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4000 SRM 482

Two-Stage Mast Assembly

Legend for Figure 11

1.

INNER WELDMENT

2.

OUTER WELDMENT

3.

BUSHING

4.

SCREW

5.

NUT

6.

LOAD ROLLER

7.

SNAP RING

8.

PLUG

9.

PIN

LIFT CYLINDERS, REMOVE AND INSTALL
DUAL-LIFT CYLINDERS

NOTE:

It is necessary to remove the mast assembly

from the truck to remove the lift cylinders.

1.

Remove the mast assembly as described in Re-
move.

WARNING

The mast weldments can move and cause an
injury even if the mast assembly has been re-
moved from the lift truck. Make sure the mast
assembly is level to prevent the components
from moving without being moved. Use safety
chains to prevent movement after components
are in the correct position.

2.

Remove the safety chains that fasten the mast
weldments together and use a pry bar to move
the inner weldment approximately 75 mm (3 in.)
out of the outer weldment carefully and slowly.

3.

Remove the capscrews, washers, and lock plate
at the base of the lift cylinder.

WARNING

Be careful when removing or installing snap
rings.

These snap rings are large and can

come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers and wear eye and
face protection during removal or installation.

4.

Remove the snap ring, backup washer, rubber
bushing, and shims (if applicable) that fasten one
cylinder rod to the inner weldment.

See Fig-

ure 12. If shims are used, make a note of the
shim arrangement. Normally, the shim arrange-
ment for the replacement cylinder will be similar.

5.

Remove the hose or tube between the lift cylinder
and the flow regulator. See Figure 10. Install a
cap on the regulator fitting to prevent leakage.

1.

INNER WELDMENT

LIFT CYLINDER

3.

OUTER
WELDMENT

4.

SNAP RING

5.

WASHER

6.

RUBBER BUSHING

7.

SHIMS (IF
REQUIRED)

8.

RETAINER

9.

LOCK PLATE

Figure 12. Lift Cylinder Removal

13

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Summary of Contents for MAST N30XMH

Page 1: ...40 45FR D138 N30XMH N30XMH2 C210 N25XMDR3 N30 40XMR3 C470 N50XMA3 C471 N30XMDR3 N45XMR3 G138 N30XMXDR3 N45XMXR3 B264 W30 40ZA B453 W20 30ZR B455 W25 30 40ZC B454 W25 30ZA2 B495 V30ZMD D210 E210 PART NO 897447 4000 SRM 482 ...

Page 2: ...ecifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follow the WARNING and CAUTION notes in the instructions Gasoline Liquid Petroleum Gas LPG Compressed Natural Gas ...

Page 3: ...heave Remove and Install 19 Load Rollers and Wear Plugs Remove and Install 20 Two Stage Mast Assembly Install 21 Three Stage Mast Assembly 22 Three Stage Mast Assembly Remove 22 N30XHM N30XMH2 C210 and V30ZMD D210 E210 Only 25 Clean and Inspect 25 Free Lift Cylinder Remove and Install 26 Main Cylinders Standard Remove and Install 28 Main Cylinders N30XMH N30XMH2 C210 and V30ZMD D210 E210 Remove an...

Page 4: ... Stage 41 Three Stage 42 Adjust Wear Strips 42 Carriage Adjustments 43 Adjust Wear Plug Carriage 43 Adjust Side Rollers Carriage 43 Adjust Thrust Rollers Carriage 44 Troubleshooting 45 This section is for the following models N50FA N40 45FR D138 N30XMH N30XMH2 C210 N25XMDR3 N30 40XMR3 C470 N50XMA3 C471 N30XMDR3 N45XMR3 G138 N30XMXDR3 N45XMXR3 B264 W30 40ZA B453 W20 30ZR B455 W25 30 40ZC B454 W25 3...

Page 5: ...dge of the channel flange WARNING The mast and carriage assemblies and their components are heavy To help prevent dam age or an injury a lifting device must be used during all service procedures The mast assemblies must have the mast weldments parallel with equal clearance on each side between all weldments Correct operation also depends on periodic cleaning lubrication and adjustment See Mast Ope...

Page 6: ... Release the lift lower control Make sure all parts of the mast that move are fully lowered OR If parts of the mast must be in a raised po sition install a safety chain to restrain the moving parts of the mast Connect moving parts to a part that does not move Follow these procedures NOTE Mast operator guard must be removed to in stall safety chain Remove safety chain and install the guard after re...

Page 7: ...sion to the carriage 4 Lift the load backrest extension off the forks 5 Reverse the procedure to install the load backrest extension Tighten the capscrews to 203 N m 150 lbf ft CARRIAGE ASSEMBLY REMOVE AND INSTALL See the section Attachment 5000 SRM 580 or At tachment 5000 SRM 1254 to remove and install the attachment carriage NOTE The carriage can be removed with the forks and load backrest exten...

Page 8: ...the LIFT LOWER control to raise the carriage assembly until the thrust rollers of the inner frame reach or the carriage frame are above the top of the outer weldment 3 Move the key to the OFF position and disconnect the battery Remove the operator guard from the mast assembly 4 Use safety chains to fasten the movable member of the mast to the outer weldment so that it can not move 5 Remove the sna...

Page 9: ...nly at the carriage Put tags on the fittings for correct connection during installation Make sure to put caps on the open fittings to keep dirt out of the system Disconnect the electrical con nections reach only at the selector valve NOTE Removing the pins at the chain anchors will disconnect the lift chains without changing the chain adjustment Always adjust the chains if new lift chains or other...

Page 10: ...ace the wear plugs by pushing at the back of the wear plug 4 Remove the snap rings from the stub shaft for the load roller 5 Use a pry bar to remove the load roller from the stub shaft for the load roller See Figure 5 6 Use a cloth to clean each load roller Inspect the load rollers for cracks flat spots or bearings that do not turn freely Replace any roller that shows wear or is damaged 7 Install ...

Page 11: ...sary to remove the two stage mast assembly from the truck FORK REPLACE Read and follow the Safety Procedures When Work ing Near Mast as well as all WARNINGS and CAU TIONS Hook Type Forks WARNING Forks are heavy and can cause an injury Do not try to remove forks without using a lifting device These forks are connected to the carriage by hooks See Figure 6 Latch pins fit through the top fork hooks a...

Page 12: ...e lower hook through the removal notch Slide the fork on the carriage so that both upper and lower hooks are engaged and the latch pin engages a notch 1 CARRIAGE BARS 2 HOOK FORK 3 BLOCKS Figure 7 Hook Fork Removal Two Stage Mast Assembly REMOVE Read and follow the Safety Procedures When Work ing Near Mast as well as all WARNINGS and CAU TIONS NOTE If the mast assembly will be disassembled af ter ...

Page 13: ...weldment for access to the four capscrews the shims and the nutplates that fasten the bot tom of the outer weldment to the truck frame See Figure 10 or Figure 11 1 OPERATOR GUARD 2 CAPSCREW Figure 9 Operator Guard Walkie High Lift Trucks 4 Install safety chains to keep the mast compo nents from moving Remove the capscrews washers and clamps that fasten the lift cylinder hoses to the mast weldments...

Page 14: ...Two Stage Mast Assembly 4000 SRM 482 Figure 10 Two Stage Mast Assembly Dual Lift Cylinders 10 ...

Page 15: ... 8 Install labels on all plugs and wires for the elec trical cable for correct connection during installa tion Disconnect the plugs and wires so that the cable is completely disconnected from the truck The plugs are near the cable tension device inside the electrical compartment above the battery 9 Move the mast assembly away from the truck NOTE To disassemble models with an overhead guard positio...

Page 16: ...Two Stage Mast Assembly 4000 SRM 482 Figure 11 Two Stage Mast Assembly Single Lift Cylinder 12 ...

Page 17: ... out of the outer weldment carefully and slowly 3 Remove the capscrews washers and lock plate at the base of the lift cylinder WARNING Be careful when removing or installing snap rings These snap rings are large and can come loose during removal or installation with enough force to cause an injury Always use the correct snap ring pliers and wear eye and face protection during removal or installati...

Page 18: ...on Lift Cylinders 4000 SRM 481 to disassemble and repair the cylinder 9 Reverse the procedure to install the lift cylinders LIFT CYLINDER REMOVE AND INSTALL SINGLE MAIN LIFT CYLINDERS For the following instructions refer to Figure 13 and Figure 14 Figure 13 Lift Chains and Sheaves Single Lift Cylinder Legend for Figure 13 1 SNAP RING 2 CAPSCREW AND LOCKWASHER 3 SUPPORT BRACKET 4 SHAFT 5 SPACER 6 S...

Page 19: ... and allow excess oil to drain into drip pan CAUTION To prevent dirt or contaminants from entering the hydraulic system always install caps on the tube and flow regulator 11 Remove hydraulic tube from lift cylinder Install caps on the tube and flow regulator 12 Clean up spilled oil 13 Remove lift chains from cylinder and chain sheaves 14 Install a sling around the cylinder at the chain weldment 15...

Page 20: ...OSES REPLACE Read and follow the Safety Procedures When Work ing Near Mast as well as all WARNINGS and CAU TIONS 1 To replace any hydraulic hoses fully lower the carriage See Figure 10 and Figure 15 Make sure that the system does not have hydraulic pressure Hold the control for each function in the forward position for approximately 5 seconds to release the pressure Make sure the hydraulic pump do...

Page 21: ...4000 SRM 482 Two Stage Mast Assembly Figure 15 Hose and Cable Assemblies Two Stage Mast Dual Lift Cylinders 17 ...

Page 22: ... the battery and put a tag or lock on the battery connector 2 Fasten the hoses to the top of the inner mast at the sheaves Disconnect or remove the hoses at the carriage Install hose caps to prevent dirt from entering the hydraulic system 3 Disconnect the spring of the tension device for the electrical cable Fasten the cable to the top of the inner mast at the sheave Install tags on the wires of t...

Page 23: ...ing Near Mast as well as all WARNINGS and CAU TIONS 1 Operate the LIFT LOWER control to raise the carriage so the forks are approximately 150 mm 6 in off the floor See Figure 16 Use safety chains to fasten the carriage to the outer weld ment so it cannot move 2 Lower the carriage so the safety chains are the support for the carriage and the lift chains do not have tension WARNING Keep control of t...

Page 24: ...ner mast load rollers are at the bottom The outer mast load rollers are at the top Use safety chains to fasten the inner weldment to the outer weldment so they do not separate completely WARNING Be careful when removing or installing snap rings These snap rings are large and can come loose during removal or installation with enough force to cause an injury Always use the correct snap ring pliers a...

Page 25: ...l the capscrews but leave them loose 5 Connect all the wires of the electrical cable ac cording to the labels made during removal CAUTION Install tape on all electrical wires for the reach carriage if the wires are not connected to the carriage If the wires are not connected they can make a short circuit and cause damage 6 Operate the LIFT LOWER control to raise the inner weldment for access to th...

Page 26: ...om the hoses for these functions 3 Operate the LIFT LOWER control to raise the inner weldment high enough to remove the four capscrews shims and nutplates that fasten the bottom of the mast to the truck frame See Fig ure 10 4 Install safety chains to keep the mast compo nents from moving Remove the capscrews washers and clamps that fasten the lift cylinder hoses to the mast weldments Do NOT discon...

Page 27: ...4000 SRM 482 Three Stage Mast Assembly Figure 18 Three Stage Mast Assembly 23 ...

Page 28: ...10 CHAIN SHEAVE ASSEMBLY RH A CHAIN SHEAVE B BALL BEARING C SNAP RING 11 MAIN LIFT CHAIN 12 LOAD ROLLER 13 FREE LIFT HOSE SHEAVE 14 FLOW REGULATOR HOUSING 15 HYDRAULIC TUBE MAIN LIFT 16 HYDRAULIC HOSE MAIN LIFT 17 TRUNNION STUB SHAFT 18 TO TRUCK CONTROL VALVE A REAR VIEW B RIGHT SIDE VIEW 1 CHAIN SHEAVE 2 HOSE SHEAVE 3 CABLE SHEAVE 4 CABLE TENSION DEVICE 5 TO TRUCK 6 ELECTRICAL CABLE FOR REACH CAR...

Page 29: ...s of the mast assembly Make sure the chains and lifting device have the capacity to lift approx imately 1500 kg 3500 lb 2250 kg 5000 lb with the attachment Use safety chains to fasten all the mast weldments together so that they can not move If installed install a chain or sling to the attachment to keep the mast assembly from tipping during removal 3 Operate the crane until it supports the weight...

Page 30: ...fittings Disconnect the spring of the cable tension device See Figure 18 Figure 19 and Figure 20 6 Lift the sheave support assembly out of the free lift cylinder and put the lift chains hoses cable and sheave support over the carriage or fasten them out of the way 7 Hold the LIFT LOWER control in the LOWER position for approximately 5 seconds to retract the free lift cylinder rod fully and to remo...

Page 31: ...ree lift cylinder must be disassembled see the section Lift Cylinders 4000 SRM 481 11 Reverse the procedure to install the cylinder Make sure the locating screw for the base of the free lift cylinder is installed before installing the cylinder Use a crane and sling to install the cylinder on the inner weldment 12 Adjust the main lift chains Check for hydraulic leaks and correct operation after the...

Page 32: ...er and the flow regulator See Figure 18 If nec essary use a pry bar to move the carriage and mast weldments carefully for access Install a cap on the regulator fitting to prevent leakage 6 Install a sling and crane to support the cylinder Remove the main cylinder retainer capscrews and washers 7 Push the cylinder toward the top of the mast as sembly to move the main cylinder off the locating dowel...

Page 33: ...pair the cylinder 13 Reverse the procedure to install the main cylin ders 14 If a cylinder is replaced it may be necessary to re shim both cylinders to make sure that the end stroke fully extended is equal on both This will prevent racking when the mast is raised to the maximum fork height Refer to the appropriate Parts Manual for the location and correct shim part numbers INNER AND INTERMEDIATE M...

Page 34: ...Three Stage Mast Assembly 4000 SRM 482 Figure 21 Hose and Cable Assemblies Outer Weldment 30 ...

Page 35: ...l and to check for leaks HOSE AND CABLE SHEAVES REPLACE Read and follow the Safety Procedures When Work ing Near Mast as well as all WARNINGS and CAU TIONS See Figure 19 and Figure 20 NOTE The following procedures describe how to re place the hose and cable sheaves without removing the carriage or mast assembly from the lift truck If the mast assembly has been removed carefully move the carriage i...

Page 36: ...capscrews fasten to the stub shafts of the chain sheaves 8 Follow the reverse procedure to install the hose and cable sheave for the carriage Make sure to operate the carriage hydraulic function s and check for leaks after the hoses are connected THREE STAGE LIFT CHAINS REMOVE AND INSTALL General WARNING Keep control of the lift chains when discon necting them from the chain anchor This procedure ...

Page 37: ...ift chains as de scribed in Three Stage Lift Chains Remove and Install WARNING Be careful when removing or installing snap rings These snap rings are large and can come loose during removal or installation with enough force to cause an injury Always use the correct snap ring pliers and wear eye and face protection during removal or installation 2 Remove the snap ring from the shaft in the sheave s...

Page 38: ...in the correct position 2 Remove the safety chains that fasten the mast weldments together and use a pry bar to care fully and slowly move the correct mast weldment for access to the load rollers The inner weld ment load rollers are at the bottom The load rollers for the outer weldment are at the top The load rollers for the intermediate weldment are at the top and the bottom of the weldment Use s...

Page 39: ...etween a mast crossmember and the truck 4 Steps 4a through 4d for the N30XMH N30XMH2 C210 and V30ZMD D210 E210 only a Position the mast assembly so the mast mounting feet are properly aligned b Install the four setscrews until the mast as sembly is vertical c Install the four capscrews and tighten them to 220 N m 160 lbf ft Remove the chain and crane d Make all adjustments and test the operation o...

Page 40: ... the Nameplate load on the forks and raise and lower the load sev eral times Lower the load Check for leaks and repair as necessary 2 Raise the carriage and the capacity load 1 m 3 ft If the carriage lowers slowly with the con trol valve in a neutral position there are leaks inside the hydraulic system The maximum speed that the carriage is allowed to lower is 50 mm 2 in in 10 minutes when the hyd...

Page 41: ...ns of the manufacturer CAUTION DO NOT use steam to clean the lift chains sheaves or load rollers The sheaves and bear ings are sealed and permanently lubricated Do not use compressed air on the bearings The air can force the lubricant out of the bear ings 1 Clean the lift chains using solvent Inspect the lift chains for wear or damage See Figure 23 A lift chain becomes longer when it is worn If a ...

Page 42: ...r Scale 1 WORN PIN 2 CRACKS 3 EDGE WEAR 4 HOLE WEAR 5 LOOSE LEAVES 6 DAMAGED PIN 7 RUST 8 CHAIN WEAR SCALE Figure 23 Lift Chains Check Mast Adjustments GENERAL Read and follow the Safety Procedures When Work ing Near Mast as well as all WARNINGS and CAU TIONS NOTE These procedures are for both the two stage and three stage mast assemblies Move the lift truck to an area with a smooth level floor to...

Page 43: ...ut on the wear plug See Fig ure 24 and Figure 25 Raise and lower the mast weldments several times to find the point of min imum clearance of the weldment 2 Adjust the wear plugs to attain zero clearance be tween the wear plug and the weldment channel at the tightest point Adjust wear plugs on oppo site sides to keep the weldment in the center 3 Adjust the clearance to approximately 0 02 in by turn...

Page 44: ...or the correct height Perform Step 5 next If the distance is NOT correct perform all of the steps 3 Raise the mast until the free lift cylinder chain anchors at the rear of the free lift cylinder can be accessed from the operator compartment Install safety chains as described in Safety Procedures When Working Near Mast Remove the mast op erator guard for easier access to the chain an chors See Fig...

Page 45: ...ion Masts with free lift cylinder Adjust chain anchors at main lift cylinders so top of inner mast weldment is even with top of outer mast weldment 1 5 mm 0 06 in All masts Adjust chains inner chains on masts with free lift cylinder so bottom of carriage is 82 55 mm 3 25 in above floor Verify that chains of each chain set are adjusted for equal tension Two Stage 1 Fully lower the carriage Measure ...

Page 46: ... the chain anchors until the tension is the same Tighten the lock nuts 4 Check the mast operation as described in Mast Operation Check 5 Install the mast operator guard if removed ADJUST WEAR STRIPS NOTE The wear plugs and lift chains must be ad justed before the wear strips are checked for wear replaced and adjusted The wear strips and shims are fastened to the lower guide blocks of weldments tha...

Page 47: ...ailable from your dealer for Hyster lift trucks See Figure 24 and Figure 25 3 Adjust the wear plugs to attain zero clearance be tween the wear plug and the weldment channel 4 Adjust the clearance to approximately 1 2 mm 0 02 in by turning the adjustment handle 1 8 turn counterclockwise Keep the clearance be tween the carriage and mast weldments equal on both sides Keep the carriage parallel to the...

Page 48: ...e Fig ure 28 Make a note of the location and the value of the maximum measurement 2 Measure and record the distance between the in side faces of the thrust rollers of the carriage as sembly See B of Figure 29 3 If distance B is more than 4 mm less than the maximum measurement of Step 1 install smaller size thrust rollers If distance B is more than 4 mm greater than the maximum measure ment of Step...

Page 49: ... seal s Check for seal leaks inside the cylinder by installing a gate valve in the hy draulic line See Hydraulic System Leaks Check of this section Replace cylinder seals Relief valve pressure is wrong Adjust relief valve to correct pressure setting The spring for the relief valve is weak or damaged Repair relief valve Rough movement of the mast assembly Air in the hydraulic system Remove air from...

Page 50: ..._________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________________________...

Page 51: ......

Page 52: ...TECHNICAL PUBLICATIONS 4000 SRM 482 4 08 11 06 5 04 4 03 5 02 5 98 12 95 4 92 2 92 Printed in U S A ...

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