Hyster S40XM User manual

HYSTER COMPANY PART NO. 1458874
OPERATING MANUAL
CHALLENGER
S40XM, S45XM, S50XM, S55XM, S55XMS, S60XM,
S65XM
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
SPACESAVER
H45XM,H50XM,H55XM,H60XM,H65XM
Property of American Airlines

LIFT TRUCK MODEL SERIAL NUMBER
ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE SERIAL NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE GROUP NUMBER
DRIVE TIRE SIZE STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
REGISTERED TRADEMARKS
Hyster, , Challenger, SpaceSaver, Monotrol, RACKLOADER, SitDrive and StanDrive are trademarks of
Hyster Company.
Property of American Airlines

FOREWORD
1
FOREWORD
To OWNERS, USERS, and OPERATORS:
The safe and efficient operation of a lift truck requires
skill and alertness on the part of the operator. To develop
the skill required the operator must:
•Receive training in the proper operation of THIS lift
truck.
•Understand the capabilities and limitations of the lift
truck.
•Become familiar with the construction of the lift truck
and see that it is maintained in good condition.
•Read and understand the warnings and operating
procedures in this manual.
In addition, a qualified person, experienced in lift truck oper-
ation,mustguideanewoperatorthroughseveraldrivingand
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 trainingprogram is avail-
able from HYSTER COMPANY. For further details, contact
your dealer for Hyster lift trucks.
This OPERATING MANUAL contains information neces-
sary for the operation and maintenance of a basic fork lift
truck. Optional equipment is sometimes installed that can
change some operating characteristics described in this
manual. Make sure the necessary instructions are avail-
able and understood before operating the lift truck.
HYSTER COMPANY 2003
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FOREWORD
2
Some of the components and systems described in this
OPERATING MANUAL will NOT be installed on your unit.
If you have a question about any item described, contact
your dealer for Hyster lift trucks.
Additional information that describes the safe operation
and use of lift trucks is available from the following
sources:
•Employment safety and health standards or
regulations (Examples: “Occupational Safety and
Health Standards (USA)”, “Canada Material Handling
Regulations”.
•Safety codes and standards (Example: American
National Standard, ANSI B56.1, Safety Standard For
Low Lift And High Lift Trucks.
•Publications from government safety agencies,
government insurers, private insurers and private
organizations (Example: Accident Prevention Manual
For Industrial Operations, from the National Safety
Council).
•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.
NOTE: Hyster lift trucks are not intended for use on public
roads.
NOTE: The following symbols and words indicate safety in-
formation in this manual:
WARNING
Indicates a condition that can cause death or injury!
CAUTION
Indicates a condition that can cause injury or property
damage!
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CONTENTS
3
CONTENTS
FOREWORD 1..................................
To OWNERS, USERS, and OPERATORS 1......
CONTENTS 3...................................
MODEL DESCRIPTION 11.........................
GENERAL 11..................................
OPERATOR PROTECTION EQUIPMENT 11......
NAMEPLATE 12...............................
SAFETY LABELS 13...........................
INSTRUMENTS AND CONTROLS 17............
OPERATING PROCEDURES 33....................
GENERAL 33..................................
Know Your Lift Truck 33......................
Stability And Center Of Gravity 35.............
Capacity (Weight And Load Center) 36.........
INSPECTION BEFORE OPERATION 37..........
Checks With The Engine Stopped 37..........
Starting Procedures 38.......................
Starting Procedures, Gasoline Or LPG
Engine 38..................................
Starting Procedures, Diesel Engine 38.........
Checks With The Engine Running 39..........
OPERATING TECHNIQUES 40..................
Basic Operating Procedures 41...............
Driving And Direction Changes 42.............
Inching 43..................................
Steering (Turning) 44........................
Load Handling, General 46...................
Load Handling, Lifting, Lowering And
Tilting 47...................................
Load Handling, How To Engage And Disengage
A Load 49..................................
Load Handling, Travelling 52..................
HIGHWAY TRUCKS, RAIL CARS AND
DOCKS 56....................................
ATTACHMENTS 58............................
STOPPING 58.................................
PARKING 58..................................
MAINTENANCE 61...............................
GENERAL 61..................................
Serial Number Data 62.......................
HOW TO MOVE A DISABLED LIFT TRUCK 62....
HowToTowtheLiftTruck 62..................
HOW TO PUT A LIFT TRUCK ON BLOCKS 63....
How To Raise the Drive Tires 63..............
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CONTENTS
4
How To Raise the Steering Tires 64...........
MAINTENANCE SCHEDULE 67...................
MAINTENANCE PROCEDURES EVERY 8 HOURS
OR DAILY 81.....................................
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED 81..................................
Tires and Wheels 81........................
Forks 83...................................
Forks, Adjustment 83........................
Forks, Removal 83..........................
Forks, Installation 85.........................
Inspection Of Forks, Mast, and Lift Chains 85...
Safety Labels 87............................
Operator Restraint System 87................
Steering Column Latch 89....................
Check For Fuel, Oil Or Coolant Leaks 89.......
Drive Belt 89...............................
Engine Oil 89...............................
Transmission Oil Temperature 92.............
Hydraulic System Oil 93.....................
Battery 94.................................
Air Filter 94................................
HOW TO MAKE CHECKS WITH THE ENGINE
RUNNING 95..................................
Gauges, Lights, Horn, Fuses and Relays 98....
“Check Engine” Light(Mazda and GM3.0L LPG
Closed--Loop With Emission System) 98........
“Check Engine” Light
(GM 3.0 Liter Gasoline) 98....................
Engine Oil Pressure 98.......................
Cooling System 99..........................
Steering System 99..........................
Service Brakes 99...........................
Parking Brake 100............................
Fuel System 101.............................
Water Separator, Diesel Engine 101.............
Fuel Filter, Diesel Engine 102..................
Remove Air From The Diesel Fuel System 102...
Control Levers and Pedals 102.................
Lift System Operation 102.....................
Cooling System 103..........................
HOW TO ADD FUEL TO THE LIFT TRUCK 104....
Liquefied Petroleum Gas (LPG) 105.............
Gasoline or Diesel Fuel 108....................
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CONTENTS
5
WHEELS AND TIRES 108.......................
General 108.................................
How To Change A Solid Rubber Tire
S40--65XM Models 109.......................
RemoveAndInstallTheTireOnThe
Wheel 109...................................
How To Repair A Pneumatic Tire H45--65XM
Models 111..................................
Remove The Wheels From The Lift Truck 111....
Remove The Wheel From The Tire 112..........
Install The Wheel in the Tire 115................
AddAirToTheTires 117......................
Install the Wheels 118.........................
INSTALLATION PROCEDURES, DUAL DRIVE
WHEELS 119...................................
SOLID RUBBER TIRES 119......................
Remove The Tire From The Wheel 120..........
Install The Tire On The Wheel 120..............
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE 123...........................
CHANGES TO THE OVERHEAD GUARD 123......
HOW TO PUT INTERNAL COMBUSTION
ENGINE (I.C.E.) TRUCKS IN STORAGE 123.......
HOW TO PUT BATTERIES IN STORAGE 124......
HOW TO STORE A LIFT TRUCK 125.............
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT 127...............................
Loading 127.................................
Unloading 128...............................
PREPARATION FOR USE 129....................
Preparation After Transport 129................
Preparation After Storage 129..................
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CONTENTS
6
NOTES
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WARNING
7
AWARNING
label with this
information
must be on the
lift truck.
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WARNING
8
NOTES
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MODEL DESCRIPTION
9
FIGURE 1. MODEL VIEW SHOWING MAJOR COMPONENTS OF S40--65XM SERIES
12779
1. OVERHEAD GUARD
2. TAIL LIGHT, BRAKE
LIGHT, REVERSE LIGHT
3. SEAT
4. COUNTERWEIGHT
5. STEERING AXLE
6. SEAT BELT AND
HIP RESTRAINT
7. DRIVE AXLE
8. FORKS
9. CARRIAGE
10. LOAD BACKREST
EXTENSION
11. PARKING BRAKE
12. STEERING WHEEL
13. MAST
9
1
3
2
4
5
6
7
8
10
11
12
13
6
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MODEL DESCRIPTION
10
1. OVERHEAD GUARD
2. TAIL LIGHT, BRAKE
LIGHT, REVERSE LIGHT
3. SEAT
4. COUNTERWEIGHT
5. STEERING AXLE
6. SEAT BELT AND
HIP RESTRAINT
7. DRIVE AXLE
8. FORKS
9. CARRIAGE
10. LOAD BACKREST
EXTENSION
11. PARKING BRAKE
12. STEERING WHEEL
13. MAST
FIGURE 2. MODEL VIEW SHOWING MAJOR COMPONENTS OF H45--65XM SERIES
12626
9
1
3
2
4
5
6
7
8
10
11
12
13
6
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MODEL DESCRIPTION
11
MODEL DESCRIPTION
GENERAL
This OPERATING MANUAL is for the following models of
lift trucks:
S45XM, S45XM, S50XM, S55XM, S55XMS,
S60XM, S65XMS
H40XM, H50XM, H55XM, H60XM, H65XM
These lift trucks are available with the following engines:
•Mazda M4--2.0G or M4--2.2G engine which use
gasoline or LPG fuel
•GM 3.0L engine that uses gasoline or LPG fuel
•Perkins 704--26 (UB) diesel engine
H45--65XM only
The single--speed powershift transmission can be
equipped with two types of controls:
•A MONOTROLRpedal that controls both the for-
ward and reverse operation of the powershift trans-
mission and the speed of the engine.
•A direction control lever on the left side of the
steering column that controls the forward, neutral
and reverse operation of the powershift transmis-
sion. A separate accelerator pedal controls the en-
gine speed.
The S40--65XM lift trucks are equipped with solid rubber
tires. The H45--65XM lift trucks are equipped with pneu-
matic 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 the opera-
tor. It must be high enough, with openings small enough
to prevent the parts of the load from falling backwards. If
a load backrest extension that is different from the one
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 can not
protect against every possible impact. Therefore, it must
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MODEL DESCRIPTION
12
not be considered a substitute for good judgment and
care when handling loads. Do not remove the overhead
guard.
The SEAT BELT AND HIP RESTRAINT provide additional
means to help the operator keep the head and torso sub-
stantially within the confines of the lift truck frame and
overhead 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 can
not protect the operator against all possible injury in a
tipover. The hip restraint will help the operator resist side
movement. It is not a substitute for the seat belt. Always
fasten the seat belt.
NAMEPLATE
WARNING
Any change to the lift truck, the tires or its equipment
can change the lifting capacity. If the Nameplate does
not show the maximum capacity, or if the lift truck
equipment, including the battery for electric trucks,
does not match that shown on the Nameplate, the lift
truck must not be operated.
The capacity is specified in kilograms (kg) and pounds
(lb). The capacity is the maximum load that the lift truck
can handle for the load condition shown on the Name-
plate.
The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities
with the load height reduced or with optional load centers,
may also be shown on the Nameplate.
The lift truck serial number code is on the Nameplate. The
serial number code is also stamped on the lift truck frame.
When a lift truck is shipped incomplete from the factory,
the Nameplate is covered by an INCOMPLETE label as
shown in FIGURE 3. If the equipment on the truck is
changed, the Nameplate is covered by a NOTICE label as
shown in FIGURE 3. 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 Name-
plate.
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MODEL DESCRIPTION
13
WARNING
DO NOT add to or modify the lift truck. Any change to
the lift truck, the tires or its equipment can change
the lifting capacity. The lift truck must be rated as
equipped and the nameplate must show the new ca-
pacity rating.
SAFETY LABELS
Safety labels are installed on the lift truck to give informa-
tion about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See
FIGURE 4.
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MODEL DESCRIPTION
14
This unit was shipped incomplete from factory/
The U.S.A. Occupational Safety and Health Act of 1970 and other
national safety codes require the installation ofa completed Nameplate
showing unitconfiguration and rated capacity.Completed Nameplates
may be obtained through yourHYSTER dealer.
NOTICE TO USER
TRUCK MODEL
Serial no.
Approx. weight
FIGURE 3. NAMEPLATE AND LABELS
NAMEPLATE
1304058R
INCOMPLETE LABEL
NOTICE LABEL
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MODEL DESCRIPTION
15
FIGURE 4. WARNING AND SAFETY LABELS (1 of 2)
SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS
1
4
567
2
9
3
8
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MODEL DESCRIPTION
16
17
1. WARNING, OPERATION
2. DRIVE TRAIN PROTECTION CAUTION
3. OPTIONAL FIRE SAFETY RATING
4. CASE WITH OPERATING MANUAL
5. NAMEPLATE
6. WARNING FOR PARKING BRAKE
7. NO ONE ON OR UNDER FORKS
8. NO RIDERS
9. TIPOVER WARNING
10. MAST WARNING
11. FAN WARNING
12. RADIAL TIRE WARNING--H45--65XM Only
13. ETHER WARNING--H45--65XM Only
14. RADIATOR CAP WARNING -- H45--65XM
Only
15. DUAL FUEL WARNING
16. TWO--PIECE WHEEL WARNING
H45--65XM Only
17. FLAMMABLE LP--GAS
18. GUARD LABEL
10
11
12
13
16
SEE THE PARTS MANUAL FOR THE PART NUMBER AND LOCATION OF LABELS
FIGURE 4. WARNING AND SAFET
Y
LABELS
(
2o
f
2
)
14 15
18
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MODEL DESCRIPTION
17
FIGURE 5. INSTRUMENTS
1
2
3
4567
8
9*
10
11
12
13
14
15
16
17
18
*USED ONLY ON S40--65XM
MODEL TRUCKS
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MODEL DESCRIPTION
18
INSTRUMENTS AND CONTROLS
WARNING
If any of the instruments, levers, or pedals do not operate as described in the following tables, report the prob-
lem immediately. DO NOT operate the lift truck until the problem is corrected.
TABLE 1. INSTRUMENTS (See FIGURE 5.)
ITEM
NO. ITEM FUNCTION
1Fuel Gauge This gauge indicates the amount of fuel in the gasoline or diesel fuel tank.
2Coolant
Temperature
Gauge
This gauge indicates engine coolant temperature when the key switch is in the
ON position. During normal operation the gauge needle will be in the green
area.
Do not continue to operate the lift truck when the gauge indicates that
the engine is too hot (needle in the red zone).
NOTE: Engine will stop after a 30 second warning buzzer if coolant is over
121°C (250°F) on S40--65XM series with protection system.
CAUTION
3Hour Meter The hour meter operates when the key switch is in the ON position. Periodic
Maintenance recommendations are based on these hours.
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