Hyster H40-60XT User manual

OPERATING MANUAL
H40-60XT (A380)
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4150900 3/19

LIFT TRUCK MODEL
ENGINE MODEL
TRANSMISSION TYPE
MAST LIFT HEIGHT
CARRIAGE TYPE
DRIVE TIRE SIZE
SERIAL NUMBER
SERIAL NUMBER
SERIAL NUMBER
GROUP NUMBER
GROUP NUMBER
STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2019. All Rights Reserved.
HYSTER, , FORTIS, MONOTROL, and YARDMASTER are Registered Trademarks of Hyster-Yale Group, Inc. HSS, DURAMATCH, UNISOURCE, and
are Trademarks in the United States and certain other jurisdictions.
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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 any potential hazards that may exist in the
work place where the lift truck is intended to be used.
•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 properly understand the warnings, instruc-
tions, and operating procedures in this manual.
In addition, a qualified person, experienced in lift truck
operation, must guide a new operator through several driv-
ing 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 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 program is avail-
able from Hyster Company. For further details, contact
your dealer for Hyster lift trucks.
This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
nance of a basic lift truck. Optional equipment is sometimes
installed that can change some operating characteristics
described in this manual. Make sure the necessary instruc-
tions are available and understood before operating the lift
truck.
Some of the components and systems described in this
Operating Manual will NOT be installed on your unit. If you
Foreword
©HYSTER COMPANY 2019 4150900 - ENGLISH-US 1

have a question about any item described, contact your
dealer for Hyster lift trucks.
Additional information that describes 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, ANSI/ITSDF
B56.1, Safety Standard for Low Lift and High Lift
Trucks).
•Publications from government safety agencies, govern-
ment 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.
•Lift Truck/Pedestrian Accidents, Causes and Prevention.
Hyster Company (LIFTPED/B 12/2003).
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 hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury and property
damage.
On the lift truck, the WARNING symbol and word are on
orange background. The CAUTION symbol and word
are on yellow background.
Foreword
2

Contents
Foreword ...................................................................... 1
TO OWNERS, USERS, AND OPERATORS: ............. 1
Warning ........................................................................ 6
Model Description ....................................................... 9
GENERAL ................................................................... 11
OPERATOR PROTECTION EQUIPMENT ................. 11
NAMEPLATE .............................................................. 12
SAFETY LABELS ....................................................... 13
CONTROLS ................................................................ 17
DASH DISPLAY .......................................................... 39
Operating Procedures ................................................ 48
GENERAL ................................................................... 48
Know Your Lift Truck ................................................ 48
Stability and Center of Gravity .................................. 50
Capacity (Weight and Load Center) ......................... 51
INSPECTION BEFORE OPERATION ........................ 52
Checks With the Engine Stopped ............................. 52
Mounting and Dismounting ....................................... 53
Lift Truck Interlocks ................................................... 53
Starting Procedure .................................................... 54
Checks With the Engine Running ............................. 55
OPERATING TECHNIQUES ...................................... 56
Basic Operating Procedures ..................................... 56
Driving and Direction Changes ................................. 61
General ................................................................... 62
Normal Operations .................................................. 62
Standard Operator Presence System ..................... 63
Basic Powershift or Electronic Powershift
Transmission .................................................... 63
Inching Control .......................................................... 64
Steering (Turning) ..................................................... 65
Load Handling, General ............................................ 66
Load Handling, Lifting, Lowering, and Tilting ............ 68
Load Handling, How to Engage and Disengage a
Load ...................................................................... 70
Load Handling, Traveling .......................................... 73
Set Up the Load Weight Sensor ............................... 77
Understanding the A/D (Analog to Digital) Value .... 77
Store a Value for Zero on the Load Meter .............. 77
Load Meter ................................................................ 78
HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ....... 79
ATTACHMENTS ......................................................... 80
DISCONNECTING ATTACHMENT HYDRAULIC
QUICK-DISCONNECT HOSES ................................ 81
CONNECTING ATTACHMENT HYDRAULIC QUICK-
DISCONNECT HOSES ............................................ 81
Contents
3

STOPPING ................................................................. 83
PARKING .................................................................... 83
Maintenance ................................................................ 84
GENERAL ................................................................... 84
Serial Number Data .................................................. 85
HOW TO MOVE A DISABLED LIFT TRUCK .............. 85
How to Tow the Lift Truck ......................................... 85
HOW TO PUT A LIFT TRUCK ON BLOCKS .............. 86
How to Raise the Drive Tires .................................... 86
How to Raise the Steering Tires ............................... 87
HOW TO CLEAN A LIFT TRUCK ............................... 89
Maintenance Schedule ............................................... 89
Maintenance Procedures Every 8 Hours or Daily .... 108
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED ................................................................. 108
Tires and Wheels ...................................................... 108
Safety Labels ............................................................ 110
Mast, Carriage, Header Hoses, Lift Chains, and
Attachment ............................................................ 110
Operator Restraint System ....................................... 112
Emergency Locking Retractor (ELR) ...................... 116
Hood and Seat Latches ............................................ 116
Engine Compartment ................................................ 117
Ground Static Strap .................................................. 117
Fuel, Oil, and Coolant Leaks, Check ........................ 119
Hydraulic Hoses ........................................................ 119
Coolant Hoses .......................................................... 119
Transmission ............................................................ 119
Hydraulic System Oil ................................................ 120
Engine Oil ................................................................. 121
Air Filter .................................................................... 126
Forks ......................................................................... 126
Forks, Remove ......................................................... 126
Forks, Inspect ........................................................... 129
Forks, Install ............................................................. 132
Forks, Adjust ............................................................. 133
Brake Fluid ................................................................ 134
HOW TO MAKE CHECKS WITH THE ENGINE
RUNNING ................................................................. 136
Indicator Lights, Horn, Fuses, and Relays ................ 136
Service Brakes .......................................................... 138
Brake Fluid Level .................................................... 138
Operation, Check .................................................... 138
Parking Brake ........................................................... 139
Engine Oil Pressure .................................................. 139
Cooling System ......................................................... 139
Steering System ....................................................... 141
Control Levers and Pedals ....................................... 141
Lift System Operation ............................................... 141
HOW TO ADD FUEL TO THE LIFT TRUCK .............. 142
Contents
4

Liquefied Petroleum Gas (LPG) ................................ 142
LPG Tank, Removal ............................................... 143
LPG Tank, Fill ......................................................... 146
LPG Tank, Install .................................................... 147
Gasoline and Diesel Fuel .......................................... 147
WHEELS AND TIRES ................................................. 148
General ..................................................................... 148
PNEUMATIC TIRE WITH TUBE, REPAIR ................. 148
Remove Wheels From Lift Truck .............................. 148
Remove Tire From Wheel ......................................... 149
Tire Removal, Two-Piece Wheel ............................ 151
Tire Removal, Three- and Four-Piece Wheels ....... 152
Install Wheel in Tire .................................................. 153
Tire Installation Three- or Four-Piece Wheel .......... 154
Tire Installation Two-Piece Wheel .......................... 155
Add Air to Pneumatic Tires With Tube ...................... 156
Install the Wheels ..................................................... 157
PNEUMATIC TUBELESS TIRE, REPAIR .................. 157
Remove Tire From Lift Truck .................................... 157
Remove Tire From Wheel ......................................... 158
Install Tire on Wheel ................................................. 159
Add Air to Pneumatic Tubeless Tire ......................... 163
Install the Wheels ..................................................... 163
SOLID RUBBER TIRES ON PNEUMATIC WHEELS,
CHANGE .................................................................. 164
Remove Tire From Wheel ......................................... 164
Install Tire on Wheel ................................................. 166
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE .................................................... 168
JUMP-STARTING THE LIFT TRUCK ......................... 168
Jump-Starting Using a Battery Charger .................... 168
Jump-Starting Using Another Lift Truck .................... 169
CHANGES TO THE OVERHEAD GUARD ................. 169
HOW TO PUT INTERNAL COMBUSTION ENGINE
(ICE) TRUCKS IN STORAGE .................................. 169
Short-Term Storage .................................................. 170
Long-Term Storage ................................................... 171
While the Lift Truck is in Storage .............................. 171
How to Put Batteries in Storage ................................ 172
Putting a Stored Lift Truck Back Into Service ........... 172
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT ............................................................ 173
Loading ..................................................................... 174
Unloading .................................................................. 175
PREPARATION FOR USE ......................................... 175
Preparation After Transport ...................................... 175
Contents
5

KNOW THE EQUIPMENT:
•ALWAYS use 3 points of contact when getting on and off
the truck.
•KNOW operating, inspection, and maintenance instruc-
tions in this Operating Manual.
• DO NOT operate or repair truck unless trained and
authorized.
•INSPECT truck before use.
• DO NOT operate if truck needs repair. Tag truck and
remove key. Repair truck before use. Always use Hyster
Approved parts when making repairs. Replacement
parts must meet or exceed the specifications of the origi-
nal equipment manufacturer.
•USE auxiliary equipment (attachments) for intended pur-
pose only.
•VERIFY truck is equipped with overhead guard and load
backrest adequate for the load.
LOOK WHERE YOU ARE GOING:
•IF YOU CAN'T SEE, DON'T GO.
•TRAVEL in reverse if load blocks forward vision.
•MAKE SURE tail swing area is clear.
•SOUND horn at intersections or where vision is blocked.
•WATCH clearances, especially overhead.
KNOW YOUR LOADS:
•HANDLE only stable loads within specified weight and
load center. See Nameplate on truck.
• DO NOT handle loose loads higher than load backrest.
•SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
6

USE COMMON SENSE:
• DO NOT use truck to lift people unless there is no other
practical option. Then, use only a securely attached spe-
cial work platform. Follow instructions in this Operating
Manual.
•OBEY traffic rules. Yield right-of-way to pedestrians.
•BE in complete control at all times.
•ALLOW NO ONE under or near lift mechanism or load.
•OPERATE truck only from operator's seat.
•KEEP arms, legs, and head inside operator's compart-
ment.
• DO NOT move truck if anyone is between truck and sta-
tionary object.
•BEFORE DISMOUNTING, neutralize travel control,
lower carriage, and set brake.
•WHEN PARKING, also shut off power, close LPG fuel
valve, block wheels on inclines.
KNOW THE AREA:
•NEVER enter a trailer or railroad car unless its wheels
are blocked.
•CONFIRM floor strength.
•FILL fuel tank or charge battery only in designated area.
•TURN OFF engine when fueling.
•AVOID sparks or open flame. Provide ventilation.
• DO NOT start if fuel is leaking.
•KEEP vent caps clear when charging battery.
•DISCONNECT battery during servicing.
•CHECK dockboard width, capacity, and security.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
7

PROTECT YOURSELF FASTEN YOUR SEAT BELT!
•AVOID bumps, holes, and loose materials.
•AVOID sudden starts or stops.
•NEVER turn on or angle across an incline.
•TRAVEL on inclines with load uphill or when unloaded
with lift mechanism downhill.
•TILT mast slowly and smoothly. LIFT or LOWER with
upright vertical or tilted slightly back. Use minimum tilt
when stacking elevated loads.
•TRAVEL with carriage as low as possible and tilted
back.
•SLOW DOWN before turning, especially without load.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
CAUSE THE LIFT TRUCK TO TIP.
DO NOT JUMP off if the truck tips over. HOLD steering
wheel firmly. BRACE your feet. LEAN FORWARD and
AWAY from point of impact.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
8

Model Description
Figure 1. Model View Showing Major Components of H40-60XT
Model Description
9

Legend for Figure 1
1. OVERHEAD GUARD
2. TAIL, BRAKE, AND REVERSE LIGHTS
3. SEAT
4. COUNTERWEIGHT
5. STEERING AXLE
6. SEAT BELT AND HIP RESTRAINT
7. DRIVE AXLE
8. CARRIAGE
9. FORKS
10. LOAD BACKREST EXTENSION
11. PARKING BRAKE
12. STEERING WHEEL
13. MAST
14. OPERATING MANUAL (BEHIND SEAT)
Model Description
10

Model Description
General
This Operating Manual is for the following models of lift
trucks:
H40-60XT (A380)
These lift trucks are available with the following engine:
•PSI 2.4L engine which uses LPG fuel
•PSI 2.4L bi-fuel engine which uses Gasoline and LPG
fuels
•Yanmar 2.6L engine which uses diesel fuel
•Yanmar 3.3L engine which uses diesel fuel
These lift truck models are equipped with a Basic Power-
shift or Electronic Powershift transmission.
The H40-60XT 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 operator. It
must be high enough, with vertical openings small enough,
to prevent parts of the load from falling backward. 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 cannot
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.
NOTE: The seat belt can be either black or red.
The SEAT BELT AND HIP RESTRAINT provide additional
means to help the operator keep the head and torso sub-
stantially within the confines of the lift truck frame and over-
head 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 cannot
Model Description
11

protect the operator against all possible injury in a tipover.
The hip restraint will help the operator resist side move-
ment. It is not a substitute for the seat belt. Always fasten
the seat belt.
This lift truck is equipped with one of the three seat belt
configurations.
•Seat belt with no operation interlock.
•Seat belt with operation interlock. Seat belt must be fas-
tened for lift truck to start or to travel.
Nameplate
WARNING
DO NOT add to or modify the lift truck. Any modifica-
tion that affects the safe operation of the truck cannot
be undertaken without the written authorization of Hys-
ter Company.
Any change to the lift truck, the tyres, 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.
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 right-hand side
of the lift truck frame, under the floorplate.
When a lift truck is shipped incomplete from the factory, the
Nameplate is covered by an INCOMPLETE label as shown
in Figure 2. If the equipment on the truck is changed, the
Nameplate is covered by a NOTICE label as shown in Fig-
ure 2. 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.
Model Description
12

A. NAMEPLATE
B. NOTICE LABEL
C. INCOMPLETE LABEL
Figure 2. Nameplate and Labels
Safety Labels
Safety labels are installed on the lift truck to provide infor-
mation about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
Figure 3.
All possible label configurations that can be on the lift
trucks covered in this Operating Manual are not shown in
Figure 3. See the Parts Manual for label part numbers and
a complete listing of all labels that are available for the lift
trucks covered in this Operating Manual.
Model Description
13

Figure 3. Warning and Safety Labels (Sheet 1 of 3)
Model Description
14

Figure 3. Warning and Safety Labels (Sheet 2 of 3)
Model Description
15

Figure 3. Warning and Safety Labels (Sheet 3 of 3)
Model Description
16

Legend for Figure 3
1. FLAMMABLE LP-GAS
2. NAMEPLATE
3. NO ONE ON OR UNDER FORKS
4. TIPOVER WARNING
5. OVERHEAD GUARD LABEL
6. NO RIDERS
7. WARNING FOR PARKING BRAKE
8. WARNING, OPERATION
9. MAST WARNING
10. MAST WARNING
11. FAN WARNING
12. AIR FILTER INSTALL CAUTION
13. LIFT AND TILT LABEL
14. TRANSMISSION LABEL (EXAMPLE ONLY)
15. LOCKING GAS SPRING
16. LPG TANK WARNING
17. UL LABEL
18. ANTIFREEZE LABEL
19. BORON-FREE LABEL
20. SPLIT WHEEL WARNING
21. DIESEL FUEL LABEL (NOT SHOWN)
22. BI-FUEL SWITCH LABEL (NOT SHOWN)
23. ETHER WARNING (DIESEL ONLY)
24. STABILITY SYSTEM LABEL (ON BOTH SIDES OF TRUCK)
25. PARK BRAKE ADJUSTMENT WARNING
Controls
WARNING
If any of the instruments, levers, or pedals do not oper-
ate as described in the following tables, report the
problem immediately. DO NOT operate the lift truck
until the problem is corrected.
Not all lift trucks have all of the controls shown in Figure 4
and Table 1.
Model Description
17

Figure 4. Controls
Model Description
18