Hyster S40XM, S45XM, S50XM, S60XM, S65XM Operating Manual

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OPERATING MANUAL
CHALLENGER
SPACESAVER
S40XM, S45XM, S50XM, S55XM, S55XMS, S60XM,
S65XM
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
Property of American Airlines
HYSTER COMP ANY
P ART NO. 1458874
LIFT TRUCK MODEL SERIAL NUMBER ENGINE MODEL SERIAL NUMBER TRANSMISSION TYPE SERIAL NUMBER MAST LIFT HEIGHT GROUP NUMBER CARRIAGE TYPE GROUP NUMBER DRIVE TIRE SIZE STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
REGISTERED TRADEMARKS Hyster,
Hyster Company.
, Challenger, SpaceSaver, Monotrol, RACKLOADER, SitDrive and StanDrive are trademarks of
Property of American Airlines
FOREWORD
FOREWORD
To OWNERS, USERS, and OPERATORS:
The safe and efficient operation of a lift truck requires
skill and alertness on the part of the operator. To develop the skill required the operator must:
Receive training in the proper operation of THIS lift
truck.
Understand the capabilities and limitations of the lift
truck.
Become familiar with the construction of the lift truck
and see that it is maintained in good condition.
Read and understand the warnings and operating
procedures in this manual.
In addition, a qualified person, experienced inlift truck oper­ation,mustguidea newoperatorthroughseveral drivingand load handling operations before the new operator attempts to operate the lift truck alone.
HYSTER COMPANY 2003
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 trainingprogram isavail­able from HYSTER COMPANY. For further details, contact your dealer for Hyster lift trucks.
This OPERATING MANUAL contains information neces­sary for the operation and maintenance of a basic fork lift truck. Optional equipment is sometimes installed that can change some operating characteristics described in this manual. Make sure the necessary instructions are avail­able and understood before operating the lift truck.
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FOREWORD
Some of the components and systems described in this OPERATING MANUAL will NOT be installed on your unit. If you have a question about any item described, contact your dealer for Hyster lift trucks.
Additional information that describes the safe operation and use of lift trucks is available from the following sources:
Employment safety and health standards or
regulations (Examples: “Occupational Safety and Health Standards (USA)”, “Canada Material Handling Regulations”.
Safety codes and standards (Example: American
National Standard, ANSI 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).
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 your dealer for Hyster lift trucks.
NOTE: Hyster lift trucks are not intended for use on public roads.
NOTE: The following symbols and words indicate safety in­formation in this manual:
WARNING
Indicates a condition that can cause death or injury!
CAUTION
Indicatesa condition that can causeinjury or property damage!
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CONTENTS
CONTENTS
FOREWORD 1..................................
To OWNERS, USERS, and OPERATORS 1......
CONTENTS 3...................................
MODEL DESCRIPTION 11.........................
GENERAL 1 1..................................
OPERATOR PROTECTION EQUIPMENT 11......
NAMEPLATE 12...............................
SAFETY LABELS 13...........................
INSTRUMENTS AND CONTROLS 17............
OPERATING PROCEDURES 33....................
GENERAL 33..................................
Know Your Lift Truck 33......................
Stability And Center Of Gravity 35.............
Capacity (Weight And Load Center) 36.........
INSPECTION BEFORE OPERATION 37..........
Checks With The Engine Stopped 37..........
Starting Procedures 38.......................
Starting Procedures, Gasoline Or LPG
Engine 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............................
STOPPING 58.................................
PARKING 58..................................
MAINTENANCE 61...............................
GENERAL 61..................................
Serial Number Data 62.......................
HOW TO MOVE A DISABLED LIFT TRUCK 62....
HowToTowtheLiftTruck 62..................
HOW TO PUT A LIFT TRUCK ON BLOCKS 63....
How To Raise the Drive Tires 63..............
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CONTENTS
How To Raise the Steering Tires 64...........
MAINTENANCE SCHEDULE 67...................
MAINTENANCE PROCEDURES EVERY 8 HOURS
OR DAILY 81.....................................
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED 81..................................
Tires and Wheels 81........................
Forks 83...................................
Forks, Adjustment 83........................
Forks, Removal 83..........................
Forks, Installation 85.........................
Inspection Of Forks, Mast, and Lift Chains 85...
Safety Labels 87............................
Operator Restraint System 87................
Steering Column Latch 89....................
Check For Fuel, Oil Or Coolant Leaks 89.......
Drive Belt 89...............................
Engine Oil 89...............................
Transmission Oil Temperature 92.............
Hydraulic System 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, 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....................
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CONTENTS
WHEELS AND TIRES 108.......................
General 108.................................
How To Change A Solid Rubber Tire
S40--65XM Models 109.......................
RemoveAndInstallTheTireOnThe
Wheel 109...................................
How To Repair A Pneumatic Tire H45--65XM
Models 1 11..................................
Remove The Wheels From The Lift Truck 111....
Remove The Wheel From The Tire 112..........
Install The Wheel in the Tire 1 15................
AddAirToTheTires 117......................
Install the Wheels 118.........................
INSTALLATION 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...............................
Loading 127.................................
Unloading 128...............................
PREPARATION FOR USE 129....................
Preparation After Transport 129................
Preparation After Storage 129..................
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CONTENTS
NOTES
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A WARNING label with this information must be on the lift truck.
WARNING
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WARNING
NOTES
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MODEL DESCRIPTION
1. OVERHEAD 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
FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS OF S40--65XM SERIES
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10
9
8
7
6
6
5
1
2
3
4
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MODEL DESCRIPTION
1. OVERHEAD 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
FIGURE 2. MODEL VIEW SHOWING MAJOR COMPONENTS OF H45--65XM SERIES
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12
11
10
9
8
7
6
6
5
1
2
3
4
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Property of American Airlines
MODEL DESCRIPTION
MODEL DESCRIPTION
GENERAL
This OPERATING MANUAL is for the following models of lift trucks:
S45XM, S45XM, S50XM, S55XM, S55XMS, S60XM, S65XMS
H40XM, H50XM, H55XM, H60XM, H65XM
These lift trucks are available with the following engines:
Mazda M4--2.0G or M4--2.2G engine which use gasoline or LPG fuel
GM 3.0L engine that uses gasoline or LPG fuel
Perkins 704--26 (UB) diesel engine
H45--65XM only
The single--speed powershift transmission can be equipped with two types of controls:
A MONOTROLR pedal that controls both the for- ward and reverse operation of the powershift trans­mission and the speed of the engine.
A direction control lever on the left side of the steering column that controls the forward, neutral and reverse operation of the powershift transmis­sion. A separate accelerator pedal controls the en­gine speed.
The S40--65XM lift trucks are equipped with solid rubber tires. The H45--65XM lift trucks are equipped with pneu­matic 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 installed to keep loose parts of the load from falling back toward the opera­tor. It must be high enough, with openings small enough to prevent the parts of the load from falling backwards. If a load backrest extension that is different from the one installed on your lift truck is required, contact your Hyster lift truck dealer.
The OVERHEAD GUARD is intended to offer reasonable protection to the operator from falling objects, but can not protect against every possible impact. Therefore, it must
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MODEL DESCRIPTION
not be considered a substitute for good judgment and care when handling loads. Do not remove the overhead guard.
The SEAT BELT AND HIP RESTRAINT provide additional means to help the operator keep the head and torso sub­stantially within the confines of the lift truck frame and overhead guard if a tipover occurs. This restraint system is intended to reduce the risk of the head and torso being trapped between the lift truck and the ground, but it can not protect the operator against all possible injury in a tipover. The hip restraint will help the operator resist side movement. It is not a substitute for the seat belt. Always fasten the seat belt.
NAMEPLATE
WARNING
Any change to the lift truck, the tires or its equipment can change the lifting capacity. If the Nameplate does not show the maximum capacity , or if the lift truck equipment, 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 Name­plate.
The maximum capacity for the lift truck, at full load height, must be shown on the Nameplate. Special capacities with the load height reduced or with optional load centers, may also be shown on the Nameplate.
The lift truck serial number code is on the Nameplate. The serial number code is also stamped on the lift truck frame
When a lift truck is shipped incomplete from the factory, the Nameplate is covered by an INCOMPLETE label as shown in FIGURE 3. If the equipment on the truck is changed, the Nameplate is covered by a NOTICE label as shown in FIGURE 3. If your lift truck has either of these labels, do not operate the lift truck. Contact your dealer for HYSTER lift trucks to obtain a complete correct Name­plate.
.
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MODEL DESCRIPTION
WARNING
DO 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 new ca­pacity rating.
SAFETY LABELS
Safety labels are installed on the lift truck to give informa­tion about possible hazards. It is important that all safety labels are installed on the lift truck and can be read. See FIGURE 4.
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MODEL DESCRIPTION
NAMEPLATE
NOTICE LABEL
FIGURE 3. NAMEPLATE AND LABELS
TRUCK MODEL
Serial no. Approx.weight
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 c ompleted Nameplate showing unit configurationand ratedcapacity.Completed Nameplates may be obtained through your HYSTER dealer.
NOTICE TO USER
1304058R
INCOMPLETE LABEL
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MODEL DESCRIPTION
1
3
2
5
SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS
FIGURE 4. WARNING AND SAFETY LABELS (1 of 2)
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4
7
8
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MODEL DESCRIPTION
Y
)
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12
16
10
13
14
15
1. WARNING, OPERATION
2. DRIVE TRAIN PROTECTION CAUTION
3. OPTIONAL FIRE SAFETY RATING
4. CASE WITH OPERATING MANUAL
5. NAMEPLATE
6. WARNING FOR PARKING BRAKE
7. NO ONE ON OR UNDER FORKS
8. NO RIDERS
9. TIPOVER WARNING
10. MAST WARNING 1 1. 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
16
17
SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS
FIGURE 4. WARNING AND SAFET
LABELS(2of2
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MODEL DESCRIPTION
5
4
3
2
1
6
FIGURE 5. INSTRUMENTS
7
17
8
18
11
9*
10
*
USED ONLY ON S40--65XM MODEL TRUCKS
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MODEL DESCRIPTION
INSTRUMENTS AND CONTROLS
WARNING
If any of the instruments, levers, or pedals do not operate as described in the following tables, report the prob­lem immediately. DO NOT operate the lift truck until the problem is corrected.
TABLE 1. INSTRUMENTS (See FIGURE 5.)
ITEM
NO.
1
2
Fuel Gauge
Coolant Temperature Gauge
ITEM
FUNCTION
This gauge indicates the amount of fuel in the gasoline or diesel fuel tank.
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.
CAUTION
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 protection system.
3 Hour Meter The hour meter operates when the key switch is in the ON position. Periodic
Maintenance recommendations are based on these hours.
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MODEL DESCRIPTION
ITEM
NO.
4
Left--Hand Turn Indicator
5 Warning Light,
Alternator
6
Warning light, Transmission Oil Temperature
7 Warning Light,
Engine Oil Pressure
ITEM FUNCTION
The light is on when the turn indicator lever is in the left turn position.
The light will be ON when the key switch is ON and the engine is not running. The light must go OFF when the engine is running.
CAUTION
Do not continue to operate the lift truck if the red light is ON at engine speeds above idle.
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 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.
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 engine immediately if the red light is ON while the engine is running. NOTE: Engine will stop after a 30 second warning buzzer if engine oil pressure
is less than 13.8 kPa (2 psi) on S40--65XM series with protection system.
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MODEL DESCRIPTION
ITEM
NO.
8 Warning Light,
Brake Fluid Level
9 Warning Light,
Coolant Level in the Radiator (Used only on S40--65XM model trucks.)
10 Warning Light,
Fasten Seat Belt
ITEM FUNCTION
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 brake fluid level in the reservoir is too low.
CAUTION
Do not continue to operate the lift truck if the light is ON during operation.
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.
CAUTION
Do not continue to operate the lift truck if the light is ON during operation.
The red light is ON for ten seconds anytime the key switch is turned to the ON position.
WARNING
Always fasten the seat belt when operating the lift truck.
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MODEL DESCRIPTION
ITEM
NO.
11
Water separator Warning Light, (Diesel Only)
12 Indicator Light,
Cold Start (Diesel Only)
13 Malfunction
Indicator Lamp (Lift trucks with
GM 3.0L engine, gas fuel system)
13 Malfunction
Indicator Lamp (Lift trucks with Gas-
oline or LPG closed loop low emission system)
ITEM FUNCTION
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 water separator must be drained.
The red light is ON when the key switch is ON and the glow plugs are activated. The length of time that the light is ON (glow plugs activated) is determined by the temperature of the engine. When the light goes out, the engine can be started. When the starter is cranking, the light will come ON again until the starter is off and the engine is running.
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 when the engine is running.
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 closed loop low emission system and the engine is running. A trained service person must make repairs and adjustments if this light is ON when the engine is running.
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MODEL DESCRIPTION
ITEM
NO.
14 Indicator Light,
Low LPG Fuel Level
15 Indicator Light,
Air Filter Restriction
16 Right--Hand
Turn Indicator
17
Engine Oil Pressure Gauge
ITEM FUNCTION
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 fuel level in the tank is low.
The red light is ON when the 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 air cleaner has a restriction and needs cleaning.
The light is on when the turn indicator lever is in the right turn position.
This gauge indicates the pressure of the oil in the engine. During normal operation the gauge needle will be in the green area.
CAUTION
Do not continue to operate the lift truck when the gauge indicates low oil pressure (needle in the red area).
NOTE: Engine will stop after a 30 second warning buzzer if engine oil pressure
is less than 13.8 kPa (2 psi) on S40--65XM series with protection system.
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MODEL DESCRIPTION
ITEM
NO.
18 Voltmeter This gauge indicates the output of the alternator. During normal operation the
ITEM FUNCTION
gauge needle will be in the green area.
CAUTION
Do not continue to operate the lift truck when the gauge indicates in the yellow or red areas of the gauge.
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MODEL DESCRIPTION
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10
9
13
14
5
4
2
1
19
17
18
16
5
6
4
3
2
1
UNITS WITH DIRECTION CONTROL LEVER UNITS WITH MONOTROLR PEDAL
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7
16
8
15
FIGURE 6. CONTROLS
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14
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TABLE 2. CONTROLS (See FIGURE 6.)
MODEL DESCRIPTION
ITEM
NO.
1
Steering Wheel
2 Latch for Tilt
Steering Column
3 Direction Control
Lever
ITEM FUNCTION
The steering wheel controls the position of the steer tires. A latch located on the lower left side of the steering column allows the operator
to select different positions for the steering wheel. Raise the latch to release the steering column. Move the steering column to the selected position. Release the latch to lock the steering column in position.
The direction control lever for 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 optional reverse alarm will be on in the REVERSE position during normal operation.
NOTE: There is a switch in the seat that actuates an audible buzzer. If the operator leaves the seat with the key switch ON and the lever is not in
NEUTRAL, the buzzer will pulse ON and OFF for 10 seconds.
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MODEL DESCRIPTION
ITEM
NO.
4 Parking Brake Lever The lift truck is equipped with a lever to apply the parking brake. Pull the lever
ITEM FUNCTION
to apply the parking brake. Use your thumb to release the button on the lever when the lever is moved to release the parking brake.
On lift trucks with a MONOTROLR pedal, applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck or 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.
WARNING
Correct adjustment is necessary to provide adequate braking. See the MAINTENANCE section for adjustment procedures.
Always apply the parking brake when leaving the lift truck.
5
Horn
6 Switch The switch controls the operation of front drive lights. Push on the top of the
The horn button controls the operation of the horn.
switch to turn the lights ON.
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MODEL DESCRIPTION
ITEM
NO.
7 Switch The switch controls the operation of the rear drive lights. Push on the top of the
8 Switch The switch controls the operation of the front windshield wiper and windshield
9 Switch The switch controls the operation of rear windshield wiper and windshield
10 Switch The switch controls the operation of the heater. Push on the top of the switch to
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Lift/Lower Control Lever
12 Tilt
Control Lever
ITEM FUNCTION
switch to turn the lights ON.
washer. Push the front of the switch to the first position to turn ON the windshield wiper. Push the front of the switch past the ON position to activate the windshield washer.
washer. Push the front of the switch to the first position to turn ON the windshield wiper. Push the front of the switch past the ON position to activate the windshield washer.
turn the heater ON.
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 carriage and forks. Push the control lever forward to lower the carriage and forks.
The tilt control lever is on the right of the lift/lower control lever. Push the control lever forward to tilt the mast and forks forward. Pull backward on the control lever to tilt the mast and forks backward.
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MODEL DESCRIPTION
ITEM
NO.
13 Control Leverfor Auxiliary
Hydraulic Functions (3 lever). See FIGURE 6.
14 Control Leverfor Auxiliary
Hydraulic Functions (4 lever). See FIGURE 6.
15
Accelerator Pedal
ITEM FUNCTION
rd
The third control lever is installed to the right of the tilt control lever. This control lever can have two methods of operation, depending on the attachment.
WARNING
The control lever with a detent must be installed when an attachment with a clamp is installed. See your dealer for Hyster lift trucks to get the correct control lever.
Control Lever with a Detent -- Attachments with a clamp action: The lever
is spring--loaded toward the operator. The lever is operated by moving it to the 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.
th
The fourth control lever is installed to the right of the third control lever. The lever is spring--loaded toward the operator. The lever is operated by moving it to the right, then forward and backward.
This pedal controls the speed of the engine and is operated by the operator’s right foot. It is used on units that have a direction control lever.
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