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Safety Procedures When Working Near Mast

The  following  procedures  MUST  be  used  when  in-
specting or working near the mast. Additional pre-
cautions  and  procedures  can  be  required  when  re-
pairing or removing the mast.

  WARNING 

Mast parts are heavy and can shift. Distances be-
tween 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  in-
stalled.  Also  make  sure  that  the  power  is
OFF and the key is removed. Put a DO NOT
OPERATE  tag  in  the  operator's  compart-
ment. Disconnect the battery 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.

Mast  repairs  require  disassembly  and  re-
moval  of  parts  and  can  require  removal  of
the mast or carriage. Follow the repair pro-
cedures in this section.

WHEN WORKING NEAR THE MAST ALWAYS:

Lower  the  mast  and  carriage  completely:
Turn the key switch to the ON position and
push the lift/lower control lever forward un-
til 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 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 procedures:

1. 

Put mast in vertical position.

2. 

Raise  mast  to  align  bottom  crossmember  of
mast  upright  that  moves  in  outer  mast  with
crossmember  on  outer  mast.  On  the  two-stage
mast, the moving part is the inner mast. On the
three-stage  mast,  it  is  the  intermediate  mast.
On the four-stage mast, it is the first intermedi-
ate mast. See Figure 2 or Figure 3.

3. 

Use  a  3/8-inch  minimum  safety  chain  with  a
hook  to  fasten  the  crossmembers  together  so
the movable member cannot lower. Put hook on
back side of mast. Make sure hook is completely
engaged  with  a  link  in  the  chain.  Make  sure
safety chain does not touch lift chains or chain
sheaves, tubes, hoses, fittings, or other parts on
the mast.

4. 

Lower  mast  until  there  is  tension  in  safety
chain and free-lift cylinder (full free-lift models)
is completely retracted.

NOTE:  

Apply the parking brake. After lowering or

restraining  the  mast,  shut  off  the  power,  and  re-
move  key.  Put  a  DO  NOT  OPERATE  tag  in  the
operator's  compartment.  Disconnect  battery  and
put a tag or lock on battery connector.

5. 

Install  another  safety  chain  (9.5  mm  (3/8  in.)
minimum) between the top or bottom bar of the
carriage  (item  6,  Figure  2)  and  a  crossmember
on the outer mast as a secondary safety device.
Install a DO NOT REMOVE tag on the safety
chain(s).

4000 SRM 1386

Safety Procedures When Working Near Mast

3

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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