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
Property of American Airlines

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!
Property of American Airlines

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....................
Property of American Airlines

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..................
Property of American Airlines

CONTENTS
6
NOTES
Property of American Airlines

WARNING
7
AWARNING
label with this
information
must be on the
lift truck.
Property of American Airlines

WARNING
8
NOTES
Property of American Airlines