Hyster S40xm Manual

PERIODIC

MAINTENANCE

S/H40-65XM [H177, D187]

PART NO. 1456991 8000 SRM 707

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

•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 Mainte-

nance 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 exceed 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 flammable. 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 condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1

Serial Number................................................................................................................................................ 1

How to Move Disabled Lift Truck ................................................................................................................. 1

How to Tow Lift Truck............................................................................................................................... 1

How to Put Lift Truck on Blocks................................................................................................................... 2

How to Raise Drive Tires.......................................................................................................................... 2

How to Raise Steering Tires ..................................................................................................................... 2

Maintenance Schedule....................................................................................................................................... 3

Maintenance Procedures Every 8 Hours or Daily............................................................................................ 21

How to Make Checks With Engine Stopped................................................................................................. 21

Tires and Wheels....................................................................................................................................... 21

Forks .......................................................................................................................................................... 22

Adjust..................................................................................................................................................... 23

Remove .................................................................................................................................................. 23

Install..................................................................................................................................................... 23

Forks, Mast, and Lift Chains, Inspect ..................................................................................................... 23

Safety Labels ............................................................................................................................................. 24

Operator Restraint System....................................................................................................................... 25

Steering Column Latch ............................................................................................................................. 25

Fuel, Oil, or Coolant Leaks, Check........................................................................................................... 26

Drive Belt................................................................................................................................................... 26

Intake Manifold Rubber Cap .................................................................................................................... 26

Powershift Transmission Oil Temperature.............................................................................................. 26

Powershift Transmission Oil Level .......................................................................................................... 26

Engine Oil.................................................................................................................................................. 26

Hydraulic System...................................................................................................................................... 28

Air Filter .................................................................................................................................................... 28

How to Make Checks With Engine Running................................................................................................28

Gauges, Indicator Lights, Horn, Fuses, and Relays................................................................................ 29

Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emission System) ......................... 30

Malfunction Indicator Lamp (GM 3.0L Gasoline Engine) ...................................................................... 30

Engine Oil Pressure .................................................................................................................................. 30

Cooling System.......................................................................................................................................... 31

Steering System ........................................................................................................................................ 31

Service Brakes........................................................................................................................................... 31

Brake Fluid Level ................................................................................................................................. 31

Operation, Check .................................................................................................................................. 31

Parking Brake ........................................................................................................................................... 31

Water Separator, Diesel Engine ............................................................................................................... 32

Drain Water From Water Separator ....................................................................................................32

Fuel Filter, Diesel Engine......................................................................................................................... 32

Diesel Fuel System, Remove Air .............................................................................................................. 32

Control Levers and Pedals........................................................................................................................ 32

Lift System, Operate................................................................................................................................. 32

Cooling System.......................................................................................................................................... 33

Maintenance Procedures Every 250 Hours or 6 Weeks ................................................................................... 33

Air Filter ........................................................................................................................................................ 33

Drive Belt ....................................................................................................................................................... 34

Mazda M4-2.0G and M4-2.2G Engines .................................................................................................... 34

Fan and Alternator Drive Belt............................................................................................................. 34

Timing Belt............................................................................................................................................ 34

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

GM 3.0L ..................................................................................................................................................... 34

Perkins 704-26 (UB).................................................................................................................................. 35

Engine Oil and Filter..................................................................................................................................... 35

Brake Fluid .................................................................................................................................................... 36

Hydraulic Tank Breather .............................................................................................................................. 36

Battery ........................................................................................................................................................... 36

Forks............................................................................................................................................................... 36

Lift Chains ..................................................................................................................................................... 36

Lubrication ................................................................................................................................................ 36

Wear, Check ............................................................................................................................................... 36

Mast................................................................................................................................................................ 37

Steering Axle.................................................................................................................................................. 37

Fuel System ................................................................................................................................................... 37

Engine Speed, Diesel, Perkins 704-26 (UB)............................................................................................. 38

Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and Aisan Closed-Loop) ............. 38

Engine Speed, LPG Carburetor, Mazda (Impco) ..................................................................................... 38

Engine Speed, LPG Carburetor, GM 3.0L (Impco).................................................................................. 39

Engine Speed, Mazda Gasoline Carburetor.............................................................................................40

Hydraulic System .......................................................................................................................................... 41

Cooling System, Clean Debris From Radiator Core .................................................................................... 41

Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 42

Drain Tar From Aisan LPG Regulator ......................................................................................................... 42

PCV Valve ...................................................................................................................................................... 42

Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 42

Diesel Fuel System ........................................................................................................................................ 42

Fuel Filter, Replace ................................................................................................................................... 42

Water Separator, Remove Water .............................................................................................................. 43

Water Separator, Replace.......................................................................................................................... 43

Diesel Fuel System Air Removal.............................................................................................................. 44

Differential and Drive Axle, Powershift Transmission ............................................................................... 45

Valve Clearance, Check and Adjust.............................................................................................................. 45

Ignition System.............................................................................................................................................. 45

GM 3.0L LPG (IMPCO)............................................................................................................................. 45

GM 3.0L LPG (Aisan)................................................................................................................................ 45

Mazda M4-2.0G and M4-2.2G .................................................................................................................. 45

Aisan Regulator Pressure/Diaphragm and O-Ring Checks ........................................................................ 46

PCV Valve ...................................................................................................................................................... 46

Integral Sideshift Carriage, Check Bearings............................................................................................... 46

Control Levers and Pedals ............................................................................................................................ 46

Cooling System, GM 3.0L EPA Compliant Engine ...................................................................................... 47

LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace ...................................................... 47

Inspect Engine Electrical System, Connectors, and FCVS Connection ..................................................... 48

Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 48

Hydraulic System .......................................................................................................................................... 48

Hydraulic Oil and Filter, Replace............................................................................................................. 48

Powershift Transmission Oil and Filter....................................................................................................... 48

Replace....................................................................................................................................................... 48

Cooling System .............................................................................................................................................. 49

Service Brakes ............................................................................................................................................... 49

Differential..................................................................................................................................................... 50

LPG Fuel Filter Replace, (Pre-2004) ............................................................................................................ 50

Periodic Maintenance Table of Contents

TABLE OF CONTENTS (Continued)

Gasoline Fuel Filter....................................................................................................................................... 50

Fuel Filter (Aisan LPG System), Replace .................................................................................................... 50

LPG Fuel Injector (Aisan Closed-Loop Low Emission System) .................................................................. 51

Integral Sideshift Carriage, Replace Bearings ............................................................................................ 51

Oxygen Sensor, GM 3.0L EPA Compliant Engine ....................................................................................... 51

Air Filter Element, GM 3.0L EPA Compliant Engine................................................................................. 51

Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks............................................................ 51

Check Throttle Shaft for Sticking................................................................................................................. 52

Inspect Exhaust Manifold and Piping for Leaks .........................................................................................52

Test LPG/GAS Regulator Pressure............................................................................................................... 53

Safety Procedures When Working Near Mast.................................................................................................. 53

Hood Latch Check.............................................................................................................................................. 55

Lift Chain Adjustments..................................................................................................................................... 55

Lift and Tilt System Leak Check ...................................................................................................................... 57

Lift Cylinder, Leak Check ............................................................................................................................. 57

Tilt Cylinder, Leak Check ............................................................................................................................. 58

Charging Battery ............................................................................................................................................... 58

Diesel Engine Fuel Injector Check.................................................................................................................... 58

Welding Repairs ................................................................................................................................................. 59

Overhead Guard Changes ................................................................................................................................. 59

Wheel and Tire Replacement ............................................................................................................................ 59

Solid Rubber Tire, Change S40-65XM Models............................................................................................. 59

Remove and Install Tire on Wheel ........................................................................................................... 60

Pneumatic Tire, Repair H45-65XM Models ................................................................................................. 61

Remove Wheels From Lift Truck.............................................................................................................. 61

Remove Wheel From Tire ......................................................................................................................... 61

Remove Tire From Two-Piece Wheel ................................................................................................... 62

Remove Tire From Three- and Four-Piece Wheels ............................................................................. 63

Install Wheel on Tire................................................................................................................................. 64

Install Tire on Three- or Four-Piece Wheels ....................................................................................... 64

Install Three-Piece or Four-Piece Wheel in Tire................................................................................. 64

Install Tire on Two-Piece Wheel........................................................................................................... 65

Install Two-Piece Wheel in Tire ........................................................................................................... 66

Add Air to Pneumatic Tires........................................................................................................................... 66

Wheels, Install........................................................................................................................................... 67

Dual Drive Wheels, Install ....................................................................................................................... 67

Solid Rubber Tire, Change H45-65XM Models ............................................................................................67

Remove Wheel From Tire ......................................................................................................................... 68

Install Wheel in Tire ................................................................................................................................. 69

Adhesives and Sealants..................................................................................................................................... 71

This section is for the following models:

S/H40-65XM [H177, D187]

iii

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 707 General

General

This section contains a Maintenance Schedule and

the instructions for maintenance and inspection.

The Maintenance Schedule has time intervals for in-

spection, lubrication, and maintenance for your lift

truck. The service intervals are given both in oper-

ating hours recorded on the lift truck hourmeter and

in calendar time. The recommendation is to use the

interval that comes first.

Therecommendationforthetimeintervalsisfor8

hours of operation per day. The time intervals must

be decreased from the recommendations in the Main-

tenance Schedule for the following conditions:

•If the lift truck is used more than 8 hours per day

•If the lift truck must work in dirty operating con-

ditions

Your dealer for Hyster lift trucks has the equipment

and trained service personnel to do a complete pro-

gram of inspection, lubrication, and maintenance. A

regular program of inspection, lubrication, and main-

tenance will help your lift truck give more efficient

performance and operate for a longer period of time.

WARNING

Do not make repairs or adjustments unless you

have both authorization and training. Repairs

and adjustments that are not correct can make

a dangerous operating condition.

WARNING

Do not operate a lift truck that needs repairs.

Report the need for repairs immediately. If re-

pair is necessary, put a DO NOT OPERATE tag

in the operator’s area. Remove the key from

the key switch.

Some users have service personnel and equipment

to do the inspection, lubrication, and maintenance

shown in the Maintenance Schedule. Service Man-

uals are available from your dealer for Hyster lift

trucks to help users who do their own maintenance.

SERIAL NUMBER

The serial number for the lift truck is on the name-

plate and also on the front crossmember of the frame,

on the right-hand side.

HOW TO MOVE DISABLED LIFT TRUCK

How to Tow Lift Truck

WARNING

Use extra caution when towing a lift truck if

any of the following conditions exist:

• Brakes do not operate correctly.

• Steering does not operate correctly.

• Tires are damaged.

• Traction conditions are bad.

• The lift truck must be towed on a slope.

If the engine cannot run, there is no power

available for the hydraulic steering system

and the service brakes. This condition can

make the lift truck difficult to steer and stop.

If the lift truck uses power from the engine to

help apply the brakes, the application of the

brakes will be more difficult. Poor traction can

cause the disabled lift truck or towing vehicle

to slide. A slope will also make the lift truck

more difficult to stop.

Never lift and move a disabled lift truck unless

the disabled lift truck MUST be moved and

cannotbetowed. Alifttruckusedtomove

a disabled lift truck MUST have a capacity

rating equal to or greater than the weight of

the disabled lift truck. The capacity of the lift

truck used to move a disabled lift truck must

have a load center equal to half the width of

the disabled lift truck. See the nameplate of

the disabled lift 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 damage the

underside of the lift truck.

1. The towed lift truck must have an operator.

2. Tow the lift truck slowly.

3. Raise carriage and forks approximately 30 cm

(12 in.) from the surface. Install a chain to pre-

vent carriage and mast channels from moving.

4. If another lift truck is used to tow the disabled lift

truck, that lift truck must have an equal or larger

capacity than the disabled lift truck. Install ap-

proximately 1/2 of a capacity load on forks of lift

truck that is being used to tow disabled lift truck.

General 8000 SRM 707

This 1/2 capacity load will increase the traction

of the towing lift truck. Keep load as low as pos-

sible.

5. Use a towing link made of steel that fastens to

the tow pins in the counterweights of both lift

trucks.

HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires

WARNING

The lift truck must be put on blocks for some

types of maintenance and repair. The removal

of the following assemblies will cause large

changes in the center of gravity: mast, drive

axle, engine and transmission, and the coun-

terweight. When the lift truck is put on blocks,

put additional blocks in the following posi-

tions to maintain stability:

a. Before removing the mast and drive axle,

put blocks under the counterweight so the

lift truck cannot fall backward.

b. Before removing the counterweight, put

blocks under the mast assembly so the lift

truck cannot fall forward.

The surface must be solid, even, and level when

the lift truck is put on blocks. Make sure any

blocks used to support the lift truck are solid,

one-piece units.

NOTE: Some lift trucks have lifting eyes. These lift-

ing eyes can be used to raise the lift truck so blocks

can be installed.

1. Put blocks on each side (front and back) of steer-

ing tires to prevent movement of lift truck. See

Figure 1.

2. Putmastinaverticalposition. Putablockunder

each outer mast channel.

3. Tilt mast fully forward until drive tires are raised

from surface.

4. Put additional blocks under frame behind drive

tires.

5. If the hydraulic system will not operate, use a

hydraulic jack under the side of the frame near

the front. Make sure jack has a capacity equal

to at least half the weight of the lift truck. See

nameplate.

How to Raise Steering Tires

1. Apply parking brake. Put blocks on both sides

(front and back) of drive tires to prevent move-

ment of lift truck. See Figure 1.

2. Use a hydraulic jack to raise steering tires. Make

sure jack has a capacity of at least 1/3 of the total

weight of lift truck as shown on nameplate.

3. Put the jack under steering axle or frame to raise

lift truck. Put blocks under frame to support lift

truck.

1. DRIVE TIRES 2. STEERING TIRES

Figure 1. Putting Lift Truck on Blocks

8000 SRM 707 Maintenance Schedule

Maintenance Schedule

NOTE: GM 3.0L ENGINE SHOWN. OTHER ENGINES SIMILAR.

Figure 2. Maintenance and Lubrication Points, Powershift Transmission S40-65XM

NOTE: GM 3.0L ENGINE SHOWN. OTHER ENGINES SIMILAR.

Figure 3. Maintenance and Lubrication Points, Powershift Transmission H45-65XM

Maintenance Schedule 8000 SRM 707

Table 1. Maintenance Schedule

Item

No. Item 8hr/

1day

250

hr/

6wk

500 hr/

3mo

1000

hr/

6mo

2000 hr/

1yr Procedure or

Quantity Specification

3Tires, Tire Pressure XSee Nameplate

14 Mast, Carriage, Lift

Chains XCheck condition See Parts Manual

18 Forks X X Check condition

Check for Leaks -

Fuel, Oil, Water XCheck for leaks

See NOTE 1

5Fuel Tank

GM 3.0L

(Gas and LPG)

CIL 39.4 liter

(10.4 gal) 86 Octane -

Gasoline

LPG - HD-5

5Fuel Tank

Mazda M4-2.0G

and M4-2.2G

(Gas and LPG)

CIL 54.5 liter

(14.4 gal) 86 Octane

- Gasoline

LPG - HD-5

5Fuel Tank

Perkins 704-26

(UB) (Diesel)

CIL 51.3 liter

(13.6 gal) Diesel No. 2

Horn, Gauges, Lights,

Alarms XCheck operation

13 Service Brakes and

Parking Brake XCheck operation

13 Service Brakes Lining XCheck

serviceability

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

NOTE 1: Checkthefuelsystemforleakspriortoanyserviceormaintenanceactivity.

NOTE 2: Change filters on NEW lift trucks at first 100 hours on hourmeter.

NOTE 3: Very dirty conditions require daily clean and check.

NOTE 4: Heavy-duty or high-temperature operations require more frequent checks.

NOTE 5: Cooling indicator light is used only on S40-65XM lift truck models.

NOTE 6: In dirty or dusty environments, replace at 1000 hours.

NOTE 7: Perkins engine is to be at operating temperature of 82 ±1.5 C (180 ±35 F) when inspecting for low

idle setting.

NOTE 8: Multipurpose grease with 2 to 4% molybdenum disulfide.

NOTE 9: Mazda M4-2.0G and M4-2.2G 2004 or newer engines, check at 5000 hours or 7 years.

NOTE 10: Replace on Mazda M4-2.0G and M4-2.2G engines every 2500 hours. Use only hour interval.

NOTE 11: On Mazda M4-2.0G and M4-2.2G engines, replace the timing belt every 3500 hours. Use only the

hour interval.

NOTE 12: Perform maintenance as specified by the manufacturer.

8000 SRM 707 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item

No. Item 8hr/

1day

250

hr/

6wk

500 hr/

3mo

1000

hr/

6mo

2000 hr/

1yr Procedure or

Quantity Specification

10 Transmission Oil

H45-65XM

Powershift

CIL X C 9liter(10qt) Mobilfluid 424

10 Transmission Oil

S45-65XM CIL X C 8.5 liter (9.0 qt) Mobilfluid 424

9Engine Oil

Mazda M4-2.0G

(Gasoline and LPG)

CIL C4.3 liter (4.5 qt) -18 to 40 C

(0 to 104 F)

SAE 10W-30

API SL

ILSAC GF-3

SAE 2362

9Engine Oil

Mazda M4-2.2G

(Gasoline and LPG)

CIL C4.6 liter (4.9 qt) -18 to 40 C

(0 to 104 F)

SAE 10W-30

API SL

ILSAC GF-3

SAE 2362

9Engine Oil

GM 3.0L

(Gasoline and LPG)

CIL C4.3 liter (4.5 qt) -18 to 40 C

(0 to 104 F)

SAE 10W-30

API SL

ILSAC GF-3

SAE 2362

X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

NOTE 1: Check the fuel system for leaks prior to any service or maintenance activity.

NOTE 2: Change filters on NEW lift trucks at first 100 hours on hourmeter.

NOTE 3: Very dirty conditions require daily clean and check.

NOTE 4: Heavy-duty or high-temperature operations require more frequent checks.

NOTE 5: Cooling indicator light is used only on S40-65XM lift truck models.

NOTE 6: In dirty or dusty environments, replace at 1000 hours.

NOTE 7: Perkins engine is to be at operating temperature of 82 ±1.5 C (180 ±35 F) when inspecting for low

idle setting.

NOTE 8: Multipurpose grease with 2 to 4% molybdenum disulfide.

NOTE 9: Mazda M4-2.0G and M4-2.2G 2004 or newer engines, check at 5000 hours or 7 years.

NOTE 10: Replace on Mazda M4-2.0G and M4-2.2G engines every 2500 hours. Use only hour interval.

NOTE 11: On Mazda M4-2.0G and M4-2.2G engines, replace the timing belt every 3500 hours. Use only the

hour interval.

NOTE 12: Perform maintenance as specified by the manufacturer.

Maintenance Schedule 8000 SRM 707

Table 1. Maintenance Schedule (Continued)

Item

No. Item 8hr/

1day

250

hr/

6wk

500 hr/

3mo

1000

hr/

6mo

2000 hr/

1yr Procedure or

Quantity Specification

9Engine Oil (Diesel)

Perkins 704-26

(UB)

CIL C8.3 liter (8.8 qt) -15 to 40 C

(5 to 104 F)

SAE 10W-30

-10 to 50 C

(14 to 122 F)

SAE 15W-40

API CG4/CH4

ACEA E3/E5

MIL-PRF-2104G

6Engine Oil Filter C1

See NOTE 2 See Parts Manual

Fuel Filter, Diesel X C Clean or replace

See NOTE 3 See Parts Manual

Water Separator,

Diesel (Prefilter) X

CIL CRemove water

Clean or replace See Parts Manual

12 Brake Fluid CIL X0.2 liter (0.4 pt) SAE J-1703

23 Hydraulic Oil

H45-65XM X X C See NOTE 4

35.0 liter

(37.0 qt)

API CC or CC/SE

18 C(0F) and

Above SAE 10W

23 Hydraulic Oil

S45-65XM X X C See NOTE 4

34.0 liter

(36.0 qt)