Hyster CHALLENGER H165XL Operating Manual Download

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OPERATING MANUAL

CHALLENGER

H165--280XL [E007]

H300--360XL [D019]

H330--360XL--EC [D019]

HYSTER COMPANY

PART NUMBER 897342

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

Property of American Airlines

Summary of Contents for CHALLENGER H165XL

Page 1: ...RATING MANUAL CHALLENGER H165 280XL E007 H300 360XL D019 H330 360XL EC D019 HYSTER COMPANY PART NUMBER 897342 DO NOT REMOVE THIS MANUAL FROM THIS UNIT 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...

Page 2: ...FT 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 an...

Page 3: ...ke sure that 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 la...

Page 4: ...ers private insurers and private organiza tions Example Accident Prevention Manual For Indus trial Operations from the National Safety Council Guide for Users of Industrial Lift Trucks describes lift...

Page 5: ...ng Procedures LPG Engine 36 Shutdown Procedures Turbo Engines 37 Checks With The Engine Running 37 OPERATING TECHNIQUES 39 Basic Operating Procedures 39 Driving And Direction Changes 42 Inching 43 Ste...

Page 6: ...rs See FIGURE 16 81 Forks 82 Forks Adjustment 82 Forks Removal 82 Forks Installation 83 Inspection Of Forks Mast And Lift Chains See FIGURE 17 and FIGURE 18 84 Tires And Wheels See FIGURE 19 85 Operat...

Page 7: ...Remove The Tire From The Wheel See FIGURE 28 103 Solid Rubber Tires Install The Tire On The Wheel See FIGURE 29 103 Install the Wheels See FIGURE 30 106 HOW TO PUT INTERNAL COMBUSTION ENGINE I C E TR...

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: ...DEL VIEW SHOWING MAJOR COMPONENTS 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 1 OPERATOR COMPARTMENT AND CAB OVERHEAD GUARD 2 CARRIAGE AND LOAD BACKREST 3 COUNTERWEIGHT 4 STEERING AXLE 5 DRIVE AXLE 6 MAST 7 HOOD...

Page 12: ...with attachments such as fork positioners a side shift carriage or a container at tachment OPERATOR PROTECTION EQUIPMENT SEE FIGURE 1 The OVERHEAD GUARD or CAB is intended to offer rea sonable protec...

Page 13: ...O NOT add to or modify the lift truck Any change to the lift truck the tires or its equipment can change the lifting capacity The lift truck must be rated as equipped and the nameplate must show the n...

Page 14: ...MODEL DESCRIPTION 12 FIGURE 3 WARNING AND SAFETY LABELS 1 of 2 SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS 1 2 3 4 7 8 5 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 15: ...ONE ON OR UNDER FORKS 8 TIPOVER WARNING 9 MAST WARNING 10 FAN WARNING 11 ETHER WARNING 12 PARKING BRAKE WARNING 13 FLAMMABLE LP GAS GM V 8 ENGINE ONLY 9 12 SEE THE PARTS MANUAL FOR THE PART NUMBER AND...

Page 16: ...MODEL DESCRIPTION 14 FIGURE 4 INSTRUMENTS s1120 1 2 5 4 6 7 8 9 10 3 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: ...em is corrected TABLE 1 INSTRUMENTS See FIGURE 4 ITEM NO ITEM FUNCTION 1 Air Pressure Gauge This gauge indicates the air pressure in the brake system 2 Low Air Pressure Indicator This red indicator li...

Page 18: ...o flashes when a transmission overspeed condition is detected The engine goes into the de throttle mode until the transmission output speed falls to acceptable pre set limits 4 Coolant Temperature Gau...

Page 19: ...ght is ON at engine speeds above idle 8 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 running CAUTION Stop the engi...

Page 20: ...ransmission Oil Temperature The red light is ON when the key switch is in the START position and must go OFF when the engine is running CAUTION Do not continue to operate the lift truck if the red lig...

Page 21: ...MODEL DESCRIPTION 19 FIGURE 5 SWITCHES s1119 11 12 17 18 19 16 1 2 3 4 6 5 7 8 9 10 13 15 14 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 22: ...tarting the engine WARNING Apply parking brake before leaving truck Parking brake is NOT automatically applied 1 Parking Brake Knob Some lift trucks have this type of knob ROUND BLACK KNOB This knob c...

Page 23: ...he switch to turn the lights ON 5 6 7 Windshield Wiper and Washer Switches Rear Wiper Washer Top Wiper Washer Front Wiper Washer There is a switch for each windshield wiper windshield washer Push the...

Page 24: ...t is in position to be locked or unlocked Both lights must be illuminated before the controls will operate Green Lights Bottom The green lights illuminate when the lock pins are extended Each lock pin...

Page 25: ...he engine A spring returns the key to position No 2 ON position when the key is released NOTE There is a mechanical lockout that prevents the key switch from being returned to the START position witho...

Page 26: ...to the left the heater vent is open When the air vent is open the heater gets air from outside the cab When the knob is pushed to the right the vent is closed and the heater gets air from inside the c...

Page 27: ...MODEL DESCRIPTION 25 FIGURE 6 CONTROLS 3 A 7 10 1 5 B 2 3 4 5 or 5 A 6 8 9 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 28: ...e positions 1 First gear The transmission stays in this gear until the operator selects another speed range 2 Second gear The transmission stays in this gear until the operator selects another speed r...

Page 29: ...valve on the hydraulic pump senses hydraulic pressure Pull back on the lever and push the button to lift at the higher speed 4 Tilt Control Lever The tilt control lever is on the right of the lift lo...

Page 30: ...e right side of the pedal causes the lift truck to move in REVERSE Pushing on the left side of the pedal causes the lift truck to move in FORWARD The speed of the engine increases as the pedal is depr...

Page 31: ...adjustment Pull up on the lever and move the steering column to the desired position then release the lever 11 Autoshift Con troller Bypass Unit J1 J2 The autoshift controller bypass unit is located u...

Page 32: ...se 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 Forw...

Page 33: ...lter 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 conta...

Page 34: ...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 lif...

Page 35: ...he mast is tilted for ward and back The CG moves up and down as the mast moves up and down CG Truck Combined CG The center of gravity and therefore the stability of the loaded lift truck is affected b...

Page 36: ...uck is shown on the Name plate The capacity is listed in terms of weight and load center The weight is specified in kilograms or pounds The load center is specified in millimeters or inches The capaci...

Page 37: ...ir filter Condition of forks carriage chains mast attachments and operator compartment Leaks from the engine transmission hydraulic system and fuel system Condition of wheels and tires Check air press...

Page 38: ...approved starting aids Use of non ap proved starting aids can result in engine damage and void engine warranty 4 If the engine does not start after four attempts get help from authorized service perso...

Page 39: ...OPERAT ING MANUAL for a description of the correct operation Shutdown Procedures Turbo Engines 1 Put the control lever for the transmission in the Neutral N position 2 With the engine at idle speed w...

Page 40: ...es contains carbon monoxide and other harmful chemicals Car bon monoxide is a colorless odorless poison and can cause unconsciousness or death without warn ing Long term exposure to exhaust or chemica...

Page 41: ...ly that can cause the lift truck to tip If you have not read the WARNING page in the front of this OPERATING MANUAL do so NOW As you study the following information about how to properly operate a lif...

Page 42: ...operator attempts to operate the lift truck alone A basic education in proper driving and load handling techniques is absolutely neces sary to prepare the new operator for proper defensive driving an...

Page 43: ...If a lift truck is used to elevate a worker a safety plat form must be attached to the forks and carriage The platform must be specially built to meet or exceed the requirements of ANSI B56 1 It must...

Page 44: ...r does not have the direction change function The Autoshift Control Lever controls the three speeds of the transmission If the lift truck has a Monotrol pedal push on the left side of the pedal to go...

Page 45: ...at allows a slow travel speed while keeping the engine speed high for fast operation of the lift mechanism The lift truck has a brake pedal and an inching pedal The brake pedal right hand pedal applie...

Page 46: ...similar dy namic forces are present In fact the lift truck will ac tually tip to the side easier when empty than when loaded with the load lowered Rearward tilt off cen ter loads and uneven ground wi...

Page 47: ...e operator steers with the left hand The right hand is used to oper ate the lift tilt and attachment controls When turning the lift truck from a wide aisle into a narrow aisle start the turn as close...

Page 48: ...the truck if they extend past the top of the carriage and mast 3 Position each fork the same distance from the center of the carriage This action will help center the load on the carriage Set the for...

Page 49: ...ad guard provides reasonable protection to the operator from falling objects but cannot protect against every pos sible impact A lift truck without an overhead guard provides no such protection and ot...

Page 50: ...r the unloading place If the lift mechanism is raised to pick up or deposit a load keep the tilt angle in either direction to a minimum Backward and forward tilt are helpful but they affect side and f...

Page 51: ...ve forward slowly until the forks are in posi tion 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 forks Make su...

Page 52: ...d 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...

Page 53: ...Y TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FROM THE POINT OF IMPACT 5 To put the load on a stack align the lift truck with the stack Raise the load higher than the point where it wi...

Page 54: ...mast fully backward to help keep the load on the forks NOTE Not every load can be lifted using only the forks of a lift truck Some loads will require a special attachment Load Handling How To Handle...

Page 55: ...off the lock pins extend The green lights on the control panel for the attachment will be illuminated when the lock pins are extended The lock pins must be retracted before the attachment can be put...

Page 56: ...TE If both lock pins are not engaged an audible alarm will sound Change the position of the container to allow the pins to engage WARNING DO NOT lift the container unless both lock pins are fully enga...

Page 57: ...or retracting the outer booms of the attach ment Load Handling Traveling 1 When traveling with the load lowered keep the load against the carriage and the mast tilted fully backward This will help kee...

Page 58: ...k in the direction of travel to avoid damage to something or injury to someone 4 When traveling up or down a grade with a heavily loaded lift truck the load should be kept upgrade to main tain control...

Page 59: ...ns Lift trucks with solid rubber tires are designed to operate on relatively smooth surfaces Lift trucks with pneumatic tires can adapt to more uneven ground Always make sure you pick the smoothest ro...

Page 60: ...ill permit it to be brought to a stop in a safe manner HIGHWAY TRUCKS RAILROAD CARS AND DOCKS Maintain a safe distance from the edge of docks ramps platforms and other similar working surfaces Watch t...

Page 61: ...oad 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 move ment of the lift truck in and out of the railroad car S Chec...

Page 62: ...to stop the engine 5 If the lift truck must be left on an incline put blocks on the down hill side of the wheels so that the lift truck can not move 6 Check engine compartment if operating in areas co...

Page 63: ...nance Regular inspec tion lubrication and maintenance will help your lift truck give more efficient performance and operate for a longer period of time Some users have service personnel and equipment...

Page 64: ...e release bolt or nut until the brake is released On the H165 280XL models the release bolt washer and nut are in a receptacle on the side of the air chamber Make sure the release bolt is engaged in t...

Page 65: ...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 the forks Be careful to not da...

Page 66: ...s used to support the lift truck are solid one piece units Put a steel plate on top of the block NOTE Some lift trucks have lifting eyes These lift points can be used to raise the lift truck so that b...

Page 67: ...the jack under the steering axle or frame to raise the lift truck Make sure that the jack has a capacity of at least 2 3 of the total weight of the lift truck as shown on the name plate 3 Put blocks u...

Page 68: ...E 9 MAINTENANCE POINTS DIESEL ENGINE SHOWN 12473 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18192021 22 23 24 25 1 7 8 26 27 28 29 30 31 32 33 34 35 25 21 30 10 13 36 11 P r o p e r t y o f A m e r i c...

Page 69: ...AGE ATTACHMENT X Check Condition and Operation 6 LIFT CHAINS X X L X X Check Condition and Lubrication Check Adjustment Check Length Engine Oil SAFETY LABELS X Replace If Necessary See Parts Manual SA...

Page 70: ...Parts Manual 13 BATTERY ELECTROLYTE LEVEL X X Clean Check Level See Parts Manual 2 Batteries 15 HYDRAULIC SYSTEM H8 00 12 00XL H165 280XL H13 00 16 00XL H300 360XL X C 113 liter 31 7 gallons 142 lite...

Page 71: ...5 qt 1 Filter See NOTES 1 2 API SE SF greater than 18 C 0 F SAE 10W 30 See Parts Manual HORN GAUGES LIGHTS ALARMS AND MIRRORS X Check Operation 31 TRANSMISSION OIL HYSTER T 50 X C 28 liter 29 qt Hyst...

Page 72: ...s 2 Fittings See NOTE 4 Multi Purpose Grease Multi Purpose Grease 10 SHAFT FOR BRAKE ACTUATORS L 2 Fittings Multi Purpose Grease See NOTE 4 5 DRIVE AXLE AND DIFFERENTIAL H8 00 12 00XL H165 280 XL H13...

Page 73: ...8 36 4 2 7 MAST PIVOTS SLIDING SURFACES SIDE SHIFT CARRIAGE FORK GUIDES TILT CYLINDER PIVOT PINS CHAIN ANCHORS Top of Mast L L L L L L 2 Fittings As Necessary 4 Fittings As necessary 4 Fittings 2 See...

Page 74: ...ry Adjust as Necessary 725 to 775 rpm 2660 to 2760 rpm 725 to 750 rpm 2700 to 2800 rpm TIMING INJECTION PUMP X Adjust as Required 23 BTDC Static TIMING GM V 8 X Adjust as Required 6 to 8 BTDC VALVE AD...

Page 75: ...C 1 See NOTE 1 See Parts Manual 16 HYDRAULIC SYSTEM OIL FILTER C 1 See NOTE 1 See Parts Manual 29 HUB BEARINGS STEER WHEELS C As Necessary Multi Purpose Grease See NOTE 4 ENGINE COMPARTMENT X Remove C...

Page 76: ...MAINTENANCE 74 FIGURE 10 MAINTENANCE POINTS EMPTY CONTAINER ATTACHMENT 12698 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 77: ...s Multi Purpose Grease4 2 SIDE SHIFT CYLINDER PINS L 2 Fittings Multi Purpose Grease4 3 LOCK PINS L 2 Fittings Multi Purpose Grease4 4 BEARING BLOCKS X L As Necessary Multi Purpose Grease4 5 ACCUMULAT...

Page 78: ...eaks and conditions that are not normal Clean any oil or fuel spills Ensure all sur faces are free of oils lubricants fuel and organic dust or fibers paper wood cotton agricultural grass grain etc Hyd...

Page 79: ...y as needed If more hy draulic oil is added than the FULL level the hydraulic oil will leak from the breather during operation Check the hydraulic system for leaks and damaged or loose components Engi...

Page 80: ...can cause burns Check the coolant level at the auxiliary coolant reservoir Make sure the coolant level is between the FULL and the ADD mark on the auxiliary coolant reservoir The coolant will expand...

Page 81: ...condition of parts When adding fuel to the lift truck refer to the How To Add Fuel To The Lift Truck procedures in this OPERAT ING MANUAL Primary Fuel Filter Diesel See FIGURE 13 Drain the water from...

Page 82: ...eep sparks or open flame away from the battery area Do not make sparks from the battery connections Discon nect the battery ground cable when doing mainte nance Keep the batteries and cable terminals...

Page 83: ...is charged battery before connecting them to the booster battery Pre Cleaner For Engine Air Filter See FIGURE 15 Clean the pre cleaner for the air filter as necessary Re move the cover for the pre cle...

Page 84: ...n forks Pin forks are fastened to the carriage with large fork pins Forks Adjustment A lock pin for each fork fits into the top carriage bar and a slot in the fork These lock pins hold the fork in pos...

Page 85: ...forks until the fork pins can be installed Install the fork pins fork guides and the retainers 3 FORK PIN DAMAGE 4 MUST BE 90 OF DIMENSION X 5 FORK WEAR 1 5 3 3 2 11195 FIGURE 17 CHECK THE FORKS X 4...

Page 86: ...ks Make sure that the nuts and bolts 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 forks for cracks and wear Chec...

Page 87: ...an cause se rious 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 pressure the tire must be rem...

Page 88: ...aged rims Check for loose or missing hardware Re move any wire strapping or other material that is wrapped around the axle Make sure the wheel nuts are tight Tighten the wheel nuts in a cross pattern...

Page 89: ...etween the flange and body of the wheel nut Also put two drops of oil on the threads of the studs Operator Restraint System See FIGURE 20 The seat belt hip restraint brackets seat and mounting are all...

Page 90: ...he 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 i...

Page 91: ...on mast and attachment operate as described in Tables 2 and 3 Check that the pedals operate as described in Table 2 Transmission Oil See FIGURE 22 Apply the parking brake Check the oil level in the po...

Page 92: ...y lowered and the engine is STOPPED If the mast cannot be lowered use chains on the mast weldments and carriage so that they can not move Make sure the moving parts are attached to a part that does no...

Page 93: ...ck ward The mast must tilt smoothly and both tilt cyl inders must stop evenly f Check that the controls operate the functions of the attachment correctly See the symbols next to each of the controls M...

Page 94: ...k fuel level or check for leaks with an open flame Breathing fuel vapor may cause nausea uncon sciousness or death Long term exposure to gasoline vapors may cause liver or kidney damage and cancer Avo...

Page 95: ...om service WARNING LPG tanks are heavy The weight of an LPG tank can exceed the maximum recommended weight for safe lifting by an individual Get assistance when lifting or lowering an LPG tank Use cor...

Page 96: ...LIQUID LEVEL INDICATOR 6 HOLE FOR ALIGNMENT PIN 7 TANK RELIEF VALVE 8 STEPS REFERENCE 9 LATCH AND STRAP 10 ACCESS PANEL 11 FRAME REFERENCE NOTE Some LPG tanks have an auxiliary fill fitting instead o...

Page 97: ...isconnect fitting to the fuel valve on the LPG tank Use your hand to tighten the fitting d Turn the fuel valve counterclockwise to open the fuel valve e Inspect the fuel system for leaks when the fuel...

Page 98: ...ndicated by the liquid level indicator Immediately close the valve at the end of the supply hose i Close the vent valve on the LPG tank j Close the fuel valve on the LPG tank k Disconnect the supply h...

Page 99: ...ed from the lift truck If dual wheels are installed remove the air pressure from both tires Air pressure in the tires can cause the tire and rim to explode causing serious injury or death 1 Raise the...

Page 100: ...m STEP 1 Loosen the tire bead from the side ring and or lock ring STEP 2 Put the tire tool into the slot between the side ring and or lock ring and the wheel rim Remove the side ring and or lock ring...

Page 101: ...he air pressure from the tire be fore it is removed from the lift truck If dual wheels are installed remove the air from both tires Air pres sure in the tires can cause the tire and rim to explode cau...

Page 102: ...he ends of the side ring must not touch The clearance at the ends of the side ring must be 2 5 to 6 5 mm 0 1 to 0 25 in after air pressure is added to the tire If the clearance is wrong the wrong part...

Page 103: ...ube is aligned with the slot in the rim SEE WARNINGS STEP 3 Turn over the rim and tire Put a block under the rim so that the rim is 8 to 10 cm 3 to 4 inches above the floor If used install the wedge b...

Page 104: ...3 psi 1 Put the tire in a safety cage 2 Add 20 kPa 3 psi of air pressure to the tire 3 Check that all wheel parts are correctly installed Hit the side ring and or lock ring lightly to make sure that i...

Page 105: ...an cause injury or death Clean and inspect all parts of the wheel before in stalling the tire DO NOT use any damaged or re paired wheel parts Make sure that all parts of the wheel are the correct part...

Page 106: ...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 o...

Page 107: ...heel rim Put the cage in position on the tire Use the press to install 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...

Page 108: ...ft in the sequence shown Check to make sure that the wheel s is tight against the hub then tighten the nuts to 640 to 680 Nm 470 to 500 lbf ft WARNING Check all wheel nuts after 2 to 5 hours of opera...

Page 109: ...ty and increased usable floor area remove the forks and tag them with the truck serial number Prior to operating a truck each month make a visual in spection for leaks or signs of deterioration Take c...

Page 110: ...tion for more than 30 days a Give an equalizing charge prior to placing new bat teries in storage Used batteries are to be fully charged then allowed to balance for approximately three more hours b Ne...

Page 111: ...e engine through cycles from idle to full throttle and back 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 l...

Page 112: ...MAINTENANCE 110 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 113: ...MAINTENANCE 111 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 114: ...F rst Essere Sicuro Paga Seguranca Paga Sikkerhet F rst Pinter Be Awas 10 02 10 99 3 99 11 98 5 97 9 93 2 91 10 89 Printed in U S A California Proposition 65 This product contains and or emits chemica...

Page 115: ...Jack Corrected autoshift details on pages 15 and 24 Added bypass unit on page 28 Added OSHA statement on page 1 Deleted reference to Operator Seat alarm buzzer on page 23 per Alan Reece review comment...

Page 116: ...2 DO NOT PUBLISH THIS PAGE REFERENCE ONLY 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: ...ractice Added Model Code designations 11 9 98 Lloyd Finished To Chris for routing printing 11 11 98 Lloyd Made Chris and Theo s changes Back to Chris for routing printing 10 11 99 Jack Corrected autos...

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Hyster CHALLENGER H165XL, Operating Manual

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