Hyster F187 Service Manual
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Hyster F187 Service Manual

Mast repairs
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  • Page 1 Hyster F001 (H1.6FT H1.8FT H2.0FTS Europe) Forklift...
  • Page 2 MAST REPAIRS 2, 3, AND 4-STAGE MASTS S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; J1.60-2.00XMT (J30- 40ZT) [J160]; J2.0-3.20XM (J40-65Z) [B416]; E2.00-3.20XM (E45-65Z) [G108] PART NO. 1580524...
  • Page 3 • 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.

  • Page 4: Table Of Contents

    Four-Stage FFL, Assemble..........................Mast, Install..............................Header Hose Arrangement..........................Two-Stage LFL............................... Two-Stage FFL............................... Three-Stage FFL............................Four-Stage FFL ............................. Adjustment..............................Lift Chains Adjustment ............................. Carriage Adjustments............................Tilt Cylinders Adjustment..........................Mast Adjustments.............................. Load Roller Adjustment ..........................Mast Side Kicking Adjustment......................... ©2008 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 Table of Contents Mast Repairs TABLE OF CONTENTS (Continued) This section is for the following models: S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; J1.60-2.00XMT (J30-40ZT) [J160];...

  • Page 7: General

    4000 SRM 1148 Safety Procedures When Working Near Mast General NOTE: For models J1.60-2.00XMT (J30-40ZT) WARNING [J160], this section applies to only to Four-Stage Before working on or near the mast, see Safety masts. Refer to Mast Repairs, 2 and 3-Stage Procedures When Working Near Mast in this Masts 4000 SRM 522 for Two-Stage and Three-Stage section.
  • Page 8 Safety Procedures When Working Near Mast 4000 SRM 1148 Figure 1. Safety Chaining the Mast...

  • Page 9: Fork Repair

    4000 SRM 1148 Fork Repair Legend for Figure 1 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 10: Checks

    Fork Repair 4000 SRM 1148 1. LOAD BACKREST 6. WEDGE 2. CARRIAGE 7. WASHER 3. FORKS 8. SPRING 4. FORK 9. PIN 5. KNOB 10. FORK REMOVAL NOTCH Figure 3. Carriage and Forks CHECKS Table 1. Fork Tip Alignment Fork Tip Alignment Specifications WARNING Never repair damaged forks by heating or Standard Fork...

  • Page 11: Carriages Repair

    4000 SRM 1148 Carriages Repair Legend for Figure 4 A. HEEL OF FORK (MUST BE 90% OF DIMENSION B) B. ORIGINAL FORK THICKNESS (DIMENSION B) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. MAXIMUM ANGLE 93 4.

  • Page 12: Repair

    195 N•m (144 lbf ft). the structure of the mast or cause incorrect ® function of the mast. Consult your Hyster 6. Install the forks. See Fork Repair. lift truck dealer for more information before INTEGRAL SIDESHIFT CARRIAGE welding on the mast.
  • Page 13 4000 SRM 1148 Carriages Repair NOTE: TWO- AND THREE-STAGE FFL IS SHOWN. 1. INNER CARRIAGE 13. PIN 2. OUTER FRAME 14. CHAIN ANCHOR 3. SIDESHIFT CYLINDER 15. SNAP RING 4. UPPER BEARING 16. PIN 5. LOWER BEARING 17. COTTER PIN 6.
  • Page 14 10. HAIRPIN 22. SPACER 11. PIN 23. FORK REMOVAL NOTCH 12. LUBE FITTING Figure 7. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)

  • Page 15: Clean And Inspect

    4000 SRM 1148 Carriages Repair 3. Clean the bearing areas. Inspect the sideshift WARNING bearings for wear as follows: Always wear the proper protective equipment a. Remove the upper bearings from the upper including eye protection and petroleum-resis- apron. If either upper bearing is worn to less tant gloves when handling hydraulic oil.

  • Page 16: Repair

    Improper welding procedures can damage the tween the hydraulic fitting and the end. structure of the mast or cause incorrect func- tion of the mast. Consult your Hyster lift truck Screw the retainer into the cylinder. Tighten dealer for more information before welding on the retainer to 325 ±30 N•m (240 ±25 lbf ft).

  • Page 17: Install

    4000 SRM 1148 Mast Repair Install 3. Use a crane with a capacity of at least 450 kg (992 lb) to install the outer frame on the inner NOTE: Use a wood block or a plastic hammer to fully frame. seat the upper bearings onto the upper carriage bar.
  • Page 18 3. ROD END 8. CAPSCREW 4. PIVOT PIN 9. TILT CYLINDER 5. GREASE FITTING Figure 11. Mast Mounting for Lift Truck Models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) 1. O-RING 7. PIVOT PIN 2. SPACER 8.
  • Page 19 4000 SRM 1148 Mast Repair NOTE: Allow the mast to tilt forward enough to gain access to the mast mount capscrews. 4. Disconnect the lower mast mounts from the lift truck: a. Pivot Pin Connections - Remove the cap- screws that hold the mast pivot pins to the mounts on the drive axle.
  • Page 20 Mast Repair 4000 SRM 1148 1. OUTER MAST 2. BUSHING 3. GREASE FITTING Figure 13. Mast Mounts, Outer Mast 1. HANGER MOUNTS 1. DRIVE AXLE 2. TRACTION MOTOR 2. HANGER MOUNTS Figure 15. Mast Mounting For Lift Truck Model Figure 14. Mast Mounts, Drive Axle J2.00-3.20XM (J40-65Z) (B416)

  • Page 21: Two-Stage Lfl And Two-Stage Ffl Masts, Disassemble

    4000 SRM 1148 Mast Repair lift cylinders and put caps on the open lines. See Figure 17 and Figure 18. 2. Remove the chains and header hoses. On the two-stage FFL mast, remove the brackets and disconnect the hydraulic line for the free-lift cylinder.

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