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Tire Removal, Three- and Four-Piece Wheels

WARNING

Make sure all of the air pressure is removed from the
tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode caus-
ing serious injury or death.

Keep tire tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
an injury.

1.

Loosen the tire bead from

the side flange.

2.

Put the tire tool into the slot

between the lock ring and wheel
rim. Remove the lock ring and
side flange. If there is a flange
seat, remove it.

3.

Loosen the bead from the other

side of the wheel rim. Remove the
valve stem from the wheel.

Maintenance

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Summary of Contents for H40-60XT

Page 1: ...OPERATING MANUAL H40 60XT A380 DO NOT REMOVE THIS MANUAL FROM THIS UNIT PART NO 4150900 3 19...

Page 2: ...SERIAL NUMBER GROUP NUMBER GROUP NUMBER STEERING TIRE SIZE SPECIAL EQUIPMENT OR ATTACHMENTS Hyster Company 2019 All Rights Reserved HYSTER FORTIS MONOTROL and YARDMASTER are Registered Trademarks of H...

Page 3: ...t truck alone It is the responsibility of the employer to make sure that the operator can see hear and has the physical and mental ability to operate the equipment safely Various laws and regulations...

Page 4: ...Industrial Operations from the National Safety Council Guide for Users of Industrial Lift Trucks Hyster Part No 852930 describes lift truck safety good maintenance practices and training programs and...

Page 5: ...S 56 Basic Operating Procedures 56 Driving and Direction Changes 61 General 62 Normal Operations 62 Standard Operator Presence System 63 Basic Powershift or Electronic Powershift Transmission 63 Inchi...

Page 6: ...int System 112 Emergency Locking Retractor ELR 116 Hood and Seat Latches 116 Engine Compartment 117 Ground Static Strap 117 Fuel Oil and Coolant Leaks Check 119 Hydraulic Hoses 119 Coolant Hoses 119 T...

Page 7: ...From Wheel 158 Install Tire on Wheel 159 Add Air to Pneumatic Tubeless Tire 163 Install the Wheels 163 SOLID RUBBER TIRES ON PNEUMATIC WHEELS CHANGE 164 Remove Tire From Wheel 164 Install Tire on Whe...

Page 8: ...ts for intended pur pose only VERIFY truck is equipped with overhead guard and load backrest adequate for the load LOOK WHERE YOU ARE GOING IF YOU CAN T SEE DON T GO TRAVEL in reverse if load blocks f...

Page 9: ...ionary object BEFORE DISMOUNTING neutralize travel control lower carriage and set brake WHEN PARKING also shut off power close LPG fuel valve block wheels on inclines KNOW THE AREA NEVER enter a trail...

Page 10: ...l or tilted slightly back Use minimum tilt when stacking elevated loads TRAVEL with carriage as low as possible and tilted back SLOW DOWN before turning especially without load FAILURE TO FOLLOW THESE...

Page 11: ...Model Description Figure 1 Model View Showing Major Components of H40 60XT Model Description 9...

Page 12: ...AKE AND REVERSE LIGHTS 3 SEAT 4 COUNTERWEIGHT 5 STEERING AXLE 6 SEAT BELT AND HIP RESTRAINT 7 DRIVE AXLE 8 CARRIAGE 9 FORKS 10 LOAD BACKREST EXTENSION 11 PARKING BRAKE 12 STEERING WHEEL 13 MAST 14 OPE...

Page 13: ...k toward operator It must be high enough with vertical openings small enough to prevent parts of the load from falling backward If a load backrest extension that is different from the one installed on...

Page 14: ...new capacity rating The capacity is specified in kilograms kg and pounds lb The capacity is the maximum load that the lift truck can handle for the load condition shown on the Nameplate The maximum ca...

Page 15: ...mportant that all safety labels are installed on the lift truck and can be read See Figure 3 All possible label configurations that can be on the lift trucks covered in this Operating Manual are not s...

Page 16: ...Figure 3 Warning and Safety Labels Sheet 1 of 3 Model Description 14...

Page 17: ...Figure 3 Warning and Safety Labels Sheet 2 of 3 Model Description 15...

Page 18: ...Figure 3 Warning and Safety Labels Sheet 3 of 3 Model Description 16...

Page 19: ...G 17 UL LABEL 18 ANTIFREEZE LABEL 19 BORON FREE LABEL 20 SPLIT WHEEL WARNING 21 DIESEL FUEL LABEL NOT SHOWN 22 BI FUEL SWITCH LABEL NOT SHOWN 23 ETHER WARNING DIESEL ONLY 24 STABILITY SYSTEM LABEL ON...

Page 20: ...Figure 4 Controls Model Description 18...

Page 21: ...7 CONTROL BUTTON PANEL 8 KEY SWITCH 9 LIGHT SWITCH TURN SIGNAL 10 LIFT LOWER LEVER 11 TILT LEVER 12 3RD AUXILIARY LEVER 13 4TH AUXILIARY LEVER 14 BRAKE PEDAL 15 INCHING BRAKE PEDAL 16 ACCELERATOR PEDA...

Page 22: ...ake Lever Parking Brake to be on when lift truck is parked Pull parking brake lever backward all the way to set it Push the top button to release the lock while pulling on the lever and push lever for...

Page 23: ...ipment and for safety NOTE This truck series has a safety alarm If the operator leaves the operator seat with the Direction Control lever not in neutral an alarm will sound even with the key switch OF...

Page 24: ...Column Tilt A Lock B Release Lock CAUTION Adjust the steering wheel when the lift truck is stopped as adjustment during travel is dangerous Adjust steering wheel as needed 4 Steering Wheel The steerin...

Page 25: ...tor lights The display also shows operator messages for the different functions All programmed warning and indicator lights will light up for two seconds Start Check when System Power is turned ON 7 C...

Page 26: ...t The key switch is on the right side of the steering column near the cowl The key switch has three positions 1 OFF position De energizes all electrical circuits except for the horn 2 ON position Ener...

Page 27: ...is turned for ward the light is turned ON When the switch is turned backward the light is turned OFF 9 Turn Signal Lever To indicate the turning direction of the lift truck push the turn signal lever...

Page 28: ...ers are standard on the trucks covered in this man ual Optional electronic hydraulic mini levers are available for the hydraulic functions NOTE To operate the mini levers the operator must be on the s...

Page 29: ...e mini levers the operator must be on the seat The tilt control lever can be either the second manual lever or second mini lever to the right of the operator s seat Push the lever forward to tilt the...

Page 30: ...o operate the truck in accordance with load handling instructions as described in Operating Techniques on the Operating Procedures section of this Operating Manual 12 Manual Control Lever for 3rd Auxi...

Page 31: ...ments the last 3rd lever controls clamp functions Control Lever with a Detent Attachments with a clamp action The lever is spring loaded toward the operator The lever is operated by moving it to the r...

Page 32: ...mp functions NOTE Third lever on four function control cannot have clamping The last 4th lever controls clamp functions The third electronic control mini lever is installed to the right of the electro...

Page 33: ...tachment the last 4th lever controls clamp functions The fourth control lever is installed to the right of the third manual control lever This lever can have two methods of operation depending on the...

Page 34: ...p functions The fourth electronic control mini lever is installed to the right of the third electronic control mini lever This lever can have two methods of operation depending on the attachment Truck...

Page 35: ...th lever controls clamp functions The fifth function is controlled by using the fourth electronic control mini lever If lift truck is equipped with a clamp attachment the last 4th mini lever controls...

Page 36: ...engage the fourth func tion toggle in the yellow override button located directly behind the third lever To engage the third function toggle out the override button After selecting desired func tion...

Page 37: ...d Direction Control Lever is in neutral 16 Accelerator Pedal This pedal controls the speed of the engine and is operated by the operator right foot 17 MONO TROL Pedal The MONOTROL Pedal controls the s...

Page 38: ...ion is in the ON posi tion and up to 20 minutes after the key or keyless ignition is turned to the OFF posi tion 19 Direction Control Switch The direction control switch for the transmission is next t...

Page 39: ...tem No Item Function 20 Traction Speed Limiter Light For lift trucks equipped with a Yanmar engine and traction speed limiter this light will illuminate if the traction speed limiter is not working pr...

Page 40: ...kward Forward Backward Forward 4 ROTATE Clockwise Counterclockwise Backward Forward 5 UPENDER Up Down Backward Forward 6 SCOOP Up Down Backward Forward 7 LOAD STABILIZER Down Clamp Up Release Backward...

Page 41: ...arning and indicator lights on the Display will vary and may not contain all the warning and indicator lights shown in Figure 5 and Table 2 When the warning lights and indi cators are on the operator...

Page 42: ...Figure 5 Dash Display Warning and Indicator Lights Model Description 40...

Page 43: ...GE 6 TORQUE CONVERTER OIL TEMPERATURE 7 WARNING 8 MAINTENANCE REQUIRED 9 DISPLAY CHANGE BUTTON FOR CLOCK 10 DISPLAY CHANGE BUTTON FOR HOUR METER 11 MODE CHANGE BUTTON 12 CONTROL BUTTON PANEL 13 COOLAN...

Page 44: ...he bottom bar a warning buzzer beeps 2 Sedimenter Diesel Only This amber indicator light will illuminate if the fuel water separator sensor indicates that water must be drained Not on at Start Check 3...

Page 45: ...ne is running 6 Torque Con verter Oil Tem perature Warning CAUTION Do not continue to operate the lift truck if the icon is ON when the engine is run ning Make sure the oil level is correct and add fl...

Page 46: ...the display changes to show operating information about the truck Each screen will show either the date and the hours recorded on that date or a fault and the hourmeter reading at which it occurred 1...

Page 47: ...this button at the same time as the Display Change Buttons will activate a different item on the display for adjustment The item will blink until changed Pressing this button once will return the disp...

Page 48: ...ine has been warmed up and the bare gauge starts raising When the bar gauge reaches around the middle bar the water temperature is optimum 14 Alarm Set The icon is ON when the alarm is on 15 Hour Mete...

Page 49: ...ion 17 Seat Belt WARNING Always fasten the seat belt when operating the lift truck The icon flashes for 10 seconds anytime the key switch is put in the ON position If the seat belt interlock option is...

Page 50: ...exposure to engine exhaust If engines are operated in confined spaces maintain adequate ventilation or vent exhaust to the outside Do not exceed applicable air contaminant limits see 29 CFR 1910 1000...

Page 51: ...classified as hazardous must be identified by signs to show the type of approved lift truck required for operation in the area Modifications or poor maintenance can result in the lift truck being uns...

Page 52: ...ined CG The lift truck has moving parts and therefore has a CG that moves The CG moves forward and back as the mast is til ted forward and back The CG moves up and down as the mast moves up and down A...

Page 53: ...ward of the drive axle the lift truck will tip forward If the CG moves outside of the line represented by the lines drawn between the drive wheels and the steer ing axle pivot the lift truck will tip...

Page 54: ...s area stating DO NOT OPERATE and remove the key from the key switch if truck is equipped with key switch option Checks With the Engine Stopped Inspect the lift truck before use and every eight hours...

Page 55: ...VE INTERLOCKS Traction is enabled when the opera tor is in the seat occupancy sensor seat belt should be fastened a direction of travel is selected engine is running and the parking brake is released...

Page 56: ...parking brake is applied 3 Put direction control lever for transmission in NEUTRAL position 4 Make sure lift truck hood is closed 5 Turn key to the ON position If lift truck is equipped with a diesel...

Page 57: ...ruck frame and over head guard if a tipover occurs This protection system is intended to reduce the risk of the head and torso being trapped between the truck and the ground but it can not protect the...

Page 58: ...to a sudden stop the locking mechanism will be activated and hold the operator s lower torso in the seat Basic Operating Procedures Many people make the mistake of thinking that operating a lift truck...

Page 59: ...pe cially built to meet or exceed the requirements of ANSI ITSDF B56 1 It must have a solid floor with a surface to prevent the feet of the worker from slipping hand rail toe board and screen or shiel...

Page 60: ...e midpoint of the 80 mm 3 15 in suspension See Figure 6 The handle can be turned counterclockwise to increase or clockwise to decrease the weight resistance pull han dle out before turning As the hand...

Page 61: ...with feet positioned on pedals This ensures that the opertor is set at the midpoint of the 80 mm 3 15 in suspension The handle can be turned as shown to increase or decrease weight resistance Pull han...

Page 62: ...Figure 6 Seat Adjustment Operating Procedures 60...

Page 63: ...elevator set the brakes put the controls in NEUTRAL and shut off the power It is advisable that all other personnel leave the elevator before the lift truck enters or leaves 6 Drive carefully observe...

Page 64: ...SE If the truck has a direction control lever move the lever toward the front of the lift truck to go FORWARD and toward the rear of the lift truck to go in REVERSE Normal Operations In normal operati...

Page 65: ...is in the seat This feature also locks out lift and tilt functions The OPS is designed with slight delay in the seat sensor to allow the operator to reposition himself without disengaging the transmi...

Page 66: ...rol WARNING Inching requires coordinated movement of the inching brake pedal and the accelerator pedal New operators must practice this procedure before attempting to han dle loads Inching is the move...

Page 67: ...ic forces are present In fact the lift truck will actually tip over easier when empty than when loaded with the load lowered Mast tilt off center loads and uneven ground will aggravate these condition...

Page 68: ...ad Handling General 1 The capacity is the maximum load that the lift truck can handle for the load condition shown on the Nameplate The operator must know whether or not a load is within the maximum c...

Page 69: ...enter the weight of the load between the forks 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...

Page 70: ...on the operator or a 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 can not...

Page 71: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause serious injury Lift and lower with the mast vertical or tilted slig...

Page 72: ...s tilted forward with a load in the raised position IF THE LIFT TRUCK TIPS OVER DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM POINT OF IMPACT Load Handli...

Page 73: ...REFUL OF FORKS BEYOND THE LOAD If the forks are longer than the load move the forks under the load so that the tips of the forks do not extend beyond the load Lift the load from the surface Move backw...

Page 74: ...ift 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 When the load is elevated the center of gravity of the lift truc...

Page 75: ...Carefully move the lift truck backward to remove the forks from under the load Lower the forks when traveling NOTE Not every load can be lifted using only the forks of a lift truck Some loads will req...

Page 76: ...mirrors for viewing along the side to observe the tail swing area These mirrors are an aid to the driver but are NOT driving mirrors and must NOT be used as such when operating in reverse Always look...

Page 77: ...he area and to be alert to possible danger 6 Anytime the lift truck is moving keep arms legs etc inside the operator s compartment Arms and legs outside the machine can be injured when passing obstruc...

Page 78: ...he load the operator can hit an object or lift another load Serious accidents can be caused by mast and overhead guards hitting pipes and beams near the ceil ing 9 DO NOT indulge in stunt driving or h...

Page 79: ...as a zero value of load weight sensor Each HEX bit is equivalent to about 7 kg 2 2 lb To calculate weight stored for zero value convert A D value from HEX to decimal format then multiply by 7 For exa...

Page 80: ...Calibratons Procedures 8000SRM2003 Controller Setting for procedures Load Meter Your lift truck may be equipped with an optional load meter The load meter calculates mast pressure and converts that pr...

Page 81: ...milar working surfa ces Watch the tail swing Remember when traveling in the forward direction and the steering wheel is turned to move the lift truck away from the edge of the dock the rear will swing...

Page 82: ...nloading Make sure that the rail cars brakes are set and the wheels are blocked while loading or unloading Do this check so that the rail cars will not move due to the move ment of the lift truck in a...

Page 83: ...OFF posi tion 2 Disconnect the negative terminal of the battery 3 Move the manual hydraulic levers forward and backward to relieve the system hydraulic pressure 4 Disconnect the Quick Disconnect hose...

Page 84: ...1 QUICK DISCONNECT FITTINGS 2 HYDRAULIC TUBES Figure 9 Quick Disconnect Hoses Connections Operating Procedures 82...

Page 85: ...y to the OFF position to stop the engine 5 To release seat belt press red release button and guide belt carefully back into retractor with your hand 6 If the lift truck must be left on an incline put...

Page 86: ...cation and maintenance for your lift truck The service intervals are given in both operating hours recorded on the lift truck hour meter and in calendar time Use the interval that occurs first The rec...

Page 87: ...d lift truck or towing vehicle to slide A slope will also make the lift truck more difficult to stop Never lift and move a disabled lift truck unless the dis abled lift truck MUST be moved and cannot...

Page 88: ...engine and transmission and the counterweight When the lift truck is put on blocks put additional blocks in the following positions to maintain stability 1 Before removing the mast and drive axle put...

Page 89: ...How to Raise the Steering Tires See Figure 10 1 Apply the parking brake Put blocks on both sides front and back of the drive tires to prevent movement of the lift truck 2 Use a hydraulic jack to raise...

Page 90: ...1 DRIVE TIRES 2 STEERING TIRES Figure 10 Put a Lift Truck on Blocks Maintenance 88...

Page 91: ...battery area and dash display during the cleaning process Portions of your lift truck may be washed with a non heated pressure washer Steam cleaning is not recommended in most instances as condensatio...

Page 92: ...Figure 11 Maintenance and Lubrication Points PSI 2 4L LPG Trucks Maintenance Schedule 90...

Page 93: ...Figure 12 Maintenance and Lubrication Points Yanmar 2 6L and 3 3L Diesel Trucks Maintenance Schedule 91...

Page 94: ...Figure 13 Maintenance and Lubrication Points PSI 2 4L Bi Fuel Trucks Maintenance Schedule 92...

Page 95: ...dition See Nameplate SAFETY LABELS X Replace as Necessary See Parts Manual 31 33 34 35 MAST CARRIAGE HEADER HOSES LIFT CHAINS AND ATTACHMENT X Check Condition and Lubrication See Parts Manual SEAT BEL...

Page 96: ...Parts Manual 9 COOLANT HOSES X Check Condition See Parts Manual 16 FUEL TANK PSI 2 4L LPG Engine CIL 29 9 liter 7 9 gal LPG HD 5 17 FUEL TANK Yanmar Diesel Engines CIL 69 liter 18 2 gal No 2 Diesel 1...

Page 97: ...OR CABLE C 1 Cable See Parts Manual 36 DRIVE AXLE X Check for Leaks Check Opera tion 36 DIFFERENTIAL AND DRIVE AXLE OIL X C 6 5 liter 6 9 qt See NOTE 14 SAE 80W 90 API GL 5 STEERING CONTROLS X Check O...

Page 98: ...ON OIL BREATHER C 1 Breather See NOTE 4 See Parts Manual 4 HYDRAULIC OIL X X C 30 liter 32 qt See NOTE 2 NOTE 3 and NOTE 12 ISO VG 46 Hydraulic Oil 20 C 4 F and Above 8 HYDRAULIC OIL RETURN FILTER C 1...

Page 99: ...10W 30 API SL ILSAC GF3 15 ENGINE OIL FILTER PSI Engine C 1 Filter See NOTE 4 and NOTE 5 See Parts Manual 14 ENGINE OIL Yanmar Engine X CIL C 10 2 liter 10 8 qt See NOTE 4 and NOTE 5 20 C 68 F and Ove...

Page 100: ...al 19 AIR FILTER X CIL C 1 Filter See NOTE 5 NOTE 6 and NOTE 10 See Parts Manual 13 DRIVE BELT PSI Engine X Check for Wear and Damage Adjust as Necessary 13 DRIVE BELT Yanmar Engine X Check for Wear a...

Page 101: ...M ENGINE GOVERNED SPEED No Load Yanmar Engine X 2625 25 RPM PCV Valve PSI Engine C Replace as Necessary See Parts Manual 23 VALVE ADJUSTMENT PSI Engine Not Adjustable 23 VALVE ADJUSTMENT Yanmar Engine...

Page 102: ...s Manual 21 FUEL WATER SEPARATOR FILTER Yanmar Diesel Engine CIL C 1 Filter Drain Water from Filter as Required See Parts Manual 21 IN LINE FUEL STRAINER Yanmar Diesel Engine C 1 Filter See Parts Manu...

Page 103: ...STEM Yanmar Engine X CIL C 11 5 liter 12 2 qt See NOTE 11 CLEAN DEBRIS FROM RADIATOR CORE X See NOTE 5 32 FORKS X X X Check Condition 32 FORK LATCHES L Lubricate as Necessary Multipurpose Grease See N...

Page 104: ...Lower Bearing Strips X L X C Lube as Required 2 Fittings for Upper Bearings and 2 Lower Bearing Strips Check Lower Bearing Strips for wear Multipurpose Grease See NOTE 7 See NOTE 9 0 mm 0 in Minimum T...

Page 105: ...L Use Silicone Spray Hyster Part No 328388 MANUAL HYDRAULIC HAND LEVERS L API SM ILSAC GF4 SAE J2362 29 BRAKE FLUID Master Cylinder X X C 0 2 liter 0 21 pt SAE J 1703 DOT 3 1 DRIVE AXLE Wheel Bearings...

Page 106: ...Spray Hyster Part No 328388 26 PARKING BRAKE ADJUSTMENT X Adjust as Necessary Must hold a Full Capacity Load on a 15 Grade 26 PARKING BRAKE L Lubricate as Necessary Use Silicone Spray Hyster Part No 3...

Page 107: ...ECT LOCK OFF FOR LEAKS AND ENSURE LOCK OFF CLOSING X TEST LPG GAS REGULATOR PRESSURE X CHECK AIR INDUCTION SYSTEM FOR LEAKS X CHECK MANIFOLD FOR VACUUM LEAKS X CHECK THROTTLE SHAFT FOR STICKING X CHEC...

Page 108: ...paper chemical or abrasive compounds poor ground conditions intensive usage at high perform ance levels or other abnormal conditions will require more frequent servicing At your request your Hyster de...

Page 109: ...ting conditions may allow for less frequent oil sampling Oil sampling should be done just prior to all oil and filter changes NOTE 13 Check fuel Injectors at 5000 hours or 7 years See PSI 2 4L Engine...

Page 110: ...the engine and apply the parking brake Open the hood and check for leaks and conditions that are not normal Clean any oil or fuel spills Ensure all surfaces are free of oils lubricants fuel and organ...

Page 111: ...1 CHECK FOR DAMAGE REMOVE NAILS GLASS AND OTHER OBJECTS FROM THE TREAD 2 MAKE SMOOTH EDGES 3 CHECK THE TIRE PRESSURE PNEUMATIC TIRES Figure 14 Check the Tires Maintenance 109...

Page 112: ...mast are completely lowered and the engine is STOPPED DO NOT try to correct the alignment of the fork tips by bending the forks or adding shims If either fork is damaged replace the forks as a set Ne...

Page 113: ...ift 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 worn or turned pins Lift chains must be replaced as a se...

Page 114: ...hip restraint seat hood and hood latches are all part of the operator restraint system see Figure 16 and Figure 17 Each item must be checked to make sure it is fastened correctly functions correctly a...

Page 115: ...Figure 16 Seat Check Maintenance 113...

Page 116: ...PENSION SEAT B STANDARD NON SUSPENSION SEAT C PREMIUM FULL SUSPENSION SEAT 1 HIP RESTRAINT 2 SEAT BELT 3 FORWARD BACKWARD ADJUSTMENT LEVER 4 WEIGHT ADJUSTMENT KNOB 5 BACKREST ANGLE ADJUSTMENT LEVER 6...

Page 117: ...1 LATCH STRIKER 2 BUMPER 3 HOOD 4 HOOD RELEASE HANDLE 5 HOOD LATCH 6 LIFT TRUCK FRAME 7 BOOT Figure 17 Hood and Hood Latch Check Maintenance 115...

Page 118: ...for a moment to remove slack from the belt in the retractor Release the seat belt Seat belt will retract and the internal latch will unlock If the seat belt cannot be pulled from the retractor assembl...

Page 119: ...rials Ground Static Strap If lift truck is equipped with a Ground Static Strap see Fig ure 18 check to be sure Ground Static Strap is securely in place and in contact with the ground Check attaching h...

Page 120: ...1 FRAME 2 PDM 3 GROUND STATIC STRAP 4 BATTERY Figure 18 Ground Static Strap Maintenance 118...

Page 121: ...and the condition of parts When fuel is added to the lift truck see the section How to Add Fuel to the Lift Truck Also check the condition of the radiator or heater hoses that are not leaking Soft or...

Page 122: ...The operation of the hydraulic pump without oil will damage the pump After the engine has stopped wait one minute before checking the oil level Keep hydraulic oil at the correct level as indicated on...

Page 123: ...hedule There is an indicator light for the engine oil pressure on the Dash Display During normal operation the red indicator light will illuminate when the key switch is turned to ON and will stay ill...

Page 124: ...COOLANT RESERVOIR 3 DRIVE BELT 4 RADIATOR CAP 5 AIR FILTER 6 FUEL FILTER 7 DIPSTICK ENGINE OIL 8 ENGINE OIL FILTER 9 ENGINE OIL FILL 10 FUEL INJECTOR Figure 20 Yanmar 2 6L Diesel Engine Maintenance P...

Page 125: ...T 3 RADIATOR CAP 4 AUXILIARY COOLANT RESERVOIR 5 AIR FILTER 6 ENGINE OIL FILTER 7 FUEL FILTER 8 DIPSTICK ENGINE OIL 9 FUEL INJECTOR 10 ENGINE OIL FILL Figure 21 Yanmar 3 3L Diesel Engine Maintenance P...

Page 126: ...4 DRIVE BELT 5 ENGINE OIL FILL 6 RADIATOR CAP 7 AUXILIARY COOLANT RESERVOIR 8 FUEL FILTER 9 ENGINE OIL FILTER 10 AIR FILTER 11 ENGINE OIL DRAIN PLUG 12 DIPSTICK ENGINE OIL Figure 22 PSI 2 4L LPG Engin...

Page 127: ...IVE BELT 6 RADIATOR CAP 7 LPG FUEL FILTER 8 AUXILIARY COOLANT RESERVOIR 9 ENGINE OIL FILTER 10 AIR FILTER 11 GASOLINE FUEL FILTER 12 ENGINE OIL DRAIN PLUG 13 DIPSTICK ENGINE OIL 14 INJECTOR Figure 23...

Page 128: ...ent Damage to forks and other carriage com ponents can occur if fork latch pins are not removed prior to using attachment NOTE Forks are to be replaced only in sets and not indi vidually NOTE If lift...

Page 129: ...1 OUTER FORK CARRIER 2 FORKS 3 INNER FORK CARRIER 4 SIDESHIFT CARRIAGE 5 FORK POSITIONER 6 CAPSCREWS 7 FORK REMOVAL NOTCH Figure 24 Fork Positioner Prior to December 2016 Maintenance 127...

Page 130: ...1 OUTER FORK CARRIER 2 FORKS 3 INNER FORK CARRIER 4 SIDESHIFT CARRIAGE 5 FORK POSITIONER 6 CAPSCREWS 7 FORK REMOVAL NOTCH Figure 25 Fork Positioner After December 2016 Maintenance 128...

Page 131: ...ly 1 Inspect the forks for cracks and wear Check that the fork tips are aligned as shown in Figure 27 Check that the bottom of the fork is not worn Item 4 in Figure 27 CAUTION Remove fork latch pins i...

Page 132: ...ion caliper at end of heel internal radius item 4 Figure 27 with opening corresponding to measured thickness of fork shank in Step a above e g for N 1 75 use N 1 75 opening This is typically the secti...

Page 133: ...m 1 42 in 1219 mm 48 in 37 mm 1 46 in 1372 mm 54 in 41 mm 1 61 in 1524 mm 60 in 45 mm 1 81 in 1829 mm 72 in 55 mm 2 17 in 1 TIP ALIGNMENT MUST BE WITHIN 3 OF FORK LENGTH 2 CRACKS 3 LATCH DAMAGE 4 HEEL...

Page 134: ...achment NOTE Forks are to be replaced only in sets and not indi vidually NOTE If lift truck is not equipped with a fork positioner go to Step 1 If lift truck is equipped with fork positioner go to Ste...

Page 135: ...onnected to the carriage by hooks and lock pins See Figure 26 and Figure 29 The lock pins are installed through the top fork hooks and fit into slots in the top carriage bar If pin does not remain eng...

Page 136: ...e sealed reservoir lid is properly replaced Replace the brake fluid in the system if there is dirt or water in the system On lift trucks with dry brakes only use SAE J 1703 DOT 3 brake fluid in the ma...

Page 137: ...Figure 30 Brake Fluid Reservoir Cover Maintenance 135...

Page 138: ...ea around the lift truck is clear before starting the engine or making any checks of the operation Be careful when making the checks If the lift truck is sta tionary during a check apply the parking b...

Page 139: ...Figure 31 PDM Showing Fuses and Relays Maintenance 137...

Page 140: ...ult if the engine is not running Loss of fluid from the brake fluid reservoir indicates a leak Repair the brake system before using the lift truck Replace the brake fluid in the system if there is dir...

Page 141: ...to ON and will stay illuminated until correct minimum oil pressure is obtained at which time the light will go off If the light con tinues to stay on when the engine is running the engine oil pressure...

Page 142: ...r protective goggles or a face shield to prevent injury to the eyes Check the radiator fins Clean the radiator with compressed air or water as needed Check for and remove any debris on the radiator co...

Page 143: ...ss all parts of the mast are completely lowered and the engine is STOPPED If the mast cannot be lowered use chains on the mast weldments and carriage so that they can not move Make sure the moving par...

Page 144: ...start option The operator must be off of the lift truck while fuel is added No Smoking All fuels for internal combustion engines are very flam mable Fill the fuel tank only in a designated area with g...

Page 145: ...e sparks or permit flammable material near the LPG system LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m 26 ft from any open flame motor vehicles electrical equipm...

Page 146: ...NOTE Lift trucks covered in this manual may be equipped with a steel LPG tank strap 5 Unlatch the tank strap and remove the LPG tank from the bracket Maintenance 144...

Page 147: ...OWN 1 LPG TANK 2 TANK STRAP 3 QUICK DISCONNECT FITTING 4 HYDROSTATIC RELIEF VALVE 5 LPG BULKHEAD BRACKET 6 FITTING 7 HOSE ASSEMBLY 8 LPG TANK BRACKET 9 LPG TANK PIN 10 TANK LATCH Figure 33 LPG Tank an...

Page 148: ...ank 3 Start the pump 4 Connect the supply hose to the quick disconnect fitting on the LPG tank see Liquefied Petroleum Gas LPG If the LPG tank has an auxiliary fill fitting connect the supply hose to...

Page 149: ...There are four methods used to inspect the fuel sys tem for leaks a Sound Listen for sound of LPG escaping from a tank fitting or hose connection b Smell LPG has a very distinctive odor If you smell...

Page 150: ...ype of tires on the lift truck If the truck is equipped with bias ply tires the ply rating lis ted on the Nameplate is the minimum ply rating that must be installed tire with ply ratings greater than...

Page 151: ...air is out of the inner tube Push a wire through the valve stem to make sure that the valve stem does not have a restriction 3 Remove the wheel nuts and remove the wheel and tire from the lift truck...

Page 152: ...A TWO PIECE WHEEL B OPTIONAL RIM ASSEMBLY C THREE PIECE WHEEL D FOUR PIECE WHEEL 1 WHEEL RIM 2 SIDE FLANGE 3 LOCK RING 4 FLANGE SEAT Figure 34 Types of Pneumatic Wheels Maintenance 150...

Page 153: ...the tire and rim parts to explode caus ing serious injury or death Keep tire tools in firm contact with the wheel parts If the tool slips it can move with enough force to cause an injury 1 Remove the...

Page 154: ...jury or death Keep tire tools in firm contact with the wheel parts If the tool slips it can move with enough force to cause an injury 1 Loosen the tire bead from the side flange 2 Put the tire tool in...

Page 155: ...r on the wheel Use a rub ber lead plastic or brass hammer to put parts together Make sure that the side ring is in the correct position The ends of the side ring must not touch The clearance at the en...

Page 156: ...dures Clean and inspect all parts of the wheel before installing the tire DO NOT use any damage or repaired wheel parts Make sure that all parts of the wheel are the correct parts for that wheel asse...

Page 157: ...Put the lock ring in the correct position on the rim Add air pres sure to the tire as described in Add Air to Pneumatic Tires With Tube Tire Installation Two Piece Wheel CAUTION DO NOT use pneumatic s...

Page 158: ...ation to stand away from the safety cage when air pressure is added to the tire WARNING DO NOT sit or stand by the safety cage DO NOT use a hammer to try and correct the position of the side flange or...

Page 159: ...and castle nut Tighten castle nut to 60 N m 44 lbf ft while wheel is rotated Loosen castle nut until hub turns freely with no end play Tighten castle nut to 3 0 to 6 0 N m 425 to 850 lbf in Install co...

Page 160: ...ved from the tire before a wheel is disassembled Air pressure in the tires can cause the tire and rim parts to explode caus ing serious injury or death Keep tire tools in firm contact with the wheel p...

Page 161: ...el assembly 5 Push the TBS toward the inside of the tire to remove it 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 p...

Page 162: ...during inflation or use 1 Clean interior and exte rior bead area of the tire Lubricate tire beads and the inside of the tire up to the tire shoulders Apply lubricant to entire under side of the TBS NO...

Page 163: ...plastic plug and insert into valve hole that will not be used 3 Place the TBS inside the tire making sure that the wings of the TBS are not fol ded over Make a mark on the tire to note the position o...

Page 164: ...ance band Ensure that it does not go in too far and damage the valve Position the arms of the press onto the loose flange Push down on press to depress the tire beads until the locking ring groove is...

Page 165: ...is added to the tire DO NOT sit or stand by the safety cage Add air to tire to the recommended pressure that is shown on the Nameplate Install valve cap to ensure air stays in the tire Figure 36 Add A...

Page 166: ...d Install cap for bearings Solid Rubber Tires on Pneumatic Wheels Change WARNING Wheels must be changed and tires repaired by trained personnel only Always wear safety glasses 1 Put the lift truck on...

Page 167: ...the tire away from the side flange 2 Put the tire tool into the slot between the lock ring and the wheel rim Remove the lock ring and side flange 3 Turn the tire over Put a support under the wheel rim...

Page 168: ...NOT mix type of tires type of tire tread or wheel assemblies of different manufacturers on any one lift truck DO NOT use a steel hammer on the wheel Use a rub ber lead plastic or brass hammer to put p...

Page 169: ...eel rim Put the cage in position on the tire Use the press to install the tire on the wheel rim 3 Remove the cage and put the flange seat if used the side ring and the lock ring in position on the whe...

Page 170: ...work conditions are slow and the loads are less than 50 of the truck capacity a simulated work condition must be used during the first four hours of operation Oper ate the lift truck with a minimum lo...

Page 171: ...rminal of discharged battery and negativejumper cable to negative terminal 2 Always connect jumper cable that is the ground cable last 3 Always connect jumper cables to discharge lift truck bat tery b...

Page 172: ...our lift truck for storage from one to six months 1 Check lubricant and fluid levels Completely fill the fuel tank Make sure the coolant mixture will protect cooling sys tem and engine to lowest tempe...

Page 173: ...tteries that are stored for long periods can become damaged Either keep batteries in service or follow the battery storage procedures below 4 Spray exterior surfaces and frame with preservative coatin...

Page 174: ...for more than 30 days 1 Give an equalizing charge prior to placing new batteries in storage Used batteries are to be fully charged then allowed to balance for approximately three more hours 2 Neutrali...

Page 175: ...HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT Before the lift truck is moved on a transport check the selected route to make sure there is enough cl...

Page 176: ...ing brake 2 If the mast is mounted on the lift truck fully lower the forks or carriage Tilt the mast FORWARD until the tips of the forks touch the surface 3 Put the direction control lever for the tra...

Page 177: ...sories are turned OFF 6 Unload the lift truck Preparation for Use After being transported or stored the lift truck must be pre pared for use for proper operation All problems must be corrected before...

Page 178: ...NOTES 176...

Page 179: ...Spacer 3 19 12 18 7 18 12 17 10 17 5 17 3 17 1 17 11 16 10 16 7 16 5 16 4 16 3 16...

Page 180: ...OPERATING MANUAL H40 60XT A380 DO NOT REMOVE THIS MANUAL FROM THIS UNIT PART NO 4150900 3 19...

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