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General

  WARNING 

DO  NOT  operate  an  aerial  work  platform  that
needs  repairs.  If  a  repair  is  necessary,  put  a  DO
NOT OPERATE tag on the control handle. Remove
the key from the key switch.

  WARNING 

Always  disconnect  and  separate  the  battery
connector  so  that  the  connector  is  completely
free  before  performing  any  service  or  repairs.  If
the  connector  is  not  completely  free,  it  can
reconnect.  Tag  the  connector  saying  DO  NOT
CONNECT.

  WARNING 

The  mast  and  carriage  assemblies,  and  their
components,  are  heavy.  To  help  prevent  damage
or an injury, a lifting device must be used during
all  service  procedures.  The  mast  and  carriage
weighs approximately 318 kg (700 lb).

This section has the repair procedures for the mast
with 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 information concerning the mast may be
included in other sections when the information is
more closely related to other systems. Sections that
may contain related information include:

Periodic Maintenance 8000SRM1918

Operator Compartment 0100SRM1915

Lift Cylinders 2100SRM1914

Electrical System 2200SRM1913

Hydraulic System 1900SRM1911

Throughout this section, forward will refer to travel
in the direction of the aerial work platform and left
and right will be determined by the point of view of
an operator situated in the operator compartment
and facing the aerial work platform. See Figure 1.

A.

LEFT SIDE

B.

RIGHT SIDE

C.

FORWARD TRAVEL

Figure 1. Aerial Work Platform Orientation

4000 SRM 1916

General

1

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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