Hyster A935 J1.6-2.0XN Service & Repair Manual
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Hyster A935 J1.6-2.0XN Service & Repair Manual

Hyster A935 J1.6-2.0XN Service & Repair Manual

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Hyster A935 J1.6-2.0XN (J30-35-40XN) Forklift

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Summary of Contents for Hyster A935 J1.6-2.0XN

  • Page 1 Hyster A935 J1.6-2.0XN (J30-35-40XN) Forklift...
  • Page 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]; E30HSD , E35HSD , E40HSD [C219] PART NO. 1696600 4000 SRM 1386...
  • 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

    Carriage Adjustments ............................71 Tilt Cylinders Adjustment ............................ 72 Mast Adjustments ..............................72 Load Roller, Adjust ............................72 Mast Side Kicking, Adjust ..........................74 This section is for the following models: J1.6-2.0XN [A935]; J1.5-2.0XNT [K160]; (E30HSD3, E35HSD3, E40HSD3) [C219] ©2015 HYSTER COMPANY...
  • Page 5 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 6 "THE QUALITY KEEPERS" HYSTER APPROVED PARTS...

  • Page 7: General

    4000 SRM 1386 General General Procedures for adjusting the carriage, lift chains, WARNING mast, and tilt cylinders are located at the end of this manual. Before working on or near the mast, see the section Safety Procedures When Working Near Mast in this SRM.
  • Page 8 General 4000 SRM 1386 NOTE: MAST AND SERIAL NUMBER SHOWN ARE NOT COVERED IN THIS MANUAL. ART USED FOR ILLUSTRATIVE PURPOSES. INFORMATION SHOWN IS FOUND IN SAME POSITION ON ALL MASTS COVERED IN THIS MANUAL. 1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILLIMETERS) 2.

  • Page 9: Safety Procedures When Working Near Mast

    4000 SRM 1386 Safety Procedures When Working Near Mast Safety Procedures When Working Near Mast The following procedures MUST be used when in- • If parts of the mast must be in a raised posi- specting or working near the mast. Additional pre- tion, install a safety chain to restrain the cautions and procedures can be required when re- moving parts of the mast.
  • Page 10 Safety Procedures When Working Near Mast 4000 SRM 1386 A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST 1. OUTER MAST 5. FREE-LIFT CYLINDER 2. INNER MAST 6. CARRIAGE BAR 3. INTERMEDIATE MAST 7.
  • Page 11 4000 SRM 1386 Safety Procedures When Working Near Mast NOTE: TWO-STAGE MASTS SHOWN. FOR THREE-STAGE MAST, ALIGN THE CROSSMEMBER OF INTER- MEDIATE WELDMENT ALONG WITH INNER AND OUTER WELDMENTS WHEN CHAINING THE MAST. A. LIMITED FREE-LIFT MAST B. FULL FREE-LIFT MAST 1.

  • Page 12: Fork Replacement

    Fork Replacement 4000 SRM 1386 Fork Replacement WARNING CAUTION DO NOT try to remove a fork without a lifting de- Remove fork latch pins if adding a fork positioner vice. Each hook fork for these lift trucks can attachment. Damage to forks and other carriage weigh 45 to 115 kg (99 to 254 lb).
  • Page 13 4000 SRM 1386 Fork Replacement 1. LOAD BACKREST 6. WEDGE 2. CARRIAGE 7. WASHER 3. FORKS 8. SPRING 4. FORK 9. PIN 5. KNOB 10. FORK REMOVAL NOTCH Figure 5. Carriage and Forks...

  • Page 14: Install

    Fork Replacement 4000 SRM 1386 Move the fork and carriage so the top hook on the fork can engage the upper carriage bar. See Fig- ure 6. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so both upper and lower hooks engage the carriage bars.
  • Page 15 4000 SRM 1386 Fork Replacement Table 1. Fork Tip Alignment Fork Tip Alignment Specifications Standard Fork Maximum Fork Tip Lengths Difference (in.) (in.) (36) (1.08) 1067 (42) (1.26) 1219 (48) (1.44) 1372 (54) (1.62) 1524 (60) (1.80) 1829 (72) (2.16) Difference of alignment between fork tips must be no more than 3% of the total fork length.

  • Page 16: Carriages Repair

    Carriages Repair 4000 SRM 1386 Carriages Repair STANDARD CARRIAGE Remove 1. Remove the forks. See Fork Replacement. 2. Remove four socket head capscrews and remove the load backrest. See Figure 8. 3. Connect a lifting device to the carriage. Lift the carriage so that the lift chains become loose.
  • Page 17 4000 SRM 1386 Carriages Repair NOTE: TWO-STAGE LFL CARRIAGE SHOWN. THREE-STAGE FFL CARRIAGES ARE SIMILAR. 1. SNAP RING 6. SHIM 2. ANCHOR PIN 7. STUBSHAFT 3. COTTER PIN 8. CHAIN PIN 4. CARRIAGE 9. CHAIN ANCHOR 5. LOAD ROLLER Figure 9. Standard Carriage...

  • Page 18: Clean And Inspect

    Improper welding procedures can damage the ing Near Mast. structure of the mast or cause incorrect function of the mast. Consult your Hyster lift truck dealer 6. Move lift truck away from the carriage. Com- for more information before welding on the mast.

  • Page 19: Install

    4000 SRM 1386 Carriages Repair 2. Remove the four capscrews securing the load Install backrest to the carriage. See Figure 8. Remove 1. Connect a crane [the capacity of the crane must the load backrest. be at least 681 kg (1501 lb)] to the top of the in- ner mast.
  • Page 20 Carriages Repair 4000 SRM 1386 NOTE: TWO-STAGE LFL CARRIAGE SHOWN. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY FOR THREE- STAGE FFL IS SIMILAR. 1. CAPSCREW 12. SNAP RING 2. WASHER 13. COTTER PIN 3. FORK REMOVAL NOTCH 14. CHAIN ANCHOR 4. OUTER FRAME 15.

  • Page 21: Disassemble

    4000 SRM 1386 Carriages Repair 6. Use a crane with a capacity of at least Clean and Inspect 450 kg (992 lb) to lift outer frame away from 1. Inspect the lower mounting hooks for wear. Re- the inner frame (see Figure 11). Lay the outer place the hooks if they are worn beyond the frame flat on a pallet or workbench.
  • Page 22 Improper welding procedures can damage the riage. See Figure 13. structure of the mast or cause incorrect function of the mast. Consult your Hyster lift truck dealer b. If either lower bearing is worn to less than for more information before welding on the mast.
  • Page 23 4000 SRM 1386 Carriages Repair A. MINIMUM THICKNESS, 2.5 mm (0.1 in.) 1. LOWER BEARINGS 3. UPPER BEARINGS 2. CARRIAGE BARS *BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE. Figure 13. Checking Upper and Lower Bearings...

  • Page 24: Assemble

    Carriages Repair 4000 SRM 1386 3. Apply a 1 mm (0.040 in.) layer of multipurpose WARNING grease to upper and lower bearing surfaces. In- stall the upper and lower bearings onto the in- Cleaning solvents can be flammable and toxic, ner frame.

  • Page 25: Two-Stage Mast With Limited Free-Lift Repair

    4000 SRM 1386 Two-Stage Mast With Limited Free-Lift Repair Two-Stage Mast With Limited Free-Lift Repair position when the tilt cylinders are disconnec- REMOVE ted. See the section Safety Procedures When Working Near Mast. WARNING The mast is heavy. The mast can weigh approxi- WARNING mately 907 kg (2000 lb).

This manual is also suitable for:

J30-35-40xn

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