Hyster B495 (W30ZA2) Forklift Service Repair Manual

SERVICE REPAIR

General

Thismanualhastheremoval,installation,andadjustmentproceduresforthetwo-stage(limitedfreelift)andthree-stage(fullfree-lift)masts.Thedescriptionandoperationofthemastsareoutlinedin thesection Mast, Description 4000SRM480.A troubleshootingchartislistedattheendofthissection.Repairproceduresforthereachcarriagesare coveredinthesection ReachCarriages 4500SRM 483or ReachCarriages 4500SRM971.Repairproceduresfortheattachmentcarriagearecoveredin Attachment 5000SRM580.

Thesemastassembliesandcarriageshavewear plugsandcanhavewearstripstoallowforwearand adjustment.Thewearplugsareinthestubshafts oftheloadrollersandslideagainstthecenterofthe channel.Asetscrewandjamnutkeepeachwear pluginthecorrectposition.Theloadrollerstake theforwardandbackstressloadsduringoperation ofthemast.Theloadrollershaveballbearingswith greaseseals.Thewearstripsaremadeofafriction materialandslideagainsttheoutsideedgeofthe channelflange.

WARNING

Themastandcarriageassemblies,andtheir components,areheavy.Tohelppreventdamageoraninjury,aliftingdevicemustbeused duringallserviceprocedures.

Themastassembliesmusthavethemastweldments parallelwithequalclearanceoneachsidebetween allweldments.Correctoperationalsodependson periodiccleaning,lubrication,andadjustment.See MastOperationCheck,HydraulicSystemLeaks Check,LiftChainsCheck,MastAdjustments,and CarriageAdjustmentsattherearofthissection.

NOTE: Forthecorrectmaintenanceandinspection proceduresforthemasts,hydrauliccylinders,forks, chains,andcarriagesforyourlifttruck,seethe section PeriodicMaintenance 8000SRM1027, PeriodicMaintenance 8000SRM555, Periodic Maintenance 8000SRM1379,or PeriodicMaintenance 8000SRM970.

NOTE: Thestandardcarriage,thereachcarriage, andtheattachmentcarriagecanberemovedfrom themastassemblywiththeloadbackrestextension andforksattached.Boththetwo-stageandthreestagemastassemblycanalsoberemovedwiththe carriageinstalled.Itisrecommendedthattheattachmentcarriageberemovedpriortoremovingthe three-stagemastassembly.Doonlythoseprocedures necessaryforyourrepair.

SafetyProceduresWhenWorkingNearMast

ThefollowingproceduresMUSTbeusedwheninspectingorworkingnearthemast.Additionalprecautionsandprocedurescanberequiredwhenrepairingorremovingthemast.

WARNING

Mastpartsareheavyandcanmove.Distances betweenpartsaresmall.Seriousinjuryor deathcanresultifpartofthebodyishitby partsofthemastorthecarriage.

•Neverputanypartofthebodyintoorunder themastorcarriageunlessallpartsofthe mastorcarriagearecompletelyloweredor asafetychainisinstalled.

•Makesurethatthepowerisoffandthekey isremoved.PutaDONOTOPERATEtagin theoperator’scompartment.Disconnectthe batteryandputatagorlockonthebattery connector.

•Becarefuloftheforks.Whenthemastis raised,theforkscanbeataheighttocause aninjury.

•DONOTclimbonthemastorlifttruckatany time.Usealadderorpersonnellifttowork onthemast.

•DONOTuseblockstosupportthemastweldmentsnortorestraintheirmovement.

•Mastrepairsrequiredisassemblyandremovalofpartsandcanrequireremovalof themastorcarriage.Followtherepairproceduresinthismanual.

WHENWORKINGNEARTHEMAST,ALWAYS:

•Lowerthemastandcarriagecompletely. Pushthelift/lowercontrolandmakesure thereisnomovementinthemast.Release thelift/lowercontrol.Makesureallpartsof themastthatmovearefullylowered. OR

•Ifpartsofthemastmustbeinaraisedposition,installasafetychaintorestrainthe movingpartsofthemast.Connectmoving partstoapartthatdoesnotmove.Follow theseprocedures:

NOTE: Mastoperatorguardmustberemovedtoinstallsafetychain.Removesafetychainandinstall theguardafterrepairsarecomplete.

1. Raisethemasttoalignthebottomcrossmemberoftheweldmentthatmovesintheouter weldmentwithacrossmemberontheouter weldment.Onthetwo-stagemast,themoving partistheinnerweldment.Onthethree-stage mast,itistheintermediateweldment.SeeFigure1.

2. Usea3/8-inchminimumsafetychainwitha hooktofastenthecrossmemberstogethersothe movablemembercannotlower.Putthehookon thebacksideofthemast.Makesurethehook iscompletelyengagedwithalinkinthechain. Makesurethesafetychaindoesnottouchlift chains,chainsheaves,tubes,hoses,fittings,or otherpartsonthemast.

3. Lowerthemastuntilthereistensionin thesafetychainandthefree-liftcylinder (three-stagemastonly)iscompletelyretracted. Movethekeytothe OFF positionandremove thekeyfromthekeyswitch.Puta DONOT OPERATE tagintheoperator’scompartment. Disconnectthebatteryandputatagorlock onthebatteryconnector.Installa DONOT REMOVE tagonthesafetychain(s).

4. Installanothersafetychain(3/8-inchminimum) betweenthetoporbottomcrossmemberofthe carriageandacrossmemberontheouterweldment.

TWO-STAGEMAST

LoadBackrestExtension,Carriage,LoadRollers, SideRollers,andForks

LOADBACKRESTEXTENSION,REMOVE ANDINSTALL

1. Loosenthetwouppercapscrewsthatfastenthe loadbackrestextensiontothecarriage.

2. Removethesetwocapscrewsandlaytheload backrestextensionontheforks.

3. Removethetwolowercapscrewsthatfastenthe loadbackrestextensiontothecarriage.

4. Lifttheloadbackrestextensionofftheforks.

5. Reversetheproceduretoinstalltheloadbackrest extension.Tightenthecapscrewsto203N•m (150lbfft).

CARRIAGEASSEMBLY,REMOVEAND INSTALL

Seethesection Attachment 5000SRM580or Attachment 5000SRM1254toremoveandinstallthe attachmentcarriage.

NOTE: Thecarriagecanberemovedwiththeforks andloadbackrestextensionattachedorwiththe forksandloadbackrestremoved.Doonlythose proceduresnecessaryforyourrepair.SeeFork, Replacetoremovetheforks.SeeLoadBackrest Extension,RemoveandInstalltoremovetheload backrestextension.

NOTE: Mostrepairsofthereachcarriagecanbecompletedwithoutremovingitfromthemast.Seethe section ReachCarriages 4500SRM483or Reach Carriages 4500SRM971forrepairprocedures.

Figure1.SafetyChaintheMast,TypicalMast

ReadandfollowtheSafetyProceduresWhenWorkingNearMast,aswellasall WARNINGSandCAUTIONS.

Removethecarriageasfollows:

1. Onreachunits,operatetheREACH/RETRACT controlbuttontoretracttheforksfully.Install safetychainssothattheforkscannotextend.Installthesafetychainsaroundthecenterplates ofthescissorarmweldmentandacrossmember ofthemast.Makesureasafetychaindoesnot touchthemountforthehosesheave,liftchains, chainorhosesheaves,hoses,tubes,orfittings.

2. OperatetheLIFT/LOWERcontroltoraisethe carriageassemblyuntilthethrustrollersofthe

innerframe(reach)orthecarriageframeare abovethetopoftheouterweldment.

3. Movethekeytothe OFF positionanddisconnect thebattery.Removetheoperatorguardfromthe mastassembly.

4. Usesafetychainstofastenthemovablemember ofthemasttotheouterweldmentsothatitcannotmove.

5. Removethesnaprings,washers,thrustrollers, andspacers.Forstandardunits,seeFigure2. Forreachunits,seeFigure3.

Figure2.TypicalStandardCarriage

WARNING

Liftchains,hoses,andcablescanrolloverthe sheavestofallandcauseaninjuryiftheends arenotfastened.Keepcontroloftheendsof theliftchains,hoses,andcablesastheyare removed.Usewiretoconnecttheendsofthe liftchains,hoses,orcabletemporarilytothe masts.

6. Onthree-stagemasts,removethesafetychains installedinStep4.Lowerthecarriageassembly foraccesstothechainanchorsatthebackofthe free-liftcylinder.Usesafetychainstofastenthe movablememberofthemasttotheouterweldmentsothatitcannotmove.Movethekeytothe OFF positionanddisconnectthebattery.

cannottipasitisremovedfromthemastweldment.Fastenthechainstotheliftingeyeson reachunits.Fastenthechainsorslingstothe carriageframeonstandardunits.Usethecrane toraisethecarriageassemblysotheliftchains becomeloose.

8. Disconnectthehydrauliclines(sideshiftorreach only)atthecarriage.Puttagsonthefittings forcorrectconnectionduringinstallation.Make suretoputcapsontheopenfittingstokeepdirt outofthesystem.Disconnecttheelectricalconnections(reachonly)attheselectorvalve.

NOTE: Removingthepinsatthechainanchors willdisconnecttheliftchainswithoutchangingthe chainadjustment.Alwaysadjustthechainsifnew liftchainsorothercomponentsareinstalled.

9. Holdtheliftchainstokeepthemfromfalling. Removethepinsinthechainanchorsattheback oftheouterweldmentoftwo-stagemasts.Removethepinsinthechainanchorsattheback ofthefree-liftcylinderofthree-stagemasts. Disconnecttheliftchains.Carefullymovethe liftchainsthroughthesheavesandlaythelift chainsoverthecarriage.

WARNING

Thecarriageassemblyisheavyandcancause aninjuryifittipsorfalls.Makesurethecarriageassemblyhasstabilityduringandafter removal.

CAUTION

Donotdamageliftchains,hoses,orelectrical cablesasthecarriageassemblyisliftedoutof themastweldment.

10. Carefullyliftthecarriageassemblyoutofthe channelsoftheinnerweldment.Carefullylower thecarriageassemblytothefloor.

WARNING

Makesurethatthecarriagehasstabilityand cannotfalltocauseaninjury.Iftheforksare removed,putthecarriageonthefloorsothat theloadrollersareup.

NOTE: Thecarriagesiderollersmustbeadjusted whilethecarriageisoutofthemast.Adjusttheside rollersasdescribedinAdjustSideRollers-Carriage beforeinstallingthecarriage.

Figure3.InnerFrameAssembly(Reach Carriage)

7. Onreachunits,installliftingeyesinthecarriage assemblyforchainsorslings.Fastenchainsor slingstothecarriageassemblysothecarriage

11. Toinstallthecarriageassembly,reversetheremovalprocedures.Alwaysusenewcotterpins wheninstallingtheliftchains.ApplyLoctite™ tothestudsofthethrustrollersduringinstallation.

12. Adjustthecarriageassembly.SeeCarriageAdjustments.Testthecarriageassemblyforcorrect operation.

CARRIAGELOADROLLERS,REMOVE ANDINSTALL

1. Removethecarriageassemblyfromthemastassemblytoremoveandinstallthecarriageload rollers.SeeCarriageAssembly,RemoveandInstall.

2. Removethejamnutsandsetscrewsfortheload rollers.SeeFigure4.

5. Useaprybartoremovetheloadrollerfromthe stubshaftfortheloadroller.SeeFigure5.

6. Useaclothtocleaneachloadroller.Inspectthe loadrollersforcracks,flatspots,orbearingsthat donotturnfreely.Replaceanyrollerthatshows wearorisdamaged.

7. Installthecarriage.SeeCarriageAssembly,RemoveandInstall.

8. Adjustthecarriage.SeeCarriageAdjustments.

1.LOADROLLERWITHSNAPRINGREMOVED

2.PRYBAR

3.MASTORCARRIAGECOMPONENT(CARRIAGE SHOWN)

4.SIDEROLLER

Figure5.RemovingLoadRoller SIDEROLLERS,DISASSEMBLEAND ASSEMBLE

1. Removethecarriageassemblyfromthemastto replacethesiderollers.SeeCarriageAssembly, RemoveandInstalltoremovethecarriage.See Figure2andFigure3.

2. Removethecapscrewsthatfastenthesideroller bracket.

NOTE: Observethepositionoftheshims.

3. Inspectandreplacealldamagedorwornparts.

4. Removethesnapringsfromthestubshaftforthe loadroller.

3. Ifnecessary,replacethewearplugsbypushing atthebackofthewearplug.

4. Reversetheproceduretoinstallthesiderollers. Adjustthecarriagesiderollersduringassembly. SeeCarriageAdjustments.

NOTE: Toremoveandreplaceloadrollers,wear plugs,weldments,orliftcylinders,itisnecessaryto removethetwo-stagemastassemblyfromthetruck.

FORK,REPLACE

ReadandfollowtheSafetyProceduresWhenWorkingNearMast,aswellasall WARNINGSandCAUTIONS.

Hook-TypeForks

WARNING

Forksareheavyandcancauseaninjury.Do nottrytoremoveforkswithoutusingalifting device.

Theseforksareconnectedtothecarriagebyhooks. SeeFigure6.Latchpinsfitthroughthetopfork hooksandintoslotsonthetopcrossmemberofthe carriagetokeeptheforksinposition.

Figure6.Forks

LegendforFigure6 A.

1.FORK

2.LATCHPIN

3.SPRING

4.WASHER

5.WASHER

Remove

Liftthelatchleverandslidetheforktotheforkremovalnotchonthecarriage.Theremovalnotchisin thebottomcrossmemberofthecarriageasshownin Figure2.Lowerthecarriagewithablockunderthe forkorraisetheforktip.SeeFigure7.Thebottom hookoftheforkwillmovethroughtheforkremoval notch.Lowerthecarriagefurtherorraisetheforkso thatthetophookoftheforkisdisengagedfromthe topcrossmember.Movethecarriageawayfromthe fork,orusetheliftingdevicetomovetheforkaway fromthecarriage.Followthesameproceduretoremovetheotherfork.

Install

Movetheforkorcarriagesothatthetophookon theforkengagesthetopcrossmemberofthecarriage. Raisethecarriageorlowertheforktomovethelower hookthroughtheremovalnotch.Slidetheforkon

REMOVE

6.WEDGE

7.KNOB

8.LEVER

9.ROLLPIN

10.LATCHPINASSEMBLY

thecarriagesothatbothupperandlowerhooksare engagedandthelatchpinengagesanotch.

1.CARRIAGEBARS

2.HOOKFORK

3.BLOCKS

Two-StageMastAssembly

ReadandfollowtheSafetyProceduresWhenWorkingNearMast,aswellasall WARNINGSandCAUTIONS.

NOTE: If the mast assembly will be disassembled after it is removed from the truck, first removethe standardcarriageorthereachcarriageasacomplete assembly.SeeCarriageAssembly,RemoveandInstall.Ifthereachcarriagewillberemovedwith the mastassembly,operatetheREACH/RETRACTcontrolbuttontoretracttheforksfully.Installsafety

chainssothattheforkscannotextend.Installthe safetychainsaroundthecenterplatesofthescissorarmweldmentandacrossmemberofthemast. Makesureasafetychaindoesnottouchthemount forthehosesheave,liftchains,chainorhosesheaves, hoses,tubes,orfittings.Ifinstalled,operatethe SIDESHIFTcontroltomovethesideshiftframeto thecenterposition.

Figure7.HookForkRemoval

1. Removethecapscrewsandnutsthatfastenthe operatorguardandremovetheguard.SeeFigure8orFigure9.

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CAUTION

DONOTmovethecontrolbuttonforthereach, retract,tilt,orsideshiftfunctions.Oilwillflow fromthehosesforthesefunctions.

4. Installsafetychainstokeepthemastcomponentsfrommoving.Removethecapscrews, washers,andclampsthatfastentheliftcylinder hosestothemastweldments.DONOTdisconnectanyhydraulicfittings.

5. RemovethesafetychainsinstalledinStep4.Do notdamagehydraulichosesasthemastlowers. CarefullyoperatetheLIFT/LOWERcontrolto lowertheinnerweldmentfully.Makesurethat allhydraulicpressureisremovedfromthesystembyholdingthecontrolintheLOWERpositionforapproximately5seconds.

4.LEGCAPSCREW 5.MASTOPERATOR GUARD 6.CAPSCREW

Figure8.OverheadGuardandOperator GuardNarrowAisleTrucks

2. FortheNarrowAislelifttrucks,removethecapscrewsthatfastentherearlegstotheoverhead guard.SeeFigure8.Theoverheadguardwillbe removedwiththemastassembly.

3. OperatetheLIFT/LOWERcontroltoraisetheinnerweldmentforaccesstothefourcapscrews, theshims,andthenutplatesthatfastenthebottomoftheouterweldmenttothetruckframe. SeeFigure10orFigure11.

1.OPERATOR GUARD

2.CAPSCREW

Figure9.OperatorGuardWalkieHighLift Trucks

Figure10.Two-StageMastAssembly(Dual-LiftCylinders)

NOTE: Onmodelswithtrunnioncaps,markthetrunnioncapssotheycanbereassembledinthesamepositionandonthesametrunnionfromwhichtheyare removed.

6. Usechainstoconnectacraneorotherliftingdevicetothetopofthemastassembly.Makesure thechainswillnotdamagethesheavesorother partsofthemastassembly.Makesurethechains andcranehavethecapacitytoliftapproximately 2000kg(4409lb).Usesafetychainstofasten allthemastweldmentstogethersotheycannot move.Ifthereachcarriageisinstalled,install achainorslingtothereachcarriagetokeep themastassemblyfromtippingduringremoval. Removethehardwaresecuringthemasttothe frame.

7. Operatethecraneuntilitgivessupporttothe weightofthemastassembly.Movethecraneto apositionsothatthemastassemblywillbelifted vertically.Raisethemastassemblyhighenough toclearthetrunnions.Movethemastassembly approximately30cm(1ft)awayfromthetruck foraccesstothehoses.

8. Installlabelsonallplugsandwiresfortheelectricalcableforcorrectconnectionduringinstallation.Disconnecttheplugsandwiressothatthe cableiscompletelydisconnectedfromthetruck. Theplugsarenearthecabletensiondeviceinside theelectricalcompartmentabovethebattery.

9. Movethemastassemblyawayfromthetruck.

NOTE: Todisassemblemodelswithanoverhead guard,positionthemastwiththeoverheadguard onthebottomasasupport.Installasecuresupport undertheotherend.Makesurethemastislevel. Keepthesafetychainsinstalled.

10. Ifthemastwillbedisassembled,positionthe mastwiththecarriageupacrosswoodenbeams onalevelfloorMakesurethemastislevel.Keep thesafetychainsthatwereinstalledinStep6on themastassembly.

11. IfthemastwillNOTbedisassembled,position themastacrossbeamsonalevelfloorwiththe overheadguardontop.

CLEANANDINSPECT

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Wearprotection foreyesandskin.Whenusingcleaningsolvents,alwaysfollowtherecommendationsof themanufacturer.

CAUTION

DONOTusesteamtocleantheliftchains, sheaves,orloadrollers.Thesheavesand rollerbearingsaresealedandpermanently lubricated. Donotusecompressedaironthe bearings.Theaircanforcethelubricantout ofthebearings.

1. Cleanthemastweldmentswithsteamorsolvent.

WARNING

Somepartsmaybedamagedbywelding.To preventaninjury,alwaysgetauthorization fromyourdealerforHysterlifttrucksbefore weldingonthemast,forks,orcarriage.

2. Inspecttheslidingandrollingsurfacesofthe channelsfordamage(dents)andwear(grooves). Inspectallweldsforcracks.

Figure11.Two-StageMastAssembly(Single-LiftCylinder)

NOTE: Itisnecessarytoremovethemastassembly fromthetrucktoremovetheliftcylinders.

1. RemovethemastassemblyasdescribedinRemove.

WARNING

Themastweldmentscanmoveandcausean injuryevenifthemastassemblyhasbeenremovedfromth elifttruck.Makesurethemast assemblyis leveltopreventthecomponents frommoving withoutbeingmoved.Usesafety chainstopreventmovementaftercomponents areinthecorrectposition.

2. Removethesafetychainsthatfastenthemast weldments togetheranduseaprybartomove theinnerweldmentapproximately75mm(3in.) outoftheouterweldmentcarefullyandslowly.

3. Removethe capscrews,washers,andlockplate atthebase oftheliftcylinder.

WARNING

Becarefulwhenremovingorinstallingsnap rings.Thesesnapringsarelargeandcan comelooseduringremovalorinstallationwith enoughforcetocauseaninjury.Alwaysuse thecorrectsnapringpliersandweareyeand faceprotectionduringremovalorinstallation.

4. Removethesnapring,backupwasher,rubber bushing,andshims(ifapplicable)thatfastenone cylinderrodtotheinnerweldment.SeeFigure12.Ifshimsareused,makeanoteofthe shimarrangement.Normally,theshimarrangementforthereplacementcylinderwillbesimilar.

5. Removethehoseortubebetweentheliftcylinder andtheflowregulator.SeeFigure10.Installa capontheregulatorfittingtopreventleakage.

1.INNERWELDMENT

2.LIFTCYLINDER

6.RUBBERBUSHING

7.SHIMS(IF REQUIRED)

8.RETAINER

9.LOCKPLATE

Figure12.LiftCylinderRemoval

6. Installaslingandcranetosupportthecylinder. Removetheliftcylinderretainer,capscrews,and washers.

7. Pushthecylindertowardthetopofthemastassemblytomovetheliftcylinderoffthelocating dowelpin.Continuetopushthecylindersothat therodmovesintothecylindertoallowremoval fromtheinnerweldment.

8. RepeatStep2throughStep7toremovetheother liftcylinder.

NOTE: Seethesection LiftCylinders 4000SRM481 todisassembleandrepairthecylinder.

9. Reversetheproceduretoinstalltheliftcylinders.

LIFTCYLINDER,REMOVEANDINSTALL SINGLEMAIN-LIFTCYLINDERS

Forthefollowinginstructions,refertoFigure13and Figure14.

Figure13.LiftChainsandSheaves,Single-Lift Cylinder

Figure14.Two-StageSingle-LiftCylinderHydraulicConnections