General • Inspections

Hyster H40-60XT (A380) Warehouse Forklift Maintenance Schedule: Every 8 Hours or Daily

Use this recommended maintenance checklist for the for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hour meter, and in calendar time. Use the interval that occurs first.

MaintainX

10/07/2022

Hyster H40-60XT (A380) Warehouse Forklift Maintenance Schedule: Every 8 Hours or Daily

The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hour meter, and in calendar time. Use the interval that occurs first.

How to Make Checks With the Engine Stopped

Put the lift truck on a level surface. Lower the carriage and forks, stop the engine, and apply the parking brake.

Open the hood and check for leaks and conditions that are not normal.

Clean any oil or fuel spills.

Ensure all surfaces are free of oils, lubricants, fuel and organic dust or fibers (paper, wood, cotton, agricultural grass/grain, etc.).

Tires and Wheels

Check the tires for damage (see Figure 14).

Check the tread and remove any objects that will cause damage.

Check for bent or damaged rims.

Check for loose or missing hardware.

Remove any wire, strapping, or other material that is wrapped around the axle.

Mast, Carriage, Header Hoses, Lift Chains, and Attachment

Figure15. Lift Chain Check

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the capscrews and nuts are tight.

Inspect the carriage to be sure fork stops are in place. Fork stops prevent forks from laterally disengaging from the carriage.

Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage.

Inspect the load backrest extension for cracks and damage.

If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear. Make sure the parts that fasten the sideshift carriage or attachment to the carriage are in good condition.

Visually inspect hoses/fittings for hydraulic leaks; hose cover for cuts, cracks, or exposed reinforcement; defective/ broken clamping devices or sheaves; and proper tracking during operation. Adjust/repair/replace hose/components as necessary.

Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains.

Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set.

Inspect the chain anchors and pins for cracks and damage.

Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Operator Restraint System

The seat belt, hip restraint, seat, hood, and hood latches are all part of the operator restraint system (see Figure 16 and Figure 17). Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition.

Figure 17. Hood and Hood Latch Check

Emergency Locking Retractor (ELR)

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips over, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator's lower torso in the seat. See Figure 16.

Figure 16.

A seat belt that is damaged, worn, or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if it is damaged or worn.

NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly.

With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt does not pull out of the retractor assembly, the internal latch may be locked. Pull firmly on the seat belt and hold for a moment to remove slack from the belt in the retractor. Release the seat belt. Seat belt will retract and the internal latch will unlock. If the seat belt cannot be pulled from the retractor assembly or the belt

With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor when it is pulled with a sudden jerk, replace the seat belt assembly.

With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

Hood and Seat Latches

Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked (see Figure 16). The seat rails must be correctly fastened to the hood and the hood fastened to the hinges on the frame. Try to lift the hood to make sure it is fastened correctly and will not move. If adjustment is required, go to Hood Latch Check in the Periodic Maintenance section of the service manual.

Engine Compartment

Check for the presence of any combustible material such as paper, leaves etc.

Remove any combustible materials.

Ground Static Strap

If lift truck is equipped with a Ground Static Strap (see Figure 18), check to be sure Ground Static Strap is securely in place and in contact with the ground.

Check attaching hardware.

. If worn, missing or not in contact with the ground, replace strap and mounting hardware as required.

Figure 18. Ground Static Strap

Legend for Figure 18

1. Frame
2. PDM
3. GROUND STATIC STRAP
4. BATTERY

Fuel, Oil, and Coolant Leaks, Check

Make a visual check for leaks on and under the lift truck. If possible, find and report the leak to maintenance for repair. Leaks often indicate a need for repair of damaged or worn components. Leaks in the LPG fuel system are usually not visible unless ice is present. There is however, usually a strong odor. Fuel leaks MUST be repaired IMMEDIATELY.

Check the fuel system for leaks and the condition of parts. When fuel is added to the lift truck, see the section, How to Add Fuel to the Lift Truck.

Also check the condition of the radiator or heater hoses that are not leaking. Soft or cracked hoses need to be replaced before a major leak occurs.

Hydraulic Hoses

Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the hydraulic hoses are not leaking.

If any hose is leaking, report it to maintenance for repair.

Coolant Hoses

Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the coolant hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

Transmission

Check the transmission for leaks, damage, and loose components. Heavy-duty or high-temperature operations can require more frequent checks.

Hydraulic System Oil

After the engine has stopped, wait one minute before checking the oil level.

Keep hydraulic oil at the correct level as indicated on the dipstick, located on top of right frame channel. See Figure 19.

Use the correct oil as shown in the Maintenance Schedule.

Check the hydraulic system for leaks and damaged or loose components. Heavy-duty or high-temperature operations can require more frequent checks.

Engine Oil

After the engine has stopped, wait one minute before checking the oil level.

See Figure 20, Figure 21, Figure 22, and Figure 23.

Keep the oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule.

There is an indicator light for the engine oil pressure on the Dash Display. During normal operation the red indicator light will illuminate when the key switch is turned to ON and will stay illuminated until correct oil pressure is obtained, at which time the light will go off.

If the light continues to stay on when the engine is running, the engine oil pressure is low. Stop the engine and check the oil level. See Figure 20, Figure 21, Figure 22, and Figure 23. DO NOT restart the engine until the low pressure condition has been corrected.

Air Filter

The air filter canister should not be opened until an air filter element replacement is required. An air filter element replacement is required when one of the following occurs:

the specified number of hours has passed since the last filter element replacement

DO NOT operate the lift truck until the air filter element has been replaced.

Forks

The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook forks.

Forks, Remove

NOTE: Forks are to be replaced only in sets and not individually.

Lower carriage and remove four capscrews from inner fork carriers. Remove inner fork carriers from integral sideshift carriage. See Figure 24 or Figure 25.

Slide fork to fork removal notch in bottom bar of carriage. See Figure 24 or Figure 25.

Lower fork onto blocks so bottom hook of fork moves through fork removal notch. Lower carriage further so top hook fo fork is disengaged from top carriage bar. Move carriage away from fork or use a lifting device to move fork away from carriage. See Figure 26.

Figure 26. Remove a Hook Fork

1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS

Forks, Inspect

Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. Replace damaged fork. Forks are to be replaced only in sets and not individually.

Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 27. Check that the bottom of the fork is not worn (Item 4 in Figure 27).

Replace any damaged or broken parts that are used to keep the forks locked in position.

Inspect fork wear. Ensure heel wear is not more than 10% of original thickness. if fork wear is more than 10%, fork must be replaced or rerated. Perform fork wear inspection using a BOL256N1 caliper ruler Hyster P/N 4092984 as follows. See Figure 28.

Determine normal thickness of "N" of fork using scale or ruler portion of caliper ruler. Measurement has to be done on fork shank using caliper ruler.
Position caliper at end of heel internal radius (item 4, Figure 27) with opening corresponding to measured thickness of fork shank in Step a above. (e.g. for N 1.75 use N 1.75 opening). This is typically the section of fork where wear is greatest. Note that opening distance has been reduced by 10% from nominal thickness.
If fork enters opening, it is mandatory to replace it. DANGER OF BREAKING. Furthermore, a 10% reduction in fork blade thickness results in 20% reduction in operating capacity.

Figure 28. Fork Wear

Forks, Install

NOTE: Forks are to be replaced only in sets and not individually.

NOTE: If lift truck is not equipped with a fork positioner, go to Step 1. If lift truck is equipped with fork positioner, go to Step 2.

Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the upper carriage bar. See Figure 26.

If lift truck is equipped with a fork positioner attachment, install inner fork carriers using four capscrews. Tighten capscrews to 35 N•m (25 lbf ft). See Figure 24 or Figure 25.

Forks, Adjust

NOTE: During the adjustment of the forks, the heel of the forks should not be touching the ground.

The forks are connected to the carriage by hooks and lock pins. See Figure 26 and Figure 29. The lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. If pin does not remain engaged in carriage slot, replace with new pin. Adjust the forks as far apart as possible for maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock p

Brake Fluid

Replace the brake fluid in the system if there is dirt or water in the system.

On lift trucks with dry brakes, only use SAE J-1703 (DOT 3) brake fluid in the master cylinder.

Open cover to brake fluid reservoir. Open reservoir and check fluid lever. If fluid is low, fill to within 2.5 mm (0.1 in.) of max line on reservoir. See Figure 30.

Figure 30. Brake Fluid Reservoir Cover

Legend for Figure 30

A. COVER CLOSED 1. COVER 2. CAPSCREW 3. NUT
B. COVER OPEN 4. BRAKE FLUID RESERVOIR 5. MOUNTING BRACKET

How to Make Checks With the Engine Running

Make sure that the area around the lift truck is clear before starting the engine or making any checks of the operation.

Be careful when making the checks. If the lift truck is stationary during a check, apply the parking brake and put the transmission in NEUTRAL. Make the checks carefully.

Indicator Lights, Horn, Fuses, and Relays

Turn key to ON position. Check all indicator lights for correct operation as described in Table 1. Check the operation of the horn. Start the engine by turning the key switch to the START position. If any of the indicator lights do not operate correctly, check the fuses. The fuses are located in the Power Distribution Module (PDM) which is under the hood next to the battery on the right side. See Figure 31.

Figure 31. PDM Showing Fuses and Relays

Service Brakes

Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before using the lift truck. Replace the brake fluid in the system if there is dirt, water, or oil in the system.

Operation, Check

Check the operation of the service brakes. Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate. The pedal must stop firmly and must not move slowly down after the brakes are applied. The service brakes must apply equally to both drive wheels. The service brakes must not pull the lift truck to either side of the direction of travel when they are applied. The service brakes are automatically adjusted when the transmission is in reverse and

Parking Brake

If the operator leaves the seat without setting the parking brake and the key is in the OFF position for a period of 3 minutes or less, an audible alarm will sound for 1 minute.

Make sure the service brakes operate correctly before checking the operation of the parking brake. Check the operation of the parking brake. The parking brake, when in good condition and correctly adjusted, will hold a lift truck with a full capacity load on a 15% grade [a slope that increases 1.5 meters in 10 meters (1.5 feet increases in 10 feet)]. If parking brake requires adjustment, notify service personnel.

Engine Oil Pressure

There is an indicator light for the engine oil pressure on the Dash Display. During normal operation the red indicator light will illuminate when the key switch is turned to ON and will stay illuminated until correct minimum oil pressure is obtained, at which time the light will go off. If the light continues to stay on when the engine is running, the engine oil pressure is low. Stop the engine and check the oil level. See Engine Oil section in this manual. DO NOT restart the engine until the low pressure c

Cooling System

There is a coolant temperature gauge on the Dash Display. When the bar gauge reaches the middle bar, the temperature is optimum. If the gauge shows full bars, the engine is too hot and a warning buzzer will sound.

Make sure the coolant level is between the ADD and FULL marks on the auxiliary coolant reservoir (See Figure 32). The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase.

Check the radiator fins. Clean the radiator with compressed air or water as needed.

Check for and remove any debris on the radiator core. If the indicator light turns on again after restarting, shut down the lift truck and do not operate the lift truck until the problem is corrected.

Figure 32. Auxiliary Coolant Reservoir

Steering System

Make sure the steering system operates smoothly and provides good steering control. Make sure the steering column can be adjusted and the gas cylinder function is correct.

Control Levers and Pedals

Check that the control levers for the transmission, mast, and attachment operate as described in Table 1. Check that the pedals operate correctly as described in Table 1.

Lift System Operation

Perform the following checks and inspections:

Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes.
NOTE: Some parts of the mast move at different speeds during raising and lowering.
Slowly raise and lower the mast several times without a load. Raise the mast to its full height at least once. The mast components must raise and lower smoothly in the correct sequence. Hose must track properly during operation.
The inner weldments and the carriage must lower completely.
Raise the mast 1 m (3 ft) with a capacity load. The inner weldments and the carriage must raise smoothly. Lower the mast. All moving components must lower smoothly.
Lower the load to approximately 0.3 m (1 ft). Tilt the mast forward and backward. The mast must tilt smoothly and both tilt cylinders must stop evenly.
Check that the controls for the attachment operate the functions of the attachment. See the symbols by each of the controls. Make sure all of the hydraulic lines are connected correctly and do not leak.

How to Add Fuel to the Lift Truck

Stop the engine. Turn the key switch to OFF, if truck is equipped with a key switch; or press the Power ON/OFF button, if truck is equipped with keyless start option. The operator must be off of the lift truck while fuel is added.

No Smoking.

All fuels for internal combustion engines are very flammable.

Fill the fuel tank only in a designated area with good ventilation. Have a fire extinguisher available.

Never fill the fuel tank near an open flame or near equipment that can create sparks. Never check fuel lever or check for leaks with an open flame.

Breathing fuel vapor may cause nausea, unconsciousness or death. Long-term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor.

Liquefied Petroleum Gas (LPG)

Frost on the surface of the tank, the valves or fittings and the odor of LPG fuel indicates a leak. Inspect the LPG system and repair a leak immediately. An LPG fuel leak creates an explosion and fire hazard. Do not attempt to start the engine if there is a leak in the LPG fuel system.

Only trained and authorized personnel are permitted to operate filling equipment.

Use only the LPG tank indicated on the label on the tank bracket. DO NOT use an LPG tank that is damaged. A damaged LPG tank must be removed from service.

LPG Tank, Removal:

Removable LPG tanks can be replaced indoors only if the lift truck is a minimum of 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Move lift truck to an area where LPG tanks are changed.
Turn the shutoff valve clockwise until the valve is completely closed.
Run the engine until it stops, then turn the key switch to the OFF position.
Disconnect the quick-disconnect fitting on the LPG tank. See Figure 33.
Unlatch the tank strap and remove the LPG tank from the bracket.

LPG Tank, Install

Install the LPG tank into the bracket so that the LPG tank pin is in the correct hole in the bracket. Replace LPG tank pin if damaged. Close the tank strap latches.
Connect the quick disconnect fitting to the shutoff valve on the tank. Hand-tighten the vale to the fitting. See Figure 33.
Turn the fuel valve counterclockwise to open the fuel valve.
Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to inspect the fuel system for leaks: a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection. b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine. c. Soapy Water - This method is used in conjunction with Step b above. If the odor of LPG is present but escaping fuel cannot be heard, apply soapy water to the fittings and observe for bubbles. d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

Gasoline and Diesel Fuel

Remove the fuel cap. Make sure the fuel tank is filled with the correct fuel for the type of engine in the lift truck. Clean the fuel cap and make sure vent is clear.
Replace the fuel cap.

Wheels and Tires

General

This series of lift trucks have pneumatic tires or solid rubber tires that look like pneumatic tires. These variations in tires also cause a variation in the types of wheels and the disassembly and assembly procedures.

Source: MaintainX (Community Member)

The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hour meter, and in calendar time. Use the interval that occurs first.

How to Make Checks With the Engine Stopped

Put the lift truck on a level surface. Lower the carriage and forks, stop the engine, and apply the parking brake.

Open the hood and check for leaks and conditions that are not normal.

Clean any oil or fuel spills.

Ensure all surfaces are free of oils, lubricants, fuel and organic dust or fibers (paper, wood, cotton, agricultural grass/grain, etc.).

Tires and Wheels

Check the tires for damage (see Figure 14).

Check the tread and remove any objects that will cause damage.

Check for bent or damaged rims.

Check for loose or missing hardware.

Remove any wire, strapping, or other material that is wrapped around the axle.

Mast, Carriage, Header Hoses, Lift Chains, and Attachment

Figure15. Lift Chain Check

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the capscrews and nuts are tight.

Inspect the carriage to be sure fork stops are in place. Fork stops prevent forks from laterally disengaging from the carriage.

Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage.

Inspect the load backrest extension for cracks and damage.

If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear. Make sure the parts that fasten the sideshift carriage or attachment to the carriage are in good condition.

Visually inspect hoses/fittings for hydraulic leaks; hose cover for cuts, cracks, or exposed reinforcement; defective/ broken clamping devices or sheaves; and proper tracking during operation. Adjust/repair/replace hose/components as necessary.

Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains.

Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set.

Inspect the chain anchors and pins for cracks and damage.

Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Operator Restraint System

The seat belt, hip restraint, seat, hood, and hood latches are all part of the operator restraint system (see Figure 16 and Figure 17). Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition.

Legend for Figure 16

A. STANDARD FULL SUSPENSION SEAT

B. STANDARD NON-SUSPENSION SEAT

C. PREMIUM FULL SUSPENSION SEAT

1. HIP RESTRAINT

2. SEAT BELT

3. FORWARD/BACKWARD ADJUSTMENT LEVER

4. WEIGHT ADJUSTMENT KNOB

5. BACKREST ANGLE ADJUSTMENT LEVER

6. RIDE POSITION INDICATOR

Figure 17. Hood and Hood Latch Check

Legend for Figure 17

1. LATCH STRIKER

2. BUMPER

3. HOOD

4. HOOD RELEASE HANDLE

5. HOOD LATCH

6. LIFT TRUCK FRAME

7. BOOT

Emergency Locking Retractor (ELR)

Figure 16.

A seat belt that is damaged, worn, or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if it is damaged or worn.

NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly.

With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor when it is pulled with a sudden jerk, replace the seat belt assembly.

With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

Hood and Seat Latches

Engine Compartment

Check for the presence of any combustible material such as paper, leaves etc.

Remove any combustible materials.

Ground Static Strap

If lift truck is equipped with a Ground Static Strap (see Figure 18), check to be sure Ground Static Strap is securely in place and in contact with the ground.

Check attaching hardware.

. If worn, missing or not in contact with the ground, replace strap and mounting hardware as required.

Figure 18. Ground Static Strap

Legend for Figure 18

1. Frame

2. PDM

3. GROUND STATIC STRAP

4. BATTERY

Fuel, Oil, and Coolant Leaks, Check

Check the fuel system for leaks and the condition of parts. When fuel is added to the lift truck, see the section, How to Add Fuel to the Lift Truck.

Also check the condition of the radiator or heater hoses that are not leaking. Soft or cracked hoses need to be replaced before a major leak occurs.

Hydraulic Hoses

Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the hydraulic hoses are not leaking.

If any hose is leaking, report it to maintenance for repair.

Coolant Hoses

Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage.

Check to insure that the coolant hoses are not leaking. If any hose is leaking, report it to maintenance for repair.

Transmission

Check the transmission for leaks, damage, and loose components. Heavy-duty or high-temperature operations can require more frequent checks.

Hydraulic System Oil

After the engine has stopped, wait one minute before checking the oil level.

Keep hydraulic oil at the correct level as indicated on the dipstick, located on top of right frame channel. See Figure 19.