE 7. tainer.

  • Page 57: Load Handling, Traveling

    OPERATING PROCEDURES 3. Lower the container and attachment until the amber Load Handling, Traveling lights come on. 1. When traveling with the load lowered, keep the load against the carriage and the mast tilted fully backward. 4. Tilt the mast slightly forward. This will help keep the load on the forks and give good forward and side stability.
  • Page 58 OPERATING PROCEDURES of travel. Normally, direction of travel is determined by the 4. When traveling up or down a grade with a heavily loaded lift truck, the load should be kept upgrade to main- best visibility available to the operator. If the lift truck must tain control.
  • Page 59 OPERATING PROCEDURES pedestrians that there is a vehicle in the area and to be are designed to operate on relatively smooth surfaces. Lift alert to possible danger. trucks with pneumatic tires can adapt to more uneven ground. Always make sure you pick the smoothest route 6.

  • Page 60: Highway Trucks, Railroad Cars And Docks

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

  • Page 61: Attachments

    OPERATING PROCEDURES Before operating in a highway truck or railroad car, ob- Make sure the dockboard is secured, in good condition serve the following: and of the proper capacity. ATTACHMENTS S DO NOT use a lift truck to move a railroad car. If an attachment is installed on the lift S DO NOT use a lift truck to open or close the door on a truck, make sure the operating in-...

  • Page 62: Parking

    OPERATING PROCEDURES PARKING 5. If the lift truck must be left on an incline, put blocks on the down hill side of the wheels so that the lift truck can not move. The operator must never leave a lift truck in a condition so that it can cause damage and injury.

  • Page 63: Maintenance

    This section contains a MAINTENANCE SCHEDULE and MAINTENANCE SCHEDULE. Service Manuals are avail- the instructions for maintenance and inspection. able from your dealer for Hyster lift trucks to help users who do their own maintenance. The MAINTENANCE SCHEDULE has time intervals for inspection, lubrication and maintenance for your lift truck.

  • Page 64: Serial Number Data

    MAINTENANCE Serial Number Data Make sure the release bolt is engaged in the piston before the nut is tightened. On the H300--360XL models, the re- The serial number for the lift truck is on the nameplate lease bolt is permanently installed in the piston. and is stamped on the frame.

  • Page 65: How To Tow The Lift Truck

    MAINTENANCE e. The lift truck must be towed on a slope. How To Tow The Lift Truck NOTE: Disconnect the drive line before towing the lift If the engine cannot run, there is no power available truck if the engine or transmission are disabled. for the hydraulic steering system and the service brakes.

  • Page 66: How To Put A Lift Truck On Blocks

    MAINTENANCE HOW TO PUT A LIFT TRUCK ON BLOCKS NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the lift truck so that blocks can be in- WARNING stalled. The lift truck must be put on blocks for some types of How To Raise The Drive Tires maintenance and repair.

  • Page 67: How To Raise The Steering Tires (See Figure 8.)

    MAINTENANCE How To Raise The Steering Tires jack under the steering axle or frame to raise the lift truck. Make sure that the jack has a capacity of at least 2/3 of (See FIGURE 8.) the total weight of the lift truck as shown on the name- 1.
  • Page 68 MAINTENANCE 23 24 18 19 20 21 12 13 14 9 10 11 12473 FIGURE 9. MAINTENANCE POINTS (DIESEL ENGINE SHOWN)
  • Page 69 MAINTENANCE TABLE 5. MAINTENANCE SCHEDULE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. TIRES Check Condition See Parts Manual TIRE PRESSURE See Nameplate FORKS Check Condition MAST, CARRIAGE, ATTACHMENT Check Condition and Operation...
  • Page 70 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. COOLING SYSTEM 26.0 liter (27.5 qt) 50% water with 50% Ethylene Glycol RADIATOR HOSES Check Condition See Parts Manual DRIVE BELTS Check Condition...
  • Page 71 SAE 10W--30 See NOTES 1 & 2 See Parts Manual HORN, GAUGES, LIGHTS, Check Operation ALARMS, AND MIRRORS TRANSMISSION OIL Hyster Part No. 336830 28 liter (29 qt) HYSTER T--50 Hyster Part No. 336831 Hyster Part No. 336832 STEERING Check Operation...
  • Page 72 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. AIR TANK Drain Moisture DRIVE SHAFT 3 Fittings Multi--Purpose Grease See NOTE 4 STEERING AXLE See NOTE 4 TIE RODS 4 Fittings Multi--Purpose Grease...
  • Page 73 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. AIR FILTER, HEATER See Parts Manual Clean (See NOTE 3) WHEEL NUTS DRIVE WHEELS Check Torque 640 to 680 Nm (470 to 500 lb STEER WHEELS...
  • Page 74 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. PEDALS, LEVERS, LINKAGES, As Necessary Engine Oil CABLES, HINGES, SEAT RAILS ENGINE SPEED (DIESEL) Adjust as Necessary IDLE SPEED 725 to 775 rpm GOVERNED SPEED...
  • Page 75 MAINTENANCE ITEM ITEM 8 Hr./ 1000 2000 PROCEDURE OR SPECIFICATION Daily Hr./ Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 6 mo. 1 yr. FINAL FUEL FILTERS (DIESEL) See Parts Manual FUEL FILTER (LPG) See Parts Manual TRANSMISSION OIL FILTER 1 (See NOTE 1) See Parts Manual HYDRAULIC SYSTEM OIL FILTER...
  • Page 76 MAINTENANCE 12698 FIGURE 10. MAINTENANCE POINTS, EMPTY CONTAINER ATTACHMENT...
  • Page 77 MAINTENANCE TABLE 6. MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT (Item Numbers Reference FIGURE 10.) ITEM PROCEDURE OR SPECIFICATION ITEM 2000 Hr./ Hr./ Hr./ QUANTITY 2 mo. 2 mo. 1 yr. SIDE--SHIFT ROLLERS 8 Fittings Multi--Purpose Grease SIDE--SHIFT CYLINDER PINS 2 Fittings Multi--Purpose Grease LOCK PINS 2 Fittings...

  • Page 78: Maintenance Procedures

    MAINTENANCE MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY faces are free of oils, lubricants, fuel and organic dust or WARNING fibers (paper, wood, cotton, agricultural grass/grain, etc.). Do not operate a lift truck that needs repairs. Report Hydraulic System Oil (See FIGURE 14.) the need for repairs immediately.

  • Page 79: Engine Oil (See Figure 13. And Figure 11.)

    MAINTENANCE Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered and the engine is stopped. Add hydraulic oil only as needed. If more hy- draulic oil is added than the ”FULL” level, the hydraulic oil will leak from the breather during operation.

  • Page 80: Cooling System (See Figure 12.)

    MAINTENANCE Cooling System (See FIGURE 12.) WARNING DO NOT remove the pressure cap from the radiator when the engine is hot. When the pressure cap is re- moved from the radiator, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.

  • Page 81: Fuel System

    MAINTENANCE Check the condition of the radiator hoses and heater hoses. Fuel System WARNING All fuels are very flammable and can burn or cause an explosion. Do not use an open flame to check the fuel level or to check for leaks in the fuel system. If there is a leak in the fuel system, extra care must be used during the repair.

  • Page 82: Battery (See Figure 14.)

    MAINTENANCE Battery (See FIGURE 14.) WARNING The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the eyes must be flushed with water immediately.

  • Page 83: Pre--Cleaner For Engine Air Filter (See Figure 15.)

    MAINTENANCE If the batteries become discharged and require a boost from another charged battery, follow these procedures carefully: a. Always connect the positive jumper cable to the positive terminal of the discharged battery and the negative jumper cable to the negative terminal. b.

  • Page 84: Forks

    MAINTENANCE be less than 210 kPa (30 psi). Apply the air from the in- To inspect the element, put a bright light inside and look side to the outside of the element. for holes or other damage. If the element is damaged, re- place it with a new element.

  • Page 85: Forks, Installation

    MAINTENANCE tainers for the fork pins and push the pins from the car- carriage. riage. Move the lift truck away from the forks. 2. Slowly move the lift truck toward the forks until the fork Forks, Installation pins can be installed. Install the fork pins, fork guides and 1.

  • Page 86: Inspection Of Forks, Mast And Lift Chains (See Figure 17. And Figure 18.)

    MAINTENANCE Inspection Of Forks, Mast And Lift Chains 2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage. (See FIGURE 17. and FIGURE 18.) 3. Inspect the forks for cracks and wear. Check that the WARNING fork tips are aligned within 13 mm (0.5 in) of each other Never work under a raised carriage, forks or mast...

  • Page 87: Tires And Wheels (See Figure 19.)

    MAINTENANCE 9. Make sure the lift chains are adjusted so that they have equal tension. Adjustment or repair of the lift chains must be done by authorized personnel. Tires And Wheels (See FIGURE 19.) WARNING Air pressure in tires can cause tire and wheel parts to explode.
  • Page 88 MAINTENANCE to the tire that has low pressure so that the air pressures are equal. The air pressure of warm tires must always be equal to or greater than air pressures specified for cold tires. Check the tires for damage. Check the tread and remove any objects that will cause damage.

  • Page 89: Operator Restraint System (See Figure 20.)

    MAINTENANCE CAUTION 1. SEAT BELT Check all wheel nuts after 2 to 5 hours of operation 2. HIP RESTRAINT when new trucks are put into operation or when 3. SEAT RAIL 4. SEAT BELT RETRACTOR wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the MAINTENANCE SCHEDULE table.

  • Page 90: Safety Labels

    MAINTENANCE The seat rails must be securely attached to the mounting Make a visual check for leaks on and under the lift truck. surface. If possible, find and repair the leak at the source. Leaks often indicate a need for repair of damaged or worn com- Safety Labels ponents.

  • Page 91: 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. The fuses are under the instrument panel on the left side. (See FIGURE 21.) Control Levers And Pedals Check that the control levers for the transmission, mast and attachment operate as described in Tables 2 and 3.

  • Page 92: Lift System Operation

    MAINTENANCE Lift System Operation WARNING Lower the lift mechanism completely. Never allow anyone under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED.

  • Page 93: Brakes

    MAINTENANCE Do the following checks and inspections: f. Check that the controls operate the functions of the attachment correctly. (See the symbols next to each of the controls.) Make sure all of the hydraulic a. Check for leaks in the hydraulic system. Check the lines are connected correctly and do not leak.

  • Page 94: Steering Column Latch

    MAINTENANCE Steering Column Latch Breathing fuel vapor may cause nausea, uncon- sciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Make sure the latch for the steering column operates cor- Avoid breathing vapor. rectly.
  • Page 95 MAINTENANCE Do not store LPG tanks near heat or an open flame. WARNING For complete instructions on the storage of LPG fuels, refer to ANSI/NFPA 58 & 505. LPG tanks are heavy. The weight of an LPG tank can exceed the maximum recommended weight for safe LPG is extremely flammable.
  • Page 96 MAINTENANCE 1. FUEL VALVE 2. QUICK DISCONNECT FITTING 3. FUEL GAUGE 4. PLUG 5. LIQUID LEVEL INDICATOR 6. HOLE FOR ALIGNMENT PIN 7. TANK RELIEF VALVE 8. STEPS (REFERENCE) 9. LATCH AND STRAP 10. ACCESS PANEL 11. FRAME (REFERENCE) NOTE: Some LPG tanks have an auxiliary fill fitting instead of a plug for Item 4.
  • Page 97 MAINTENANCE f. Release the latch that holds the LPG tank in its d. Turn the fuel valve counterclockwise to open the bracket. Remove the LPG tank from the bracket. fuel valve. Use the following procedure to install the LPG tank: e.

  • Page 98: Tires And Wheels

    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 fit- m.

  • Page 99: Remove The Wheels From The Lift Truck

    MAINTENANCE Remove The Wheels From The Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. Completely remove the air pressure from the tire be- fore it is removed from the lift truck. If dual wheels 1.
  • Page 100 MAINTENANCE SEE WARNINGS STEP 1. Loosen the tire bead from the side ring STEP 3. Turn the tire over. Separate the tire from and/or lock ring. the wheel rim. STEP 2. Put the tire tool into the slot between the side STEP 4.

  • Page 101: Pneumatic Tires, Remove The Tire From The Wheel (See Figure 25.)

    MAINTENANCE 3. Remove the wheel nuts and remove the wheel from the Keep tire tools in firm contact with the wheel. If the lift truck. Be careful not to damage the studs when remov- tool slips, it can move with enough force to cause se- ing the wheels.
  • Page 102 MAINTENANCE 1. Clean and inspect all parts of the wheel. If the wheel WARNING has rust or corrosion, remove loose rust and corrosion Failure to follow the procedures can cause the wheel and paint the parts. assembly to explode and cause injury or death. Clean and inspect all parts of the wheel before in- 2.
  • Page 103 MAINTENANCE SEE WARNINGS STEP 1. Install the inner tube and the flap in the tire. STEP 3. Turn over the rim and tire. Put a block under the rim so that the rim is 8 to 10 cm (3 to 4 inches) above the floor.

  • Page 104: Add Air To The Tires (See Figure 27.)

    MAINTENANCE Add Air To The Tires (See FIGURE 27.) 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 to the tire, use a chuck that fas- tens onto the valve stem of the inner tube.

  • Page 105: Solid Rubber Tires, Remove The Tire From The Wheel (See Figure 28.)

    MAINTENANCE Solid Rubber Tires, Clean and inspect all parts of the wheel before in- Remove The Tire From The stalling the tire. DO NOT use any damaged or re- Wheel (See FIGURE 28.) paired wheel parts. Make sure that all parts of the NOTE: When disassembling the wheels, see FIGURE 24.
  • Page 106 MAINTENANCE STEP 3. Turn the tire SEE WARNINGS over. Put a support under the wheel rim. STEP1. Put the wheel Make sure the wheel rim rim on the bed of the is at least 150 to 200 mm press. Put the cage in (6 to 8 inches) from the position on the tire.
  • Page 107 MAINTENANCE SEE WARNINGS STEP 3. Remove the cage and put the flange seat (if STEP 1. Lubricate the used), the side flange and the wheel rim and the inner lock ring in position on the surface of the tire with wheel rim.

  • Page 108: Install The Wheels (See Figure 30.)

    MAINTENANCE Install the Wheels (See FIGURE 30.) 1. WHEEL RIM 2. HUB 1. Install the wheel on the hub. When dual wheels are 3. WHEEL STUD used, install the inner wheel so that it is tight against the 4. WHEEL NUT brake drum.

  • Page 109: How To Put Internal Combustion Engine (I.c.e.) Trucks In Storage

    MAINTENANCE HOW TO PUT INTERNAL COMBUSTION For safety and increased usable floor area, remove the forks and tag them with the truck serial number. ENGINE (I.C.E.) TRUCKS IN STORAGE Prior to operating a truck each month, make a visual in- Experience has taught that complications can arise as a spection for leaks or signs of deterioration.

  • Page 110: How To Put Batteries In Storage

    MAINTENANCE HOW TO PUT BATTERIES IN STORAGE b. Neutralize and clean the battery. Clean with a solu- tion of 16 ounces of baking soda to one (1) gallon Batteries are to be placed on a wooden pallet and stored of water. in a dry, moderately cool area.

  • Page 111: Changes To The Overhead Guard

    MAINTENANCE 1. Make sure the fluid levels of oil and coolant are correct. tion. High engine speeds with a light load can cause dam- age to the cylinders in the engine. 2. Start and run the engine at approximately one--half CHANGES TO THE OVERHEAD GUARD throttle for 30 minutes for the first operation.
  • Page 112 MAINTENANCE...
  • Page 113 MAINTENANCE NOTES...
  • Page 114 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.

This manual is also suitable for:

Challenger h210xlChallenger h190xlChallenger h280xlChallenger h360xlChallenger h330xlChallenger h300xl ... Show all

Table of Contents

Save PDF