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Hyster A380 Manual

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Hyster A380 (H40XT, H50XT, H60XT) Forklift Service
Repair Manual

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  • Page 1 Hyster A380 (H40XT, H50XT, H60XT) Forklift Service Repair Manual...
  • Page 2 MAST REPAIR (S/N A387, A389, A397, A399) TWO-STAGE LFL AND THREE- STAGE FFL MAST H2.0-3.0XT (H40-60XT) [A380] PART NO. 4150993 4000 SRM 1999...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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.

  • Page 4: Table Of Contents

    Remove ................................41 Clean and Inspect ............................43 Install ................................43 Integral Sideshift Carriage ..........................44 Remove ................................44 Disassemble ..............................46 Clean and Inspect ............................46 Assemble ............................... 48 Install ................................48 Fork Positioner Carriage ..........................48 ©2016 HYSTER COMPANY...
  • Page 5 Lift Trucks Equipped With Manual Hydraulic Controls ................87 Connecting Attachment Hydraulic Quick Disconnect Hoses ................. 87 Lift Trucks Equipped With E-Hydraulic Controls ..................87 Lift Trucks Equipped With Manual Hydraulic Controls ................88 This section is for the following models: H2.0-3.0XT (H40-60XT) [A380]...
  • Page 6 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: admin@servicemanualperfect.com...

  • Page 7: General

    4000 SRM 1999 General General This section contains the repair procedures for the WARNING Two-Stage, Limited Free-Lift (LFL) mast with serial numbers A389 and A399 and the Three- Before working on or near the mast, see Safety Stage, Full Free-Lift (FFL) mast with serial Procedures When Working Near Mast in this numbers A387 and A397.
  • Page 8 General 4000 SRM 1999 NOTE: THE MAST AND TEXT SHOWN IN ABOVE ILLUSTRATION ARE FOR ILLUSTRATIVE PURPOSES ONLY. YOUR MAST AND TEXT MAY BE DIFFERENT, BUT THE TEXT IS FOUND IN THE SAME LOCATION. 1. MAST SERIAL NUMBER SERIES 4. MAST LIFT HEIGHT (IN MILLIMETERS) 2.

  • Page 9: Safety Procedures When Working Near Mast

    4000 SRM 1999 Safety Procedures When Working Near Mast Safety Procedures When Working Near Mast The following procedures MUST be used when in- specting or working near the mast. Additional pre- • If parts of the mast must be in a raised posi- cautions and procedures can be required when re- tion, install a safety chain to restrain the pairing or removing the mast.
  • Page 10 Safety Procedures When Working Near Mast 4000 SRM 1999 A. TWO-STAGE LFL MAST B. THREE-STAGE FFL MAST 1. OUTER WELDMENT 5. FREE-LIFT CYLINDER 2. INNER WELDMENT 6. CROSSMEMBER 3. INTERMEDIATE WELDMENT 7. CROSSMEMBER 4. HOOK Figure 2. Two-Stage LFL and Three-Stage FFL Masts...

  • Page 11: Fork Replacement

    4000 SRM 1999 Fork Replacement Fork Replacement STANDARD CARRIAGE AND INTEGRAL Remove SIDESHIFT CARRIAGE WARNING On lift trucks equipped with a standard carriage or DO NOT try to remove a fork without a lifting de- an integral sideshift carriage, the forks are held on vice.
  • Page 12 Fork Replacement 4000 SRM 1999 1. LOAD BACKREST 6. SPRING 2. CARRIAGE 7. PIN (FORK LATCH) 3. FORK(S) 8. FORK REMOVAL NOTCH 4. KNOB 9. LOWER HOOK 5. PIN RETAINER 10. UPPER HOOK Figure 3. Carriage and Forks Legend for Figure 4 1.

  • Page 13: Install

    4000 SRM 1999 Fork Replacement Install Checks WARNING WARNING DO NOT try to remove a fork without a lifting de- Never repair damaged forks by heating or weld- vice. Each hook fork for these lift trucks can ing. Forks are made of tempered steel using spe- weigh 50 to 98 kg (110 to 216 lb).

  • Page 14: Fork Positioner Carriage

    Fork Replacement 4000 SRM 1999 A. HEEL OF FORK (MUST BE 90% OF DIMEN- SION B) 1. OUTER FORK CARRIER B. ORIGINAL FORK THICKNESS (DIMENSION B) 2. CAPSCREWS 3. INNER FORK CARRIER 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF 4.

  • Page 15: Install

    4000 SRM 1999 Fork Replacement 4. Move carriage away from fork or use a lifting device to move fork away from carriage. NOTE: FORK POSITIONER AND INTEGRAL SIDESHIFT CARRIAGE FOR THREE-STAGE FFL MAST SHOWN. REMOVAL OF FORKS FROM TWO-STAGE LFL MAST IS SIMILAR. 1.

  • Page 16: Checks

    Fork Replacement 4000 SRM 1999 Some applications may require closer alignment. If Checks forks do not meet specification, they both must be replaced. Repair or replace any damaged or broken WARNING fork components and lubricate, as necessary. See Figure 8. Never repair damaged forks by heating or weld- ing.

  • Page 17: Carriages Repair, Two-Stage Lfl Mast

    4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast Legend for Figure 8 A. HEEL OF FORK (MUST BE 90% OF DIMEN- SION B) B. ORIGINAL FORK THICKNESS (DIMENSION B) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3.

  • Page 18: Clean And Inspect

    Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999 WARNING When disconnecting the lift chains, keep control 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 and caus- ing an injury or damage.

  • Page 19: Install

    4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast 4. Clean and inspect the chain anchors and chain WARNING anchor pins. Check chain anchors and anchor pins for wear and serviceability. Discard worn Compressed air can move particles so that they or unserviceable chain anchors and chain an- cause injury to the user or to other personnel.

  • Page 20: Integral Sideshift Carriage

    Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999 4. Disconnect hydraulic hoses from sideshift cylin- INTEGRAL SIDESHIFT CARRIAGE der. Put caps and plugs on open lines and cylin- der ports. See Figure 11. Remove 1. Lower carriage completely. Remove forks. See Fork Replacement for removal procedures.
  • Page 21 4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast 1. INNER FRAME 11. LUBE FITTING 2. OUTER FRAME 12. CHAIN ANCHOR 3. SIDESHIFT CYLINDER 13. COTTER PIN 4. UPPER BEARING 14. SNAP RING 5. LOWER BEARING 15. LOAD ROLLER 6. LOWER HOOK 16.

  • Page 22: Disassemble

    Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast. Consult your Hyster lift truck dealer for more information before welding on the mast. 2. Clean and inspect carriage bars for damage and smoothness.
  • Page 23 4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast Legend for Figure 14 A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM Figure 14.

  • Page 24: Assemble

    Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999 Assemble FORK POSITIONER CARRIAGE 1. Assemble the integral sideshift cylinder. See Remove the Cylinder Repair manual listed in the General section of this manual for procedures. NOTE: The fork positioner can be removed from the integral sideshift carriage with integral side- 2.

  • Page 25: Remove

    4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast 5. Install an M12 x 1.75 lifting eye in tapped hole Never check for leaks by putting hands on hy- (7, Figure 17) on integral sideshift carriage and draulic lines or components under pressure. Hy- lifting device, with...

This manual is also suitable for:

H40xtH50xtH60xt

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