Hyster S100XL Page 91 Operating Manual Download

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MAINTENANCE

FIGURE 22. ENGINE COMPARTMENT FUSES AND RELAYS, PERKINS 1104C--44 (RE) DIESEL ENGINE

(S135--155XL, S135--155XL

AND S135XLS [C024] TRUCKS ONLY)

HO190289

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

Property of American Airlines

Summary of Contents for S100XL

Page 1: ...S80XL S80XL BCS S100XL S120XLS S120XL D004 S135XL S155XL S155XLS S135XL2 S155XL2 B024 C024 DO NOT REMOVE THIS MANUAL FROM THIS UNIT SPACESAVER HYSTER COMPANY PART NO 897366 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 2: ...ortist Fortenst Pacesetter VSMt DuraMatcht Spectrumt TouchPointt TouchControlt 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 ...

Page 3: ... the operator can see hear and has the physical and men tal ability to operate the equipment safely Various laws and regulations require the employer to train lift truck operators These laws and regulations include Occupational Safety and Health Act USA Canada Material Handling Regulations NOTE A comprehensive operator training program is available from HYSTER COMPANY For further details contact y...

Page 4: ... B56 1 Safety Standard For Low Lift And High Lift Trucks publications from government safety agencies government insurers private insurers and private organizations Example Accident Prevention Manual For Industrial Operations from the National Safety Council NOTE Hyster lift trucks are not intended for use on public roads NOTE The following symbols and words indicate safety information in this man...

Page 5: ...gine Running 28 OPERATING TECHNIQUES 29 Basic Operating Procedures 29 Driving And Direction Changes 32 Operator Presence System 33 Inching 33 Steering Turning 34 Load Handling General 36 Load Handling Lifting Lowering And Tilting 38 Load Handling How To Engage And Disengage A Load 40 Load Handling Traveling 43 HIGHWAY TRUCKS RAILROAD CARS AND DOCKS 47 ATTACHMENTS 49 STOPPING 49 PARKING 49 MAINTENA...

Page 6: ...ency Locking Retractor ELR 83 Hood And Seat Latches 84 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING 86 Gauges Lights Horn And Fuses 87 Oil Level Powershift Transmission 90 Oil Level Oil Clutch System 90 Control Levers and Pedals 91 Lift System Operation 92 Inching Brake Pedal 92 Service Brakes 93 Parking Brake 93 Steering System 93 HOW TO ADD FUEL TO THE LIFT TRUCK 94 Liquified Petroleum Gas LPG...

Page 7: ...WARNING 5 A WARNING label with this information must be on the lift truck P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 8: ...VERHEAD GUARD 2 COUNTERWEIGHT 3 STEERING AXLE 4 DRIVE AXLE S70 120XL S135 155XL 5 MAST 6 FORKS 7 CARRIAGE 8 LOAD BACKREST EXTENSION 9 SEAT BELT AND HIP RESTRAINT BRACKET 12443 12177 1 1 2 2 5 5 6 6 8 8 7 7 4 4 3 3 9 9 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 9: ...55XL series of lift trucks can have either a three speed manual transmission with an oil clutch B024 models only or a two speed powershift transmission Lift trucks with a three speed manual transmission have two control levers on the left side of the steering wheel One lever controls the forward and reverse direction of the lift truck and the other lever is used to select the speed range These lif...

Page 10: ...and torso being trapped between the lift truck and the ground but it can not protect the operator against all pos sible injury in a tipover The hip restraint bracket will help the operator resist side movement if the seat belt is not fastened It is not a substitute for the seat belt Always fas ten the seat belt NAMEPLATE WARNING Any change to the lift truck the tires or its equipment can change th...

Page 11: ...about possible hazards It is important that all safety labels are installed on the lift truck and can be read See FIGURE 3 FIGURE 2 NAMEPLATE AND LABEL LABEL NAME PLATE TRUCK MODEL Serial no Approx weight NOTICE TO USER This unit was shipped incomplete from factory The U S A Occupational Safety and Health Act of 1970 and other national safety codes require the installation of a completed Nameplate...

Page 12: ...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 MAST WARNING 13 OPERATOR PRESENCE SYSTEM SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION 1 7 9 5 6 8 3 11 4 10 2 12 13 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 13: ...RANSMISSION WITH MONOTROL PEDAL POWERSHIFT TRANSMISSION WITH DIRECTION CONTROL LEVER NOTE THIRD FUNCTION CONTROL LEVER 17a IS AVAILABLE ON ALL UNITS 6 1 2 2 1 3 3 4 5 7 8 8 9 9 10 10 11 11 12 15 15 16 16 17 17a 17a 18 19 20 20 16 17 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 14: ...TH MONOTROL PEDAL 12189 12402 FIGURE 5 CONTROLS AND INSTRUMENTS S135 155XL NOTE THIRD FUNCTION CONTROL LEVER 17a IS AVAILABLE ON ALL UNITS 1 2 3 4 5 6 7 8 9 10 11 11 11 14 12 12 13 15 15 14 15 16 16 16 17 17a 17 17a 16 18 18 19 20 20 21 22 17a P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 15: ... ITEM FUNCTION 1 Hour Meter The hour meter operates when the key switch is in the ON position Periodic Maintenance recommendations are based on these hours 2 Coolant Temperature Gauge Indicates engine coolant temperature when the key switch is in the ON position During normal operation the needle will indicate in the green zone of the gauge Do not continue to operate the lift truck when the gauge ...

Page 16: ...n CAUTION Stop the engine immediately if the light is ON when the engine is running 6 Warning Light Check Engine Lift trucks with electronic engine control electronic spark timing and fuel injection This light will be ON when the key switch is ON and the engine is not running This light will illuminate when the ECM computer senses a fault in the operation of the engine If the engine will start the...

Page 17: ... light is ON when the key switch is in the START position Manual Transmission The red light is ON when the oil pressure in the clutch system is too low for continued operation The red light is ON when the key switch is ON and the engine is not running Do not continue to operate the lift truck if the light is ON during operation CAUTION P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 18: ...ion 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 3 Position START position Energizes the starter motor for starting the engine A spring returns the key to position No 2 ON position when the key is released NOTE ...

Page 19: ... and to keep the parking brake lever in the engaged position See the Maintenance section for adjustment procedures Always apply the parking brake when leaving the lift truck WARNING 12 Direction Control Lever S70 120XL S135 155XL The direction control for the transmission is to the left of the steering column The direction control lever is used on lift trucks with a manual transmission and those l...

Page 20: ...ols the two speed ranges of the powershift transmission 15 Lift Lower Control Lever The lift lower control lever is the first lever to the right of the steering wheel Pull backward on the control lever to raise the carriage and forks Push the control lever forward to lower the carriage and forks 16 Tilt Control Lever The tilt control lever is on the right of the lift lower control lever Push the c...

Page 21: ...for a single function attachment and two control spools for a two function attachment Single Function Operation The lever is spring loaded to the left and must be pushed to the right before operating the auxiliary function Two Function Operation The lever is spring loaded to the left and will operate one auxiliary function in this position The lever must be pushed to the right before operating the...

Page 22: ...ment for moving paper rolls as described in the following example Button not depressed Push the control lever forward to rotate the attachment to the left Pull the control lever backward to rotate the attachment to the right Button depressed Push the control lever forward to swing the attachment to the left Pull the control lever backward to swing the attachment to the right Push the control lever...

Page 23: ...rator can move the lift truck slowly while a high engine speed is used for lifting loads Completely depressing the pedal disengages the transmission and applies the service brakes The engine can be started when the inching brake pedal is fully depressed 21 Brake Pedal Manual Transmission S135 155XL Only This pedal controlled by the operator s right foot controls the application of the service brak...

Page 24: ...ght Left Retract Extend SIDE SHIFT PUSH PULL ROTATE UPENDER SCOOP LOAD STABILIZER SWING FORKS SWING CLAMP L H FORK POSITIONER R H FORK POSITIONER TURN FORK FORK SPREAD Backward Forward Clockwise Counterclockwise Up Down Up Down Down Clamp Up Release Clamp Release Together Apart Horizontal Vertical FUNCTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Right Left Right Left Together Apart Together Apart TABLE 3...

Page 25: ...rinci 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 ter of gravity of both the truck and the load is also a factor This basic principle is used for picking up a load The ability of the lift truck to handle a load is discussed in terms of cen ter of gravity and both forward and side stability Stability and Center Of Grav...

Page 26: ...acceleration braking turning and operating on uneven surfaces or on an incline These factors must be considered when traveling with an unloaded truck as well because an unloaded truck will tip over to the side eas ier than a loaded truck with its load in the lowered position In order for the lift truck to be stable not tip over forward or to the side the CG must stay within the area of the lift th...

Page 27: ...s in the Centered and Side shifted conditions Capacities listed under Centered on the Nameplate apply when transporting loads that are cen tered on the centerline of the lift truck Capacities listed un der Sideshifted on the Nameplate apply if loads are trans ported that are not centered on the centerline of the lift truck Loads should be transported while centered on the centerline of the lift tr...

Page 28: ...ft truck A lift truck will only do its job when it is in proper working order If repairs are required install a tag in the operator s area stating DO NOT OPERATE and remove the key from the key switch Starting Procedures Do not start nor operate the lift truck including any of its func tions or attach ments from any place other than the designated operator s posi tion Gasoline Or LPG Engine WARNIN...

Page 29: ...ng brake is applied or push on the inching brake pedal 2 If equipped put the direction control lever for the trans mission in the NEUTRAL N position 3 Turn the key to START to engage the starter If the out side temperature is 7 C 45 F or below crank the engine two revolutions to prime the fuel system Turn the key to the OFF position Push the HEAT button and hold it for 20 to 25 seconds then engage...

Page 30: ...so sub stantially within the confines of the truck 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 operator against all possible injury in a tipover Make sure that the area around the lift truck is clear before starting the engine or making any operati...

Page 31: ...operly operate a lift truck remember the WARNINGS NOTE Lift trucks manufactured before November 1 2005 are equipped with the Automatic Locking Retractor ALR type seat belts The seat belt must fasten securely Make sure the seat belt extends and retracts smoothly and is not frayed or torn If the seat belt is damaged or does not oper ate properly it must be replaced NOTE Lift trucks manufactured afte...

Page 32: ...in lift truck operation must guide the operator through several driving and load han dling operations before the operator attempts to operate the lift truck alone A basic education in proper driving and load handling techniques is absolutely necessary to prepare the new operator for proper defensive driving and to expect the unexpected 2 Operate the lift truck only in areas that have been ap prove...

Page 33: ... the lift mechanism Before anyone is allowed in the platform lift and lower the mast slowly with the platform in place to make sure the mast functions properly Apply the parking brake Do not travel with people in the platform The operator must remain at the controls Watch for overhead ob structions 4 Do not drive a lift truck into an elevator unless authorized to do so Approach the elevator slowly...

Page 34: ... a grade select a lower gear Do not select first gear when the lift truck is moving When second gear is selected from third gear increase the engine speed before changing to the lower gear Also change to a lower gear before traveling down a steep grade To change directions apply the brakes and depress the clutch pedal to stop the lift truck Move the direction control lever to select the opposite d...

Page 35: ... injury or property damamge Lift trucks produced after November 1 2005 are equipped with an Operator Presence System OPS The OPS fea ture has an electrical switch in the seat which senses the presence of the operator and a operator presence module which disengages the transmission This allows the trans mission in internal combustion engine trucks to be engaged only when the operator is in the seat...

Page 36: ...d high while inching If the lift truck is equipped with a manual transmission the inching operation is done by not fully applying the clutch and using the accelerator pedal to keep the engine speed high Steering Turning WARNING TRAVEL SLOWLY WHEN TURN ING Lift trucks can tip over even at very slow speeds The combination of speed and sharpness of a turn can cause a tipover A lift truck is less stab...

Page 37: ...ce they can turn sharper than some other vehicles Most lift trucks are steered by the rear wheels and the rear of the lift truck can move to the side very fast during a turn This movement is called tail swing An operator must be aware of tail swing and always check to make sure the tail swing area is clear before turning TAIL SWING Do not turn on an incline To reduce the pos sibility of a tip over...

Page 38: ...perator must know whether or not a load is within the max imum capacity of the lift truck before the load is handled However such factors as weak floors uneven terrain spe cial load handling attachments or loads having a high center of gravity can mean that the 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...

Page 39: ... 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 4 For carriages or attachments that can be sideshifted the load should be centered on the centerline of the lift truck before the load is transported Capacities listed under Cen tered on the Nameplate apply when...

Page 40: ...ting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury The LIFT and TILT functions are con trolled by separate levers See the In struments and Controls section for the correct op eration The speed of the hydraulic functions is controlled by the position of the control levers and the speed of the engine The farther the hand lever is moved from...

Page 41: ...p over forward when the load is raised Forward tipping is even more likely when tilting forward braking when traveling forward or accelerating in reverse Lift and lower with the mast vertical or tilted slightly back ward from vertical Tilt elevated loads forward only when directly over the unloading place If the lift mechanism is raised to pick up or deposit a load keep the tilt angle in either di...

Page 42: ... to tip People can be hurt or killed and material can be damaged 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 2 Move forward slowly until the forks are in position under the load The forks must support at least two thirds 2 3 of the length of the load Make sure that the load is centered between the for...

Page 43: ... put on the floor tilt the mast forward to a vertical position and lower the load Tilt the mast forward to permit smooth removal of the forks Carefully move the lift truck backward to remove the forks from under the load 4 If the load is being removed from a stack slowly move the lift truck away from the stack When the load is clear of the stack lower the load for traveling Always travel with the ...

Page 44: ... over when the load is raised IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE OR FORWARD DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT Move forward slowly When the load is in position for lower ing on a stack tilt the mast to a vertical position and lower the load Lower the forks just enough to remove them from under the load Do not...

Page 45: ...k is not carrying a load The ability of the lift truck to resist side tipping can be less on a lift truck without a load than it is on a lift truck with a load in the lowered travel position Therefore a lift truck without a load is more likely to tip sideways especially in a turn than a lift truck with a load carried in the lowered position WARNING Some lift trucks have mirrors for viewing along t...

Page 46: ...uck on a steep grade keep the counterweight upgrade 5 Watch out for pe destrians at all times Do not drive up to anyone stand ing in front of an ob ject Use extra care at cross aisles doorways and other loca tions where pedestrians can step into the path of travel of the lift truck Slow down when approaching blind intersec tions or turns and sound the horn This alarm is to warn pe destrians that t...

Page 47: ... designed to operate under different conditions Lift trucks with solid rubber tires are designed to operate on relatively smooth firm surfaces Lift trucks with pneumatic tires can adapt to more uneven ground Always make sure you choose the smoothest route for your lift truck 8 Watch clearances especially forks mast overhead guard and tail swing A lift truck is designed to perform a wide variety of...

Page 48: ... or horseplay 10 Do not pass another lift truck traveling in the same di rection at intersections blind spots or at other dangerous locations 11 Stay away from the edge of the road Keep the wheels of the lift truck particularly the steer wheels on the road way If the wheels are allowed to run off the edge of the travel surface onto soft ground the lift truck can tip over P r o p e r t y o f A m e ...

Page 49: ...S RAILROAD CARS AND DOCKS WARNING Maintain a safe distance from the edge of docks ramps plat forms and other similar working sur faces Watch the tail swing WARNING IF THE LIFT TRUCK FALLS OFF THE DOCK DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 50: ...des of the rear wheels unless a dock locking mechanism is engaged Fixed jacks may be necessary to support the front and rear of a semi trailer to prevent it from moving or tipping during loading or unloading Make sure that the railroad car brakes are set and the wheels are blocked while loading or unloading Do this so that the railroad car will not move due to the movement of the lift truck in and...

Page 51: ...the forks and damage the load or hurt someone PARKING The operator must never leave a lift truck in a condition so that it can cause damage and injury When parking the lift truck do the following operations 1 Stop the lift truck and apply the parking brake 2 Fully lower the forks or carriage Tilt the mast forward until the tips of the forks touch the ground 3 Put the direction control lever for th...

Page 52: ...e the fuel valve at the tank If the lift truck is going to be left over night or longer the truck must be parked outside or the LPG tank must be removed and stored outside Do not park the lift truck so that it limits access to fire aisles stairways and fire equipment P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 53: ...r eight hours of operation per day The time intervals must be decreased from the recommendations in the MAINTE NANCE SCHEDULE for the following conditions 1 If the lift truck is used more than eight hours per day 2 If the lift truck must work in dirty operating condi tions Your dealer for Hyster lift trucks has the equipment and trained service personnel to do a complete program of inspection lubr...

Page 54: ...reater than the weight of the disabled lift truck The capacity of the lift truck used to move a disabled lift truck must have a load center equal to half the width of the dis abled lift truck See the Nameplate of the disabled lift truck for the approximate total weight The forks must extend the full width of the disabled lift truck Put the weight center of the disabled lift truck on load center of...

Page 55: ...ks Make sure that any blocks used to support the lift truck are solid one piece units NOTE Some lift trucks have lifting eyes These lift points can be used to raise the lift truck so that blocks can be installed How To Raise The Drive Tires See FIGURE 6 1 Put blocks on each side front and back of the steering tires to prevent movement of the lift truck 2 Put the mast in a vertical position Put a b...

Page 56: ...t 2 3 of the total weight of the lift truck as shown on the Nameplate 3 Put the jack under the steering axle or frame to raise the lift truck Put blocks under the frame to support the lift truck FIGURE 6 PUT THE LIFT TRUCK ON BLOCKS 12177 DRIVE TIRES STEERING TIRES P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 57: ...AINTENANCE SCHEDULE S135 155XL 12183 FIGURE 7 MAINTENANCE POINTS 1 1 3 2 4 5 6 7 8 9 10 11 9 12 13 14 15 16 17 18 19 20 21 22 23 22 24 25 26 27 28 GM V 6 ENGINE SHOWN P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 58: ...5 1 litre 16 0 qt 50 Water and 50 Ethylene Glycol Boron Free Anti Freeze 4 COOLING SYSTEM GM V 6 EPA Compliant Engine X C 15 1 litre 16 0 qt 50 Water and 50 Ethylene Glycol Boron Free Anti Freeze CLEAN DEBRIS FROM RADIATOR CORE X Clean as Necessary 5 VALVE ADJUSTMENT GM V 6 X Not Adjustable VALVE ADJUSTMENT DIESEL ALL UNITS Inlet Valves Cold X Adjust as Required 0 20 mm 0 008 in X Check C Change L...

Page 59: ...X Clean or Replace See NOTE 2 See Parts Manual 6 AIR FILTER ELEMENT GM V 6 EPA Compliant Engine C See NOTE 3 See Parts Manual 7 FUEL TANK S70 120XL X 66 2 litre 17 5 gallon Gasoline 86 Octane minimum Diesel No 2 LPG HD 5 7 FUEL TANK S135 155XL XL2 and S155XLS X 66 2 litre 17 5 gallon Gasoline 86 Octane minimum Diesel No 2 LPG HD 5 X Check C Change L Lubricate NOTE 2 Very dirty conditions require d...

Page 60: ...GINE OIL DIESEL Perkins1004 42 X C 8 0 litre 8 5 qt 15 to 40 C 5 to 104 F SAE 10W 30 10 to 50 C 14 to 122 F SAE 15W 40 API CG4 CH4 ACEA E3 E5 MIL PRF 2104G ENGINE OIL DIESEL Perkins1104C 44 RE X C 8 0 litre 8 5 qt 15 to 40 C 5 to 104 F SAE 10W 30 10 to 50 C 14 to 122 F SAE 15W 40 API CG4 CH4 ACEA E3 E5 MIL PRF 2104G SEAT BELTS AND SEAT RAILS X Check Condition X Check C Change L Lubricate P r o p e...

Page 61: ...4 HORN GAUGES LIGHTS ALARMS X Check Operation 9 BRAKE FLUID X 0 2 litre 0 4 pt SAE J 1703 10 TIMING GM V 6 X Adjust as Required 0 BTDC 650 rpm TIMING DIESEL ALL UNITS X Adjust as Required 16 BTDC Static ENGINE IDLE SPEED GM V 6 X Adjust as Required 625 to 675 rpm ENGINE IDLE SPEED Diesel X Adjust as Required 725 to 775 rpm X Check C Change L Lubricate NOTE 4 Check fuel system for leaks prior to an...

Page 62: ...RVICE BRAKES X X Check Operation 11 PARKING BRAKES X L Check Operation Check Condition Engine Oil STEERING AND STEERING WHEEL POSITION LATCH X Check Operation CLUTCH BRAKE AND INCHING BRAKE PEDALS X L Adjust as Required Hyster Part No 328388 12 WHEEL NUTS DRIVE WHEELS X Check Torque All Wheel Nuts 610 to 680 Nm 450 to 500 lbf ft 13 MAST CARRIAGE AND ATTACHMENTS X X Check Condition and Operation X ...

Page 63: ... Required Multipurpose Grease See NOTE 1 18 MAST FORK GUIDES L As Required Multipurpose Grease See NOTE 1 19 MAST PIVOTS L 2 Fittings Multipurpose Grease See NOTE 1 15 FORKS X X Check Condition 16 LIFT CHAINS X L X Check for Condition and Lubrication Engine Oil PEDALS LEVERS LINKAGES CABLES HINGES SEAT RAILS L As Required Engine Oil X Check C Change L Lubricate NOTE 1 Multipurpose grease with 2 to...

Page 64: ...0 17 MANUAL TRANSMISSION DIFFERENTIAL OIL S135 155XL B024 X C 14 2 litre 15 0 qt See NOTE 5 SAE 80W 90 85W 140 20 POWERSHIFT TRANSMISSION OIL Single Speed Powershift S70 120XL X C 15 1 litre 16 qt See NOTE 6 Hyster Part No 336831 Change oil filter when transmission oil is changed X Check C Change L Lubricate NOTE 5 Check the thrust screw adjustment on the differential after the first 150 hours of ...

Page 65: ...VEL S135 155XL B024 X C 9 4 liter 10 qt Hyster Part No 336831 Change oil filter when clutch oil is changed TRANSMISSION AND CLUTCH X Check Operation 22 OIL FILTER HYDRAULIC SYSTEM C 1 See NOTE 6 See Parts Manual 23 HYDRAULIC TANK BREATHER X Clean or Replace See Parts Manual 24 HYDRAULIC SYSTEM S70 120XL X C 37 litre 9 7 gallon 18 C 0 F and Above SAE 10W API CC or CC SE SF SG MIL L 46152 X Check C ...

Page 66: ...anual CRANKCASE BREATHER Perkins 1004 42 Perkins 1104C 44 RE X C 1 See NOTE 7 See Parts Manual PRIMARY FUEL FILTER DIESEL X C Drain Water See Parts Manual 26 BATTERY ELECTROLYTE BATTERY CASE AND CABLES X X Check Level Clean See Parts Manual 27 DRIVE BELTS X X Check Condition See Parts Manual 28 WHEEL NUTS STEER WHEELS X Check Torque All Wheel Nuts 610 to 680 Nm 450 to 500 lbf ft X Check C Change L...

Page 67: ...rts Manual ENGINE OIL FILTER Diesel Perkins 1004 42 C See NOTE 6 See Parts Manual ENGINE OIL FILTER Diesel Perkins 1104C 44 RE C See NOTE 6 See Parts Manual FINAL FUEL FILTER DIESEL C 1 See Parts Manual SPARK PLUGS C 6 Check Wires See Parts Manual Gap 1 6 mm 0 062 in X Check C Change L Lubricate NOTE 1 Multipurpose grease with 2 to 4 Molybdenum Disulfide NOTE 6 Change filter on new lift trucks at ...

Page 68: ...R GASOLINE C 1 See Parts Manual FUEL FILTER LPG C 1 See Parts Manual FUEL FILTER LPG GM V 6 EPA Compliant Engine C 1 See Parts Manual INSPECT ENGINE ELECTRICAL SYSTEM CONNECTORS AND FCVS CONNECTION X INSPECT ENGINE VACUUM AND FUEL LINES AND FITTINGS X INSPECT LOCK OFF FOR LEAKS AND ENSURE LOCK OFF CLOSING X X Check C Change L Lubricate P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 69: ...ST LPG GAS REGULATOR PRESSURE X INSPECT LOW PRESSURE REGULATOR FOR OIL BUILDUP AND LEAKS X Drain Oil If Necessary CHECK AIR INDUCTION SYSTEM FOR LEAKS X CHECK MANIFOLD FOR VACUUM LEAKS X CHECK THROTTLE SHAFT FOR STICKING X CHECK INJECTORS AND RAILS FOR LEAKS X X Check C Change L Lubricate P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 70: ... 6 mo 2000 Hr 1 yr PROCEDURE OR QUANTITY SPECIFICATION INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS X INSPECT CATALYST INLET AND OUTLET X OXYGEN SENSOR GM V6 EPA Compliant Engine X Check Indicator Light X Check C Change L Lubricate P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 71: ... CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed Never operate the pump without oil in the hydraulic system The operation of the hydraulic pump without oil will damage the pump 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 mo...

Page 72: ...120XL S135 155XL 11725 11618 4 BREATHER HYDRAULIC TANK 5 BREATHER ENGINE 6 FILL CAP HYDRAULIC OIL 7 FILTER HEAD 1 2 3 4 5 6 7 3 NOTE BREATHER IS ON TOP OF HYDRAULIC TANK AND UNDER THE TOP OF THE FRAME FIGURE 8 MAINTENANCE POINTS P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 73: ...IL 2 ENGINE OIL FILL CAP 3 AIR FILTER 12185 12186 4 AUXILIARY COOLANT RESERVOIR 5 PCV VALVE GM V 6 6 BATTERY 7 FILL CAP FUEL 8 COLD START AID DIESEL 1 2 3 4 6 7 8 1 2 3 4 5 FIGURE 9 ENGINE MAINTENANCE POINTS P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 74: ...n cause burns DO NOT remove the cover for the radia tor when the engine is running Make sure the coolant level is between the FULL and the ADD marks on the auxiliary coolant reservoir The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase Add coolant to the auxiliary reservoir if additional coolant is needed WARNING Compressed air can move particles ...

Page 75: ...ANCE 73 11619 FIGURE 10 AUXILIARY COOLANT RESERVOIR 12205 2 1 3 4 5 6 1 CANISTER 2 O RING 3 FILTER ELEMENT 4 BAFFLE 5 CLAMP 6 END COVER FIGURE 11 AIR FILTER P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 76: ...the element is damaged re place it with a new element Use a cloth with solvent to clean the inside of the canister when the filter element is cleaned or replaced 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 for leaks in the fuel system If there is a leak in the fuel system extra care must be used during the ...

Page 77: ...ttery and cable terminals clean Check the electrolyte level unless maintenance free battery Keep the electrolyte level above the separators and plates Use distilled water Do not fill the battery more than to the bot tom of the internal filler neck If the battery becomes discharged and requires a booster battery to start the engine follow these procedures care fully when connecting the jumper cable...

Page 78: ...hown in the MAINTENANCE SCHEDULE CAUTION Check all wheel nuts after 2 to 5 hours of operation when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and installed Tighten the nuts in a cross pattern to the correct torque value shown in the MAINTENANCE SCHEDULE When the nuts stay tight for eight hours the interval for checking the torque can be extended ...

Page 79: ...gaged in the carriage bar to lock the fork in position af ter the width adjustment is made Forks Removal And Installation A fork can be removed from the carriage for replacement of the fork or other maintenance WARNING Do not try to remove a fork without a lifting device Each hook fork for these lift trucks can weigh 66 kg to 183 kg 145 to 402 lb Hook Fork Removal Slide a hook fork to the fork re ...

Page 80: ...K LOCK PIN ASSEMBLY NEW STYLE LOCK PIN ASSEMBLY OLD STYLE LOCK PIN ASSEMBLY 1 FORK 2 LOCK PIN 3 SPRING 4 WASHER 5 WASHER 6 WEDGE 7 KNOB 8 LEVER 9 COTTER PIN 10 LOCK PIN ASSEMBLY P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 81: ...the fork can engage the upper car riage bar Raise the carriage to move the lower hook through the fork removal notch See FIGURE 16 Slide the fork toward its position on the side of the carriage so that both upper and lower hooks engage the carriage Engage the lock pin with a notch in the upper carriage bar FIGURE 15 HOOK FORK REMOVAL 1 3 2 1 CARRIAGE BARS 2 HOOK FORK 3 BLOCKS P r o p e r t y o f A...

Page 82: ...Forks are made of special steel using special proce dures Replace damaged forks 1 Inspect the welds on the mast and carriage for cracks Make sure that the capscrews and nuts are tight 2 Inspect the channels for wear in the areas where the rollers travel Inspect the rollers for wear or damage 3 Inspect the load backrest extension for cracks and damage 4 Inspect the forks for cracks and wear Check t...

Page 83: ...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 10221 8 915 mm 36 in 27 mm 1 10 in 1220 mm 48 in 37 mm 1 45 in 1830 mm 72 in 55 mm 2 15 in FORK TIP ALIGNMENT LENGTH OF FORKS 3 DIMENSION P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 84: ... See FIGURE 17 9 Inspect the chain anchors and pins for cracks and dam age 10 Make sure the lift chains are adjusted so that they have equal tension Adjustment or replacement of the lift chains must be done by authorized personnel Safety Labels WARNING Safety labels are installed on the lift truck to give in formation about operation and possible hazards It is important that all safety labels are ...

Page 85: ...mber 1 2005 are equipped with the ALR type seat belts See FIGURE 18 A AUTOMATIC LOCKING RETRACTOR ALR B EMERGENCY LOCKING RETRACTOR ELR FIGURE 18 SEAT BELTS The seat belt must fasten securely Make sure the seat belt extends and retracts smoothly and is not frayed or torn If the seat belt is damaged or does not operate prop erly it must be replaced Emergency Locking Retractor ELR NOTE Lift trucks p...

Page 86: ...or assembly or the belt will not retract re place the seat belt assembly With the hood closed and in the locked position pull the seat belt with a sudden jerk Make sure the seat belt will not pull from the retractor assembly If the seat belt can be pulled from the retractor when it is pulled with a sudden jerk replace the seat belt as sembly With the hood in the open position make sure the seat be...

Page 87: ... LATCH 6 HIP RESTRAINT 7 SEAT RAIL 8 FLOOR PLATE 9 HOOD 10 GAS CYLINDER 11 HINGE 11858 1 1 4 GASOLINE AND DIESEL ARRANGEMENT LPG ARRANGEMENT 2 3 6 5 9 4 6 5 10 7 7 8 11 S70 120XL SHOWN FIGURE 19 CHECK THE HOOD AND SEAT LATCHES P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 88: ...ces maintain adequate ventilation or vent exhaust to the outside Do not exceed applicable air contaminant limits S Follow the inspection and maintenance schedule and procedures in this manual Do not alter exhaust ignition or fuel systems FASTEN YOUR SEAT BELT The seat belt is installed to help the operator stay on the truck if the lift truck tips over IT CAN ONLY HELP IF IT IS FASTENED Make sure t...

Page 89: ...tru ment panel on the right side of the cowl See FIGURE 20 On S135 155XL S135 155XL2 and S135XLS C024 lift truck models only there are additional fuses and relays located in the engine compartment See FIGURE 21 and FIGURE 22 12200 LIGHT DSL COLD START HORN GAGES XMSN SHIFT 1 2 3 4 5 6 1 GAUGES 2 TRANSMISSION SOLENOIDS 3 HORN 4 COLD START AID DIESEL 5 LIGHTS 6 OTHER OPTIONS LH GAGES RH 5 PLNG 7 5A ...

Page 90: ...NGINE S135 155XL S135 155XL2 AND S135XLS C024 TRUCKS ONLY HO190288 1 FUSE PANEL 2 MOUNTING BRACKET F1 20 AMPS F2 5 AMPS F3 15 AMPS F4 15 AMPS F5 SPARE F6 SPARE R1 STARTER RELAY R2 POWER RELAY R3 FUEL PUMP RELAY R4 SPARE P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 91: ...PERKINS 1104C 44 RE DIESEL ENGINE S135 155XL S135 155XL2 AND S135XLS C024 TRUCKS ONLY HO190289 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 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 92: ...e oil level at the FULL mark on the dipstick The most accurate check of the oil level is when the transmission is at operating temperature Oil Level Oil Clutch System S135 155XL B024 See FIGURE 23 Put the direction control lever in the NEUTRAL N posi tion Apply the parking brake Check the oil level in the oil clutch system when the engine is running at idle speed Make sure the oil is at operating ...

Page 93: ...ATE 11703 11638 1 2 3 3 FIGURE 23 TRANSMISSION DIPSTICK LOCATIONS S70 120XL S135 155XL Control Levers and Pedals Check that the control levers for the transmission mast and attachment operate as described in TABLE 2 and TABLE 3 Check that the pedals operate as described in TABLE 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 94: ... Raise the mast to its full extension height at least once The mast components must raise and lower smoothly in the correct sequence 3 The inner weldments and the carriage must lower completely 4 Raise the mast one metre three feet with a capac ity load The inner weldments and the carriage must raise smoothly Lower the mast All moving compo nents must lower smoothly 5 Lower the load to approximate...

Page 95: ...edal can be hard to push when the engine is not running and when the hydraulic system is not operating Parking Brake Check the operation of the parking brake The parking brake when in good condition and correctly adjusted will 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 Turn the knob on the end of the hand lever to adjust the parking brake ...

Page 96: ... momentarily 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 fuels refer to ANSI NFPA 58 505 LPG is extremely flammable When checking or filling an LPG tank No smoking Stop engine Frost or LPG odor indicates a leak Inspect and repair a leak immediately Do not start the engine Only trained and au...

Page 97: ...the LPG tank is installed on the lift truck check the operation of the fuel gauge Look at the fuel gauge and move the tank If the gauge needle does not move a new tank must be installed 2 Put the tank in the tank bracket Make sure that the tank is aligned with the alignment pin 3 Close the latch 4 See FIGURE 24 Connect the quick disconnect fit ting to the fuel valve on the tank Use your hand to ti...

Page 98: ...ities that have jurisdiction have specific rules and regulations for filling LPG tanks Make sure these rules and regulations are available and understood 1 Check the LPG tank to make sure it needs filling During the filling operation the LPG tank must be in a position so that the liquid level indicator will al ways be in the vapor space above the liquid level See FIGURE 24 2 Open the liquid outlet...

Page 99: ...of the hose 9 Close the vent valve 10 Close the fuel valve on the tank 11 Disconnect the supply hose 12 Stop the pump 13 Close liquid outlet valve and by pass return valve on the storage tank Gasoline Or Diesel Fuel WARNING When fuel is added keep the funnel or fuel nozzle in contact with the metal of the fuel tank to reduce the possibility of static electric sparks Clean any spilled fuel 1 Remove...

Page 100: ... solid rubber tires on the wheels unless you have the cor rect tools equipment and experience Make sure the tires are installed on the wheels according to the dimensions shown in FIGURE 25 Install the tires on both drive wheels at the same dimensions Install the tires on both steering wheels at the same dimensions Check the Nameplate on the lift truck for the correct tread width The tread width is...

Page 101: ...o the torque value in the MAINTENANCE SCHEDULE table OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE A new or rebuilt engine must be operated under special conditions during the first 50 hours These special condi tions prevent damage to the engine until the new parts can wear and adjust to fit each other 1 Make sure the fluid levels of oil and coolant are correct 2 Start and run the engine at app...

Page 102: ...st Essere Sicuro Paga Seguranca Paga Sikkerhet Først Pinter Be Awas 10 05 12 03 5 02 8 00 5 96 6 94 10 91 10 90 6 89 Printed In U S A 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 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

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