Hyster H40.00-48.00XM-12 User manual

ASSEMBLY GUIDE
H40.00-48.00XM-12
(H800-1050HD/HDS) [A917];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917];
H40XM-12, H44XM-12, H48XM-12, H36XMS-12,
H40XMS-12, H44XMS-12, H48XMS-12
(H800HDS, H900HDS, H970HDS, H1050HDS,
H900HD, H970HD, H1050HD) [C917]
PART NO. 1648460 8000 SRM 1306

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
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 back-
ground. The CAUTION symbol and word are on yellow background.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Weight and Dimensions .......................................................................................................................................... 2
Loading Procedures .................................................................................................................................................8
Loading Truck on a Transport ........................................................................................................................... 8
Loading Disassembled Components .................................................................................................................. 8
Unloading Procedures ...........................................................................................................................................12
Unloading Truck From Transport ....................................................................................................................12
Driving On/Off a Trailer ...............................................................................................................................12
Unloading Disassembled Components .............................................................................................................12
Moving and Towing ...............................................................................................................................................12
Precautions ........................................................................................................................................................12
Moving a Disabled Truck ..................................................................................................................................13
Safety Procedures When Working Near Mast .....................................................................................................14
Before Starting Repairs to the Hydraulic System Always: ........................................................................ 14
Truck Assembly .....................................................................................................................................................15
Mast Assembly .................................................................................................................................................. 15
Preparations ..................................................................................................................................................15
Install Hose Sheaves .................................................................................................................................... 15
Place Mast Labels .........................................................................................................................................16
Installing the Mast ....................................................................................................................................... 18
Installing the Tilt Cylinders ........................................................................................................................ 20
Connecting the Tilt Cylinder Hoses .............................................................................................................20
Adjusting the Tilt Cylinders ........................................................................................................................ 22
Connecting the Lift Cylinders ......................................................................................................................22
Connecting the Mast Supply Hoses .............................................................................................................22
Carriage .............................................................................................................................................................23
Install Carriage .............................................................................................................................................23
Connect Hoses and Cables to the Carriages ............................................................................................... 24
Lift Chain Adjustment ................................................................................................................................. 24
Install Cab Lights ............................................................................................................................................. 25
Lubrication ........................................................................................................................................................ 26
Automatic Greasing System (Optional) .......................................................................................................26
General Checks After Assembly ...........................................................................................................................27
Plumbing Check ................................................................................................................................................ 27
Lubrication Check .............................................................................................................................................27
Fluid Level Check ............................................................................................................................................. 27
Functionality Check ..........................................................................................................................................27
Literature Package ........................................................................................................................................... 27
Cleaning .............................................................................................................................................................27
Labels .................................................................................................................................................................27
Pneumatic Tires and Wheels ................................................................................................................................28
Remove Wheels From Lift Truck ..................................................................................................................... 28
Remove Tire From Wheel ................................................................................................................................. 29
Tire Removal From the Wheel ..................................................................................................................... 30
Install Tire on the Wheel ..................................................................................................................................31
Tire Installation on the Wheel .....................................................................................................................31
Adding Air Pressure to the Tires ..................................................................................................................... 34
Install Wheels on Lift Truck ............................................................................................................................ 34
Pre-Delivery ...........................................................................................................................................................35
Adjust Timing for Automatic Engine Shut Down ........................................................................................... 35
Table of Contents
i

TABLE OF CONTENTS (Continued)
Perform Pre-Delivery Inspection ......................................................................................................................35
Delivery on Operator .............................................................................................................................................36
Instructions Operating Manual ....................................................................................................................... 36
Instructions Daily Maintenance .......................................................................................................................36
Handing Over Truck .........................................................................................................................................36
This section is for the following models:
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-12, H44XM-12, H48XM-12, H36XMS-12, H40XMS-12, H44XMS-12,
H48XMS-12 (H800HDS, H900HDS, H970HDS, H1050HDS, H900HD, H970HD,
H1050HD) [C917]
Table of Contents
ii

General
WARNING
Read all the instructions contained in this manual
before starting any work on the unit. Also read all
procedures contained in the Operating Manual
before operating the truck. Make sure to check all
fluid levels and tire pressures before moving the
truck from the trailer.
This manual contains the information that is
required for transportation and reassembly of truck
series A917, B917, and C917. The information
covers each component that may have been
disassembled for transportation purposes. Select
the appropriate assembly procedures accordingly.
8000 SRM 1306 General
1

Weight and Dimensions
A. WIDTH
B. LENGTH
C. HEIGHT
Figure 1. Basic Truck A917 Width, Length, and Height
Table 1. Basic Truck A917
Model Width Length Height Weight
MIN MAX
H36.00XM-12/
H800HD
4,230 mm
(127 in.)
7,180 mm
(282.6 in.)
3,845 mm
(151.3 in.)
36,900 kg
(81,350 lb)
39,750 kg
(87,633 lb)
H40.00XMS-12/
H900HD
4,230 mm
(127 in.)
7,180 mm
(282.6 in.)
3,845 mm
(151.3 in.)
40,000 kg
(88,184 lb)
43,000 kg
(94,798 lb)
H44.00XMS-12/
H970HDS
4,230 mm
(127 in.)
7,180 mm
(282.6 in.)
3,845 mm
(151.3 in.)
41,950 kg
(92,483 lb)
44,750 kg
(98,656 lb)
H48.00XMS-12/
H1050HDS
4,230 mm
(127 in.)
7,180 mm
(282.6 in.)
3,845 mm
(151.3 in.)
45,000 kg
(99,208 lb)
48,050 kg
(105,932 lb)
H40.00XM-12 4,230 mm
(127 in.)
7,690 mm
(302.7 in.)
3,845 mm
(151.3 in.)
37,400 kg
(82,452 lb)
40,050 kg
(88,295 lb)
H44.00XM-12 4,230 mm
(127 in.)
7,690 mm
(302.7 in.)
3,845 mm
(151.3 in.)
39,550 kg
(87,192 lb)
42,250 kg
(93,145 lb)
H48.00XM-12/
H1050HD
4,230 mm
(127 in.)
7,690 mm
(302.7 in.)
3,845 mm
(151.3 in.)
41,950 kg
(92,483 lb)
44,750 kg
(98,656 lb)
NOTE: Height dimension is for trucks with open cab and cab lights removed or fitted upside down.
•Add 43 mm (1.6 in.) to the height for closed cab without airco.
• Add 78 mm (3 in.) to the height for closed cab with airco.
• Add 105 mm (4 in.) when fitted with 18.00×33 tires.
Weight and Dimensions 8000 SRM 1306
2

A. WIDTH
B. LENGTH
C. HEIGHT
Figure 2. Basic Truck B917 and C917 Width, Length, and Height
Table 2. Basic Truck B917 and C917
Model Width Length Height Weight
MIN MAX
H36XMS-12/
H800HDS
4,210 mm
(165.7 in.)
7,250 mm
(385.4 in.)
3,890 mm
(153.1 in.)
36,900 kg
(81,350 lb)
39,750 kg
(87,633 lb)
H40XMS-12/
H900HDS
4,210 mm
(165.7 in.)
7,250 mm
(385.4 in.)
3,890 mm
(153.1 in.)
40,000 kg
(88,184 lb)
43,000 kg
(94,798 lb)
H44XMS-12/
H970HDS
4,210 mm
(165.7 in.)
7,250 mm
(385.4 in.)
3,890 mm
(153.1 in.)
41,950 kg
(92,483 lb)
44,750 kg
(98,656 lb)
H48XMS-12/
H1050HDS
4,210 mm
(165.7 in.)
7,250 mm
(385.4 in.)
3,890 mm
(153.1 in.)
45,000 kg
(99,208 lb)
48,050 kg
(105,932 lb)
H40XM-12/
H900HD
4,210 mm
(165.7 in.)
7,765 mm
(305.7 in.)
3,890 mm
(153.1 in.)
37,400 kg
(82,452 lb)
40,050 kg
(88,295 lb)
H44XM-12/
H970HD
4,210 mm
(165.7 in.)
7,765 mm
(305.7 in.)
3,890 mm
(153.1 in.)
39,550 kg
(87,192 lb)
42,250 kg
(93,145 lb)
H48XM-12/
H1050HD
4,210 mm
(165.7 in.)
7,765 mm
(305.7 in.)
3,890 mm
(153.1 in.)
41,950 kg
(92,483 lb)
44,750 kg
(98,656 lb)
NOTE: The indicated height dimension is for trucks without airco and with the cab lights removed or fitted
upside down.
• Add 35 mm (1.4 in.) to the height for closed cab with airco.
• Add 100 mm (4 in.) to the height when fitted with 18.00×33 tires.
NOTE: The indicated length dimension is for trucks with 18.00 x 25 tires.
• Add 100 mm (4 in.) to the length dimension when fitted with 18.00×33 tires.
8000 SRM 1306 Weight and Dimensions
3

A. LENGTH
B. HEIGHT
C. WIDTH
Figure 3. Mast Width, Length, and Height
Weight and Dimensions 8000 SRM 1306
4

Table 3. Mast
Lift Height Length Height Width Weight
4,267 mm
(167.9 in.)
4,760 mm
(187.4 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
9,220 kg
(20,326 lb)
7,010 mm
(275.9 in.)
6,130 mm
(241 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
11,110 kg
(24,493 lb)
8,534 mm
(335.9 in.)
6,895 mm
(271.4 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
12,400 kg
(27,337 lb)
9,144 mm (360 in.) 7,200 mm
(283.4 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
12,780 kg
(28,175 lb)
9,754 mm (384 in.) 7,505 mm
(295.4 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
13,220 kg
(29,145 lb)
12,650 mm (498 in.) 9,030 mm
(355.5 in.)
806 mm
(31.7 in.)
2,800 mm
(110 in.)
16,200 kg
(35,714 lb)
NOTE: Deduct 236 mm (9 in.) from width when hose sheaves are dismounted and secured to the mast.
A. LENGTH
B. WIDTH
C. HEIGHT
Figure 4. Carriage Width, Length, and Height
Table 4. Carriage
Model Type Length Width Height Weight
ALL Standard
Carriage
3,165 mm
(124.6 in.)
2,175 mm
(85.6 in.)
765 mm
(30 in.)
3,130 kg
(6,900 lb)
36.00-48.00
(800-1050)
(18.00X25 Tires)
Side Shift
Carriage
3,165 mm
(124.6 in.)
2,225 mm
(87.5 in.)
840 mm
(33 in.)
5,060 kg
(11,155 lb)
36.00-48.00
(800-1050)
(18.00X33 Tires)
Side Shift
Carriage
3,165 mm
(124.6 in.)
2,245 mm
(88 in.)
945 mm
(37 in.)
5,410 kg
(11,927 lb)
8000 SRM 1306 Weight and Dimensions
5

A. WIDTH
B. LENGTH
C. HEIGHT
Figure 5. Container Attachment Width, Length, and Height (optional for A917 and B917)
Table 5. Container Attachment (optional for A917 and B917)
Width Length Height Weight
2,433 mm
(95.7 in.)
6,042 mm
(237.8 in.)
1,193 mm
(46.9 in.)
7,400 kg
(16,314 lb)
Weight and Dimensions 8000 SRM 1306
6

A. WIDTH
B. HEIGHT
C. LENGTH
Figure 6. Forks Width, Length, and Height
Table 6. Forks
Type Width Height Length Weight
QD 5.5X12-96 600 mm
(23.6 in.)
2,240 mm
(88 in.)
2,720 mm
(107 in.)
2,680 kg
(5,908 lb)
QD 5.5X12-83 600 mm
(23.6 in.)
2,240 mm
(88 in.)
2,390 mm
(94 in.)
2,560 kg
(5,643 lb)
8000 SRM 1306 Weight and Dimensions
7

Loading Procedures
LOADING TRUCK ON A TRANSPORT
WARNING
Stay a safe distance from the edge of docks,
ramps, platforms, and other similar working surfa-
ces. Watch the "tail swing". Remember when trav-
eling in the forward direction and the steering
wheel is turned to move the lift truck away from
the edge of the dock, the rear will swing toward
the edge. This can cause the lift truck to fall off
the dock.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO
NOT JUMP OFF! HOLD FIRMLY TO STEERING
WHEEL, BRACE YOUR FEET, AND LEAN FOR-
WARD AND AWAY FROM THE POINT OF IMPACT.
Before the lift truck is moved on transport, check
the selected route to make sure there is enough
clearance for the lift truck as loaded on the trans-
port vehicle. Bridges, overpasses, power lines, and
natural barriers can prevent clearance. Removal of
the mast can be necessary.
If a trailer is the method of transportation, use
blocks in front and back of the trailer tires to pre-
vent movement of the trailer when the lift truck is
loaded and unloaded. If a loading ramp is used,
make sure that the ramp is the correct design and
capacity.
A crane can only be used to load or unload the lift
truck if the lift truck is equipped with lifting eyes.
Otherwise, the lift truck must be driven on or off
the transport.
LOADING DISASSEMBLED
COMPONENTS
1. Put blocks under the disassembled components
for stability during transport and to allow load-
ing and unloading with a fork lift. See Figure 7
through Figure 11.
2. When lifting the components with slings and/or
hooks, attach these at the indicated lifting
points and/or lifting eyes. Make sure the lifting
device has the required capacity, see Figure 1
through Figure 6 for the weights of the compo-
nents.
WARNING
DO NOT use the bores for the mast pivot and the
tilt cylinder mounting as a slinging point or as a
tie down point.
3. Secure the components by connecting slings or
chains to the indicated tie down points on Fig-
ure 7 through Figure 11 and the load surface of
the trailer.
Loading Procedures 8000 SRM 1306
8

1. TIE DOWN POINT
Figure 7. Lift Truck Tie Down Placement
1. SLING OR TIE DOWN POINT
Figure 8. Attachment Tie Down Placement
8000 SRM 1306 Loading Procedures
9

1. SLING OR TIE DOWN POINT
Figure 9. Mast Tie Down Placement
Loading Procedures 8000 SRM 1306
10

1. SLING OR TIE DOWN POINT
Figure 10. Carriage Tie Down Placement
1. SLING OR TIE DOWN POINT
Figure 11. Forks Tie Down Placement
8000 SRM 1306 Loading Procedures
11

Unloading Procedures
UNLOADING TRUCK FROM TRANSPORT
Driving On/Off a Trailer
When the truck will be driven from a trailer make
sure to have read and understood the Starting Pro-
cedures as described in the Operating Manual.
1. Make sure the parking brake is applied.
2. Disconnect the straps or chains that attach the
truck to the trailer.
3. Remove the wheel blocks.
4. Start the truck, release the park brake and let
a assistant provide directions when driving off
the trailer.
5. Park the truck. Apply the hand brake and turn
the ignition OFF.
See the procedures under Moving and Towing if the
truck cannot be started and must be moved.
See the procedures under Add Air Pressure to the
Tires if air pressure in one of the tires is less than
80% of the pressure as indicated on the nameplate.
UNLOADING DISASSEMBLED
COMPONENTS
To lift the components from a transport either use a
fork lift or attach hooks and/or slings to the lifting
eyes and slinging points as indicated on Figure 7
through Figure 11.
WARNING
DO NOT use the bores for the mast pivot and the
tilt cylinder mounting as a slinging point.
For the required capacity of the lifting device see
Table 1 through Table 6 for the weights of the com-
ponents.
Use blocks to support the component when tempo-
rarily storing the component on the ground.
The blocks for the carriage must be high enough to
keep the fork guides from the ground.
Moving and Towing
PRECAUTIONS
CAUTION
While the lift truck is being towed the engine must
stay running in order to generate sufficient hy-
draulic oil pressure. Without hydraulic pressure
the steering system and service brake system do
not operate, and the park brake will automatically
apply. The parking brake can be manually re-
leased if no hydraulic pressure is available.
CAUTION
Without oil pressure the transmission will be dam-
aged during towing. If the engine cannot run dur-
ing towing, remove the drive shaft between trans-
mission and drive axle.
WARNING
When the parking brake is manually released, the
lift truck does not have any parking brake func-
tion. Block the wheels to prevent the lift truck
from moving. If the wheels are not blocked, seri-
ous personal injury and damage to components
can occur.
NOTE: If the parking brake is manually released,
it will need to be adjusted before the lift truck is re-
turned to service. With hydraulic pressure applied
to the parking brake, adjust play between brake
disc and park brake pads to 1.0 mm (0.03936 in.).
The parking brake caliper is mounted on a support
bracket which is mounted on the differential carrier
assembly. To manually release the parking brake,
perform the following procedures:
Unloading Procedures 8000 SRM 1306
12