Hyster G160 Operating instructions

Hyster G160 (J1.60XMT, J1.80XMT, J2.00XMT) Forklift

MAST
REPAIRS
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT2[H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897507 4000 SRM 522

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!

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Forks Repair....................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 4
Carriages Repair ................................................................................................................................................ 4
Standard Carriage, Remove.......................................................................................................................... 4
Hang-On Sideshift Carriage, Remove .......................................................................................................... 5
Standard Carriage and Hang-On Sideshift Carriage, Repair..................................................................... 6
Standard Carriage, Install............................................................................................................................ 6
Hang-On Sideshift Carriage, Install ............................................................................................................ 7
Integral Sideshift Carriage ........................................................................................................................... 7
Remove....................................................................................................................................................... 7
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 9
Install......................................................................................................................................................... 10
Mast Repair........................................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Two-Stage LFL and Two-Stage FFL Masts, Disassemble........................................................................... 12
Three-Stage FFL Mast .................................................................................................................................. 19
Disassemble............................................................................................................................................... 19
Mast and Chains, Clean and Inspect ....................................................................................................... 22
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 23
Three-Stage FFL Mast, Assemble ................................................................................................................ 24
Install ............................................................................................................................................................. 26
Lift Cylinders Repair ......................................................................................................................................... 27
Main Lift Cylinders, Remove ........................................................................................................................ 27
Free-Lift Cylinder, Remove........................................................................................................................... 27
Lift Cylinders, Disassemble .......................................................................................................................... 28
Lift Cylinders, Assemble ............................................................................................................................... 28
Main Lift Cylinders, Install .......................................................................................................................... 31
Free-Lift Cylinder, Install ............................................................................................................................. 32
Header Hose Arrangements .............................................................................................................................. 32
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 32
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 38
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 38
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 43
Three-Stage FFL Mast, New Hose Install ................................................................................................... 45
Three-Stage FFL Mast, Adjust Hoses After Installation ............................................................................ 55
Header Hose Arrangement................................................................................................................................ 56
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 56
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 56
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 60
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 65
Three-Stage FFL Mast, New Hose Install ................................................................................................... 67
Three-Stage FFL Mast, Adjust Hoses After Install..................................................................................... 72
Lift and Tilt System Leak Check ...................................................................................................................... 76
Lift Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Adjustment................................................................................................................................. 77
Lift Chains Adjustment..................................................................................................................................... 78
©2004 HYSTER COMPANY i

Table of Contents Mast
TABLE OF CONTENTS (Continued)
Mast Adjustment ............................................................................................................................................... 80
Carriage Adjustment ......................................................................................................................................... 82
Troubleshooting.................................................................................................................................................. 82
This section is for the following models:
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM2)[D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT2[H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]
ii

4000 SRM 522 Safety Procedures When Working Near Mast
General
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
This section has the repair procedures for the
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL)
masts; and for the sideshift carriages. Carriage
Adjustment and Troubleshooting are at the end of
this section. See the section Mast,Description
4000 SRM 521 for the description and operation of
the masts.
NOTE: Hoses have a service life that is determined
by application and time. All hoses must be inspected
at the intervals specified in the Maintenance Sched-
uleforthehy
draulic system. Install a new hose if the
hose is worn, damaged, soft or hard, and no longer
flexible. If necessary, make a comparison to a new
hose that is the correct replacement for the hose you
are inspecting.
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 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 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:
• 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 all parts of the mast that move are
fully lowered.
OR
• If parts of the mast must be in a raised po-
sition, 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 crossmem-
ber of the weldment that moves in the outer
weldment with a crossmember on the outer
weldment. On the two-stage and free-lift mast,
the moving part is the inner weldment. On the
three-stage mast, it is the intermediate weld-
ment. See Figure 1.
3. Usea9.5mm(3/8in.) minimumsafetychain
with a hook to fasten the crossmembers together
so the movable member cannot lower. 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.
4. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (two-stage
full free-lift and three-stage masts only) is com-
pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
NOTE: After lowering or restraining the mast, shut
off the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment.
1

Thanks very much for your reading,
Want to get more 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 please write to me:
[e-mail]

Safety Procedures When Working Near Mast 4000 SRM 522
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
2

4000 SRM 522 Forks Repair
Forks Repair
The forks are held on the carriage by hooks. The
forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the top
bar carriage. Always check that the latch pins for
the forks keep the forks in position on the carriage.
Replace damaged latch pins parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage.
REMOVE
WARNING
Do NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
Aforkcanb
e removed from the carriage for replace-
ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car-
riage further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
from the fork, or use a lifting device to move the fork
away from the carriage.
1. CARRIAGE BARS
2. HOOK FORK 3. BLOCKS
Figure 2. Hook Fork Removal
A. EARLIER MODELS B. LATER MODELS
1. FORKS
2. CARRIAGE
3. LOAD BACKREST EXTENSION
4. FORK REMOVAL NOTCH
5. LATCH PIN ASSEMBLY
6. LEVER
7. WASHER
8. SPRING
9. PIN
10. KNOB
Figure 3. Carriage and Forks
3

Carriages Repair 4000 SRM 522
INSTALL
Movetheforkandcarriagesothetophookonthe
fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork
removal notch. Slide the fork on the carriage so both
upperandlowerhooksengagethecarriagebars.En-
gagethelatchpinwithanotchintheuppercarriage
bar.
Carriages Repair
STANDARD CARRIAGE, REMOVE
1. Put a one-quarter capacity load on the forks. The
load must give the carriage stability so the car-
riage cannot fall when it is disconnected from the
mast.
2. Lower the carriage and forks on blocks so the lift
chains become loose.
3. Remove the load backrest extension.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pinfromeachchainanchoratthe
carriage. See Figure 4. Disconnect the lift chains
from the carriage. Usewiretoconnecttheends
of the liftchainstoapartofthemast.Makesure
the chains can move freely when the inner mast
weldmentisraised.
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast weld-
ment is above the load rollers of the carriage.
5. Use the lift cylinders to raise the inner mast
weldment. If the hydraulic system cannot be
used, disconnect the lift cylinders from the inner
or intermediate mast weldment. Connect a crane
[the capacity of the crane must be at least 681 kg
(1501 lb)] to the top of the inner mast weldment.
Carefully raise the inner mast weldment until it
is above the load rollers of the carriage.
NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
1. CARRIAGE
2. SNAP RING
3. SHIM
4. LOAD ROLLER
5. CHAIN ANCHOR
6. CHAIN PIN
7. COTTER PIN
8. ANCHOR PIN
9. SPACER
Figure 4. Standard Carriage
6. Move the lift truck away from the carriage. Com-
pletely lower the inner mast weldment so it can-
not move.
7. Connect a lifting device to the carriage. Remove
the load from the forks with another lift truck.
Lower the carriage to the floor so the load rollers
are facing up.
8. Iftheforksareremoved,usealiftingdeviceto
put the carriage on the floor so the load rollers
are up.
4