Hyster MAST H16XM9-12 User manual

MAST
H16XM9-12, H18XM-7.5-9
(H360-36HD, H360-48HD) [A238] [B238]
PART NO. 4097319 4000 SRM 1664

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 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 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2017 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description And Operation ..................................................................................................................................... 1
Mast System ........................................................................................................................................................ 1
Tilting ...................................................................................................................................................................1
Tilt Control (for A238 and B238 until Mid-2017) .......................................................................................... 2
Tilt Control (for B238 after Mid-2017) ........................................................................................................... 2
Lifting ...................................................................................................................................................................3
Operation ......................................................................................................................................................... 3
Pilot Operated Check Valves .......................................................................................................................... 3
Gland Lubrication ........................................................................................................................................... 4
Emergency Lowering Valve ............................................................................................................................ 5
Operation ..................................................................................................................................................... 5
Lift Chains ....................................................................................................................................................... 6
Elongation Through Wear ...........................................................................................................................7
Speed of Wear .............................................................................................................................................. 7
Plate Height Wear ....................................................................................................................................... 7
Lubrication ...................................................................................................................................................7
Restoring the Oil Film .................................................................................................................................7
Maintenance .................................................................................................................................................7
Maintaining the Presence of Oil ................................................................................................................. 8
Corrosion Protection ....................................................................................................................................8
Requirements for Chain Lubricant .............................................................................................................8
Load Rollers ..................................................................................................................................................... 8
Bearing Blocks .................................................................................................................................................9
Carriage ............................................................................................................................................................... 9
Standard Carriage with Manual Fork Positioning ......................................................................................10
Standard Carriage with Hydraulic Fork Positioning ..................................................................................10
Integral Side Shift (ISS) Carriage with Pin-Type Forks .............................................................................11
Dual Function Side Shift and Fork Positioning Carriage (DFSSFP) ......................................................... 11
DFSSFP Carriage with Quick Disconnect Forks .....................................................................................11
DFSSFP Carriage with Integrated Forks ................................................................................................ 12
Carriage Valve ...............................................................................................................................................12
Alternating Pressure and Tank (P & T) ...................................................................................................12
Forks .................................................................................................................................................................. 15
Safety Procedures When Working Near Mast .....................................................................................................16
Before Starting Repairs To The Hydraulic System Always: ...........................................................................17
Remove and Replace ..............................................................................................................................................18
Forks .................................................................................................................................................................. 18
Pin-Type Forks .............................................................................................................................................. 18
Remove ....................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Quick Disconnect DFSSFP Forks .................................................................................................................20
Remove ....................................................................................................................................................... 20
Install ......................................................................................................................................................... 21
Integrated DFSSFP Forks ............................................................................................................................ 21
Remove ....................................................................................................................................................... 21
Clean and Inspect ...................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Fork Hanger for Quick Disconnect Forks ........................................................................................................ 23
Remove ...........................................................................................................................................................23
Clean and Inspect ..........................................................................................................................................23
Install ............................................................................................................................................................. 23
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TABLE OF CONTENTS (Continued)
Carriage ............................................................................................................................................................. 24
Remove ...........................................................................................................................................................24
Install ............................................................................................................................................................. 25
Carriage Bearing Blocks ............................................................................................................................... 26
Remove ....................................................................................................................................................... 26
Install ......................................................................................................................................................... 26
Carriage Load Rollers ................................................................................................................................... 27
Remove ....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Apron Wear Pads (DFSSFP Carriage) ......................................................................................................... 28
Replace ....................................................................................................................................................... 28
Fork Positioner Cylinder ...............................................................................................................................29
Remove ....................................................................................................................................................... 29
Disassemble - Fork Positioner Cylinder for Pin Type Carriage ..............................................................31
Clean and Inspect ...................................................................................................................................... 32
Assemble - Fork Positioner Cylinder for Pin Type Carriage ...................................................................32
Disassemble - Fork Positioner Cylinder for DFSSFP Carriage .............................................................. 32
Clean and Inspect ...................................................................................................................................... 32
Assemble - Fork Positioner Cylinder for DFSSFP Carriage ................................................................... 33
Install ......................................................................................................................................................... 34
Side Shift Cylinder ........................................................................................................................................ 34
Remove ....................................................................................................................................................... 34
Disassemble ............................................................................................................................................... 34
Clean and Inspect ...................................................................................................................................... 35
Assemble .................................................................................................................................................... 36
Install ......................................................................................................................................................... 36
Carriage Valve ...............................................................................................................................................36
Remove ....................................................................................................................................................... 36
Disassemble ............................................................................................................................................... 37
Clean and Inspect ...................................................................................................................................... 38
Assemble .................................................................................................................................................... 39
Install ......................................................................................................................................................... 39
Mast ....................................................................................................................................................................39
Lift Chains ..................................................................................................................................................... 39
Remove ....................................................................................................................................................... 39
Install ......................................................................................................................................................... 40
Chain Anchor on Carriage ............................................................................................................................ 40
Remove ....................................................................................................................................................... 40
Install ......................................................................................................................................................... 41
Top Chain Anchor ..........................................................................................................................................41
Remove ....................................................................................................................................................... 41
Install ......................................................................................................................................................... 42
Chain Sheave .................................................................................................................................................42
Remove ....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Header Hoses .................................................................................................................................................43
Remove ....................................................................................................................................................... 43
Install ......................................................................................................................................................... 44
Electric Mast Cable ....................................................................................................................................... 45
Remove ....................................................................................................................................................... 45
Install ......................................................................................................................................................... 45
Hose Sheave ...................................................................................................................................................45
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TABLE OF CONTENTS (Continued)
Remove And Disassemble ......................................................................................................................... 45
Assemble And Install .................................................................................................................................46
Tilt Cylinder ...................................................................................................................................................... 46
Remove ...........................................................................................................................................................46
Disassemble ................................................................................................................................................... 47
Clean .............................................................................................................................................................. 47
Inspect ............................................................................................................................................................48
Assemble ........................................................................................................................................................ 48
Install ............................................................................................................................................................. 49
Mast Assembly ...................................................................................................................................................49
Remove ...........................................................................................................................................................49
Disassemble ................................................................................................................................................... 50
Assemble ........................................................................................................................................................ 52
Install ............................................................................................................................................................. 53
Inner Mast Load Rollers ............................................................................................................................... 54
Remove and Disassemble ..........................................................................................................................54
Assemble and Install ................................................................................................................................. 55
Mast Bearing Blocks ..................................................................................................................................... 55
Remove ....................................................................................................................................................... 55
Install ......................................................................................................................................................... 55
Lift Cylinders .................................................................................................................................................56
Remove ....................................................................................................................................................... 56
Disassemble ............................................................................................................................................... 57
Clean and Inspect ...................................................................................................................................... 58
Assemble .................................................................................................................................................... 58
Install ......................................................................................................................................................... 59
Checks and Adjustments ...................................................................................................................................... 59
General Checks ..................................................................................................................................................59
Mast Condition Check ...................................................................................................................................59
Mast Operation Check ...................................................................................................................................60
Fork Inspection ..............................................................................................................................................60
Lift Chains ..................................................................................................................................................... 61
Lift Chains Cleaning ................................................................................................................................. 61
Lift Chain Inspection .................................................................................................................................61
Lift Chain Lubricant Requirements ......................................................................................................... 62
Lift Chain Lubrication Procedure .............................................................................................................62
Leak Checks ...................................................................................................................................................63
Mast Vertical Creep ...................................................................................................................................63
Mast Tilt Drift ............................................................................................................................................63
Adjustments .......................................................................................................................................................63
Lift Cylinder Shimming ................................................................................................................................ 63
Lift Chain and Fork Height Adjustment ......................................................................................................65
Dual Function Fork Guide Shimming ..........................................................................................................67
Header Hose Tension Adjustment ................................................................................................................68
Electric Mast Cable Tension Adjustment .................................................................................................... 68
Tilt Cylinder Backward Tilt Adjustment ..................................................................................................... 68
Mast Support Pad Adjustment ..................................................................................................................... 69
Capacities and Specifications ............................................................................................................................... 70
Torque Values For Mast and Carriage .............................................................................................................70
Troubleshooting .....................................................................................................................................................71
Introduction ....................................................................................................................................................... 71
No Hydraulic Movement With Engine Running ..............................................................................................71
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