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Two-Stage Mast With Limited Free-Lift Repair

REMOVE

  WARNING 

The  mast  is  heavy.  The  mast  can  weigh  approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast. Seri-
ous injury can occur if the mast falls.

  CAUTION

Make sure all the mast weldments are fastened to-
gether. Make sure the safety chains will not dam-
age  the  sheaves,  tubing,  or  other  parts  of  the
mast.

NOTE:   

If  the  mast  needs  to  be  disassembled,  re-

move the forks and carriage. See the sections Fork
Replacement
  and  Carriages  Repair  for  procedures.
If only the main lift cylinders or tilt cylinders need
to  be  repaired,  the  mast  does  not  need  to  be  re-
moved from the lift truck. See the section 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  proce-
dures.  For  header  hose  installation  and  adjust-
ment, see the section Header Hose Installation and
Adjustment.

1. 

Fully  lower  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 mast in an upright

position  when  the  tilt  cylinders  are  disconnec-
ted.  See  the  section  Safety  Procedures  When
Working Near Mast
.

  WARNING 

Hydraulic  oil  is  hot  after  system  operation  and
can  cause  burns.  DO  NOT  disconnect  any  hy-
draulic  hoses  until  the  oil  in  the  system  has
cooled.

Completely  lower  forks  to  relieve  hydraulic  pres-
sure before disconnecting any hoses.

  CAUTION

Protect  the  hydraulic  system  from  dirt  and  con-
taminants  when  disconnecting  hydraulic  hoses
from the mast. If hydraulic system becomes con-
taminated,  damage  to  hydraulic  system  can  oc-
cur.

  CAUTION

Disposal of lubricants and fluids must meet local
environmental regulations.

2. 

Position  a  drip  pan  with  a  capacity  of  21  li-
ter (22.5 qt) under the area of the hydraulic fit-
tings.

3. 

Remove  the  floor  mat.  Lift  the  floor  plate  up
enough  to  disconnect  the  electrical  connectors
from the accelerator pedal or pedal, and remove
floor  plate  with  accelerator  pedal  or  still  at-
tached. See Figure 14.

4000 SRM 1386

Two-Stage Mast With Limited Free-Lift Repair

19

Содержание A935 J1.6-2.0XN

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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