Hyster A254 Service Manual Download Page 10

WORKING NEAR POWER LINES

  DANGER 

The  lift  is  NOT  insulated  for  use  near  electrical
power  lines  and  DOES  NOT  provide  protection
from  contact  with  or  close  proximity  to  any
electrically  charged  conductor.  Operator  rmust
maintain a safe distance at all times. See Table 1
for  minimum  safe  approach  distances  between
electrical  power  lines  and  lift.  Always  allow  for
operator  compartment  movement  due  to  gusty
winds.  Always  contact  local  power  company
before  working  near  power  lines.  Assume  all
powerlines are live.

  WARNING 

Failure  to  observe  the  following  rules  can  cause
serious  injury  or  death!  Authorized  and  trained
operator only!

Table 1.  Minimum Safety Approach Distance

(MSAD) 

Approach Distances For Qualified

Employees - Alternating Current

Voltage Range

(Phase to Phase)

Minimum Approach

Distance

300V And Less

Avoid Contact

Over 300V,

Not Over 750V

30.5 cm  (1.0 ft)

Over 750V,

Not Over 2kV

46.0 cm  (1.6 ft)

Over 2kV,

Not Over 15kV

61.0 cm  (2.0 ft)

Over 15kV,

Not Over 37kV

91.0 cm  (3.0 ft)

Over 37kV,

Not Over 87.5kV

107.0 cm  (3.6 ft)

Over 87.5kV,

Not Over 121kV

122.0 cm  (4.0 ft)

Over 121kV,

Not Over 140kV

137.0 cm  (4.6 ft)

Special Precautions

DISCHARGING THE CAPACITORS

  WARNING 

DO NOT make repairs or adjustments unless you
have  been  properly  trained  and  authorized  to  do
so.  Improper  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 necessary, attach a DO NOT OP-
ERATE  tag  to  the  control  handle  and  disconnect
the battery. DO NOT place tools on top of the bat-
tery. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.

Some checks and adjustment are performed with
the  battery  connected.  DO  NOT  connect  the  bat-
tery  until  the  procedure  instructs  you  to  do  so.
Never  wear  any  metallic  items  on  your  fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.

Before performing any tests or adjustment, block
the  aerial  work  platform  to  prevent  unexpected
movement.

The  capacitor  in  the  transistor  controller(s)  can
hold  an  electrical  charge  after  the  battery  is  dis-
connected.

To avoid injury and prevent electrical shock, per-
form the following steps before doing any trouble-
shooting,  adjustments,  connecting,  or  discon-
necting a handset or PC:

1. Block the platform so that the drive wheels

are off the floor. See the Operator's Manual.

2. Turn the key switch to the OFF position.
3. Discharge the capacitors in the controllers.

DO  NOT  short  across  the  motor  controller
terminals with a screwdriver or jumper wire.
Remove the 200-ohm, 2-watt resistor before
reconnecting the battery.

General

4000 SRM 1916

2

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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