Hyster H40.00-52.00XM-16CH Manual

PERIODIC
MAINTENANCE
H40.00-52.00XM-16CH
(H1050HD-CH, 1150HD-CH) [F117];
H40.00-48.00XM-12
(H800-1050HD/HDS) [A917]
PART NO. 1616443 8000 SRM 1237

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number Data ...................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 1
How to Tow Lift Truck............................................................................................................................... 2
How to Put Lift Truck on Blocks................................................................................................................... 2
How to Raise Drive Tires.......................................................................................................................... 2
How to Raise Steering Tires ..................................................................................................................... 3
Maintenance Schedule....................................................................................................................................... 4
Spreader Maintenance .................................................................................................................................. 14
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 15
How to Make Checks With the Engine Stopped .......................................................................................... 15
Safety Labels ............................................................................................................................................. 15
Operator Restraint System....................................................................................................................... 16
Safety Belt and Seat Rails.................................................................................................................... 16
Steering Column Latch......................................................................................................................... 16
Tires and Wheels....................................................................................................................................... 16
Forks .......................................................................................................................................................... 17
Adjust..................................................................................................................................................... 17
Remove .................................................................................................................................................. 17
Low Mount Forks, Install..................................................................................................................... 17
Forks, Mast, and Lift Chains, Inspect ..................................................................................................... 18
Drive Belt................................................................................................................................................... 19
Crankcase Breather Tube ......................................................................................................................... 19
Air Intake Piping and Charge Air Piping ................................................................................................ 19
Cooling Fan................................................................................................................................................ 20
Pre-Cleaner for Air Filter ......................................................................................................................... 20
Fuel, Oil, or Coolant Leaks....................................................................................................................... 21
Hydraulic Tank Breather.......................................................................................................................... 21
Engine Oil.................................................................................................................................................. 21
Hydraulic System Oil................................................................................................................................ 22
Hydraulic High Pressure Oil Filter.......................................................................................................... 22
Battery ....................................................................................................................................................... 23
Fuel Filter/Water Separator ..................................................................................................................... 23
Cooling System.......................................................................................................................................... 24
How to Add Fuel to Lift Truck ...................................................................................................................... 25
How to Make Checks With Engine Running................................................................................................25
Gauges, Lights, Horn, Fuses, and Relays................................................................................................ 25
Sealed Fuses.......................................................................................................................................... 28
Transmission Oil ....................................................................................................................................... 28
Engine Air Filter ....................................................................................................................................... 28
Engine Oil Pressure .................................................................................................................................. 29
Electrical System....................................................................................................................................... 29
Steering System ........................................................................................................................................ 29
Service Brakes........................................................................................................................................... 29
Parking Brake ........................................................................................................................................... 29
Control Levers and Pedals........................................................................................................................ 29
Lift System Operation............................................................................................................................... 29
Attachments .............................................................................................................................................. 30
First Inspection After First 100 Hours of Operation ....................................................................................... 30
Engine Oil Filter............................................................................................................................................ 30
Drive Axle and Differential........................................................................................................................... 30
©2007 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
Lift Chains ..................................................................................................................................................... 30
Transmission Oil Filter ................................................................................................................................. 30
Air Conditioning ............................................................................................................................................ 30
Steer Wheel Hubs .......................................................................................................................................... 30
Maintenance Procedures Every 250 Hours Or Monthly.................................................................................. 31
Transmission Oil Filter ................................................................................................................................. 31
Twist Locks (F117 Only)................................................................................................................................ 31
Gantry Carriage and Container Attachments (F117 Only)......................................................................... 31
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 31
Drive Belt....................................................................................................................................................... 31
Lift Chains ..................................................................................................................................................... 31
Hydraulic Return Line Oil Filter.................................................................................................................. 32
Air Conditioning ............................................................................................................................................ 32
Wheel Nuts..................................................................................................................................................... 32
Heater Air Filter............................................................................................................................................ 32
Steering Axle Kingpins ................................................................................................................................. 32
Steering Axle Tie Rods .................................................................................................................................. 33
Drive Shaft..................................................................................................................................................... 33
Steering Axle Pivots ...................................................................................................................................... 33
Mast and Carriage Load Rollers................................................................................................................... 33
Mast Pivots, Sliding Surfaces ....................................................................................................................... 33
Sideshift Carriage.......................................................................................................................................... 33
Maintenance Procedures Every 500 Hours or 6 Months ................................................................................. 34
Fuel Filter ...................................................................................................................................................... 34
Engine Oil and Filter..................................................................................................................................... 34
Oil Filter for Oil-Cooled Brakes (Brake Filter)............................................................................................ 34
Transmission Oil............................................................................................................................................ 34
Change ....................................................................................................................................................... 34
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 35
Drive Axle and Differential Oil..................................................................................................................... 35
Service Brake System.................................................................................................................................... 35
Brake System Accumulator .......................................................................................................................... 35
Hub Bearings, Steer Wheels ......................................................................................................................... 35
General Lubrication ...................................................................................................................................... 35
Maintenance Procedures Every 1500 Hours or 1 Year .................................................................................... 35
Engine ............................................................................................................................................................ 35
Water Pump ................................................................................................................................................... 35
Turbocharger.................................................................................................................................................. 36
Engine Mounting Bolts ................................................................................................................................. 36
Air Leaks, Air Intake and Exhaust .............................................................................................................. 37
Valve and Injector Adjustments.................................................................................................................... 38
General....................................................................................................................................................... 38
Adjust......................................................................................................................................................... 39
Injector Adjustment .............................................................................................................................. 39
Valve Adjustment.................................................................................................................................. 40
Maintenance Procedures Every 2000 Hours or 1 Year .................................................................................... 42
Parking Brake Assembly............................................................................................................................... 42
Clean .......................................................................................................................................................... 42
Inspect........................................................................................................................................................ 42
Maintenance Procedures Every 3000 Hours or 18 Months ............................................................................. 44
Hydraulic Suction Oil Filters........................................................................................................................ 44
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Periodic Maintenance Table of Contents
TABLE OF CONTENTS (Continued)
Maintenance Procedures Every 5000 Hours .................................................................................................... 44
Container Attachment (F117) ....................................................................................................................... 44
Maintenance Procedures Every 6000 Hours or 2 Years................................................................................... 44
Vibration Damper .......................................................................................................................................... 44
Fan Drive Idler Pulley................................................................................................................................... 45
Fan Hub ......................................................................................................................................................... 46
Turbocharger.................................................................................................................................................. 46
Cooling System Fluid .................................................................................................................................... 46
Maintenance Procedures Every 10,000 Hours or 5 Years................................................................................ 47
High Pressure Hydraulic Oil Filter.............................................................................................................. 47
Safety Procedures When Working Near Mast.................................................................................................. 48
Lift and Tilt System Leaks Check..................................................................................................................... 49
Lift System..................................................................................................................................................... 49
Tilt System..................................................................................................................................................... 49
Pneumatic Tires and Wheels............................................................................................................................. 50
Remove Wheels From Lift Truck .................................................................................................................. 50
Remove Tire From Wheel.............................................................................................................................. 50
Remove Tire From Five-Piece Wheel ....................................................................................................... 51
Install Tire on Wheel..................................................................................................................................... 52
Install Tire on Five-Piece Wheel .............................................................................................................. 53
Add Air Pressure to Tires.............................................................................................................................. 54
Install Wheels on Lift Truck ......................................................................................................................... 55
This section is for the following models:
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117];
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]
iii

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8000 SRM 1237 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 recommendation for the time intervals are for 8
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 personnel to do a complete program of
inspection, lubrication, and maintenance. A regular
program of inspection, lubrication, and maintenance
will help your lift truck give more efficient perfor-
mance 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 made on a lift truck by people
without authorization and training can make a
dangerous operating condition.
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 operators 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 DATA
The serial number for the lift truck is on the name-
plate and also on the right hand frame rail, near the
counterweight. The serial number indicates the de-
sign series, manufacturing plant, and the year man-
ufactured.
F117 E4369 AExample:
(1) (2) (3) (4)
(1) The first letter and number of the serial number
indicates the design series and the model number of
the lift truck.
(2) The second letter identifies the manufacturing
plant.
Examples:
D=Danville, IL U.S.A.
E=Nijmegen, The Netherlands
(3) The number series indicates the sequence of man-
ufacture where the lift truck was made.
(4) The letter indicates the year of manufacture start-
ing with A=2003. The letter B=2004 and so on.
HOW TO MOVE DISABLED LIFT TRUCK
The service brake system requires hydraulic pres-
sure to operate. The park brake will automatically
apply when hydraulic pressure drops. If there is no
hydraulicpressuretoreleasetheparkingbrake,the
parking brake caliper must be manually released.
Put blocks on both sides (front and back) of the drive
tires to prevent movement of the lift truck. The park-
ing brake caliper is installed at the back of the dif-
ferential housing. To manually release the parking
brake, remove cotter pin from bolt in caliper. Tighten
nut to compress spring that applies brake.
NOTE: If there is no hydraulic pressure to release
the parking brake, the parking brake caliper must be
manually released. Put blocks on both sides, front
and rear, of the drive tires to prevent movement of
the lift truck. To manually release the parking brake,
remove the cotter pin and tighten the nut to compress
the spring that applies the brake.
1

General 8000 SRM 1237
How to Tow Lift Truck
WARNING
Use extra caution when moving 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
assist available for the steering and service
brakes. This can make the control of the lift
truck difficult. Poor traction can cause the
disabled lift truck or towing vehicle to slide.
Steep grades will increase the required brake
effort.
Never lift and move a disabled lift truck unless
the disabled lift truck MUST be moved and
cannot be towed. A lift truck used to move
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
truckusedtomoveadisabledlifttruckmust
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
under side of the lift truck.
1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. Using a lift truck or a lifting device that can be
attached to the mast (I.E. come-a-long), raise the
carriage and forks approximately 30 cm (12 in.)
from surface. Install a chain around the mast
crossmember and the carriage, to prevent car-
riage 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. In-
stall an approximate half-capacity load on the
forks of the lift truck that is being used to tow the
disabled lift truck. This half-capacity load will
increase the traction of the lift truck. Keep the
load as low as possible.
5. Use a towing link made of steel that attaches to
the tow pins in the counterweights of both lift
trucks.
HOW TO PUT LIFT TRUCK ON BLOCKS
How to Raise Drive Tires
WARNING
Thelifttruckmustbeputonblocksforsome
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: drive axle,
engine and transmission, and the counter-
weight. 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 that
the lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so that the
lift truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Verify that any
blocks used to support the lift truck are solid,
one piece units. Put a steel plate on top of the
block.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
NOTE: The lifting eyes of the counterweight are for
lifting of the counterweight only. Never use the lift-
ing eyes or the counterweight to lift the truck.
1. Putblocksoneachside(frontandback)ofthe
steering tires to prevent movement of the lift
truck. See Figure 1 and Figure 2.
2. Put the mast in a vertical position. Put a block
under each outer mast channel.
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put additional blocks under the frame behind the
drive tires.
5. If the hydraulic system will not operate, use a
hydraulic jack under the side of the frame near
the drive axle. Verify that the jack has a capacity
of at least half the weight of the lift truck. See the
nameplate.
2

8000 SRM 1237 General
How to Raise Steering Tires
1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to prevent
movement of the lift truck. See Figure 1 and Fig-
ure 2.
2. Use a hydraulic jack to raise the steering tires.
Verify that the jack has a capacity of at least 2/3
of the weight of the lift truck. See the nameplate.
3. Put the jack under the steering axle or frame to
raise the lift truck. Put blocks under the frame
to support the lift truck.
1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES
Figure 1. Put Lift Truck on Blocks (F117)
1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES
Figure 2. Put Lift Truck on Blocks (A917)
3

Maintenance Schedule 8000 SRM 1237
Maintenance Schedule
NOTE: Portions reproduced by permission of Cum-
mins Inc.
Figure 3. Maintenance Points (F117) (Sheet 1 of 2)
Figure 3. Maintenance Points (F117) (Sheet 2 of 2)
4

8000 SRM 1237 Maintenance Schedule
Figure 4. Maintenance Points (A917) (Sheet 1 of 2)
Figure 4. Maintenance Points (A917) (Sheet 2 of 2)
5