Hyster S40XM Operating Manual Download Page 6

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CONTENTS

How To Raise the Steering Tires

. . . . . . . . . . .

MAINTENANCE SCHEDULE

. . . . . . . . . . . . . . . . . . .

MAINTENANCE PROCEDURES EVERY 8 HOURS

OR DAILY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO MAKE CHECKS WITH THE ENGINE

STOPPED

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires and Wheels

. . . . . . . . . . . . . . . . . . . . . . . .

Forks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forks, Adjustment

. . . . . . . . . . . . . . . . . . . . . . . .

Forks, Removal

. . . . . . . . . . . . . . . . . . . . . . . . . .

Forks, Installation

. . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Of Forks, Mast, and Lift Chains

. . .

Safety Labels

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Restraint System

. . . . . . . . . . . . . . . .

Steering Column Latch

. . . . . . . . . . . . . . . . . . . .

Check For Fuel, Oil Or Coolant Leaks

. . . . . . .

Drive Belt

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Oil Temperature

. . . . . . . . . . . . .

Hydraulic System Oil

. . . . . . . . . . . . . . . . . . . . .

Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO MAKE CHECKS WITH THE ENGINE

RUNNING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges, Lights, Horn, Fuses and Relays

. . . .

“Check Engine” Light(Mazda and GM3.0L LPG

Closed--Loop With Emission System)

. . . . . . . .

“Check Engine” Light

(GM 3.0 Liter Gasoline)

. . . . . . . . . . . . . . . . . . . .

Engine Oil Pressure

. . . . . . . . . . . . . . . . . . . . . . .

Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . .

Steering System

. . . . . . . . . . . . . . . . . . . . . . . . . .

Service Brakes

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake

100

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System

101

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Separator, Diesel Engine

101

. . . . . . . . . . . . .

Fuel Filter, Diesel Engine

102

. . . . . . . . . . . . . . . . . .

Remove Air From The Diesel Fuel System

102

. . .

Control Levers and Pedals

102

. . . . . . . . . . . . . . . . .

Lift System Operation

102

. . . . . . . . . . . . . . . . . . . . .

Cooling System

103

. . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO ADD FUEL TO THE LIFT TRUCK

104

. . . .

Liquefied Petroleum Gas (LPG)

105

. . . . . . . . . . . . .

Gasoline or Diesel Fuel

108

. . . . . . . . . . . . . . . . . . . .

Property of American Airlines

Summary of Contents for S40XM

Page 1: ...RT NO 1458874 OPERATING MANUAL CHALLENGER S40XM S45XM S50XM S55XM S55XMS S60XM S65XM DO NOT REMOVE THIS MANUAL FROM THIS UNIT SPACESAVER H45XM H50XM H55XM H60XM H65XM 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: ...IFT 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 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 3: ...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 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 p...

Page 4: ...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 Guide for Users of Industrial Lift Trucks Hyster Part No 852930 describes lift truck safety good maintenance practices and training programs and is available from y...

Page 5: ...ne 38 Starting Procedures Diesel Engine 38 Checks With The Engine Running 39 OPERATING TECHNIQUES 40 Basic Operating Procedures 41 Driving And Direction Changes 42 Inching 43 Steering Turning 44 Load Handling General 46 Load Handling Lifting Lowering And Tilting 47 Load Handling How To Engage And Disengage A Load 49 Load Handling Travelling 52 HIGHWAY TRUCKS RAIL CARS AND DOCKS 56 ATTACHMENTS 58 S...

Page 6: ...em Oil 93 Battery 94 Air Filter 94 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING 95 Gauges Lights Horn Fuses and Relays 98 Check Engine Light Mazda and GM3 0L LPG Closed Loop With Emission System 98 Check Engine Light GM 3 0 Liter Gasoline 98 Engine Oil Pressure 98 Cooling System 99 Steering System 99 Service Brakes 99 Parking Brake 100 Fuel System 101 Water Separator Diesel Engine 101 Fuel Filter Di...

Page 7: ...LLATION PROCEDURES DUAL DRIVE WHEELS 119 SOLID RUBBER TIRES 119 Remove The Tire From The Wheel 120 Install The Tire On The Wheel 120 OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE 123 CHANGES TO THE OVERHEAD GUARD 123 HOW TO PUT INTERNAL COMBUSTION ENGINE I C E TRUCKS IN STORAGE 123 HOW TO PUT BATTERIES IN STORAGE 124 HOW TO STORE A LIFT TRUCK 125 HOW TO MOVE A LIFT TRUCK ON A TRANSPORT 127 Load...

Page 8: ...CONTENTS 6 NOTES 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: ...WARNING 7 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 10: ...WARNING 8 NOTES 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 11: ...D GUARD 2 TAIL LIGHT BRAKE LIGHT REVERSE LIGHT 3 SEAT 4 COUNTERWEIGHT 5 STEERING AXLE 6 SEAT BELT AND HIP RESTRAINT 7 DRIVE AXLE 8 FORKS 9 CARRIAGE 10 LOAD BACKREST EXTENSION 11 PARKING BRAKE 12 STEERING WHEEL 13 MAST 9 1 3 2 4 5 6 7 8 10 11 12 13 6 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 12: ...5 STEERING AXLE 6 SEAT BELT AND HIP RESTRAINT 7 DRIVE AXLE 8 FORKS 9 CARRIAGE 10 LOAD BACKREST EXTENSION 11 PARKING BRAKE 12 STEERING WHEEL 13 MAST FIGURE 2 MODEL VIEW SHOWING MAJOR COMPONENTS OF H45 65XM SERIES 12626 9 1 3 2 4 5 6 7 8 10 11 12 13 6 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: ...e powershift transmis sion A separate accelerator pedal controls the en gine speed The S40 65XM lift trucks are equipped with solid rubber tires The H45 65XM lift trucks are equipped with pneu matic tires or solid rubber tires that look like pneumatic tires See Wheels And Tires in the MAINTENANCE SECTION for a description of these tires OPERATOR PROTECTION EQUIPMENT The LOAD BACKREST EXTENSION is ...

Page 14: ...ent including the battery for electric trucks does not match that shown on the Nameplate the lift truck must not be operated 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 Name plate The maximum capacity for the lift truck at full load height must be shown on the Nameplate Special capacitie...

Page 15: ...ity The lift truck must be rated as equipped and the nameplate must show the new ca pacity rating SAFETY LABELS Safety labels are installed on the lift truck to give informa tion about possible hazards It is important that all safety labels are installed on the lift truck and can be read See FIGURE 4 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 16: ...codes require the installation of a completed Nameplate showing unit configuration and rated capacity Completed Nameplates may be obtained through your HYSTER dealer NOTICE TO USER TRUCK MODEL Serial no Approx weight FIGURE 3 NAMEPLATE AND LABELS NAMEPLATE 1304058R INCOMPLETE LABEL NOTICE LABEL 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 17: ...MODEL DESCRIPTION 15 FIGURE 4 WARNING AND SAFETY LABELS 1 of 2 SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS 1 4 5 6 7 2 9 3 8 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: ...R WARNING 10 MAST WARNING 11 FAN WARNING 12 RADIAL TIRE WARNING H45 65XM Only 13 ETHER WARNING H45 65XM Only 14 RADIATOR CAP WARNING H45 65XM Only 15 DUAL FUEL WARNING 16 TWO PIECE WHEEL WARNING H45 65XM Only 17 FLAMMABLE LP GAS 18 GUARD LABEL 10 11 12 13 16 SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS FIGURE 4 WARNING AND SAFETY LABELS 2 of 2 14 15 18 P r o p e r t y o f A m e ...

Page 19: ...MODEL DESCRIPTION 17 FIGURE 5 INSTRUMENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 USED ONLY ON S40 65XM MODEL TRUCKS 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 20: ... Gauge This gauge indicates engine coolant temperature when the key switch is in the ON position During normal operation the gauge needle will be in the green area Do not continue to operate the lift truck when the gauge indicates that the engine is too hot needle in the red zone NOTE Engine will stop after a 30 second warning buzzer if coolant is over 121 C 250 F on S40 65XM series with protectio...

Page 21: ...START position and must go OFF when the engine is running Do not continue to operate the lift truck if the red light is ON NOTE Engine will stop after a 30 second warning buzzer if transmission oil is over 121 C 250 F on S45 65XM series with protection system CAUTION 7 Warning Light Engine Oil Pressure The red light is ON when the key switch is in the ON position and must go OFF when the engine is...

Page 22: ...t Level in the Radiator Used only on S40 65XM model trucks The red light is ON when the key switch is in the START position and must go OFF when the engine is running If the light is ON when the engine is running the level of the coolant in the radiator is too low Do not continue to operate the lift truck if the light is ON during operation CAUTION 10 Warning Light Fasten Seat Belt The red light i...

Page 23: ...ngine gas fuel system This light will be ON when the key switch is ON and the engine is not running This light will illuminate when the Electronic Control Module computer senses a fault in the operation of the engine If the engine will start the operation of the engine will not be correct until the fault is corrected A trained service person must make repairs and adjustments if this light is ON wh...

Page 24: ...n the engine is running the air cleaner has a restriction and needs cleaning 16 Right Hand Turn Indicator The light is on when the turn indicator lever is in the right turn position 17 Engine Oil Pressure Gauge This gauge indicates the pressure of the oil in the engine During normal operation the gauge needle will be in the green area Do not continue to operate the lift truck when the gauge indica...

Page 25: ...dicates the output of the alternator During normal operation the gauge needle will be in the green area Do not continue to operate the lift truck when the gauge indicates in the yellow or red areas of the gauge 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 26: ...PTION 24 FIGURE 6 CONTROLS 1 4 5 6 7 3 8 9 10 11 12 13 14 UNITS WITH DIRECTION CONTROL LEVER UNITS WITH MONOTROLR PEDAL 2 15 16 17 18 19 4 5 2 11 12 13 14 16 17 1 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 27: ...the transmission is on the left side of the steering column The direction control lever is used on lift trucks without a MONOTROLR pedal This direction control lever has three positions FORWARD NEUTRAL N and REVERSE Move the lever to one of the direction positions for travel The direction control lever must be in the NEUTRAL N position before the engine can be started The reverse lights and the op...

Page 28: ... when starting the engine NOTE There is a switch in the seat that actuates an audible buzzer If the operator leaves the seat or turns the key to the OFF position without applying the parking brake the buzzer will be ON for 10 seconds Correct adjustment is necessary to provide adequate braking See the MAINTENANCE section for adjustment procedures Always apply the parking brake when leaving the lift...

Page 29: ...position to turn ON the windshield wiper Push the front of the switch past the ON position to activate the windshield washer 10 Switch The switch controls the operation of the heater Push on the top of the switch to turn the heater ON 11 Lift Lower Control Lever The lift lower control lever is the first lever to the right of the operator s seat Pull backward on the control lever to raise the carri...

Page 30: ... loaded toward the operator The lever is operated by moving it to the right then forward and backward Control Lever without a Detent Attachments without a clamp action The lever is operated by moving it forward and backward WARNING 14 Control Lever for Auxiliary Hydraulic Functions 4th lever See FIGURE 6 The fourth control lever is installed to the right of the third control lever The lever is spr...

Page 31: ...E There is a mechanical lockout that prevents the key switch from being returned to the START position without first being returned to the OFF position 17 Inching Brake Pedal By varying the position of the inching brake pedal the operator 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 se...

Page 32: ... normal operation 19 Turn Signal Lever When installed this lever is on the right side of the steering column Move the lever toward the front of the lift truck to operate the left hand turn signals Move the lever toward the rear of the lift truck to operate the right hand turn signals Battery Disconnect Switch Not Shown In FIGURE 6 This switch is to the rear of the hydraulic control levers on the h...

Page 33: ...ition Always close the valve at the LPG tank and operate the engine until it stops before switching the system to gasoline operation FOLLOW THE INSTRUCTIONS ON THE LABEL NEAR THE SWITCH NOTE Connect the LPG tank hose to the fitting of the storage bracket when operating on gasoline if the LPG tank is not installed No 2 Position GAS position For operation using Gasoline fuel No 3 Position LPG positi...

Page 34: ...eft Backward Forward 3 PUSH PULL Backward 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 Forward 8 SWING FORKS Right Left Backward Forward 9 FORK SPREAD Together Apart Backward Forward 10 CLAMP Clamp Release Backward Forward 10 EXTEND RETRACT Extend Re...

Page 35: ...edule and procedures in this manual Do not alter exhaust igni tion or fuel systems WARNING FIRE HAZARD The hot engine surfaces and exhaust of internal com bustion engine powered lift trucks can present fire hazards when operating in areas containing flam mable gases vapors liquids dusts or fibers Engine and exhaust component surface temperatures can exceed the ignition temperatures of common sol v...

Page 36: ... lift truck being unsuitable for operation in areas classified as hazardous The fork lift truck is designed to pick up and move materi als The basic lift truck has a lift mechanism and forks on the front to engage the load The lift mechanism lifts the load so that it can be moved and stacked In order to understand how the fork lift truck can pick up a load you must first know some basic things abo...

Page 37: ...es up and down as the mast moves up and down Combined CG CG Load CG Truck The center of gravity and therefore the stability of the loaded lift truck is affected by a number of factors such as size weight shape and position of the load the height to which the load is raised the amount of forward and backward tilt tire pressure and the dynamic forces created when the truck is moving These dynamic fo...

Page 38: ...The capacity is listed in terms of weight and load center The weight is specified in kilograms and pounds The load center is specified in millimeters and inches The capacity is the maximum load that the lift truck can handle for the load condition shown on the Nameplate The load center of a load is determined by the location of its center of gravity The load center is measured from the front face ...

Page 39: ...ift truck has a diesel engine drain water from the primary filter Electrolyte level of the battery unless maintenance free Oil level in the engine and hydraulic tank Coolant level in the cooling system and condition of the drive belts Condition of the engine compartment Ensure all surfaces are free of oils lubricants fuel and or ganic dusts or fibers paper wood cotton agricul tural grass grain etc...

Page 40: ...ds before engaging the starter again 4 Turn the key to the START position to engage the starter 5 If the engine does not start after four attempts get help from authorized service personnel 6 When the engine is running check the gauges and in dicator lights for the correct operation See the IN STRUMENTS AND CONTROLS section in this OPERAT ING MANUAL for a description of the correct operation Start...

Page 41: ...n dicator lights for the correct operation See the IN STRUMENTS AND CONTROLS section for a description of the correct operation Checks With The Engine Running WARNING FASTEN SEAT BELT If Lift Truck Tips Over Do Not Jump Stay On Truck Hold Firmly To Steering Wheel Brace Feet Lean Forward And Away From Impact The seat belt is installed to help the operator stay on the truck if the lift truck tips ov...

Page 42: ...s as de scribed in the MAINTENANCE section Check the operation of the horn gauges and indi cator lights For models H45 65XM check the oil level in the powershift transmission when the oil is at operating temperature the transmission is in NEUTRAL the parking brake is applied and the engine is running at idle speed Operate the LIFT TILT and auxiliary functions to check for correct operation of the ...

Page 43: ...be trained to drive the lift truck and it means that the operator must thoroughly un derstand the procedures for lift truck operation It also means that a qualified person experienced in lift truck op eration must guide the operator through several driving and load handling operations before the operator attempts to operate the lift truck alone A basic education in proper driving and load handling...

Page 44: ...t truck into an elevator unless autho rized to do so Approach the elevator slowly After the ele vator is properly levelled the lift truck must be centered so that the elevator is balanced When the lift truck is in the proper position in the 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 en...

Page 45: ...maged if the lift truck is trav elling too fast when the controls are changed to the opposite direction of travel The operator can change the direction of travel at slow travel speeds less than a walking speed but the mast must not be in a raised position If the lift truck is moving rapidly slow to a walking speed before changing the di rection of travel Inching Inching is the movement of a lift t...

Page 46: ...hen the forks are elevated with or without a load WARNING IF THE LIFT TRUCK TIPS OVER DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT Most operators can understand the need to be careful when handling loads But some operators do not realize that a tipover can occur with an empty lift truck because similar dynamic forces are present I...

Page 47: ...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 re duce the possibility of a tipover a lift truck must not be driven across an incline When possible keep both hands on the steering wheel During most loading or unloading operations the operator steers with the left hand The right hand is used to oper ate t...

Page 48: ...r must reduce the load so that the lift truck will remain stable 2 Handle only stable loads A load can have unstable items that can easily shift and fall on someone WARNING Do not handle a load if any loose part of it is above the load backrest or any part of the load is likely to fall 3 Position each fork the same distance from the cen ter of the carriage This action will help center the load on ...

Page 49: ... the control levers The farther the hand lever is moved from the NEUTRAL position the faster the speed of the hydraulic function Do not lift or hit anything that can fall on the operator or a bystander Remember a lift truck equipped with a HYS TER overhead guard and load backrest extension pro vides reasonable protection to the operator from falling objects but can not protect against every possib...

Page 50: ...ances that can cause serious injury 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 WARNING The lift truck can tip over forward when the load is raised Forward tipping is even more likely when tilt ing forward braking when travelling forward or accel erating in reverse If the lift mechanism is ...

Page 51: ...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 P3 of the length of the load Make sure that the load is centered between the forks Make sure that the forks do not extend past the load so that loads or equipment that are behind the load being lifted are not damaged ...

Page 52: ... Tilt the mast for ward to permit smooth removal of the forks Carefully move the lift truck backward to remove the forks from un der 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 travelling Always travel with the load as low as possible and tilted backward Low ering speed is controlled by t...

Page 53: ...t the load for ward until it is level Raise the load higher than the point where it will be placed Do not raise the load to a point below where the load is to be placed and jog the load up into position This operation uses added energy particu larly with an electric lift truck Be careful not to damage or move adjacent loads IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE OR FORWARD DO NOT JUMP OFF ...

Page 54: ...forks when travelling NOTE Not every load can be lifted using only the forks of a lift truck Some loads will require a special attachment 6 When lifting round objects use a block behind the ob ject Tilt the mast forward so that the forks can slide along the floor under the object to be lifted Tilt the mast fully backward to help keep the load on the forks Load Handling Travelling 1 When travelling...

Page 55: ...G Some lift trucks have 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 re verse Always look in the direction of travel to avoid damage to something or injury to someone 3 For better visibility with large loads travel with the load trailing but always keep a proper lo...

Page 56: ...ans that there is a vehicle in the area and to be alert to possible danger 6 Any time 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 tions 7 Avoid bumps holes slick spots and loose materials that may cause the lift truck to swerve or tip If unavoid able slow down Different models of lift trucks are...

Page 57: ...n hit an object or lift another load Serious accidents can be caused by mast and overhead guards hitting pipes and beams near the ceiling 9 Do not indulge in stunt driving or horseplay 10 Do not pass another lift truck travelling in the same direction at intersections blind spots or at other danger ous locations 11 Stay away from the edge of the road Keep the wheels of the lift truck particularly ...

Page 58: ...ks ramps platforms and other similar working surfaces Watch the tail swing Remember when travelling in the forward di rection and the steering wheel is turned to move the lift truck away from the edge of the dock the rear will swing toward the edge This action can cause the lift truck to fall off the dock IF THE LIFT TRUCK FALLS OFF THE DOCK DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL P r o p e ...

Page 59: ...m is engaged Fixed jacks may be necessary to support the front and rear of a highway truck trailer to prevent it from moving or tipping during loading or unloading S Make sure that the rail car brakes are set and the wheels are blocked while loading or unloading Do this check so that the rail car will not move due to the movement of the lift truck in and out of the rail car S Check the condition o...

Page 60: ...he 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 Applying the parking brake puts the transmission in NEUTRAL when the lift truck has a MONOTROLR pedal 2 Fully lower the forks or carriage Tilt mast forward until the tips of the forks touch the grou...

Page 61: ...PG fuel system and is parked more than momentarily close 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 62: ...OPERATING PROCEDURES 60 NOTES 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 63: ...er and in calendar time Use the interval that occurs first The recommendation for the time intervals are for 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 Hys...

Page 64: ...isabled lift truck MUST have a capacity rating equal to or greater than the weight of the disabled lift truck The capacity of the lift truck used to move a disabled lift truck must 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 th...

Page 65: ...locks under the mast assembly so that the lift truck can not fall forward The surface must be solid even and level when the lift truck is put on blocks Make sure that any blocks used to support the lift truck are solid one piece units NOTE Some lift trucks have lifting eyes These lifting eyes can be used to raise the lift truck so that blocks can be installed How To Raise the Drive Tires See FIGUR...

Page 66: ...aulic jack to raise the steering tires Make sure that the jack has a capacity of at least 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 7 PUT A LIFT TRUCK ON BLOCKS STEERING TIRES DRIVE 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 67: ...E AND LUBRICATION POINTS S40 65XM 9 27 4 28 24 5 7 10 22 23 3 14 18 13 19 12 6 3 2 20 17 25 26 21 29 1 29 8 11 14 15 1 2 15 2 2 12788 16 4 9 GM 3 0L ENGINE SHOWN OTHERS ENGINES SIMILAR 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 68: ...7 10 22 23 3 14 18 13 19 12 6 3 20 21 29 1 29 8 11 14 15 1 2 15 2 16 4 9 17 25 26 2 2 FIGURE 9 MAINTENANCE AND LUBRICATION POINTS H45 65XM GM 3 0L ENGINE SHOWN OTHERS ENGINES SIMILAR 30 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: ...ANK GM 3 0L Gas LPG Mazda M4 2 0G and 2 2G Gas LPG Perkins 704 26 UB Diesel X CIL 39 4 liter 10 4 gal 54 5 liter 14 4 gal 51 3 liter 13 6 gal 86 Octane Gasoline Diesel No 2 LPG HD 5 HORN GAUGES LIGHTS ALARMS X Check operation 13 SERVICE BRAKES AND PARKING BRAKE SERVICE BRAKES LINING X X X Check operation Check operation Check serviceability X Check C Change L Lubricate CIL Check indicator light du...

Page 70: ...C 4 3 liter 4 5 qt 4 6 liter 4 9 qt 18 to 40 C 0 to 104 F SAE 10W 30 API SL ILSAC GF 3 SAE 2362 9 ENGINE OIL GM 3 0L Gasoline and LPG X CIL C 4 3 liter 4 6 qt 18 to 40 C 0 to 104 F SAE 10W 30 API SL ILSAC GF 3 SAE 2362 9 ENGINE OIL DIESEL Perkins 704 26 UB X CIL C 8 3 liter 6 9 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 X Check C Chan...

Page 71: ...34 0 liter 36 0 qt API CC or CC SE 18 C 0 F and above SAE 10W 4 COOLING SYSTEM Mazda M4 2 0G and 2 2G GM 3 0L Perkins 704 26 UB CIL X C See NOTE 5 11 0 liter 11 7 qt 11 0 liter 11 7 qt 9 8 liter 10 4 qt 50 Water and 50 Ethylene Glycol Boron Free Anti Freeze X Check C Change L Lubricate CIL Check indicator light during operation NOTE 2 Change filters on NEW lift trucks at first 100 hours on hour me...

Page 72: ...LTER CIL X Clean or replace See NOTE 3 and NOTE 4 See PARTS MANUAL 7 AIR FILTER ELEMENT GM 3 0L EPA Compliant Engine C Clean or replace See NOTE 6 See PARTS MANUAL X Check C Change L Lubricate CIL Check indicator light during operation NOTE 3 Very dirty conditions will require daily clean and check NOTE 4 Heavy duty or high temperature operations will require more frequent checks NOTE 5 Indicator ...

Page 73: ...Clean or replace See PARTS MANUAL 1 WHEEL NUTS S40 65XM DRIVE WHEELS X Check torque 237 to 305 Nm 175 to 225 lbf ft 1 WHEEL NUTS H45 65XM DRIVE WHEELS STEER WHEELS Two Piece Wheels X Check torque 490 510 Nm 361 to 376 lbf ft 237 to 305 Nm 175 to 225 lbf ft 16 LIFT CHAINS X L As required Engine Oil X Check C Change L Lubricate CIL Check indicator light during operation P r o p e r t y o f A m e r i...

Page 74: ...4 25 UB Powershift Trans Mazda M4 2 0G Gasoline Mazda M4 2 2G Gasoline GM 3 0L Gasoline X X X X X X X X X X Adjust as required See NOTE 7 700 to 750 rpm 775 to 825 rpm 775 to 825 rpm 675 to 725 rpm 775 to 825 rpm 775 to 825 rpm 700 to 750 rpm 700 to 750 rpm 775 to 825 rpm 775 to 825 rpm X Check C Change L Lubricate CIL Check indicator light during operation NOTE 7 Perkins engine is to be at operat...

Page 75: ...G IMPCO GM 3 0L Aisan Open Loop GM 3 0L Aisan Closed Loop Perkins 704 26 UB Mazda M4 2 0G Gas Mazda M4 2 2G Gas GM 3 0L IMPCO Gas X X X X X X X X X X Adjust as required 2600 to 2700 rpm 2700 to 2800 rpm 2700 to 2800 rpm 2850 to 2950 rpm 2700 to 2800 rpm 2700 to 2800 rpm 2700 to 2800 rpm 2350 to 2550 rpm 2700 to 2800 rpm 2850 to 2950 rpm X Check C Change L Lubricate CIL Check indicator light during...

Page 76: ... PARTS MANUAL 0 8 mm 0 032 in 1 1 mm 0 045 in See PARTS MANUAL Change only if defective 26 FUEL INJECTOR Gasoline X 1 See NOTE 9 Check and clean if required FUEL INJECTOR Aisan X 1 See NOTE 9 Check and clean if required PEDALS LEVERS SEAT RAILS CABLES HINGES LINKAGES HOOD LATCH L Lubricate as necessary Hyster Part No 328388 X Check C Change L Lubricate CIL Check indicator light during operation NO...

Page 77: ... X C Replace as necessary See NOTE 10 See PARTS MANUAL 30 BREATHER ASSEMBLY Perkins 704 26 UB X C Replace as necessary See PARTS MANUAL BREATHER HOSE Perkins 704 26 UB X Clean and replace as necessary See PARTS MANUAL INCHING BRAKE PEDAL X Adjust as required 27 DRIVE BELT AND TIMING BELT X X Adjust or replace See NOTE 11 See PARTS MANUAL X Check C Change L Lubricate CIL Check indicator light durin...

Page 78: ... SIDE SHIFT CARRIAGE INTEGRAL SIDE SHIFT CARRIAGE Upper Lower Bearings L L L X C 2 Fittings As required 3 Fittings Check Wear 4 Bearings Multipurpose Grease See NOTE 8 2 5 mm 3 32 in or less 20 HYDRAULIC OIL FILTER C 1 See NOTE 1 See PARTS MANUAL 8 FUEL FILTER GASOLINE C 1 See PARTS MANUAL LPG REGULATOR Aisan X Drain tar X Check C Change L Lubricate CIL Check indicator light during operation NOTE ...

Page 79: ...isan X Check and clean if required FUEL FILTER Aisan X C 2 See PARTS MANUAL LOW EMISSIONS SYSTEM Mazda LPG and GM Closed Loop CIL 11 TRANSMISSION OIL FILTER C 1 See NOTE 1 See PARTS MANUAL 2 WHEEL BEARINGS Drive Wheel Inner Steer Wheels L L 45 kg 1 lb As required Multipurpose Grease See NOTE 8 X Check C Change L Lubricate CIL Check indicator light during operation NOTE 1 Change filters on NEW lift...

Page 80: ... BELT HIP RESTRAINTS AND SEAT RAILS X Check condition HOOD AND SEAT LATCHES X Check condition STEERING CONTROLS STEERING COLUMN LATCH X X Check operation Check operation 19 TRANSMISSION X Check operation ATTACHMENTS AND OPTIONS See NOTE 12 As specified X Check C Change L Lubricate CIL Check indicator light during operation NOTE 12 Perform maintenance as specified by the manufacturer P r o p e r t ...

Page 81: ...M AND FUEL LINES AND FITTINGS X INSPECT LOCK OFF FOR LEAKS AND ENSURE LOCK OFF CLOSING X TEST LPG GAS REGULATOR PRESSURE X INSPECT LOW PRESSURE REGULATOR FOR COOLANT LEAKS X CHECK AIR INDUCTION SYSTEM FOR LEAKS X CHECK MANIFOLD FOR VACUUM LEAKS X CHECK THROTTLE SHAFT FOR STICKING X X Check C Change L Lubricate CIL Check indicator light during operation P r o p e r t y o f A m e r i c a n A i r l i...

Page 82: ...RE OR QUANTITY SPECIFICATION INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS X INSPECT CATALYST INLET AND OUTLET X OXYGEN SENSOR CONNECTOR GM 3 0L EPA Compliant Engine X X Check C Change L Lubricate CIL Check indicator light during operation 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 83: ...ious injury or death Remove all of the air from the tires before the tires are removed from the lift truck If the air pressure is less than 80 of the correct air pressure the tire must be removed before air is add ed Put the tire in a safety cage when adding air pres sure to the tire Follow the procedures described in Add Air To The Tires When air is added to the tires use a remote air chuck The p...

Page 84: ...r damage Inspect the tread and remove any objects that will cause damage Check for bent or damaged rims Check for loose or missing parts Remove any wire straps or other material wrapped around the axle WARNING 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 P r o p e r t y o f A m e r i c a...

Page 85: ...e by hooks and one of two types of lock pins See FIGURE 12 These lock pins are installed through the top fork hooks and fit into slots in the top carriage bar Adjust the forks as far apart as possible for maximum support of the load Hook forks will slide along the carriage bars to adjust for the load to be lifted Raise the lock pin in each fork to slide the fork on the carriage bar Make sure the l...

Page 86: ... WASHER 6 WEDGE 7 KNOB 8 LEVER 9 COTTER PIN 10 LOCK PIN ASSEMBLY A fork can be removed from the carriage for replacement of the fork or other maintenance Slide a hook fork to the fork removal notch on the carriage See FIGURE 13 low er the fork onto blocks so that the bottom hook of the fork 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 87: ...o 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 Do not try to correct the alignment of the fork tips by bending the forks or adding shims Replace damaged forks Never repair damaged forks by heating or welding Forks are made of special steel using special proce dures Replace damaged forks 1 Inspect the we...

Page 88: ...MUST BE 90 OF DI MENSION X 5 CARRIAGE 6 LOAD BACKREST EXTENSION 7 MAXIMUM ANGLE 93 8 FORK REMOVAL NOTCH FIGURE 13 CHECK THE FORKS 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 89: ...for cracks and dam age 10 Make sure the lift chains are adjusted so that they have equal tension Adjustments 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 installed on the lift truck and can be read Check t...

Page 90: ...ely when unlocked The seat rails must be correctly fastened to the hood and the hood fastened to the cowl with the latch Try to lift the hood to make sure it is fastened correctly and will not move FIGURE 15 CHECK THE HOOD LATCH AND SEAT 1 LATCH STRIKER 2 HOOD LATCH 3 LATCH LEVER 4 SEAT 5 SEAT BELT LATCH 6 HIP RESTRAINT 7 SEAT RAIL 8 HOOD 9 HINGE 10 OPERATOR WEIGHT ADJUSTMENT 11 FORWARD BACKWARD A...

Page 91: ...the lift truck until a leak is repaired Make a visual check for leaks on and under the lift truck If possible find and repair the leak at the source Leaks often indicate a need for repair of damaged or worn com ponents Leaks in the LPG fuel system are usually not visible unless ice is visible There is however usually a strong odor Fuel leaks MUST be repaired NOW Check the fuel system for leaks and...

Page 92: ... MAZDA M4 2 0G GASOLINE AND LPG 1 DIPSTICK FOR ENGINE OIL 2 BATTERY 3 AUXILIARY COOLANT RESERVOIR 4 RADIATOR CAP 5 ENGINE OIL FILL 6 DRIVE BELTS 7 AIR FILTER 8 FUEL FILTER 9 ENGINE OIL FILTER 10 PCV VALVE 11 SPARK PLUGS 10 11 7 8 4 3 6 1 9 11 10 5 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 93: ...NGINE OIL 2 BATTERY 3 AUXILIARY COOLANT RESERVOIR 4 RADIATOR CAP 5 ENGINE OIL FILL 6 DRIVE BELTS 7 AIR FILTER 8 FUEL FILTER 9 ENGINE OIL FILTER 10 GLOW PLUGS 11 FUEL INJECTORS 3 4 6 7 8 2 5 1 PERKINS 704 26 UB 9 10 11 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: ...too high Stop the operation of the lift truck Make a visual check of the transmission and check the level of the transmission oil To check the transmission oil apply the parking brake and if the lift truck has a direction control lever put the direction control lever in the NEUTRAL N position Run the engine for one minute to fill the torque converter with oil Stop the engine and check the oil leve...

Page 95: ...every 250 hours Heavy duty or high temperature operations can require more fre quent checks 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 The oil level indicated by the dipstick...

Page 96: ...ttery to start the engine follow these proce dures carefully when connecting the jumper cables 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 Always connect the jumper cable that is the ground cable last c Always connect the jumper cables to the dis charged battery before connecting them to the ...

Page 97: ...ed FIGURE 20 AIR FILTER 1 CANISTER 2 FILTER ELEMENT 3 SEAL 4 CLAMP 5 WING NUT 6 BAFFLE 7 END COVER 1 2 3 4 5 6 7 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING WARNING 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 that the area around the lift truck is clear be fore starting the engine or...

Page 98: ...RUMENT CLUSTER 30 amp 8 HEATER 9 FRONT WIPER 10 REAR WIPER 11 HORN RELAY 12 LIGHT RELAY 13 TURN SIGNAL RELAY 14 REAR LIGHT RELAY 15 ACCESSORY RELAY 1 3 2 4 5 6 7 8 9 10 12 13 15 11 14 NOTE There is also a 50 amp alternator fuse near the alternator Some units also have a relay near the battery FIGURE 21 FUSES AND RELAYS 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 99: ...NE COMPARTMENT FUSES AND RELAYS GM 3 0L EPA COMPLIANT ENGINES NEWER LIFT TRUCK MODELS F1 20 AMPS F2 5 AMPS F3 15 AMPS F4 15 AMPS R1 STARTER RELAY R2 POWER RELAY R3 FUEL PUMP 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 100: ...e is started the light will go off If the light stays on while the engine is running refer to LPG FUEL SYSTEM AISAN CLOSED LOOP 900 SRM 948 or LPG GASOLINE FUEL SYSTEM GM 3 0L 4 3L EPA COMPLIANT ENGINES 900 SRM 1088 for troubleshoot ing Check Engine Light GM 3 0 Liter Gasoline When the ignition switch is turned to the ON position the Check Engine light on the instrument panel will illumi nate to i...

Page 101: ...N when the key switch is in the START posi tion and must go OFF when the engine is running If the light is ON when the engine is running the coolant and engine are too hot Stop the engine and check the coolant level in the coolant recovery reservoir Some units have a gauge for coolant temperature If the needle is in the red zone when the engine is running the coolant and engine are too hot Stop th...

Page 102: ...on of the inching brake pedal applies the service brakes and puts the transmission in NEUTRAL Lift trucks with a MONOTROLR pedal when the inch ing brake pedal is fully applied a switch in the starting circuit is closed so that the engine can be started Parking Brake Check the operation of the parking brake The operator must adjust the parking brake so that the lift truck does not move if it is par...

Page 103: ... 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 Do not operate the lift truck until a leak is repaired Check the fuel system for leaks and the condition of parts When fuel is added to the lift truck see the section How To Add Fuel To The Lift Truck Water Separator Diesel Engine The water separator is replaced every 100...

Page 104: ...el filter is empty it is necessary to disconnect a fitting and fill the components of the fuel system before the engine will start See the SERVICE MANUAL for the procedure Control Levers and Pedals Check that the control levers for the transmission mast and attachment operate as described in TABLE 2 Check that the pedals operate correctly as described in TABLE 2 Lift System Operation WARNING Lower...

Page 105: ...se the mast one meter three feet with a capac ity load The inner weldments and the carriage must raise smoothly Lower the mast All moving components must lower smoothly 5 Lower the load to approximately 0 3 meter one foot Tilt the mast forward and backward The mast must tilt smoothly and both tilt cylinders must stop evenly 6 Check that the controls for the attachment operate the functions of the ...

Page 106: ...ace shield to prevent injury to the eyes Check the radiator fins Clean the radiator with com pressed air or water as needed FIGURE 26 AUXILIARY COOLANT RESERVOIR 12777 1 FILL CAP 2 AUXILIARY COOLANT RESERVOIR 1 2 3 4 5 3 FULL MARK 4 ADD MARK 5 RADIATOR CAP HOW TO ADD FUEL TO THE LIFT TRUCK WARNING Stop the engine Turn the key switch to OFF The op erator must be off of the lift truck while fuel is ...

Page 107: ...ark the lift truck near heat or ignition sources Do not store LPG tanks near heat or an open flame 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 on the surface of the tank the valves or fittings and the odor of LPG fuel indicates a leak Inspect the LPG system and repair a ...

Page 108: ...doors Stay at least 15 meters 50 feet from buildings motor vehicles electrical equip ment or other ignition sources Stay at least 5 meters 15 feet from LPG storage tanks Use the following procedure to remove the LPG tank 1 Removable LPG tanks can be replaced indoors only if the lift truck is a minimum of 8 meters 25 feet from any open flame or ignition source 2 Move the lift truck to the area wher...

Page 109: ...el valve on the LPG tank Use your hand to tighten the fitting 4 Turn the fuel valve counter clockwise to open the fuel valve 5 Inspect the fuel system for leaks when the fuel valve is open Frost on the surface of the tank valves or fittings or a strong odor of LPG fuel indi cates a leak Use the following procedure to fill the LPG tank WARNING Read and follow all the refuelling precautions and inst...

Page 110: ... 10 Close the fuel valve on the LPG tank 11 Disconnect the hose supply 12 Stop the pump 13 Close the liquid outlet and the 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 the fuel cap Make sure the ...

Page 111: ...and a press ring must be used for each size of wheel Use a press to push the wheel from the rim and tire The capacity of the press must be approximately 355 kN to 1779 kN 80 000 to 400 000 lb For the tire sizes see the Nameplate NOTE Make sure the tires are installed on the wheels so that the outside edges of the tire and wheel are as shown in FIGURE 28 Also check the Nameplate of the lift truck f...

Page 112: ...oosen the castle nut until the hub turns freely with no looseness The torque must be less than 27 Nm 20 lbf ft Tighten the castle nut to 34 Nm 25 lbf ft torque Install the cotter pin in the castle nut at the first alignment Install the cap for the bearings NOTE Outside edges of wheel and tire rim are even for all drive and steer wheel assemblies 2 1 SOLID RUBBER TIRE 2 WHEEL FIGURE 28 TIRES AND WH...

Page 113: ...trained personnel only Deflate tire completely before removing the wheel from the lift truck If dual wheels are used deflate both tires Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death Always wear safety glasses Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire 1 Put the lift truck o...

Page 114: ...e wheels See FIGURE 29 There are several types of wheels used on this series of lift trucks 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 causing 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 caus...

Page 115: ...he wheel rim FIGURE 30 TIRE REMOVAL TWO PIECE WHEEL STEP 3 Remove the wheel rims from tire Remove the inner tube and flap SEE WARNINGS 11939 STEP 1 Remove the nuts that fasten the wheel rims together 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 116: ...he valve stem from the wheel FIGURE 31 TIRE REMOVAL THREE AND FOUR PIECE WHEELS STEP 4 Remove the wheel rim from the tire STEP 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 SEE WARNINGS 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 117: ...ub ber lead plastic or brass hammer to put parts to gether Make sure that the lock ring is in the correct position The ends of the lock ring must not touch The clearance at the ends of the lock ring will be approximately 13 to 25 mm 0 5 to 1 0 in after it is installed If the clearance is wrong the wrong part has been used 1 Clean and inspect all parts of the wheel Paint any parts that have rust or...

Page 118: ... aligned with the slot in the rim STEP 3 Turn over the rim and tire Put blocks under the rim so that the rim is 8 to 10 cm 3 to 4 in above the floor Install the flange seat if used and the side flange Hold them in the correct position STEP 4 Put the lock ring in the correct position on the rim Add air pressure to the tire as described in Add Air To The Tires SEE WARNINGS P r o p e r t y o f A m e ...

Page 119: ...eel in the tire as shown in FIGURE 32 Install the two piece wheel in the tire as shown in FIGURE 33 Add Air To The Tires See FIGURE 34 WARNING Add air pressure to the tires only in a safety cage Inspect the safety cage for damage before use When air pressure is added use a chuck that fastens onto the valve stem of the inner tube Make sure there is enough hose to permit the operator to stand away f...

Page 120: ...pproximately 13 to 25 mm 0 5 to 1 0 in when the tire has the correct air pressure Install the Wheels WARNING 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 f...

Page 121: ...ke drum when they are installed 2 Install the spacer to the axle shaft Tighten the nuts 98 Nm 80 lbf ft 3 Install the outer wheel on the spacer Tighten the nuts as shown in the MAINTENANCE SCHEDULE If the wheels are the two piece rims make sure the nuts that fasten the rim halves together are toward the brake drum when they are installed 12614 1 2 3 4 1 INNER WHEEL 2 SPACER 3 OUTER WHEEL 4 EXTENSI...

Page 122: ...of the wheel before installing the tire DO NOT use any damaged or repaired wheel parts Make sure that all parts of the wheel are the correct parts for the wheel assembly DO NOT mix parts between different types or manufacturers of wheels DO 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 ...

Page 123: ... tire Use the press to push the tire away from the side flange STEP 3 Turn the tire over Put a support under the wheel rim Make sure the wheel rim is at least 150 to 200 mm 6 to 8 inches from the bed of the press STEP 4 Put the cage in position on the tire Use the press to push the tire from the wheel rim FIGURE 36 REMOVE THE TIRE FROM THE WHEEL SEE WARNINGS P r o p e r t y o f A m e r i c a n A i...

Page 124: ...wheel rim Put the cage in position on the tire Use the press to in stall the tire on the wheel rim CAUTION Too much lubricant can cause the tire to slide and move around the wheel rim STEP 3 Remove the cage and put the flange seat if used the side flange and the lock ring in position on the wheel rim In stall the cage on the tire Use the press to push the tire onto the wheel rim so that the side f...

Page 125: ...to idle Avoid long periods of high engine speeds with a light load during the first 50 hours of opera tion High engine speeds with a light load can cause dam age to the cylinders in the engine CHANGES TO THE OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck Do not make changes to the overhead guard by weld ing Changes that are made...

Page 126: ...s To protect the tilt cylinder rods park your lift trucks with the mast tilted fully BACKWARD cylinders retracted When parked with the power OFF actuate each control handle to relieve hydraulic pressure Mast is to be stored fully lowered Coat any exposed portion of all cylinder rods with fresh high grade SAE 30 or 40 weight engine oil Install blocks front and rear at the drive wheels when parked D...

Page 127: ... above When a lift truck is to be placed in service after storage it must be given the 250 hour inspection shown in the REC OMMENDED SCHEDULE OF MAINTENANCE HOW TO STORE A LIFT TRUCK The following storage procedures are for conditions and temperatures above 0 C Adjust these procedures for local conditions and any changes in conditions during storage The preparations necessary for storage is also d...

Page 128: ...n 8 If the lift truck is not stored in a shelter put a cover over the lift truck to prevent damage from the weather In wet conditions a cover will not prevent corrosion to a lift truck that is in long term storage outside of a dry storage area Long Term Storage Do the following steps to prepare the lift truck for storage for 6 months or longer 1 Complete all short term storage procedures 2 Wrap or...

Page 129: ...n prevent clearance Removal of the mast can be necessary If a trailer is the method of transportation use blocks in front and back of the trailer tyres to prevent movement of the trailer when the lift truck is loaded and unloaded If a loading ramp is used make sure that the ramp is the cor rect design and capacity If the lift truck is equipped with lifting eyes use a crane to load and unload the l...

Page 130: ...NOT leave a manual trans mission in NEUTRAL N 4 Turn the key switch to OFF to stop the engine Check that all switches and accessories are turned OFF 5 Put blocks in front and back of the lift truck tyres to prevent any movement of the lift truck Make sure the blocks are attached to the load surface If the lift truck is equipped with an LPG fuel system and is parked more than momentarily close the ...

Page 131: ...po nents 3 Follow the steps in the section CHECKS WITH THE ENGINE STOPPED Preparation After Storage 1 Remove all tape covers and preservation materials 2 Check the lift truck for damage and missing compo nents Repair damage and or replace missing compo nents NOTE If the lift truck has been stored longer than one year all lubricants and fluids must be drained and re placed See the PERIODIC MAINTENA...

Page 132: ...MAINTENANCE 130 NOTES 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 133: ...ssere Sicuro Paga Seguranca Paga Sikkerhet Først Pinter Be Awas 12 03 8 03 10 02 1 02 5 01 1 01 7 00 6 00 5 00 5 98 1 98 9 95 Litho in U S A 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 WARNING 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 134: ...RT NO 1458874 OPERATING MANUAL CHALLENGER S40XM S45XM S50XM S55XM S55XMS S60XM S65XM DO NOT REMOVE THIS MANUAL FROM THIS UNIT SPACESAVER H45XM H50XM H55XM H60XM H65XM 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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Hyster S40XM, Operating Manual

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