Hyster C176 User manual

Hyster C176 (R40EH) Forklift

LIFT CYLINDERS
ALL MODELS, EXCEPT
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-EC (H360HD-EC) [E019, F019];
H20.00-32.00F (H440-700FS) [E008];
H36.00-48.00E (H800-1050E) [D117];
H3.50-5.50XM (H70-120XM) [K005, L005];
S3.50-5.50XM, S5.50XMS (S70-120XM,
S120XMS) [E004, F004]
PART NO. 910119 4000 SRM 135

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
•Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance 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 making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Lift Cylinders Table of Contents
TABLE OF CONTENTS
Safety Procedures When Working Near Mast.................................................................................................. 1
General ............................................................................................................................................................... 5
Description ......................................................................................................................................................... 5
Lowering Control Valve................................................................................................................................. 5
Cylinders (General) ....................................................................................................................................... 8
Cylinders (H520-620B, H700-800A) ............................................................................................................. 8
Retainer, Install......................................................................................................................................... 8
Cylinders (H360-460B).................................................................................................................................. 10
Cylinders (Two-Speed)................................................................................................................................... 12
Lift Cylinder Repair........................................................................................................................................... 14
Lift Cylinder Removal Without Removing Mast..........................................................................................14
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast............................ 14
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead ................................... 14
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder ...................................... 14
Disassemble ................................................................................................................................................... 16
Assemble ........................................................................................................................................................ 16
Lift Cylinder Installation in Mast ................................................................................................................ 18
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast............................ 18
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead ................................... 18
Chevron-Style Packing.................................................................................................................................. 18
Chevron-Style Packing Installation on Piston......................................................................................... 19
Chevron-Style Packing Installation in Packing Gland ........................................................................... 21
Lift Cylinders for VISTA®Masts....................................................................................................................... 22
Description ..................................................................................................................................................... 22
Lowering Control Valve............................................................................................................................. 22
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 25
Assemble ........................................................................................................................................................ 26
Install ............................................................................................................................................................. 27
Main Lift Cylinders................................................................................................................................... 27
Free-Lift Cylinder ..................................................................................................................................... 27
Lift System Leak Check .................................................................................................................................... 28
Specifications...................................................................................................................................................... 29
Troubleshooting.................................................................................................................................................. 30
This section is for the following models:
All Models, ExceptH8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-EC (H360HD-EC) [E019, F019];
H20.00-32.00F (H440-700FS) [E008];
H36.00-48.00E (H800-1050E) [D117];
H3.50-5.50XM (H70-120XM) [K005, L005];
S3.50-5.50XM, S5.50XMS (S70-120XM, S120XMS) [E004, F004]
©2003 HYSTER COMPANY i

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"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

4000 SRM 135 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
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 com-
pletely 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.
• 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. Usealadderorpersonnellifttowork
on the mast.
• Do NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. 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
2. If parts of the mast must be in 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:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom cross-
member of the inner weldment with a cross-
member on the outer weldment. See Fig-
ure1,Figure2,andFigure3.
c. Use a 12 mm (0.5 in.) minimum safety chain
with a hook to fasten the crossmembers to-
gether so that the movable member cannot
lower. Put the hook on the back side of the
mast. Make sure the hook is completely en-
gaged 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.
d. Lower the mast until there is tension in the
safety chain. If running, stop the engine. Ap-
ply the parking brake. Install a DO NOT RE-
MOVE tag on the safety chain(s).
e. Install another safety chain 12 mm (0.5 in.)
minimum between the top or bottom cross-
member of the carriage and a crossmember
on the outer weldment.
3. Apply the parking brake. After lowering or re-
straining the mast, shut off the power and re-
move the key. Put a DO NOT OPERATE tag in
the operator’s compartment.
1

Safety Procedures When Working Near Mast 4000 SRM 135
1. INNER WELDMENT
2. OUTER WELDMENT 3. HOOK 4. CARRIAGE
Figure 1. Mast
2

4000 SRM 135 Safety Procedures When Working Near Mast
1. INNER WELDMENT
2. TILT CYLINDERS 3. HOOK
Figure 2. Mast
3

Safety Procedures When Working Near Mast 4000 SRM 135
Figure 3. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
4