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Hyster A254 (AP20Z) Forklift

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Summary of Contents for A254

Page 1: ...Hyster A254 AP20Z Forklift...

Page 2: ...MAST REPAIR S N A615 AP20Z A254 PART NO 4131893 4000 SRM 1916...

Page 3: ...tenance or repair on aerial work platforms Always use correct blocks to prevent the unit from rolling or falling See HOW TO PUT THE LIFT ON BLOCKS in the Operating Manual for your lift Keep the unit c...

Page 4: ...On the lift the DANGER symbol and word are on red background The WARNING symbol and word are on orange background The CAUTION symbol and word are on yellow background...

Page 5: ...ore 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 pl...

Page 6: ......

Page 7: ...Precautions 2 Discharging the Capacitors 2 Description 4 Mast Repair 6 Remove 6 Disassemble 8 Clean and Inspect 15 Assemble 15 Install 20 Mast Adjustments 21 Lateral Mast Adjustment 21 Vertical Mast A...

Page 8: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 9: ...th serial number A615 used on the aerial work platform covered in this manual Procedures to repair the carriage and adjust the lift chains carriage and mast are also covered in this manual Additional...

Page 10: ...er repairs and adjustments can create dangerous operating conditions DO NOT operate an aerial work platform that needs repairs Report the need for repairs to your supervisor immedi ately If repair is...

Page 11: ...are off the floor to prevent aerial work platform from moving 4 Remove the electrical compartment cover to ac cess the combination and traction controller See the Frame manual listed in the General se...

Page 12: ...dment second inter mediate mast weldment third intermediate mast weldment fourth intermediate mast weldment and a carriage weldment fifth intermediate mast weld ment See Figure 4 One main lift cylinde...

Page 13: ...DIATE MAST WELDMENT 2 SECOND INTERMEDIATE MAST WELDMENT 3 THIRD INTERMEDIATE MAST WELDMENT 4 FOURTH INTERMEDIATE MAST WELDMENT 5 CARRIAGE WELDMENT 6 LIFT CYLINDER Figure 4 Mast Weldments 4000 SRM 1916...

Page 14: ...urn off all power to aerial work platform by disconnecting the battery and discharging the capacitors See the Special Precautions section for procedures to discharge the capacitors 9 Zip tie lift cyli...

Page 15: ...CABLE 6 THIRD PHASE CABLE 7 FOURTH PHASE CABLE 8 BRACKET 9 FIRST INTERMEDIATE MAST WELDMENT 10 SECOND INTERMEDIATE MAST WELDMENT 11 THIRD INTERMEDIATE MAST WELDMENT 12 FOURTH INTERMEDIATE MAST WELDMEN...

Page 16: ...k See Parts Manual 2 Remove self tapping screws setscrews and mast slider blocks from top and bottom of car riage weldment See Figure 9 3 Remove two cotter pins and two chain anchor pins and disconnec...

Page 17: ...PANEL 4 MAST SIGNAL CABLE 5 SPRING 6 BRACKET 7 CAPSCREWS 8 WIRE HARNESS CABLE 9 ROUND BELT PULLEY 10 HYDRAULIC TUBE CONNECTION EXCESS FLOW PROTECTOR 11 HYDRAULIC TANK Figure 7 Mast Tensioning System...

Page 18: ...B BOTTOM OF MAST 1 CHAIN ANCHOR 2 CHAIN ANCHOR PIN 3 COTTER PIN 4 LIFT CYLINDER 5 CHAIN RETAINER BLOCK 6 LIFT CHAIN 7 SAIL COVER BRACKET Figure 8 Disconnecting First Set of Lift Chains Mast Repair 400...

Page 19: ...A OUTSIDE VIEW B INSIDE VIEW 1 MAST SLIDER BLOCKS 2 SETSCREWS 3 SELF TAPPING SCREWS Figure 9 Mast Slider Blocks Removal 4000 SRM 1916 Mast Repair 11...

Page 20: ...MUST FACE OUTBOARD SIDE OF MAST DURING INSTALLATION AS SHOWN ABOVE A BOTTOM VIEW OF MAST B TOP VIEW OF MAST 1 COTTER PIN 2 CHAIN ANCHOR PIN 3 LIFT CHAIN 4 CHAIN ANCHOR 5 PIN 6 CHAIN RETAINER BLOCK 7...

Page 21: ...third intermediate mast weldment See Figure 11 24 Using lifting device lift third intermediate mast weldment up and slide it off of second in termediate mast weldment 25 Remove self tapping screws se...

Page 22: ...AIN SHEAVES AND CABLE PULLEYS ON ALL OTHER INTERMEDIATE MAST WELDMENTS ARE SIMI LAR A TOP OF MAST B BOTTOM OF MAST 1 SNAP RING 2 WASHER 3 CABLE PULLEY 4 CHAIN SHEAVE ASSEMBLY SHEAVE SNAP RING AND BEAR...

Page 23: ...elf tapping screws with hand tools and not power tools The use of power tools can strip the self tapping screws and damage them 1 If lift cylinder was removed see the Lift Cylin der Repair manual list...

Page 24: ...se the mast weldments so that the sec ond intermediate mast weldment is flush with the first intermediate mast weldment NOTE Do not adjust setscrews at this moment Start the thread and do not apply pr...

Page 25: ...llation chain anchor pins must face outboard side of mast See Figure 10 22 Install free end of lift chain no chain anchor at tached to chain retainer blocks at top of first intermediate mast weldment...

Page 26: ...mediate mast weldment using snap rings See Figure 11 38 Install two lift chains with a length of 1924 05 mm 75 3 4 in to two chain anchors with two chain anchor pins and two cotter pins See Figure 10...

Page 27: ...oximately 68 kg 150 lb 53 Using a lifting device lift carriage weldment and slide it through mast slider blocks on top of fourth intermediate mast weldment to the posi tion shown in Figure 15 This pro...

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