Hyster A935 J1.6-2.0XN Service & Repair Manual Download | Manualshive

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©2015 HYSTER COMPANY

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Safety Procedures When Working Near Mast .......................................................................................................3
Fork Replacement ................................................................................................................................................... 6

Remove ................................................................................................................................................................ 6
Install ...................................................................................................................................................................8
Checks ..................................................................................................................................................................8

Carriages Repair ................................................................................................................................................... 10

Standard Carriage ............................................................................................................................................ 10

Remove .......................................................................................................................................................... 10
Clean and Inspect ......................................................................................................................................... 12
Install ............................................................................................................................................................ 13

Integral Sideshift Carriage ...............................................................................................................................13

Remove .......................................................................................................................................................... 13
Disassemble .................................................................................................................................................. 15
Clean and Inspect ......................................................................................................................................... 15
Assemble ....................................................................................................................................................... 18
Install ............................................................................................................................................................ 18

Two-Stage Mast With Limited Free-Lift Repair ................................................................................................. 19

Remove .............................................................................................................................................................. 19
Disassemble .......................................................................................................................................................27
Clean and Inspect ............................................................................................................................................. 31
Assemble ............................................................................................................................................................33
Install .................................................................................................................................................................34
Header Hose Installation and Adjustment ......................................................................................................35

Installation ....................................................................................................................................................35
Adjustment ....................................................................................................................................................42

Three-Stage Mast With Full Free-Lift Repair .....................................................................................................42

Remove .............................................................................................................................................................. 42
Disassemble .......................................................................................................................................................51
Clean and Inspect ............................................................................................................................................. 57
Assemble ............................................................................................................................................................59
Install .................................................................................................................................................................60
Header Hose Installation and Adjustment ......................................................................................................61

Installation ....................................................................................................................................................61
Adjustment ....................................................................................................................................................68

Lift Chains Adjustment ........................................................................................................................................ 69
Carriage Adjustments ...........................................................................................................................................71
Tilt Cylinders Adjustment .................................................................................................................................... 72
Mast Adjustments ................................................................................................................................................. 72

Load Roller, Adjust ........................................................................................................................................... 72
Mast Side Kicking, Adjust ................................................................................................................................74

This section is for the following models:

J1.6-2.0XN [A935];

J1.5-2.0XNT [K160];

(E30HSD3, E35HSD3, E40HSD3) [C219]

Table of Contents

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Summary of Contents for A935 J1.6-2.0XN

Page 1: ...Hyster A935 J1 6 2 0XN J30 35 40XN Forklift...

Page 2: ...MAST REPAIR S N A270 A271 A272 2 AND 3 STAGE HIGH VISIBILITY MASTS J1 6 2 0XN A935 J1 5 2 0XNT K160 E30HSD3 E35HSD3 E40HSD3 C219 PART NO 1696600 4000 SRM 1386...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...emble 27 Clean and Inspect 31 Assemble 33 Install 34 Header Hose Installation and Adjustment 35 Installation 35 Adjustment 42 Three Stage Mast With Full Free Lift Repair 42 Remove 42 Disassemble 51 Cl...

Page 5: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 6: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 7: ...as been damaged if the hose cover is cracked exposing the braiding or if the hose has been kinked or crushed or if the hose is no longer flexible Install a new hose if the hose has been tensioned beyo...

Page 8: ...RATIVE PURPOSES INFORMATION SHOWN IS FOUND IN SAME POSITION ON ALL MASTS COVERED IN THIS MANUAL 1 MAST SERIAL NUMBER 2 MANUFACTURING PLANT 3 PRODUCTION SEQUENCE 4 MAST LIFT HEIGHT IN MILLIMETERS 5 MAS...

Page 9: ...e are fully lowered OR If parts of the mast must be in a raised posi tion install a safety chain to restrain the moving parts of the mast Connect moving parts to a part that does not move Follow these...

Page 10: ...D FOUR STAGE FFL MAST 1 OUTER MAST 2 INNER MAST 3 INTERMEDIATE MAST 4 HOOK 5 FREE LIFT CYLINDER 6 CARRIAGE BAR 7 CROSSMEMBER 8 FIRST INTERMEDIATE MAST Figure 2 Safety Chaining the Mast Sit Down Lift...

Page 11: ...ER WELDMENTS WHEN CHAINING THE MAST A LIMITED FREE LIFT MAST B FULL FREE LIFT MAST 1 SAFETY CHAIN AND HOOK 2 MAST CROSSMEMBERS ALIGNED 3 INNER WELDMENT 4 CARRIAGE TOP BAR 5 FREE LIFT CYLINDER 6 OUTER...

Page 12: ...ending on the size and configuration of forks installed on lift truck there may be a spacer bar between the inner and outer fork carriers See Figure 4 Forks are removed from carriage by aligning forks...

Page 13: ...1 LOAD BACKREST 2 CARRIAGE 3 FORKS 4 FORK 5 KNOB 6 WEDGE 7 WASHER 8 SPRING 9 PIN 10 FORK REMOVAL NOTCH Figure 5 Carriage and Forks 4000 SRM 1386 Fork Replacement 7...

Page 14: ...notch Slide the fork on the carriage so both upper and lower hooks engage the carriage bars Engage the latch pin with a notch in the upper carriage bar CHECKS WARNING Never repair damaged forks by hea...

Page 15: ...alignment If the forks do not meet specification they both must be replaced Check that the bottom of each fork is not excessively worn Check for smooth and proper operation of the fork lock pins Repa...

Page 16: ...o the mast This procedure will prevent the lift chains from falling and caus ing an injury or damage 4 Remove the chain pin from each chain anchor at the carriage See Figure 9 Disconnect the lift chai...

Page 17: ...RRIAGE SHOWN THREE STAGE FFL CARRIAGES ARE SIMILAR 1 SNAP RING 2 ANCHOR PIN 3 COTTER PIN 4 CARRIAGE 5 LOAD ROLLER 6 SHIM 7 STUBSHAFT 8 CHAIN PIN 9 CHAIN ANCHOR Figure 9 Standard Carriage 4000 SRM 1386...

Page 18: ...r can move particles so that they cause injury to the user or to other personnel Make sure that the path of the compressed air is away from all personnel Wear protective goggles or a face shield to pr...

Page 19: ...to 195 N m 144 lbf ft 6 Install the forks See Fork Replacement INTEGRAL SIDESHIFT CARRIAGE Remove 1 Lower the carriage completely Remove the forks See Fork Replacement for removal proce dures 2 Remov...

Page 20: ...CH 4 OUTER FRAME 5 LOWER HOOK 6 LUBE FITTING 7 LOWER BEARING 8 HAIRPIN 9 CLEVIS PIN 10 PIN 11 UPPER BEARING 12 SNAP RING 13 COTTER PIN 14 CHAIN ANCHOR 15 CHAIN ANCHOR MOUNTING BRACKET 16 INNER FRAME 1...

Page 21: ...Cylinder Repair Mast S N A270 72 A551 A555 A559 A626 A627 A751 52 B551 B555 B586 91 B749 54 C661 63 C665 D507 09 D515 D562 64 E509 E564 2100SRM1382 for procedures Clean and Inspect 1 Inspect the lowe...

Page 22: ...pper bearing is worn to less than 2 5 mm 0 1 in thickness replace both up per bearings by driving the upper bearings from the inner frame See Figure 13 To install new upper bearing align the pins on t...

Page 23: ...IMUM THICKNESS 2 5 mm 0 1 in 1 LOWER BEARINGS 2 CARRIAGE BARS 3 UPPER BEARINGS BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE Figure 13 Checking Upper and Lower Bearings 4000 SRM 1386 Carriages Repai...

Page 24: ...me See Figure 10 NOTE Use a wood block or a plastic hammer to fully seat the upper bearings onto the inner frame Proper lower hook clearance requires the upper bearings be fully seated 3 Apply a 1 mm...

Page 25: ...all mast weldments Tilt the mast fully forward Connect a crane or lifting device with a capacity of at least 907 kg 2000 lb to all top crossmembers of the mast weldments using chains to support the m...

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