Hyster CHALLENGER H70XL User manual

OPERATING MANUAL
CHALLENGER
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
H70XL, H80XL, H90XLS, H90XL, H100XL,
H110XL (G005)
H135XL, H135XL2, H155XL, H155XL2, H155XLS
(F006, G006)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
HYSTER COMPANY PART NO. 897364
Property of American Airlines

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
Hyster,,Vista, MONOTROLand Yardmasterare registered trademarks of Hyster Company in certain
countries. ,Fortist, Fortenst, Pacesetter VSMt, DuraMatcht, Spectrumt, TouchPointt, TouchControlt,
EZXchanget,HSMt, ReachStackert, SitDrivet, StanDrivet, Multiquipt, and Unisourcetare trademarks of Hyster
Company in the united States and/or in certain countries where rights in unregistered trademarks are recognized. Hyster
Company products included in this document may be covered by U.S. Patenet No. 6,684,148 and other U.S. and foreign
patents pending. EHyster Company 2005. All rights reserved.
Property of American Airlines

FOREWORD
HYSTER COMPANY 2005 897364 -- ENGLISH 1
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 in lift truck opera-
tion, must guide a new operator through several driving and
load handling operations before the new operator attempts
to operate the lift truck alone.
It is the responsibility of the employer to make 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 laws and regulations include:
Occupational Safety and Health Act (USA)
Canada Material Handling Regulations
NOTE: A comprehensive operator training program is
available from HYSTER COMPANY. For further details,
contact your dealer for Hyster lift trucks.
This OPERATING MANUAL contains information neces-
sary 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 avail-
able and understood before operating the lift truck.
Some of the components and systems described in this
OPERATINGMANUALwillNOTbeinstalledonyourunit.
If you have a question about any item described, contact
your dealer for Hyster lift trucks.
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FOREWORD
2
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: Industrial Truck
Standards Development Foundation, ITSDF B56.1,
Safety Standard For Low Lift And High Lift Trucks.
•publications from government safety agencies,
government insurers, private insurers and private
organizations (Example: Accident Prevention Manual
For Industrial Operations, from the National Safety
Council).
NOTE: Hyster lift trucks are not intended for use on public
roads.
NOTE: The following symbols and words indicate safety
information in this manual:
WARNING
Indicates a condition that can cause death or injury!
CAUTION
Indicates a condition that can cause injury or property
damage!
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CONTENTS
3
CONTENTS
FOREWORD 1..................................
CONTENTS 3...................................
MODEL DESCRIPTION 9.........................
GENERAL 9..................................
OPERATOR PROTECTION EQUIPMENT 10......
NAMEPLATE 10...............................
SAFETY LABELS 11............................
INSTRUMENTS AND CONTROLS 19.............
OPERATING PROCEDURES 29....................
GENERAL 29..................................
Know Your Lift Truck 29......................
Stability and Center Of Gravity 29..............
Capacity (Weight and Load Center) 30.........
INSPECTION BEFORE OPERATION 31..........
Checks With the Engine Stopped 31...........
Starting Procedures 32.......................
Gasoline Or LPG Engine 32...................
Diesel Engine 33............................
Checks With the Engine Running 34...........
OPERATING TECHNIQUES 35..................
Basic Operating Procedures 35................
Driving And Direction Changes 38.............
Operator Presence System 39................
Inching 40..................................
Steering (Turning) 40........................
Load Handling, General 42...................
Load Handling, Lifting, Lowering, And Tilting 43..
Load Handling,
How To Engage And Disengage A Load 46......
Load Handling, Traveling 48..................
HIGHWAY TRUCKS, RAILROAD CARS AND
DOCKS 51....................................
ATTACHMENTS 52.............................
STOPPING 53.................................
PARKING 53..................................
MAINTENANCE 55...............................
GENERAL 55..................................
HOW TO MOVE A DISABLED LIFT TRUCK 56.....
HowToTowTheLiftTruck 56.................
HOW TO PUT A LIFT TRUCK ON BLOCKS 57.....
HowToRaiseTheDriveTires 57..............
How To Raise The Steering Tires 58...........
HOW TO MAKE THE CHECKS WITH THE ENGINE
STOPPED 75..................................
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CONTENTS
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Hydraulic System Oil 75......................
Engine Oil 75...............................
Air Filter 75.................................
Drive Belts 78...............................
Cooling System 78..........................
Fuel System 79.............................
Primary Fuel Filter, Diesel Engine 79...........
Battery 80.................................
Tires and Wheels 80.........................
Forks 82...................................
Forks, Adjustment 82........................
Forks, Removal And Installation 85............
Inspection of Forks, Mast and Lift Chains 86.....
Safety Labels 89............................
Operator Restraint System 89.................
Automatic Locking Retractor (ALR) 91..........
Emergency Locking Retractor (ELR) 91.........
HOW TO MAKE THE CHECKS WITH THE ENGINE
RUNNING 92..................................
Gauges, Lights, Horn and Fuses 93............
Oil Level, Powershift Transmission 96..........
Oil Level, Oil Clutch System, H70--110XL 96....
Control Levers and Pedals 97.................
Lift System Operation 98.....................
Inching/Brake Pedal 98.......................
Service Brakes 99...........................
Parking Brake 99............................
Steering System 99..........................
HOW TO ADD FUEL TO THE LIFT TRUCK 100.....
Liquified Petroleum Gas (LPG) 100.............
Gasoline or Diesel Fuel 103....................
WHEELS AND TIRES 104........................
How To Repair A Pneumatic Tire 104............
Remove The Wheels From The Lift Truck 104....
Remove The Wheel From The Tire 105..........
Install The Wheel In The Tire 109...............
AddAirToTheTires 111......................
Install The Wheels 112........................
INSTALLATION PROCEDURES, DUAL DRIVE
WHEELS 113...................................
PNEUMATIC TUBELESS TIRE, REPAIR 114........
Remove Tire From Lift Truck 114...............
Remove Tire From Wheel 115..................
Install Tire on Wheel 117......................
Add Air to Pneumatic Tubeless Tire 122.........
Install the Wheels 123.........................
SOLID RUBBER TIRES 123...................
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CONTENTS
5
Remove The Tire From The Wheel 123.........
Install The Tire On The Wheel 125..............
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE 127...........................
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MODEL DESCRIPTION
6
AWARNING
label with this
information
must be on
the lift truck.
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WARNING
5
NOTES
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MODEL DESCRIPTION
8
H70--110XL (with LPG Tank) 11781
11621
1. OVERHEAD GUARD
2. COUNTERWEIGHT
3. STEERING AXLE
4. DRIVE AXLE
5. PARKING BRAKE
6. MAST
7. FORKS
8. CARRIAGE
9. LOAD BACKREST
EXTENSION
10. SEAT BELT AND
HIP RESTRAINT
BRACKET
6
6
9
9
1
1
22
3
3
44
5
510 10
77
88
FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS
H135--155XL
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MODEL DESCRIPTION
9
MODEL DESCRIPTION
GENERAL
This Operating Manual is for the following models of lift
trucks:
•the H70--110XL (G005) series includes the H70XL,
H80XL, H90XLS, H90XL, H100XL, and H110XL
•the H135--155XL (F006, G006) series includes the
H135XL, H135XL2, H155XL, H155XL2, and
H155XLS.
The H70--110XL and the H135--155XL series of lift trucks
are available with an engine that uses gasoline or LPG
fuel, or a diesel engine.
Some later production lift trucks quipped with gasoline en-
gines have an electronic engine control (electronic spark
timing and fuel injection). These lift trucks can also have a
steering pod that allows the operator to select one of five
different positions for the steering wheel.
The H70--110XL lift trucks can have either a three--speed
manual transmission or a single--speed powershift trans-
mission. The single--speed powershift transmissions can
be equipped with two kinds of controls:
•a MONOTROLpedal that controls both the for-
ward and reverse operation of the powershift trans-
mission and the speed of the engine.
•a direction control lever near the left side of the
steering wheel that controls the forward and reverse
operation of the powershift transmission. A separate
accelerator pedal controls the engine speed.
The H135--155XL lift trucks can have either a four--speed
manual transmission with an oil clutch (F006 models only)
or a two--speed powershift transmission. A range selector
lever near the right side of the operator’s seat controls the
four speed ranges of the manual transmission. A range
selector lever near the left side of the steering column con-
trols the two speed ranges of the powershift transmission.
The two--speed powershift transmissions can be equipped
with two kinds of controls:
•a MONOTROLpedal that controls both the for-
ward and reverse operation of the powershift trans-
mission and the speed of the engine.
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MODEL DESCRIPTION
10
•a direction control lever near the left side of the
steering wheel that controls the forward and reverse
operation of the powershift transmission. A separate
accelerator pedal controls the engine speed.
OPERATOR PROTECTION EQUIPMENT
The LOAD BACKREST EXTENSION is installed to keep
loose parts of the load from falling back toward the opera-
tor. 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 in-
stalled on your lift truck is required, contact your dealer for
HYSTER lift trucks.
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
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 BRACKET pro-
vide 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 re-
straint 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 pos-
sible injury in a tipover. The hip restraint bracket will help
the operator resist side movement if the seat belt is not
fastened. It is not a substitute for the seat belt. Always fas-
ten the seat belt.
NAMEPLATE
WARNING
Any change to the lift truck, the tires or its equipment
can change 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 Name-
plate.
The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities with
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MODEL DESCRIPTION
11
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 a label as shown in
FIGURE 2. If your lift truck has this type of label, do not
operate the lift truck. Contact your dealer for HYSTER lift
trucks to obtain a complete nameplate.
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 3.
LABEL
NAMEPLATE
TRUCK MODEL
Serial no.
Approx. weight
NOTICE TO USER
This unit was shipped incomplete from factory/
The U.S.A. Occupational Safety and Health Act of 1970 and other national
safety codes require the installation of a completed nameplate showing unit
configuration and rated capacity. Completed nameplates may be obtained
through your HYSTER dealer.
FIGURE 2. NAMEPLATE AND LABEL
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MODEL DESCRIPTION
12
1. WARNING, OPERATION
2. CASE WITH OPERATING MANUAL
3. NAMEPLATE
4. IMPACT TEST
5. NO ONE ON OR UNDER FORKS
6. TIPOVER WARNING
7. FIRE SAFETY
8. FAN WARNING
9. NO RIDERS
10. FLAMMABLE LP--GAS
11. WARNING FOR PARKING BRAKE
12. MAST WARNING
13. OPERATOR PRESENCE SYSTEM
SEE THE PARTS MANUAL FOR THE
PART NUMBER AND LOCATION
1
7
9
5
6
8
3
11 4
10
2
12
FIGURE 3. WARNING AND SAFETY LABELS
13
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MODEL DESCRIPTION
13
11701
11701
11701
FIGURE 4. INSTRUMENTS AND CONTROLS (H70--110XL, EARLIER PRODUCTION)
POWERSHIFT WITH MONOTROL PEDAL
POWERSHIFT WITHOUT MONOTROL PEDAL
MANUAL TRANSMISSION
1
2
34
5
8
11 11
11
9
3
12
13
20
910
10
10
21
2119
21
18
18
15
15
15
16
16
16
17
17
17
12
14
20
22
13
12
9
Property of American Airlines

MODEL DESCRIPTION
14
12402
FIGURE 5. INSTRUMENTS AND CONTROLS (H70--110XL, LATER PRODUCTION)
12402
12402
POWERSHIFT WITH MONOTROL PEDAL
POWERSHIFT WITHOUT MONOTROL PEDAL
MANUAL TRANSMISSION
1
234
5
6, 8
910
11
12
12
12
13
13
14
15
15
1516
16
16
17
17
17
19
18
18
21
21
21
22
9
9
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MODEL DESCRIPTION
15
12402
FIGURE 6. INSTRUMENTS AND CONTROLS (H70--110XL, WITH ELECTRONIC ENGINE CONTROL)
12402 POWERSHIFT WITH MONOTROL PEDAL
POWERSHIFT WITHOUT MONOTROL PEDAL
MANUAL TRANSMISSION
6, 8
23
7
5
4
1
10
7
3
12 11
14
12
13
22
21
18
15
16
17
19
18
21 21
12
12 13 15
15
16
16
17
17
9
9
23
23
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MODEL DESCRIPTION
16
MANUAL TRANSMISSION POWERSHIFT WITHOUT MONOTROL PEDAL
POWERSHIFT WITH MONOTROL PEDAL
FIGURE 7. INSTRUMENTS AND CONTROLS (H135--155XL, [F006], EARLIER PRODUCTION)
11639
11639
11639
1
2
34
5
6910
11
12
13
14
15
1617
17
17
16
16
15
15
18 18
19
20
12
12
13
14
20
22 21
21
21
5
14
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MODEL DESCRIPTION
17
MANUAL TRANSMISSION
POWERSHIFT WITHOUT MONOTROL PEDAL
POWERSHIFT WITH MONOTROL PEDAL
FIGURE 8. INSTRUMENTS AND CONTROLS (H135--155XL,[F006, G006], LATER PRODUCTION)
11639
11639
11639
1
2
3456
910
11
12
12
12
13
13
14
14
14
15
15
15
16
16
17
17
17
16
19
18
18
21
21
21
22
20
20
10
11
11
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MODEL DESCRIPTION
18
MANUAL TRANSMISSION
POWERSHIFT WITHOUT MONOTROL PEDAL
POWERSHIFT WITH MONOTROL PEDAL
FIGURE 9. INSTRUMENTS AND CONTROLS (H135--155XL WITH ELECTRONIC ENGINE CONTROL)
12581
12581
12581
1
23
45
6
910
11
13
12
14
15
1617
18
21
22
7
15
15
10
16
16
17
17
12
12
13
14
14
19
11
20
20
21
21
23
23
11
23
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