Hyster (E138) N30XMR Forklift Service Repair Manual

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.

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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.

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)