Hyster N30XMDR3 Safety Precautions Maintenance And Repair
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Hyster N30XMDR3 Safety Precautions Maintenance And Repair

Hyster N30XMDR3 Safety Precautions Maintenance And Repair

Reach carriages
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REACH CARRIAGES
N30XMDR3, N45XMR3 [G138]; N30XMXDR3,
N45XMXR3 [B264]; W20/30ZR [B455]; N25XMDR3,
N30-40XMR3 [C470]; N50XMA3 [C471]
PART NO. 1503619
4500 SRM 971

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  • Page 1 REACH CARRIAGES N30XMDR3, N45XMR3 [G138]; N30XMXDR3, N45XMXR3 [B264]; W20/30ZR [B455]; N25XMDR3, N30-40XMR3 [C470]; N50XMA3 [C471] PART NO. 1503619 4500 SRM 971...
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Reach Cylinders ..............................Remove ................................Disassemble ..............................Clean and Inspect ............................Assemble ................................ Install ................................Tilt Cylinder ............................... Remove ................................Clean, Inspect, and Repair..........................Install ................................Sideshift Cylinder .............................. Remove ................................Clean and Inspect ............................Reach/Tilt Selector Valve........................... ©2007 HYSTER COMPANY...
  • Page 4 Adjust Thrust Rollers ............................ Adjust Reach Cylinders ..........................Specifications..............................Troubleshooting..............................(N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2, N30XMDR2, N45XMR2 and N50XMA3)..............................(W20/30ZR) ..............................This section is for the following models: N30XMDR3, N45XMR3 [G138]; N30XMXDR3, N45XMXR3 [B264]; W20/30ZR [B455]; N25XMDR3, N30-40XMR3 [C470]; N50XMA3 [C471]...

  • Page 5: General

    4500 SRM 971 Safety Procedures When Working Near Mast General This manual has a description and the repair procedures for the single-reach and double-reach carriages on two-stage or three-stage masts. Safety Procedures When Working Near Mast WARNING All chains, ropes, and lifting equipment MUST •...
  • Page 6 Safety Procedures When Working Near Mast 4500 SRM 971 Legend for Figure 1 A. TWO-STAGE MAST B. THREE-STAGE MAST 1. OUTER WELDMENT 2. INNER WELDMENT 3. INTERMEDIATE WELDMENT 4. SAFETY CHAIN 5. FREE-LIFT CYLINDER 6. CARRIAGE Figure 1. Safety Chain the Mast...

  • Page 7: Description

    4500 SRM 971 Description Description The reach carriages are used to extend the reach of by a scissor linkage. The top of the scissor arm the carriage. There are two types of reach carriages. weldment at the inner frame is fastened to the top There is a single-reach carriage with one set of scis- of the inner frame by pins.
  • Page 8 Description 4500 SRM 971 Figure 2. Hydraulic Parts for Double-Reach Assembly (Single-Reach is Similar)

  • Page 9: Repair - General

    4500 SRM 971 Load Backrest Removal and Installation Legend for Figure 2 1. COVER PLATE 20. EXTERNAL SNAP RING 2. VALVE ASSEMBLY 21. FRONT PIVOT PINS 3. 6×4 FITTING WITH O-RING 22. WASHER 4. 4×4 FITTING WITH O-RING 23. LOCKWASHER 5.

  • Page 10: Fork Replacement

    Fork Replacement 4500 SRM 971 Fork Replacement HOOK 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. Latch pins fit through the top fork hooks and into slots on the top crossmember of the carriage to keep the forks in position.

  • Page 11: Reach Assembly Removal And Installation

    4500 SRM 971 Reach Assembly Removal and Installation Reach Assembly Removal and Installation 1. Operate the LIFT/LOWER controls to raise the 7. Hold the lift chains to keep them from falling. reach assembly until the rollers of the rear frame Remove the pins in the chain anchors at the back (reach) are above the top of the outer weldment.

  • Page 12: Carriage Load Rollers Removal And Installation

    Carriage Load Rollers Removal and Installation 4500 SRM 971 Carriage Load Rollers Removal and Installation For the following procedures, refer to Figure 5 and 4. On three-stage masts, remove the safety chains Figure 6. installed in Step 4. Lower the reach assembly for access to the chain anchors at the back of the 1.

  • Page 13: Side Rollers Disassembly And Assembly

    4500 SRM 971 Reach Assembly Repair 6. Remove the snap rings from the stub shaft for the 9. Install the reach assembly. See Reach Assembly load roller. Removal and Installation. 7. Use a pry bar to remove the load roller from the 10.

  • Page 14: Reach Assembly Outer Frame

    Reach Assembly Outer Frame 4500 SRM 971 Reach Assembly Outer Frame For the following procedures refer to Figure 7, Fig- Move the outer frame away from the lift truck ure 8, and Figure 9. and place it face down on the floor. REMOVE WARNING There are pinch points on the reach car-...
  • Page 15 4500 SRM 971 Reach Assembly Outer Frame 1. RETAINER 8. PIVOT PIN 2. LOCKWASHER 9. BUSHING 3. CAPSCREW 10. BUSHING 4. PIN 11. TILT CYLINDER 5. CAPSCREW 12. TILTING FRAME 6. TRUNNION CAP 13. CAPSCREW 7. FIXED FRAME 14. CAPSCREW Figure 8.

  • Page 16: Clean And Inspect

    Reach Assembly Outer Frame 4500 SRM 971 1. WEAR STRIP 10. FIXED FRAME 19. WEAR STRIP 2. WEAR STRIP 11. TRUNNION CAP 20. NUT 3. WEAR STRIP 12. CAPSCREW 21. MOBILE FRAME 4. WASHER 13. ROD 22. CAPSCREW 5. LOCKWASHER 14.

  • Page 17: Assemble

    4500 SRM 971 Reach Assembly Outer Frame ASSEMBLE CAUTION 1. To assemble, reverse the removal procedure. Do NOT use steam to clean the load bearings. Do not use compressed air on the bearings. 2. If removed, install the hydraulic hoses for the tilt The bearings are sealed and permanently lu- and sideshift cylinder.

  • Page 18: Disassemble Without Sideshifter

    Reach Assembly Outer Frame 4500 SRM 971 The bearings are sealed and permanently lu- CAUTION bricated. The air can force the lubricant out of Do not let the load bearings or shims fall off the the bearings. scissor arms. NOTE: Inspect the load bearings of the scissor arms 5.
  • Page 19 4500 SRM 971 Reach Assembly Outer Frame 3. Use the crane to move the outer frame for align- CAUTION ment with the scissor arms. Tip the outer frame Do not let the load bearings or shims fall off the forward and align the channels with the load scissor arms.

  • Page 20: Single-Reach Scissor Arms

    Single-Reach Scissor Arms 4500 SRM 971 Single-Reach Scissor Arms REMOVE AND DISASSEMBLE 3. Remove the shoulder bolt and nut. Use a drift to remove the pins that fasten the rod ends of the NOTE: The reach assembly must be in the fully-ex- reach cylinders to the scissor arm weldment.
  • Page 21 4500 SRM 971 Single-Reach Scissor Arms 1. CAPSCREW, LOCKWASHER, 10. MAIN BUSHING 19. SCREW ® AND LOCTITE 11. THRUST WASHER 20. PIN 2. END CAP 12. SHEAVE 21. PIN ROD END 13. RETAINING RING 22. LOCK NUT 3. THRUST WASHER 14.

  • Page 22: Clean And Inspect

    Single-Reach Scissor Arms 4500 SRM 971 new bushings, all thrust washers, all shims, all stub WARNING shafts, and all pins of the scissor arm assembly. The points between the scissor arms and the rear frame are pinch points and can cause an WARNING injury.

  • Page 23: Double-Reach Scissor Arms

    4500 SRM 971 Double-Reach Scissor Arms necessary, use tape to keep the load rollers on the come loose during removal or installation with scissor arms. enough force to cause an injury. Always use the correct snap ring pliers and wear eye and 4.
  • Page 24 Double-Reach Scissor Arms 4500 SRM 971 Figure 11. Double-Reach Scissor Arms...
  • Page 25 4500 SRM 971 Double-Reach Scissor Arms Legend for Figure 11 1. INNER ARM WELDMENT 14. INNER ARM WELDMENT 27. FITTING WITH O-RING 2. BEARING 15. SHIM 28. EXTEND CYLINDER (RH) 3. BUSHING 16. OUTER ARM ASSEMBLY (LH) 29. FITTING WITH O-RING 4.

  • Page 26: Clean And Inspect

    Double-Reach Scissor Arms 4500 SRM 971 CLEAN AND INSPECT 9. Install a safety chain between the inner frame and scissor arm weldment B so the weldment cannot move. Move the crane and chains or WARNING slings so they are a support for scissor arm weld- Cleaning solvents can be flammable and toxic ment A.
  • Page 27 4500 SRM 971 Double-Reach Scissor Arms position of alignment to install the pins that fas- put any part of your body between the inner ten the weldment to the inner frame. Install the frame and the scissor arm assembly. NEVER bushings, pins, and shoulder bolts.

  • Page 28: Inner Frame Assembly

    Inner Frame Assembly 4500 SRM 971 NOTE: Correct placement of shims is critical for the WARNING operation of the reach mechanism. Unless the shims Be careful when removing or installing snap are installed correctly, the reach mechanism will not rings. These snap rings are large and can operate.
  • Page 29 4500 SRM 971 Inner Frame Assembly Figure 12. Inner Frame...
  • Page 30 Inner Frame Assembly 4500 SRM 971 Legend for Figure 12 1. INNER FRAME WELDMENT 25. O-RING FITTING 2. BUSHING 26. O-RING FITTING 3. VALVE BODY 27. CAPSCREW 4. BRACKET 28. BRACKET 5. SHIM 29. LOCKWASHER 6. SIDE ROLLER 30. CAPSCREW 7.

  • Page 31: Disassemble

    4500 SRM 971 Inner Frame Assembly DISASSEMBLE enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and NOTE: It is usually not necessary to remove all the face protection during removal or installation. parts of the inner frame assembly.

  • Page 32: Clean And Inspect

    Inner Frame Assembly 4500 SRM 971 CLEAN AND INSPECT rollers on the inner frame. Install the shims at each location as marked during disassembly. WARNING 2. Adjust the carriage side rollers during assembly. Cleaning solvents can be flammable and toxic See Adjust Side Rollers, Carriage or Reach As- and can cause skin irritation.

  • Page 33: Reach Cylinders

    4500 SRM 971 Reach Cylinders Install the thrust rollers as marked during removal. WARNING If the thrust rollers are replaced, install the correct Lift chains, hoses, and cables can roll over the size [74, 76, or 78 mm (2.88, 2.96, or 3.04 in.) OD] sheaves to fall and cause an injury if the ends thrust rollers.

  • Page 34: Disassemble

    Reach Cylinders 4500 SRM 971 2. Install labels on the hydraulic lines for correct fasten each end of cylinder to the frame. Remove connection during installation. Disconnect the the other reach cylinder using the same proce- hydraulic lines at the reach cylinders. Install dure.

  • Page 35: Clean And Inspect

    4500 SRM 971 Reach Cylinders CLEAN AND INSPECT 1. If removed, install the correct rod end on the rod as marked during removal. Install new bushings in all four mounts for the reach cylinders. Lubri- WARNING cate the bushings with multipurpose grease. Cleaning solvents can be flammable and toxic and can cause skin irritation.

  • Page 36: Tilt Cylinder

    Tilt Cylinder 4500 SRM 971 Tilt Cylinder REMOVE Cylinder components can be disassembled to repair the seals if damaged. Consult the Parts Manual to Refer to Reach Assembly Outer Frame, Assemble in select the proper cylinder repair kit for your truck. this section.
  • Page 37 4500 SRM 971 Tilt Cylinder 1. NUT 8. WIPER RING 2. TILTING FRAME 9. SEAL 3. WASHER 10. ROD 4. WASHER 11. BLOCK 5. SEAL 12. BUSHING 6. PISTON 13. FRONT FRAME 7. SEAL Figure 17. Tilt Cylinder...

  • Page 38: Sideshift Cylinder

    Reach/Tilt Selector Valve 4500 SRM 971 Sideshift Cylinder REMOVE for eyes and skin. When using cleaning sol- vents, always follow the recommendations of The sideshift cylinder is not removable, see Reach the manufacturer. Assembly Outer Frame, Remove, part is integral to tilting frame.

  • Page 39: Carriage Or Reach Assembly Adjustments

    4500 SRM 971 Carriage or Reach Assembly Adjustments CLEAN AND INSPECT INSTALL 1. Installation is done by reversing the removal WARNING process. Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection 2. Hold the selector valve in the correct position on for eyes and skin.

  • Page 40: Adjust Side Rollers

    Carriage or Reach Assembly Adjustments 4500 SRM 971 A. TWO-STAGE B. THREE-STAGE MAIN LIFT 1. INNER WELDMENT 7. SNAP RING 2. CHAIN SHEAVE 8. OUTER WELDMENT 3. LIFT CHAIN 9. ADJUSTMENT NUT 4. COTTER PIN 10. REACH ASSEMBLY 5. ANCHOR PIN 11.

  • Page 41: Adjust Thrust Rollers

    4500 SRM 971 Carriage or Reach Assembly Adjustments 2. Measure and record the distance between the in- side faces of the thrust rollers of the reach assem- bly. See B of Figure 20. Figure 20. Reach Assembly Side and Thrust Roller Widths 3.

  • Page 42: Adjust Reach Cylinders

    Carriage or Reach Assembly Adjustments 4500 SRM 971 ADJUST REACH CYLINDERS reach cylinders. Use a wrench on the wrench flats to rotate the cylinder rods for adjustment. NOTE: The reach cylinders must be adjusted if either Temporarily tighten the capscrews. reach cylinder has been replaced or the rod ends have been removed.

  • Page 43: Specifications

    4500 SRM 971 Specifications Specifications Table 1. General Specifications Action Specification Load Backrest Capscrews, Torque 203 N•m (150 lbf ft) Scissor Arms, Torques Center Pivot Capscrews 41 N•m (30 lbf ft) End Pivot Capscrews (Double Reach Only) 39 N•m (29 lbf ft) Reach Cylinder, Torques M8 Bolt 34 N•m (25 lbf ft)
  • Page 44 Specifications 4500 SRM 971 Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2, N30XMDR2, and N45XMR2 Voltage Action Time Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec. Fast Reach Time, Maximum Load [ 2041 kg (4500 lb)] 3.2 to 4.0 sec.
  • Page 45 4500 SRM 971 Specifications Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2, N30XMDR2, and N45XMR2 (Continued) Voltage Action Time Relief 24 V 16,547.4 kPa 175 Amps (2400 psi) 36 V 16,547.4 kPa 112 Amps (2400 psi) Reach No Load 24 V 7584 kPa 90 Amps (1100 psi)

  • Page 46: Troubleshooting

    Troubleshooting 4500 SRM 971 Table 3. Operating Times W20/30ZR Action Time Reach - No Load Extend 4.06 sec. 3.93 sec. Retract Reach - 1360 kg (3000 lb) Extend 4.37 sec. 4.03 sec. Retract Tilt - No Load Tilt (Up) 1.52 sec. Tilt (Down) 1.52 sec.

  • Page 47: (W20/30Zr)

    4500 SRM 971 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION The forks will not extend, Control valve not operating. Clean, repair, or replace control tilt, or sideshift, and there is valve. power steering. (Cont.) Selector valve is damaged or not op- Clean, repair, or replace selector erating.
  • Page 48 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 50 TECHNICAL PUBLICATIONS 4500 SRM 971 10/07 (4/03)(11/02)(7/02)(5/01) Printed in U.S.A.

This manual is also suitable for:

N45xmr3 g138N30xmxdr3N45xmxr3 b264W20zr b455W30zr b455N25xmdr3 ... Show all

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