Guia de Montagem - 360

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GUIA DE MONTAGEM
H8-12XM-6, H10XMS-6 H190-280HD2 ,
(
H230HDS2 [ L007];
)
H13-16XM-6, H6-7XM-12EC (H210-250-48HD ,
2
H300-360HD , H360HD -EC) [K019]
2 2
PARTE NO. 4133482 8000 SRM 1940
PRECAUÇÕES DE
SEGURANÇA MANUTENÇÃO E
REPAROS
• Os Manuais de Serviço são atualizados regularmente, mas podem não refletir alterações recentes no
projeto do produto. Informações de serviço técnico atualizadas podem estar disponíveis em seu
®
revendedor autorizado Hyster local . Os Manuais de Serviço fornecem diretrizes gerais para
manutenção e serviço e devem ser usados por técnicos treinados e experientes. A falha em manter
adequadamente o equipamento ou não seguir as instruções contidas no Manual de Serviço pode
resultar em danos aos produtos, ferimentos pessoais, danos materiais ou morte.
• Ao levantar peças ou conjuntos, certifique-se de que todas as eslingas, correntes ou cabos estejam
https://www.hypassonline.com/lib/service/US/EN/html/8000SRM1940.html 1/45
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presos corretamente e que a carga que está sendo levantada esteja equilibrada. Certifique-se de que o
guindaste, cabos e correntes tenham capacidade para suportar o peso da carga.
• Não levante peças pesadas manualmente, use um mecanismo de elevação.
• Use óculos de segurança.
• DESCONECTE O CONECTOR DA BATERIA antes de fazer qualquer manutenção ou reparo em
empilhadeiras elétricas. Desconecte o cabo de aterramento da bateria em empilhadeiras de combustão
interna.
• Sempre use os blocos corretos para evitar que a unidade role ou caia. Veja COMO COLOCAR O

EMPILHADOR EM BLOCOS no Manual de Operação ou na seção Manutenção Periódica .
• Mantenha a unidade limpa e a área de trabalho limpa e organizada.
• Use as ferramentas corretas para o trabalho.
• Mantenha as ferramentas limpas e em boas condições.
• Sempre use peças HYSTER APPROVED ao fazer reparos. As peças de reposição devem atender ou

exceder as especificações do fabricante do equipamento original.
• Certifique-se de que todas as porcas, parafusos, anéis elásticos e outros dispositivos de fixação foram

removidos antes de usar força para remover as peças.
• Sempre prenda uma etiqueta NÃO OPERAR nos controles da unidade ao fazer reparos ou se a

unidade precisar de reparos.
• Certifique-se de seguir as notas de ADVERTÊNCIA e CUIDADO nas instruções.
• Gasolina, Gás Líquido de Petróleo (GLP), Gás Natural Comprimido (GNC) e óleo diesel são
inflamáveis. Certifique-se de seguir as precauções de segurança necessárias ao manusear esses
combustíveis e ao trabalhar nesses sistemas de combustível.
• As baterias geram gás inflamável quando estão sendo carregadas. Mantenha fogo e faíscas longe da

área. Certifique-se de que a área esteja bem ventilada.
NOTA: Os seguintes símbolos e palavras indicam informações de segurança

neste manual:
AVISO
Indica uma situação perigosa que, se não for evitada, pode resultar
em morte ou ferimentos graves.
CUIDADO
Indica uma situação perigosa que, se não for evitada, pode resultar
em ferimentos leves ou moderados e danos materiais.
Na empilhadeira, o símbolo de AVISO e a palavra estão em fundo
laranja. O símbolo de CUIDADO e a palavra estão em fundo
amarelo.
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"A
QUALIDADE
GUARDIÕES"
HISTER
APROVADO
© 2016
HYSTER COMPANY
PEÇAS
ÍNDICE
Em geral
Peso e Dimensões
Procedimentos de carregamento
Carregando um caminhão em um transporte
Carregando Componentes Desmontados
Procedimentos de Descarga
Descarregando um caminhão do transporte
Levantando um caminhão
Conduzindo um caminhão fora de um trailer
Descarregando Componentes Desmontados
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ÍNDICE
Remoção de garfos anexados a um caminhão básico
Remoção de Garfos Presos ao Carro
Movimentação e reboque
Movendo uma empilhadeira desativada
Precauções
Rebocando uma empilhadeira
Procedimentos de segurança ao trabalhar perto do mastro
Ao Trabalhar Perto do Mastro Sempre
Antes de iniciar reparos no sistema hidráulico Sempre
Montagem do caminhão
Montagem do Mastro
Preparações
Instalando o Mastro
Instalando os Cilindros de Inclinação
Ajustando os Cilindros de Inclinação
Removendo a trava de transporte do carro
Conectando os Cilindros de Elevação
Conectando as Mangueiras de Alimentação do Mastro
Carro e garfos ou anexo
Instalar Carro/Acessório
Conectando Mangueiras ao Carro/Acessório
Instalar garfos
Ajustar carro
Instalar luzes da cabine
Lubrificar
Verificações gerais após a montagem
Verificação de encanamento
Verificação de lubrificação
Verificação do nível de fluido
Verificação de Funcionalidade
Verificação do Pacote de Literatura
Limpeza
Rótulos
Rodas e Pneus
Remova as rodas da empilhadeira
Remova o pneu pneumático da roda
Instale o Pneu Pneumático na Roda
Adicionando pressão de ar aos pneus
Remova o pneu de borracha sólida da roda
Instale o pneu de borracha sólida na roda
Instalar rodas na empilhadeira
Porcas de roda nas rodas de tração e direção
Pre-Delivery
Ajustar o tempo para desligamento automático do motor
Realizar inspeção pré-entrega
Entrega
Manual de Instruções
Instruções Manutenção diária
Entrega de caminhão
Esta seção é para os seguintes modelos:
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H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS2) [L007];

H13-16XM-6, H6-7XM-12EC (H210-250-48HD2, H300-360HD2, H360HD2-EC) [K019]
Em geral
AVISO
Leia todas as instruções contidas neste manual antes de iniciar qualquer trabalho na
unidade. Leia também todos os procedimentos contidos no Manual de Operação antes de
operar o caminhão. Certifique-se de verificar todos os níveis de fluido e a pressão dos
pneus antes de retirar o caminhão do trailer.
Este manual contém as informações necessárias para o transporte e remontagem dos caminhões das séries
L007 e K019 . As informações abrangem cada componente que pode ter sido desmontado para fins de
transporte. Selecione os procedimentos de montagem apropriados de acordo.
Peso e Dimensões
UMA. ALTURA VER NOTA NA TABELA 1

B. COMPRIMENTO VER NOTA NA TABELA 1
C. LARGURA
Figura 1. Altura, comprimento e largura completos do caminhão
Tabela 1. Caminhão Completo
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Tabela 1. Caminhão Completo
Modelo Transporte Comprimento Largura

Tipo de pino padrão 4.234 mm
(166,6 pol.) 2.245 mm
(88 pol.)
H8-9XM-6 Com Posicionador de Garfo 4.284 milímetros
(168.6 in.) 2.245 mm
(88 pol.)
H190-210HD
2 Carro de Deslocamento Lateral 4.296 mm
(169 pol.) 2.245 mm
(88 pol.)
Add 115 mm (4 in.) for 3-stage mast.
Standard Pin-Type 4,474 mm
(176 in.) 2,446 mm
(96.2 in.)
H10-12XM-6 With Fork Positioner 4,519 mm
(177.9 in.) 2,446 mm
(96.2 in.)
H230-280HD2 Side Shift Carriage 4,526 mm
(178.1 in.) 2,446 mm
(96.2 in.)
Add 95 mm (3.7 in.) for 3-stage mast.
Standard Pin-Type 4,962 mm
(195.3 in.) 2,607 mm
(102.6 in.)
H13-16XM-6 With Fork Positioner 4,962 mm
(195.3 in.) 2,607 mm
(102.6 in.)
H300-360HD2 Side Shift Carriage 4,997 mm
(196.7 in.) 2,607 mm
(102.6 in.)
Add 100 mm (3.9 in.) for 3-stage mast.
H6XMH12-EC3 Total width too large for road transport.
H7XM12EC4
H360HD2EC4
NOTE:
• The total weight of the truck must be calculated by adding up the weights shown in Table 2,

Table 3, Table 4 and Table 5.
• The total length of the truck must be calculated by adding up the length in Table 1 with the length

shown in Table 5.
• The total height of the truck is shown in Table 3, column Truck Height.
A. HEIGHT B. LENGTH C. WIDTH
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Figure 2. Basic Truck Height, Length and Width
Table 2. Basic Truck
Weight
Model Length Width Height
"MIN" "MAX"
L007
3,763 mm 2,425 mm 2,972 mm 9,400 kg 10,150 kg
H8.00XM-6 H190HD2
(148 in.) (94.5 in.) (117 in.) (20,723 lb) (22,376 lb)
3,763 mm 2,425 mm 2,972 mm 9,700 kg 10,450 kg
H9.00XM-6 H210HD2
(148 in.) (94.5 in.) (117 in.) (21,384 lb) (23,038 lb)
H10.00XM-6 3,963 mm 2,425 mm 2,972 mm 10,700 kg 11,450 kg
H230HD2 (156 in.) (95.4 in.) (117 in.) (23,589 lb) (25,242 lb)
H250HD2 3,963 mm 2,446 mm 2,972 mm 10,900 kg 11,600 kg
(156 in.) (96.2 in.) (117 in.) (24,030 lb) (25,573 lb)
H12.00XM-6 280HD2 3,963 mm 2,446 mm 2,990 mm 11,5500 kg 12,300 kg

(156 in.) (96.2 in.) (117.7 in.) (25,463 lb) (27,116 lb)
K019
H13.00XM-6 4,363 mm 2,607 mm 3,021 mm 12,500 kg 13,700 kg
H300HD2 (171.7 in.) (102.6 in.) (118.9 in.) (27,557 lb) (30,203 lb)
H14.00XM-6 4,363 mm 2,607 mm 3,021 mm 13,200 kg 14,350 kg
H330HD2 (171.7 in.) (102.6 in.) (118.9 in.) (29,101 lb) (31,636 lb)
H16.00XM-6 4,363 mm 2,607 mm 3,021 mm 14,250 kg 15,400 kg
H360HD2 (171.7 in.) (102.6 in.) (118.9 in.) (31,415 lb) (33,951 lb)
4,363 mm 2,607 mm 3,201 mm 14,250 kg 15,400 kg
H10.00XM-12
(171.7 in.) (102.6 in.) (118.9 in.) (31,415 lb) (33,951 lb)
H210-48HD2 4,363 mm 2,607 mm 3,201 mm 12,500 kg 13,700 kg

(171.7 in.) (102.6 in.) (118.9 in.) (27,557 lb) (30,203 lb)
H230-48HD2 4,363 mm 2,607 mm 3,201 mm 13,200 kg 14,350 kg

(171.7 in.) (102.6 in.) (118.9 in.) (29,101 lb) (31,636 lb)
H250-48HD2 4,363 mm 2,607 mm 3,201 mm 14,250 kg 15,400 kg

(171.7 in.) (102.6 in.) (118.9 in.) (31,415 lb) (33,951 lb)
K019 Empty Container Handler
4,363 mm 2,607 mm 3,201 mm 13,200 kg 14,350 kg
H6.00XM-12EC3
(171.7 in.) (102.6 in.) (118.9 in.) (29,101 lb) (31,636 lb)
H7.00XM-12EC4 4,363 mm 2,607 mm 3,201 mm 14,900 kg 16,050 kg
H360HD2-EC4 (171.7 in.) (102.6 in.) (118.9 in.) (32,848.8 lb) (35,384 lb)
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Table 2. Basic Truck
Weight
Model Length Width Height
"MIN" "MAX"
NOTE:
• Add 90 kg (198.4 lb) for a completely topped off fuel tank.
• The minimum weight indicates the weight for trucks with an open cab and pneumatic tires.
The maximum weight indicates the weight for trucks with an open cab and solid tires.
To calculate the total weight of the basic truck include the weight of following options:
Add 200 kg (440.9 lb) for a closed cab.
Add 50 kg (110 lb) for air conditioning.
Add 90 kg (198.4 lb) for a completely topped up fuel tank.
• The total height of the basic truck is for trucks with an open cab and pneumatic tires.
Add 43 mm (1.6 in.) to the total height for trucks with a closed cab without air conditioning.
Add 78 mm (3 in.) to the total height for trucks with a closed cab with air conditioning.
1. WIDTH
2. HEIGHT
3. LENGTH
Figure 3. Mast and Carriage Width, Height and Length
Table 3. Mast
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Table 3. Mast
Truck
Model Lift Height Length Width Height Weight
Height
3,686 mm 3,066 mm 1,220 mm 567 mm 1,510 kg 3,361 mm
(145 in.) (120.7 in.) (48 in.) (22.3 in.) (3,328 lb) (132.3 in.)
H8-9XM-6
H190-210HD2 4,586 mm 3,520 mm 1,220 mm 567 mm 1,670 kg 3,811 mm
(180.5 in.) (138.5 in.) (48 in.) (22.3 in.) (3,681 lb) (150 in.)
2-Stage NFL
5,336 mm 3,520 mm 1,220 mm 567 mm 1,670 kg 4,186 mm
(210 in.) (138.5 in.) (48 in.) (22.3 in.) (3,681 lb) (164.8 in.)
3,686 mm 3,368 mm 1,220 mm 597 mm 2,060 kg 3,642 mm
(145 in.) (132.5 in.) (48 in.) (23.5 in.) (4,541 lb) (143.4 in.)
4,586 mm 3,808 mm 1,220 mm 597 mm 2,270 kg 4,086 mm
(180.5 in.) (149.9 in.) (48 in.) (23.5 in.) (5,004 lb) (160.8 in.)
H10-12XM-6
5,336 mm 4,193 mm 1,220 mm 597 mm 2,510 kg 4,461 mm
H230-280HD2
(210 in.) (165 in.) (48 in.) (23.5 in.) (5,533 lb) (175.6 in.)
2-Stage NFL
6,130 mm 4,593 mm 1,220 mm 597 mm 2,670 kg 4,861 mm
(241.3 in.) (180.8 in.) (48 in.) (23.5 in.) (5,886 lb) (191.3 in.)
6,630 mm 4,843 mm 1,220 mm 597 mm 2,780 kg 5,111 mm
(261 in.) (190.6 in.) (48 in.) (23.5 in.) (6,128 lb) (201.2 in.)
3,660 mm 3,440 mm 1,220 mm 684 mm 2,506 kg 3,623 mm
(144 in.) (135.4 in.) (48 in.) (26.9 in.) (5,524 lb) (142.6 in.)
4,560 mm 3,890 mm 1,220 mm 684 mm 2,771 kg 4,073 mm
(179.5 in.) (153 in.) (48 in.) (26.9 in.) (6,109 lb) (160.3 in.)
5,310 mm 4,262 mm 1,220 mm 684 mm 3,119 kg 4,448 mm
(209 in.) (167.7 in.) (48 in.) (26.9 in.) (6,876 lb) (175.1 in.)
H13-16XM-6
H300-360HD2 6,110 mm 4,661 mm 1,220 mm 684 mm 3,313 kg 4,848 mm
(240 in.) (183.5 in.) (48 in.) (26.9 in.) (6,862 lb) (190.8 in.)
2-Stage NFL
6.610 mm 4,912 mm 1,220 mm 684 mm 3,439 kg 5,098 mm
(260.2 in.) (193.3 in.) (48 in.) (26.9 in.) (7,581 lb) (200.7 in.)
6,920 mm 5,151 mm 1,220 mm 684 mm 3,500 kg 5,365 mm
(272.4 in.) (202.7 in.) (48 in.) (26.9 in.) (7,716 lb) (211.2 in.)
9,910 mm 6,646 mm 1,220 mm 696 mm 4,000 kg 6,859 mm
(390 in.) (261.6 in.) (48 in.) (27.4 in.) (8,818 lb) (270 in.)
4,310 mm 2,880 mm 1,500 mm 760 mm 3,262 kg 3,062 mm
(169.6 in.) (113.3 in.) (59 in.) (29.9 in.) (7,191 lb) (120.5 in.)
4,910 mm 3,080 mm 1,500 mm 760 mm 3,385 kg 3,262 mm
H13-16XM-6 (193.3 in.) (121.2 in.) (59 in.) (29.9 in.) (7,462 lb) (128.4 in.)
H300-360HD2
3-Stage NFL 5,910 mm 3,413 mm 1,500 mm 760 mm 3,591 kg 3,595 mm
(232.6 in.) (134.3 in.) (59 in.) (29.9 in.) (7,916 lb) (141.5 in.)
6,910 mm 3,747 mm 1,500 mm 760 mm 3,997 kg 3,930 mm
(272 in.) (147.5 in.) (59 in.) (29.9 in.) (8,811 lb) (154.7 in.)
Table 4. Carriage
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Table 4. Carriage
Model Type Height Width Length Weight

Standard Pin-Type 1,125 mm 2,400 mm 370 mm 762 kg
(48.2 in.) (94.4 in.) (14.5 in.) (1,679.9 lb)
Standard Pin-Type with 1,125 mm 2,400 mm 420 mm 970 kg
H8-9XM-6
H190- Fork Positioner (48.2 in.) (94.4 in.) (16.5 in.) (2,138.4 lb)
210HD2 Side Shift 1,410 mm 2,400 mm 432 mm 1,266 kg
(55.5 in.) (94.4 in.) (17 in.) (2,791 lb)
Side Shift with Fork 1,415 mm 2,400 mm 432 mm 1,358 kg
Positioner (55.7 in.) (94.4 in.) (17 in.) (2,987 lb)
Standard Pin-Type 1,470 mm 2,400 mm 390 mm 912 kg
(57.8 in.) (94.4 in.) (15.3 in.) (2,993.8 lb)
Standard Pin-Type with 1,470 mm 2,400 mm 435 mm 1,160 kg
H10-12XM-6 Fork Positioner (57.8 in.) (94.4 in.) (17.1 in.) (2,552 lb)
H230-280HD2 Side Shift 1,470 mm 2,400 mm 442 mm 1,311 kg
(57.8 in.) (94.4 in.) (17.4 in.) (2,557.3 lb)
Positioner (57.8 in.) (94.4 in.) (17.4 in.) (3,150.4 lb)
Standard Pin-Type 1,590 mm 2,550 mm 465 mm 1,382 kg
(62.5 in.) (100.3 in.) (18.3 in.) (3,046.7 lb)
Standard Pin-Type with 1,590 mm 2,550 mm 465 mm 1,450 kg
H13-16XM-6 Fork Positioner (62.5 in.) (100.3 in.) (18.3 in.) (3,196.7 lb)
H300-360HD2 Side Shift 1,600 mm 2,550 mm 500 mm 1,784 kg
(62.9 in.) (100.3 in.) (19.6 in.) (3,993 lb)
Positioner (62.9 in.) (100.3 in.) (19.6 in.) (7,683 lb)
A. WIDTH C. LENGTH
B. HEIGHT
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Figure 4. Forks Width, Height and Length
Table 5. Forks
Model Type Width Height Length Weight

H8-9XM-6 H190- Pin-Type 400 mm 934 mm 2,550 mm 528 kg
210HD2 Fork (15.7 in.) (36.7 in.) (100.3 in.) (1,164 lb)
Pin-Type 400 mm 934 mm 2,550 mm 692 kg
H10-12XM-6 H190- Fork (15.7 in.) (36.7 in.) (100.3 in.) (1,525 lb)
280HD2 DFSSFP 400 mm 941 mm 2,643 mm 630 kg
Fork (15.7 in.) (37 in.) (104 in.) (1,388 lb)
Pin-Type 400 mm 1,069 mm 2,560 mm 844 kg
H13-16XM-6 H300- Fork (15.7 in.) (42 in.) (100.7 in.) (1,860 lb)
360HD2 DFSSFP 400 mm 1.070 mm 2,668 mm 894 kg
Fork (15.7 in.) (42.1 in.) (105 in.) (1,970 lb)
A. WIDTH B. LENGTH C. HEIGHT
Figure 5. Container Attachment Width, Length and Height
Table 6. Container Attachment
Model Length Height Width Weight

ECH Attachment 6,100 mm
(240 in.) 2,551 mm
(100.4 in.) 850 mm
(33.4 in.) 4,100 kg
(9,038.9 lb)
Loading Procedures
LOADING A TRUCK ON A TRANSPORT
WARNING
Stay a safe distance from the edge of docks, ramps, platforms, and other similar working
surfaces. Watch the "tail swing". Remember when traveling in the forward direction and the
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steering wheel is turned to move the lift truck away from the edge of the dock, the rear will
swing toward the edge. This can cause the lift truck to fall off the dock.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO NOT JUMP OFF! HOLD FIRMLY TO
STEERING WHEEL, BRACE YOUR FEET, AND LEAN FORWARD AND AWAY FROM THE
POINT OF IMPACT.
Before the lift truck is moved on transport, check the selected route to make sure there is enough clearance
for the lift truck as loaded on the transport vehicle. Bridges, overpasses, power lines, and natural barriers can
prevent clearance. Removal of the mast can be necessary.
If a trailer is the method of transportation, use blocks in front and back of the trailer tires to prevent
movement of the trailer when the lift truck is loaded and unloaded. If a loading ramp is used, make sure that
the ramp is the correct design and capacity.
A crane can only be used to load or unload the lift truck with the mast assembled. When lifting a complete
truck, use rear lifting eyes in combination with mast lifting eyes.
If the mast has been removed, the lift truck
must be driven on or off the transport.
LOADING DISASSEMBLED COMPONENTS
1. Put blocks under the disassembled components for stability during transport and to allow loading and

unloading with a fork lift.
A. FRONT TIE DOWN POINTS

B. REAR TIE DOWN POINTS
Figure 6. Lift Truck Tie Down Placement
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1. WOODEN BLOCKS OR PALLETS

2. SLING OR TIE DOWN POINT
Figure 7. Mast and Carriage Tie Down Placement
2. When lifting the components with slings and/or hooks, attach these at the indicated lifting points
and/or lifting eyes. Make sure the lifting device has the required capacity, see Table 2 through Table 6
for the weights of the components and the suggested location for the slings and hooks.
WARNING
DO NOT use the bores for the mast pivot and the tilt cylinder mounting as a slinging point or
as a tie down point.
3. Secure the components by connecting slings or chains to the indicated tie down points on Figure 6 and

Figure 7 and the load surface of the trailer. Keep slings and chains clear from tires or other parts.
Unloading Procedures
UNLOADING A TRUCK FROM TRANSPORT
Lifting a Truck
WARNING
DO NOT lift a truck with the mast removed. Use counterweight lifting eyes (optional) in
combination with mast lifting eyes when lifting a complete truck.
To lift a truck, use the lifting points on the mast and counterweight as indicated in Figure 8. For the required
capacity of the lifting device, see Table 2.
1. If used, remove any protective cover.
2. Make sure the parking brake is applied.
3. Disconnect the slings or chains that secure the truck to the trailer.
4. Remove the wheel blocks.

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5. Check that all switches and accessories are switched OFF.
6. Attach a lifting device to the lifting points. See Figure 8.
1. COUNTERWEIGHT LIFTING POINTS

2. MAST LIFTING POINTS
Figure 8. Lift Truck Lifting Points
Driving a Truck off a Trailer
When the truck will be driven from a trailer make sure to have read and understood the Starting Procedures as
described in the Operating Manual.
1. Make sure the parking brake is applied.
2. Disconnect the straps or chains that attach the truck to the trailer.
3. Remove the wheel blocks.
4. Start the truck, release the park brake and let a assistant provide directions when driving off the trailer.
5. Park the truck. Apply the hand brake and turn the ignition OFF.
See the procedures under Moving a Disabled Lift Truck if the truck cannot be started and must be moved.
See the procedures under Adding Air Pressure to the Tires if air pressure in one of the tires is less than 80%
of the pressure as indicated on the nameplate.
UNLOADING DISASSEMBLED COMPONENTS
To lift the components from a transport either use a fork lift or attach hooks and/or slings to the lifting eyes
and slinging points as indicated on Figure 7 through Figure 8.
WARNING
DO NOT use the bores for the mast pivot and the tilt cylinder mounting as a slinging point.
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Use rear lifting eyes in combination with mast lifting eyes when lifting complete truck. DO
NOT lift basic truck with mast removed.
For the required capacity of the lifting device, see Table 2 through Table 5 for the weights of the components.
Use blocks to support the component when temporarily storing the component on the ground.
The blocks for the attachment must be high enough to keep the twistlocks from the ground.
The blocks for the carriage must be high enough to keep the fork guides from the ground.
REMOVAL OF FORKS ATTACHED TO A BASIC TRUCK
1. Put blocks under the tips of the forks. See Figure 9.
2. Support the plate under the forks and remove the four attaching nuts and capscrews. Remove the plate.
1. BLOCK 5. ROD END

2. NUT AND CAPSCREW 6. TUBE
3. PLATE 7. BOLT
4. MOUNTING PLATE 8. MAST MOUNTING PIN
Figure 9. Forks to Basic Truck
3. Position a lifting device with a pallet under the two forks and support the weight of the forks. Remove

the blocks under the tips of the forks.
4. Remove the two bolts that attach the two upper plates to the lift truck frame.
5. Lower the pallet with the forks.
6. Remove the two rod ends that are attached to the mast mounting pins.
7. Remove the four plates that connect between forks and frame. Secure the mast mounting pins.
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8. Remove the tube from the forks and move the forks away from the truck.
REMOVAL OF FORKS ATTACHED TO THE CARRIAGE
1. Put a lifting device under the upper fork and lift the fork until the bracket at the carriage has released.

While lifting, pay attention that the bracket moves over the carriage plate. See Figure 10.
1. BRACKET 4. BRACKET
2. CARRIAGE PLATE 5. RUBBER PLATE
3. SECURING BOLT
Figure 10. Forks Attached to Carriage
2. Lower the fork on a pallet.
3. Remove the securing bolt from the bracket and slide the bracket out of the fork.
4. Remove the rubber plate on the lower fork.
5. Remove the lower fork by following Step 1 through Step 3.
6. Remove the bracket that hooks on the lower carriage bar.
Moving and Towing

MOVING A DISABLED LIFT TRUCK
Precautions
While the lift truck is being towed the engine must

stay running in order to generate sufficient hydraulic
oil
pressure. Without hydraulic pressure
the steering system and service brake system do
not operate, and the
park brake will automatically
apply. The parking brake can be manually released
if no hydraulic pressure is
available.
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WARNING
When the parking brake is manually released, the
lift truck does not have any parking brake
function.
Block the wheels to prevent the lift truck
from moving. If the wheels are not
blocked, serious
personal injury and damage to components
can occur.
NOTE: If the parking brake is manually released,
it will need to be adjusted before the lift truck is returned
to service. With hydraulic pressure applied
to the parking brake, adjust play between brake
disc and park
brake pads to 1.0 mm (0.04 in.). Refer to the manual Brake System 1800SRM1933 and Hydraulic System
1900SRM1934.
The parking brake caliper is mounted on a support

bracket at the differential carrier assembly. To
manually
release the parking brake, perform the
following steps:
1. Place blocks on both sides (front and rear) of the drive and steering tires to prevent movement of the

lift truck.
2. Remove the plastic screw cap. See Figure 11.
1. PLASTIC SCREW CAP

2. ADJUSTING SCREW
3. LOCK NUT
Figure 11. Parking Brake Release
3. Loosen the lock nut.
4. Turn the adjustment screw counterclockwise until the brake disc is free.
5. Tighten the lock nut and install the screw cap hand tight.
TOWING A LIFT TRUCK
WARNING
DO NOT tow the lift truck if a load is attached.
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.
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• Tires are damaged.

• Traction conditions are bad.
• The lift truck must be towed on a slope.
If the engine cannot run, there is no hydraulic

pressure available for the steering system and
service brake system. 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.
1. The towed lift truck must have an operator.
2. Make sure transmission oil level is above minimum. Observe a maximum towing speed of 5 km/hr

and a maximum towing distance of 5 km (3 miles).
3. Use a lifting device to raise the carriage approximately 30 cm (12 in.) from the surface. Install a chain

around the mast crossmember and the carriage to prevent the 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
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 fastens to

both lift trucks. Connect the towing link to an
adequate

provision, such as a towing pin or lifting
eye.
6. After towing is completed, place blocks on both

sides (front and rear) of all drive and steering
tires

and re-apply the parking brake.
Safety Procedures When Working Near The Mast

The following procedures MUST be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. Follow the repair procedures in this
section.
WARNING
Mast parts are heavy and can move. Distances between parts are small. Serious injury or
death can result if part of the body is hit by parts of the mast or the carriage.
• Never put any part of the body into or under the mast or carriage unless all parts are
completely lowered or a safety chain is installed. Also make sure that the power is OFF and

the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment.
Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.
• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an

injury.
• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on

the mast.
• DO NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal of the mast

or carriage. Follow the repair procedures in the correct Service Manual for the mast.
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WHEN WORKING NEAR THE MAST ALWAYS
• Lower the mast and carriage completely. Push the lift/lower control lever forward and make
sure there is no movement in the mast. Make sure that all parts of the mast that move are fully
lowered.
OR
• If parts of the mast must be in a raised position, install a safety chain to restrain the moving

parts of the mast. Connect moving parts to a part that does not move. Follow these procedures:
1. Put the mast in a vertical position.
2. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment

with a crossmember on the outer weldment.
3. Use a safety chain with a hook to secure the crossmembers to prevent the movable member from
lowering. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a

link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses,
fittings, or other parts on the mast. See Figure 12.
1. OUTER MAST
2. HOOK
Figure 12. Mast Safety Chains
BEFORE STARTING REPAIRS TO THE HYDRAULIC SYSTEM ALWAYS
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Tilt the mast completely forward.
4. Lower the carriage and inner mast completely.
5. Make sure the lift cylinders are completely retracted.
6. Turn engine OFF.
7. Turn the key switch to the ON position.

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8. Operate the lift and tilt levers completely forward and backward to remove any trapped hydraulic

pressure.
9. Apply the brake pedal until the brake lights do not longer come ON when the brake pedal is fully

depressed.
10. Turn the key switch to the OFF position.
11. Place blocks against both sides (front and back) of the tires to prevent movement of the lift truck.
Truck Assembly
MAST ASSEMBLY
WARNING
When working on or near the mast, review and follow the Safety Procedures When Working
Near the Mast.
Preparations
1. Remove mast pin components from the truck.
2. Remove the tilt cylinder pins from the rod ends of the tilt cylinders. See Figure 13.
3. Remove the chain packaging and tie wraps.
1. ROD END
2. ANCHOR PIN
3. EYE BOLT
4. WASHER
5. CAP SCREW
6. GREASE NIPPLE
Figure 13. Tilt Cylinder Pin
Installing the Mast

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WARNING
When working on or near the mast, review and follow the Safety Procedures When Working
Near the Mast.
WARNING
Verify that the mast lifting device has the correct capacity rating to lift the mast assembly.
See Table 3.
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Switch the engine OFF.
4. Turn the key switch to the ON position.
5. Operate the lift and tilt levers completely forward and backward to remove any trapped hydraulic

pressure.
6. Apply and release the brake pedal until no resistance is felt when fully depressing the brake pedal.
7. Turn the key switch to the OFF position.
8. Place blocks against both sides (front and back) of the tires to prevent movement of the lift truck.
9. Apply grease to the mast shims to stick them against the RH hanger. Position one shim at the inside
and two or three shims at the outside of the RH hanger. Turn the shims with their opening facing up.
Do NOT install shims at the LH hanger.
10. Connect a lifting device to the lifting eyes on the outer mast. See Figure 14.
1. LIFTING EYES
Figure 14. Lifting Eyes
11. Position the mast in front of the truck.

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12. Lower the mast hanger on the mast mounting pins. See Figure 15.
1. MAST
2. CAPSCREWS
3. GREASE FITTING
4. SHIM
5. FRAME
6. BUSHING
7. MAST MOUNTING PIN
Figure 15. Mast Mount to Frame
NOTE: Make sure that before installation, the mast mounting pins are completely free of grease at the
conical faces that contact the frame, respectively the outer cap.
13. Connect mast pins with hangers using 4 capscrews.
• Tighten capscrews to 435 N•m (321 lbf ft) for lift truck models L007.

• Tighten capscrews to 522 N•m (385 lbf ft) for lift truck models K019.
Installing the Tilt Cylinders
1. Start the engine.
2. Extend the tilt cylinders until the mast is properly positioned with the lifting device.
3. Operate the lifting device to align the tilt cylinder holes in the mast bracket and the tilt cylinder.
4. Install the tilt cylinder pins with lube fittings facing outside of truck. See Figure 16.
5. Install the cap screws and large washers to retain the tilt cylinder keepers to the tilt cylinder pins.
6. Install the cap screws and washers to retain the tilt cylinder keepers to the mast.
7. Disconnect the lifting device from the lifting eyes of the outer mast.
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1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (K007 ONLY)
10. HYDRAULIC LINES
11. PLUG
Figure 16. Tilt Cylinder Installation
Adjusting the Tilt Cylinders
1. Check the distance from the rod end to the shoulder of the rod, and adjust the distance to

5 mm (0.2 in.). See Figure 17.
2. Slowly tilt the mast backward until one cylinder rod is against its stop.
3. On the opposite tilt cylinder, loosen the two capscrews, washers, and nuts on the rod end.
4. Insert a 16 mm wrench in the rod drillings to turn the tilt cylinder rod out of the rod end until both rods

stop at the same time.
5. If necessary, release hydraulic pressure in the tilt cylinder.
6. Repeat the procedure to make sure the tilt cylinder rods stop at the same time within 1.0 mm (0.04 in.).
7. Check that the tilt angles are correct as specified on the nameplate of the lift truck. A limited tilt angle

correction can be made by turning both cylinder rods the same amount.
8. Make sure that dimension "X" is less than 10 mm (0.4 in.). See Figure 17.
9. Verify thread of cylinder rod extends approximately 48 mm (1.89 in.). Turn both rods into the rod end
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if one of the threads extends more than 50 mm (1.97 in.).
10. After the adjustments are complete, tighten the nuts to secure the rod end to 66 N•m (49 lbf ft).
NOTE: X = ROD END THREAD DISTANCE

1. ROD
2. WRENCH FLAT
3. NUTS
4. ROD END
Figure 17. Tilt Cylinder Adjustment
Removing the Carriage Transport Lock
WARNING
Remove the carriage transport lock before operating the mast.
During transport the carriage is secured in the lowered position by a transport lock.
After mast installation,
remove the transport lock and tag by removing the bolt, which is threaded into the inner mast, just above the
carriage.
Retain the tag, bolt and bracket for future transports. See Figure 18.
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1. TRANSPORT LOCK TAG

2. WASHER
3. CAP SCREW
4. TRANSPORT LOCK BRACKET
5. MAST
6. CARRIAGE
Figure 18. Carriage Transport Lock
Connecting the Lift Cylinders
1. Remove hydraulic pressure from the system. Follow the procedures: Before Starting Repairs To The

Hydraulic System Always.
2. Remove the caps at the base of the lift cylinders and the plugs in the lift cylinder supply hoses.
3. Connect the hoses with the base of each lift cylinder.
Connecting the Mast Supply Hoses
1. Remove plugs at the end of the three hydraulic header hoses.
2. Remove the caps from the hoses and the control valve which connect with the lift cylinders and the

header hoses. See part A. Mast Side from Figure 19.
3. Connect the electrical supply cable to the connector for the mast cable.
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A. MAST SIDE B. CARRIAGE SIDE
Figure 19. Header Hose Connections
Table 7. Legend for Mast Side Header Hose Connection
Item Description Control Valve Carriage Valve Strap Color

Number Connection Connection Code
1 Supply T3 T Yellow
2 Supply A (AUX) P Green
3 Drain T (AUX) T0 White/Yellow
4 Breather N/A N/A White/Green
Hose
5 Electric N/A N/A CRP139/ CPS148
Cable
Table 8. Legend for Carriage Side Header Hose Connection
Item Description Control Valve Carriage Valve Strap Color

Number Connection Connection Code
1 Supply Aux B B1 Green/Green
2 Supply Aux A A1 Green/Yellow
3 Breather N/A N/A White/Green
Hose
5 Electric N/A N/A CRP139/ CPS148
Cable
CARRIAGE AND FORKS OR ATTACHMENT
Install Carriage/Attachment
1. Place blocks at the front and the back of all tires to prevent movement of the lift truck.
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2. Attach a lifting device:

• to the lifting eyes at each side of the carriage.
• to attachment main frame using lifting straps. Make sure the frame will have stability during

lifting. Lifting device and lifting straps must be able to hold 10,000 kg (22,046 lb).
3. Lift the carriage/attachment and move it in front of the mast. Make sure that the upper and lower load

rollers are aligned with the inner mast channel. Correct the carriage/attachment position as necessary.
4. Start the engine and operate the lift cylinders to raise the inner mast until the mast channels are well
above the upper bearing blocks. Tilt the mast backward until the mast and carriage/attachment have
the same tilt position.
5. Move the carriage/attachment to position the upper bearing blocks into the inner mast channels.
6. Lower the mast slowly and carefully align the upper bearing blocks with the mast channels. DO NOT

damage the bearing blocks when they enter the mast channel.
7. Lower the mast further and align the lower bearing blocks with the mast channels.
8. Lower the mast to enter the lower load rollers into the mast channels.
9. Lower the mast completely.
10. Reconnect the lift chains to the chain anchors by installing the chain pin and snap ring at both sides of

the carriage.
11. Lower the lifting device, detach and remove from the carriage/attachment.
12. Remove caps and plugs from the header hoses and install the header hoses to the fittings on the

carriage/attachment bracket.
13. Maintain tension on the electric mast cable and tighten the cable clamp. See Figure 20.
14. Attach the electrical connector.
A. MEASURING POINT A
B. MEASURING POINT B
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1. CARRIAGE
2. INNER MAST
3. OUTER MAST
Figure 20. Lift Chain Adjustment
WARNING
DO NOT try to locate hydraulic leaks by placing hands on pressurized hydraulic
components. Hydraulic oil can be injected into the body by pressure.
15. Start the engine and operate the hydraulic functions on the carriage. Make sure that the functions

operate correctly. Check for leaks.
16. Adjust the chain length. See Figure 20.
17. Remove the blocks that have been placed at both sides of the tires.
Connecting Hoses to Carriage/Attachment
1. Remove plugs and caps from hose fittings at carriage/attachment side.
2. Connect hydraulic hoses to fittings on carriage/attachment bracket. See part B. Carriage Side of

Figure 19.
3. Remove plugs and caps from hose fittings at lower mast side.
4. Connect hydraulic hoses to fittings on lower mast hose bracket.
5. Lift mast to remove blocks under carriage. Lower carriage/attachment.
6. Put tension on hoses and reinstall clamps at upper mast bracket. See Figure 19.
7. Install hose clamps which retain hoses to right hand lift cylinder.
Install Forks
1. Put the mast in a vertical position and lower the carriage almost completely.
2. Position the fork hangers half way the carriage, in front of the hoist chains.
3. Only for the standard pin-type fork: Attach a rope to a lifting device and to the fork hanger. The fork

hanger weighs 12 kg (26 lb). Put tension on the rope until it carries the weight of the fork hanger.
4. Remove the four capscrews, washers and the bracket that retain the fork pin to the carriage. See

Figure 21 and Figure 22.
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1. CARRIAGE
2. CAP SCREW
3. WASHER
4. BRACKET
5. FORK PIN
6. FORK HANGER
7. FORK
Figure 21. Install Pin-Type Forks
1. CARRIAGE
2. CAP SCREW
3. WASHER
4. FORK PIN
5. FORK HANGER
6. FORK
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Figure 22. Install DFSSFP Forks
5. Move the fork pin out of the carriage until its inner end is still inside the side plate of the fork hanger.

The fork pin weighs 55 kg (121 lb).
6. Place each fork on a separate pallet.
7. Use a hydraulic jack or hand pallet wagon to position a fork in the fork hanger, while the back of the

fork touches the carriage.
8. Lift the fork on the pallet until the fork pin aligns with the pin tube of the fork.
9. Slide the fork pin through the fork pin tube to its final mounting position in the carriage.
10. A spacer may have been installed between the two fork pins in the central carriage bracket that holds

the two inner ends of the fork pins. Make sure that this possibly installed spacer is put back.
11. Install the bracket with the four washers, and capscrews that retain the fork pin to the carriage. Torque

the bolts to 165 N•m (122 lbf ft).
12. Repeat Step 1 through Step 11 to install the remaining fork.
13. Apply grease to the brackets of the fork hanger and the fork positioning cylinder.
Adjust Carriage
CAUTION
The carriage can be set higher and lower on the lift chain anchor, however the carriage load
rollers must remain within the inner mast channel both in the lowest and in the highest
carriage positions to avoid damage to the lift truck.
NOTE: The purpose of carriage adjustment is to align the carriage in the inner mast and to position the forks
or the attachment at the required height when completely lowered. Carriage alignment is required when
chains, chain anchors or carriage is replaced. Carriage alignment is also required when carriage does not lift
and lower smoothly. A symptom is that one of the chains has a lower tension and shows bigger deflection
compared with the other chain. Incorrect carriage alignment causes premature wear of bearing blocks.
Alignment of the carriage is obtained by adjusting two chain anchors individually.
1. Put the mast in a vertical position and lower the carriage completely.
2. Side shift the carriage until it is at the center line of the mast.
3. Move both forks/the attachment into the maximum extended position.
4. Loosen chain anchor lock nut to release the securing plate and the large nut. See Figure 23.
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1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. SMALL NUT
9. WASHER
10. CAPSCREW
Figure 23. Chain Anchor on Carriage
5. Make sure that the clearance between the forks or the attachment and the ground has at least

1 cm (0.40 in.). Turn the large nuts on both chain anchors if necessary.
6. Measure that the vertical carriage bar runs parallel with the inner mast channel. Apply an accuracy of

0.5 mm (0.006 in.). See Figure 24.
7. Tighten the large nut of the chain anchor that is in the lowest position to align the vertical carriage bar

with the inner mast channel.
8. Tighten the lock nuts.
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A. MEASURING POINT A
B. MEASURING POINT B
1. CARRIAGE
2. INNER MAST
3. OUTER MAST
Figure 24. Lift Chain Adjustment
INSTALL CAB LIGHTS

NOTE: Cab lights may have been removed, or installed upside down for transport.
1. Remove the hardware that retains the bracket of the light assembly, or remove the plugs that cover the

threads.
2. Install the light assemblies in the correct position. See Figure 25.
3. Connect the electrical connectors and check the lights for correct operation.
4. Tighten the bolts to 35 N•m (26 lbf ft).
1. LIGHTS
2. BEACON
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Figure 25. Cab Lights
LUBRICATE
Apply Lubricant to the following items. See the Operating Manual for the location of these maintenance
points and for Approved Oils, Fluids and Grease.
Lift Chains 2 chains Lubricate with engine oil

Mast Pivot Pins 2 fittings Lubricate with grease under no load condition
Tilt Cylinder Pivot Pins 4 fittings Grease fittings
Fork Pins and Guides Sliding surfaces Grease fittings
Dual Function Carriage Wear Blocks Pad wear area Grease area
General Checks After Assembly

PLUMBING CHECK
Check that all the hydraulic fittings, hoses, or tubes have been correctly fastened and properly routed (no
scuffing and running over sharp edges). Verify visually there are no leaks in the system. Correct any
discrepancies.
LUBRICATION CHECK
Check that all required grease points have sufficient grease. For additional information, see the section
Periodic Maintenance 8000SRM1939 for L007 and K019 trucks.
FLUID LEVEL CHECK
Check all fluid levels. For additional information, see the section Periodic Maintenance 8000SRM1939 for
L007 and K019 trucks.
FUNCTIONALITY CHECK
Warm up the lift truck to approximately 80°C (176°F) and verify full functionality. Check that all functions
are working properly. Operate the machine and test the brake, steering, and all the hydraulic functions with
and without load. Correct any discrepancies. For additional information, see the section Periodic
Maintenance 8000SRM1939 for L007 and K019 trucks.
LITERATURE PACKAGE CHECK
Check content of standard literature package (may deviate per market area). Be sure SPED literature package
is included. Deliver the literature package to the maintenance people. Explain the purpose of each item in the
literature package. Explain where this truck may deviate from the standard product.
CLEANING
It is also the dealer’s responsibility to deliver the truck to the customer in a perfectly clean condition. During
transport and reassembly, grease, dust, and oil will cover some parts of the machine making it dirty or
slippery. Degrease and clean the machine completely. DO NOT steam clean the hoist chains!
LABELS
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Check that all labels supplied by the factory are in place at the correct location. Put the mast, truck, and
attachment labels in the correct position on the truck after having cleaned and dried the location where they
will be fitted.
Wheels and Tires

REMOVE WHEELS FROM LIFT TRUCK
WARNING
The type of tire and tire pressure are shown on
the nameplate. Make sure the nameplate is
correct
for the type of tires on the lift truck.
Wheels and tires must be changed and repaired
by trained personnel only.
Always wear safety glasses.
Always use a tire inflator with a clip-on chuck
when deflating or adjusting the tire pressure.
The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft)
length. During
deflation or when adjusting the tire pressure,
the technician must not stand
in-line with the axis
of the wheel. See Figure 26.
Adjusting tire pressure is allowed only if residual
air pressure exceeds 80% of the pressure
as indicated
on the nameplate.
If the tire is removed from the truck and flat on the
ground, the technician should not have
any body
part within the diameter of the tire when adjusting
the tire pressure. See Figure 27.
Wheels can explode and cause injury or death if
the above procedures are not followed.
1. ACCURATE IN-LINE PRESSURE GAUGE
Figure 26. Adjusting and Deflating Position
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1. HOSE LONG ENOUGH FOR USER TO STAND

OUTSIDE POTENTIAL TRAJECTORY OF EXPLOSION
Figure 27. Adjusting Tire Pressure Position
CAUTION
Lift truck wheels are very heavy, use caution when removing wheels or personal injury may
occur.
1. Raise the lift truck as described in Periodic Maintenance 8000SRM1939, Putting a Lift Truck on

Blocks.
2. Attach a tire inflator as described above. Note

tire pressure. After air is drained from tire,
check the
tire pressure to ensure there is no residual
pressure. Remove chuck. Remove the
tire stem valve core.
Push a wire through the
valve stem to make sure that the stem does not
have a blockage causing a flow
restriction. For
dual tires, remove air pressure from both tires
using the described procedure before
loosening
the wheel nuts.
WARNING
Lift truck wheels are heavy and can cause personal injury.
3. Remove the wheel nuts and remove the wheel from the lift truck. Be careful NOT to damage the studs

when removing the wheels.
4. Use a tire jack to remove the wheel assembly.
REMOVE PNEUMATIC TIRE FROM WHEEL

NOTE: There are two types of wheels used on this series of lift trucks. If pneumatic shaped solid rubber
tires are installed, the four-piece wheel assemblies must be used. If pneumatic tires are installed, the three-
piece wheel assemblies must be used. See Figure 28 and Remove Pneumatic Tire From Wheel.
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1. SIDE FLANGE 4. WHEEL RIM FOR PNEUMATIC TIRE

2. WHEEL RIM FOR SOLID TIRE 5. LOCK RING
3. FLANGE SEAT
Figure 28. Types of Wheels
WARNING
Completely remove the air pressure from the tire before it is removed from the lift truck. If
dual wheels are installed, remove the air from both tires. Air pressure in the tires can cause
the tire and rim to explode causing serious injury or death.
WARNING
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough
force to cause serious injury. See Figure 28.
STEP 1.
For tubeless tires, remove the air valve by rotating it 60 degrees until the valve releases from the
valve slot.
STEP 2.
Loosen the tire bead from the side ring and/or
lock ring.
STEP 3.
Put the tire tool into the slot between the side ring

and/or lock ring and the wheel rim. Remove the
side ring and/or lock ring.
STEP 4.
Turn the tire over. Separate the tire from the
wheel rim.
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STEP 5.

For tires with an inner tube, push the air valve through the rim opening into the tire.
STEP 6.
Remove the wheel rim from the tire. Remove the
inner tube and flap.
INSTALL PNEUMATIC TIRE ON WHEEL

piece wheel assemblies must be used. See Figure 28.
WARNING
Wheels can explode and cause injury or death if the following procedures are not followed:
• Clean and inspect all parts of the wheel before installing the tire.
• Inspect all wheel components for deformation, corrosion and fractures.
• Look for fractures at the contact area between tire and wheel parts in particular.
• Unacceptable deformation includes progressed wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the above defects, and replace by new ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers

on any one lift truck.
• Check with your dealer whether a specific tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put
parts together. Make sure that the lock ring is in the correct position. The ends of the lock
ring must not touch. The clearance at the ends of the lock ring will be approximately 4 to 14
mm (0.15 to 0.55 in.) after it is installed. If the clearance is wrong, the wrong part has been
used.
STEP 1.
Clean and inspect all parts of the wheel. If the wheel has rust or corrosion, remove loose rust and
corrosion and paint the parts.
STEP 2.
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Apply a rubber lubricant or a soap solution to the tire bead and tube.
STEP 3.
Make sure that the wheel is the correct size for the tire. Lubricate the part of the wheel that is in
contact with the bead and flap.
STEP 4.
For tire with inner tube, install the inner tube and

the tire flap in the tire. For tubeless tires, install
the bead seal in the tire.
STEP 5.
For tires with inner tube, align the valve slot in
the rim with the air valve and install the wheel
rim in the tire. Guide the air valve through the

valve slot in the rim. For tubeless tires, align the
valve slot hole in the rim with the valve bead hole
in the valve bead, and install the wheel rim in the
tire.
STEP 6.
Turn over the rim and tire. Put a block under the
rim so that the rim is 8 to 10 cm (3.15 to 3.94 in.)
above the floor. Install the side ring and the lock
ring. When correctly installed, there will be a 4 to
14 mm (0.15 to 0.55 in.) clearance between the
ends of the side ring and the lock ring.

WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough
force to cause serious injury.
STEP 7.
For tubeless tires insert the air valve into the bead seal and rotate the valve 60 degrees until the air
valve locks into the valve slot.
ADDING AIR PRESSURE TO THE TIRES
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WARNING
Add air pressure to the tires only in a safety cage.
Inflating or adjusting tire pressure outside
of a
cage is allowed only if residual air pressure exceeds
80% of the pressure as indicated
on the
nameplate.
Inspect the safety cage for damage before use.
Always use a tire inflator with a clip-on chuck
when inflating or adjusting the tire pressure.
The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in
length.
During inflation the technician must stand away
from the safety cage. See Figure 29.
Do not use a hammer to try and correct the position of the side flange or lock ring when the
tire has air pressure greater than 20 kPa (3 psi).
WARNING
Wheels can explode and cause injury or death if
the above procedures are not followed.
1. QUICK-RELEASE COUPLING
Figure 29. Adding Air Pressure to the Tire Position
1. Put the tire in a safety cage. See Figure 29.
2. Add 20 kPa (3 psi) of air pressure to the tire.
3. Check that all wheel parts are correctly installed. Hit the side ring and/or lock ring lightly to make sure

that it is in the seat.
4. If installation is correct, add air pressure to the tire. The correct pressure is shown on the Nameplate.
5. Check that all wheel parts are correctly installed. If installation is not correct, remove all of the air
pressure from the tire. Remove the valve core to make sure all of the air pressure has been removed

and make adjustments. The clearance at the ends of the lock ring will be 4 to 14 mm (0.15 to 0.55 in.)
when the tire has the correct air pressure.
REMOVE SOLID RUBBER TIRE FROM WHEEL
WARNING
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Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force
to cause serious injury. See Figure 28.
Always use a cage when removing the solid rubber tire from the rim or personal injury may
occur.
STEP 1.
Put the wheel rim on the bed of the press. Put the

cage in position on the tire. Use the press to push
the tire away from the side ring.
STEP 2.
Put the tire tool into the slot between the side ring

and/or lock ring and the wheel rim. Remove the
side ring, lock ring, and wedge band.
STEP 3.
Turn the tire over. Put a support under the wheel

rim. Make sure the wheel rim is at least 150 to
200 mm (6 to 8 in.) from the bed of the press.
STEP 4.
Put the cage in position on the tire. Use the press
to push the tire from the wheel rim.
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INSTALL SOLID RUBBER TIRE ON WHEEL
WARNING
Wheels can explode and cause injury or death if the following procedures are not followed:
• Clean and inspect all parts of the wheel before installing the tire.
• Inspect all wheel components for deformation, corrosion and fractures.
• Look for fractures at the contact area between tire and wheel parts in particular.
• Unacceptable deformation includes progressed wear, buckling, twisting or presence of dents.
• Discard all wheel components showing any of the above defects, and replace by new ones.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers

on any one lift truck.
• Check with your dealer whether a specific tire is approved for use on this lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put
parts together. Make sure that the lock ring is in the correct position. The ends of the lock
ring must not touch. The clearance at the ends of the lock ring will be approximately 4 to 14
mm (0.15 to 0.55 in.) after it is installed. If the clearance is wrong, the wrong part has been
used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.

Lubricate the wheel rim and the inner surface of the tire with tire lubricant or soap.

14/04/2022 18:56 Document
STEP 2.
Put the wheel rim on the bed of the press. Put the
tire over the wheel rim. Put the cage in position
on the tire. Use the press to install the tire on the
wheel rim.
STEP 3.
Remove the cage and put the wedge band, the
side ring, and the lock ring in position on the
wheel assembly. Install the cage on the tire. Use
the press to push the tire onto the wheel rim so
that the wedge band and side ring can be
installed.
STEP 4.
While the cage is holding the tire on the wheel
rim, install the lock ring. Use a tire tool to make
sure the lock ring is in the correct position.

Slowly release the press and verify that the
clearance at the ends of the lock ring will be 4 to
14 mm (0.15 to 0.55 in.) when the cage almost
loses contact with the tire.
INSTALL WHEELS ON LIFT TRUCK
Align and Install the wheel(s) and tire(s) on the hub. Tighten the nuts according to Step 1.
Wheel Nuts on Drive and Steer Wheels

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CAUTION
Check all wheel nuts after 2 to 5 hours of operation, when new lift trucks begin operation,
and on all lift trucks when the wheels have been removed and installed. Tighten the nuts as
shown in Figure 30. When the nuts stay tight for 8 hours, the interval for checking the torque
can be extended to 250 hours.
Start with the wheel nut at the top and tighten the nuts to
68 to 136 N•m (50 to 100 lbf ft) in the sequence
shown in
Figure 30 Check to make sure that the wheel(s) is tight against the hub, then tighten the nuts to 615
to 710 N•m (454 to 524 lbf ft).
Figure 30. Wheel Nut Tightening Sequence
Pre-Delivery
ADJUST TIMING FOR AUTOMATIC ENGINE SHUT DOWN
The engine will automatically shut down 15 minutes after the operator has left the truck seat. Verify which
timing for engine shut down has been ordered by the customer and adjust the timer accordingly. The timer for
empty seat engine shut down is located in the side console. Remove the fuse panel cover and unhook the
relay from its bracket. See Figure 31 for its location. Adjust the relay by turning the phillips screw that is
visible through the top cover of the relay.
O relé pode ser ajustado entre 30 segundos na posição mais distante no sentido anti-horário e 15 minutos na
posição mais distante no sentido horário. Nunca ajuste o tempo de desligamento para um valor inferior a 5
minutos para garantir que o turbo do motor esfrie o suficiente antes que o motor seja desligado
automaticamente. Meça e eventualmente reajuste o tempo de desligamento. Reposicione o temporizador e
feche a tampa do fusível.
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1. RETRANSMISSÃO
2. PARAFUSO DE AJUSTE
Figura 31. Relé do temporizador de desligamento do motor
Realizar inspeção pré-entrega
Realize uma Inspeção Pré-entrega e preencha o Relatório de Inspeção Pré-entrega, conforme o Manual de
Operações de Serviço do Revendedor'.
Entrega
MANUAL DE INSTRUÇÕES
Certifique-se de que o operador leu o Manual de Operação. Mostre ao operador e ao pessoal de manutenção a
localização de todas as funções e explique sua finalidade.
INSTRUÇÕES MANUTENÇÃO DIÁRIA
Revise as verificações diárias com o operador. Repita os procedimentos de 8 horas junto com o operador para
garantir que ele esteja ciente e tenha entendido esses procedimentos.
ENTREGA DE CAMINHÃO
Fique junto com o operador quando a máquina for acionada pela primeira vez e forneça orientação durante os
primeiros passos.
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PARTE NO. 4133482 8000 SRM 1940

NOTA: Os seguintes símbolos e palavras indicam informações de segurança

Esta seção é para os seguintes modelos:

H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS2) [L007];

UMA. ALTURA VER NOTA NA TABELA 1

Figura 1. Altura, comprimento e largura completos do caminhão

Tabela 1. Caminhão Completo

Tabela 1. Caminhão Completo

Modelo Transporte Comprimento Largura

A. HEIGHT B. LENGTH C. WIDTH

Figure 2. Basic Truck Height, Length and Width

H12.00XM-6 280HD2 3,963 mm 2,446 mm 2,990 mm 11,5500 kg 12,300 kg

H210-48HD2 4,363 mm 2,607 mm 3,201 mm 12,500 kg 13,700 kg

H230-48HD2 4,363 mm 2,607 mm 3,201 mm 13,200 kg 14,350 kg

H250-48HD2 4,363 mm 2,607 mm 3,201 mm 14,250 kg 15,400 kg

Figure 3. Mast and Carriage Width, Height and Length

Model Type Height Width Length Weight

Figure 4. Forks Width, Height and Length

Model Type Width Height Length Weight

A. WIDTH B. LENGTH C. HEIGHT

Figure 5. Container Attachment Width, Length and Height

Model Length Height Width Weight

LOADING DISASSEMBLED COMPONENTS

A. FRONT TIE DOWN POINTS

Figure 6. Lift Truck Tie Down Placement

1. WOODEN BLOCKS OR PALLETS

Figure 7. Mast and Carriage Tie Down Placement

1. If used, remove any protective cover.

2. Make sure the parking brake is applied.

4. Remove the wheel blocks.

6. Attach a lifting device to the lifting points. See Figure 8.

1. COUNTERWEIGHT LIFTING POINTS

Figure 8. Lift Truck Lifting Points

Driving a Truck off a Trailer

1. Make sure the parking brake is applied.

3. Remove the wheel blocks.

UNLOADING DISASSEMBLED COMPONENTS

REMOVAL OF FORKS ATTACHED TO A BASIC TRUCK

1. BLOCK 5. ROD END

Figure 9. Forks to Basic Truck

5. Lower the pallet with the forks.

REMOVAL OF FORKS ATTACHED TO THE CARRIAGE

Figure 10. Forks Attached to Carriage

2. Lower the fork on a pallet.

4. Remove the rubber plate on the lower fork.

5. Remove the lower fork by following Step 1 through Step 3.

Moving and Towing

While the lift truck is being towed the engine must

The parking brake caliper is mounted on a support

2. Remove the plastic screw cap. See Figure 11.

1. PLASTIC SCREW CAP

Figure 11. Parking Brake Release

3. Loosen the lock nut.

TOWING A LIFT TRUCK

• Tires are damaged.

If the engine cannot run, there is no hydraulic

1. The towed lift truck must have an operator.

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

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

6. After towing is completed, place blocks on both

Safety Procedures When Working Near The Mast

WHEN WORKING NEAR THE MAST ALWAYS

1. Put the mast in a vertical position.