Hyster MAST N50F Repair Manual
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Hyster MAST N50F Repair Manual

Hyster MAST N50F Repair Manual

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MAST
REPAIR
N50FA; N40-45FR [D138]; N30XMH,
[C210]; N25XMDR3, N30-
N30XMH
2
40XMR3 [C470]; N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138]; N30XMXDR3,
N45XMXR3 [B264]; W30-40ZA [B453];
W20-30ZR [B455]; W25-30-40ZC [B454];
W25-30ZA
[B495]; V30ZMD [D210/E210]
2
PART NO. 897447
4000 SRM 482

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Summary of Contents for Hyster MAST N50F

  • Page 1 MAST REPAIR N50FA; N40-45FR [D138]; N30XMH, [C210]; N25XMDR3, N30- N30XMH 40XMR3 [C470]; N50XMA3 [C471]; N30XMDR3, N45XMR3 [G138]; N30XMXDR3, N45XMXR3 [B264]; W30-40ZA [B453]; W20-30ZR [B455]; W25-30-40ZC [B454]; W25-30ZA [B495]; V30ZMD [D210/E210] PART NO. 897447 4000 SRM 482...
  • 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

    Three-Stage Chain Sheaves, Disassemble and Assemble ................Free-Lift Chain Sheaves ........................... Main-Lift Chain Sheaves .......................... Load Rollers and Wear Plugs, Remove and Install..................Three-Stage Mast Assemble, Install ......................Mast Operation Check ............................Hydraulic System Leaks Check ........................Lift Chains Check .............................. ©2008 HYSTER COMPANY...
  • Page 4 Table of Contents Mast TABLE OF CONTENTS (Continued) General ................................Clean and Inspect ............................Lubrication..............................Mast Adjustments.............................. General ................................Adjust Wear Plugs - Mast ..........................Adjust Free-Lift Chain (Three-Stage Only) ....................Adjust Main-Lift Chains ..........................Two-Stage..............................Three-Stage ............................... Adjust Wear Strips ............................Carriage Adjustments............................

  • Page 5: General

    4000 SRM 482 General General This manual has the removal, installation, and ad- The mast assemblies must have the mast weldments justment procedures for the two-stage (limited free- parallel with equal clearance on each side between lift) and three-stage (full free-lift) masts. The de- all weldments.

  • Page 6: Safety Procedures When Working Near Mast

    Safety Procedures When Working Near Mast 4000 SRM 482 Safety Procedures When Working Near Mast The following procedures MUST be used when in- • If parts of the mast must be in a raised po- specting or working near the mast. Additional pre- sition, install a safety chain to restrain the cautions and procedures can be required when re- moving parts of the mast.

  • Page 7: Load Backrest Extension, Carriage, Load Rollers, Side Rollers, And Forks

    4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks A. TWO-STAGE MAST B. THREE-STAGE MAST 1. OUTER WELDMENT 3. INTERMEDIATE WELDMENT 5. FREE-LIFT CYLINDER 2. INNER WELDMENT 4. SAFETY CHAIN HOOK 6. CROSSMEMBER Figure 1. Safety Chain the Mast, Typical Mast Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks LOAD BACKREST EXTENSION, REMOVE...
  • Page 8 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 4000 SRM 482 Read and follow the Safety Procedures When Work- inner frame (reach) or the carriage frame are ing Near Mast, as well as all WARNINGS and CAU- above the top of the outer weldment. TIONS.
  • Page 9 4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks cannot tip as it is removed from the mast weld- ment. Fasten the chains to the lifting eyes on reach units. Fasten the chains or slings to the carriage frame on standard units.

  • Page 10: Carriage Load Rollers, Remove And Install

    Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 4000 SRM 482 11. To install the carriage assembly, reverse the re- 5. Use a pry bar to remove the load roller from the moval procedures. Always use new cotter pins stub shaft for the load roller.

  • Page 11: Fork, Replace

    4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks Hook-Type Forks 4. Reverse the procedure to install the side rollers. Adjust the carriage side rollers during assembly. See Carriage Adjustments. WARNING Forks are heavy and can cause an injury. Do NOTE: To remove and replace load rollers, wear not try to remove forks without using a lifting plugs, weldments, or lift cylinders, it is necessary to...

  • Page 12: Remove

    Two-Stage Mast Assembly 4000 SRM 482 Legend for Figure 6 A. OLD STYLE LATCH PIN ASSEMBLY B. NEW STYLE LATCH PIN ASSEMBLY 1. FORK 6. WEDGE 2. LATCH PIN 7. KNOB 3. SPRING 8. LEVER 4. WASHER 9. ROLL PIN 5.
  • Page 13 4000 SRM 482 Two-Stage Mast Assembly 1. OVERHEAD 4. LEG CAPSCREW GUARD 5. MAST OPERATOR 2. LEG GUARD 3. MAST CAPSCREW 6. CAPSCREW 1. OPERATOR 2. CAPSCREW Figure 8. Overhead Guard and Operator GUARD Guard Narrow Aisle Trucks Figure 9. Operator Guard Walkie High Lift Trucks 2.
  • Page 14 Two-Stage Mast Assembly 4000 SRM 482 Figure 10. Two-Stage Mast Assembly (Dual-Lift Cylinders)

  • Page 15: Clean And Inspect

    Some parts may be damaged by welding. To prevent an injury, always get authorization 9. Move the mast assembly away from the truck. from your dealer for Hyster lift trucks before NOTE: To disassemble models with an overhead welding on the mast, forks, or carriage.
  • Page 16 Two-Stage Mast Assembly 4000 SRM 482 Figure 11. Two-Stage Mast Assembly (Single-Lift Cylinder)

  • Page 17: Lift Cylinders, Remove And Install Dual-Lift Cylinders

    4000 SRM 482 Two-Stage Mast Assembly Legend for Figure 11 1. INNER WELDMENT 4. SCREW 7. SNAP RING 2. OUTER WELDMENT 5. NUT 8. PLUG 3. BUSHING 6. LOAD ROLLER 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.

  • Page 18: Lift Cylinder, Remove And Install Single Main-Lift Cylinders

    Two-Stage Mast Assembly 4000 SRM 482 6. Install a sling and crane to support the cylinder. Legend for Figure 13 Remove the lift cylinder retainer, capscrews, and 1. SNAP RING washers. 2. CAPSCREW AND LOCKWASHER 3. SUPPORT BRACKET 7. Push the cylinder toward the top of the mast as- 4.

  • Page 19: Remove

    4000 SRM 482 Two-Stage Mast Assembly Legend for Figure 14 CAUTION 1. CAPSCREW To prevent dirt or contaminants from entering 2. WASHER the hydraulic system, always install caps on 3. LIFT CYLINDER the tube and flow regulator. 4. FITTING 5. TUBE 11.

  • Page 20: Inner Mast Assembly, Remove And Install

    Two-Stage Mast Assembly 4000 SRM 482 13. Install load backrest to carriage. 4. Reverse the removal procedure to install the in- ner mast assembly into the outer weldment. INNER MAST ASSEMBLY, REMOVE AND HOSES, REPLACE INSTALL Read and follow the Safety Procedures When Work- Read and follow the Safety Procedures When Work- ing Near Mast, as well as all WARNINGS and CAU- ing Near Mast, as well as all WARNINGS and CAU-...
  • Page 21 4000 SRM 482 Two-Stage Mast Assembly Figure 15. Hose and Cable Assemblies - Two-Stage Mast (Dual-Lift Cylinders)

  • Page 22: Hose And Cable Sheaves, Replace

    Two-Stage Mast Assembly 4000 SRM 482 HOSE AND CABLE SHEAVES, REPLACE TWO-STAGE LIFT CHAINS Read and follow the Safety Procedures When Work- Read and follow the Safety Procedures When Work- ing Near Mast, as well as all WARNINGS and CAU- ing Near Mast, as well as all WARNINGS and CAU- TIONS.

  • Page 23: Remove And Install

    4000 SRM 482 Two-Stage Mast Assembly Remove and Install (6 in.) off the floor. See Figure 16. Use safety chains to fasten the carriage to the outer weld- 1. Operate the LIFT/LOWER control to raise the ment so it cannot move. carriage so that the forks are approximately 150 mm (6 in.) off the floor.

  • Page 24: Load Rollers And Wear Plugs, Remove And Install

    Two-Stage Mast Assembly 4000 SRM 482 LOAD ROLLERS AND WEAR PLUGS, WARNING REMOVE AND INSTALL The mast weldments can move and cause an injury. Make sure the mast assembly is level Read and follow the Safety Procedures When Work- to prevent unexpected movement of the mast ing Near Mast, as well as all WARNINGS and CAU- weldments.

  • Page 25: Two-Stage Mast Assembly, Install

    4000 SRM 482 Two-Stage Mast Assembly TWO-STAGE MAST ASSEMBLY, INSTALL CAUTION Read and follow all WARNINGS and CAUTIONS. If Install tape on all electrical wires for the reach the carriage is installed on the mast, it must have a carriage if the wires are not connected to the safety chain installed as described in Safety Proce- carriage.

  • Page 26: Three-Stage Mast Assembly

    Three-Stage Mast Assembly 4000 SRM 482 Three-Stage Mast Assembly THREE-STAGE MAST ASSEMBLY, capscrews, shims, and nutplates that fasten the bottom of the mast to the truck frame. See Fig- REMOVE ure 10. Read and follow the Safety Procedures When Work- 4.
  • Page 27 4000 SRM 482 Three-Stage Mast Assembly Figure 18. Three-Stage Mast Assembly...
  • Page 28 Three-Stage Mast Assembly 4000 SRM 482 Legend for Figure 18 A. REAR VIEW HOSE ROUTING - LIFT 1. INNER WELDMENT 8. CHAIN ANCHOR 2. INTERMEDIATE WELDMENT 9. CLAMP 3. OUTER WELDMENT 10. CHAIN SHEAVE ASSEMBLY (RH) 4. FREE-LIFT CYLINDER A. CHAIN SHEAVE 5.

  • Page 29: N30Xhm, N30Xmh (C210), And V30Zmd (D210/E210) Only

    Get authorization from your 2. Use a chain to connect a crane or other lifting de- dealer for Hyster lift trucks before welding on vice to the top of the mast assembly. Make sure the mast, forks, or carriage.

  • Page 30: Free-Lift Cylinder, Remove And Install

    Three-Stage Mast Assembly 4000 SRM 482 FREE-LIFT CYLINDER, REMOVE AND at the free-lift cylinder. Install caps on the hy- draulic fittings. Disconnect the spring of the INSTALL cable tension device. See Figure 18, Figure 19, NOTE: Cylinder seals can be replaced without remov- and Figure 20.
  • Page 31 4000 SRM 482 Three-Stage Mast Assembly Figure 20. Hose and Cable Assemblies - Inner and Intermediate Weldments 10. Remove the cylinder strap. Use a crane and sling free-lift cylinder is installed before installing the to lift the free-lift cylinder off the locating screw cylinder.

  • Page 32: Main Cylinders (Standard), Remove And Install

    Three-Stage Mast Assembly 4000 SRM 482 MAIN CYLINDERS (STANDARD), REMOVE 6. Install a sling and crane to support the cylinder. Remove the main cylinder retainer, capscrews, AND INSTALL and washers. Read and follow the Safety Procedures When Work- 7. Push the cylinder toward the top of the mast as- ing Near Mast, as well as all WARNINGS and CAU- sembly to move the main cylinder off the locating TIONS.

  • Page 33: Inner And Intermediate Mast Assemblies, Remove And Install

    4000 SRM 482 Three-Stage Mast Assembly the correct snap ring pliers and wear eye and stroke (fully extended) is equal on both. This will face protection during removal or installation. prevent racking when the mast is raised to the maximum fork height. Refer to the appropriate 5.
  • Page 34 Three-Stage Mast Assembly 4000 SRM 482 Figure 21. Hose and Cable Assemblies - Outer Weldment...

  • Page 35: Hoses, Replace

    4000 SRM 482 Three-Stage Mast Assembly Legend for Figure 21 A. REACH OR SIDESHIFT CARRIAGE ONLY C. FRONT VIEW B. REAR VIEW 1. HOSE BRACKET 10. TO LIFT TRUCK 2. HOSE BRACKET 11. HYDRAULIC HOSE (LIFT) 3. TO FLOW REGULATOR 12.

  • Page 36: Carriage Sheaves

    Three-Stage Mast Assembly 4000 SRM 482 Carriage Sheaves THREE-STAGE LIFT CHAINS, REMOVE AND INSTALL Remove the sheaves for the hoses and cable to the carriage as follows: General 1. Fully lower the carriage. Fully retract the forks WARNING if the reach carriage is installed. Install safety chains between the tops of the inner and outer Keep control of the lift chains when discon- carriage weldments of the reach carriage to pre-...

  • Page 37: Main-Lift Chains

    4000 SRM 482 Three-Stage Mast Assembly Main-Lift Chains come loose during removal or installation with enough force to cause an injury. Always use 1. Raise the mast until the lower chain anchors are the correct snap ring pliers, and wear eye and visible on the inner weldment.

  • Page 38: Load Rollers And Wear Plugs, Remove And Install

    Three-Stage Mast Assembly 4000 SRM 482 LOAD ROLLERS AND WEAR PLUGS, 1. Remove the mast assembly as described in Three-Stage Mast Assembly, Remove. Remove REMOVE AND INSTALL the free-lift cylinder as described in Free-Lift Read and follow the Safety Procedures When Work- Cylinder, Remove and Install.

  • Page 39: Three-Stage Mast Assemble, Install

    4000 SRM 482 Three-Stage Mast Assembly 4. Use a pry bar to remove the load roller from the a. Position the mast assembly so the mast mast weldment. See Figure 5. mounting feet are properly aligned. 5. Use a cloth to clean each load roller. Inspect the b.

  • Page 40: Mast Operation Check

    Hydraulic System Leaks Check 4000 SRM 482 the chain and crane are no longer the support. 14. Make all adjustments and test the operation of Remove the chain and crane. the mast assembly before returning the truck to service. See Mast Operation Check. 13.

  • Page 41: Lift Chains Check

    4000 SRM 482 Lift Chains Check 6. If the leak rate for the tilt function is greater than 7. If the forks do not move, open the gate valve and specifications, remove the load from the forks. check for movement again. If the forks move for- Install a gate valve between the port at the rod ward when the gate valve is open, check for leaks end of the tilt cylinder and the hydraulic line.

  • Page 42: Mast Adjustments

    Mast Adjustments 4000 SRM 482 Pitch Total Length of 20 Links Wear Limit (Pitch) of New Chain Maximum of 20 Links 25.4 mm (1.00 in.) 508 mm (20.0 in.) 523 mm (20.6 in.) 31.8 mm (1.25 in.) 635 mm (25.0 in.) 654 mm (25.7 in.) 38.1 mm (1.50 in.) 762 mm (30.0 in.)

  • Page 43: Adjust Wear Plugs - Mast

    4000 SRM 482 Mast Adjustments The only adjustment for the load rollers is the ad- justment of the wear plugs. These adjustments are made for minimum side clearance and to keep the weldments parallel with equal clearance on each side between all weldments.

  • Page 44: Adjust Free-Lift Chain (Three-Stage Only)

    Mast Adjustments 4000 SRM 482 3. Raise the mast until the free-lift cylinder chain WARNING anchors at the rear of the free-lift cylinder can be NEVER loosen the wear plugs if a mast weld- accessed from the operator compartment. Install ment does not move freely during checks after safety chains as described in Safety Procedures an adjustment.

  • Page 45: Adjust Main-Lift Chains

    4000 SRM 482 Mast Adjustments A. TWO-STAGE B. THREE-STAGE MAIN-LIFT C. THREE-STAGE FREE-LIFT 1. INNER WELDMENT 6. CHAIN ANCHOR 11. TYPICAL FIXED ANCHOR 2. CHAIN SHEAVE 7. LOCK NUT 12. INTERMEDIATE WELDMENT 3. LIFT CHAIN 8. OUTER WELDMENT 13. FREE-LIFT CYLINDER 4.

  • Page 46: Three-Stage

    Mast Adjustments 4000 SRM 482 5. Check chain tension by pushing on both chains The wear strips and shims are adjusted: at the same time. If the tension is not the same, • For minimum clearance to prevent too much side adjust the nuts on the chain anchors until the movement of the weldments.

  • Page 47: Carriage Adjustments

    2. Loosen the jamnut on the wear plug using the 3. Measure and record the distance across the side special tool available from your dealer for Hyster rollers of the carriage assembly. See A of Fig- lift trucks. See Figure 24 and Figure 25.

  • Page 48: Adjust Thrust Rollers - Carriage

    Carriage Adjustments 4000 SRM 482 ADJUST THRUST ROLLERS - CARRIAGE 1. Measure the width between the outside edges of the inner weldment in several places. See Fig- ure 28. Make a note of the location and the value of the maximum measurement. 2.

  • Page 49: Troubleshooting

    4000 SRM 482 Troubleshooting Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION No operation of lift cylinders. No oil or not enough oil to supply Check oil level and add oil as needed. cylinders. Bad hydraulic leaks, bad pump or Repair hydraulic leaks. Replace pump drive, relief valve set too low, pump or pump drive.
  • Page 50 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • 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.

This manual is also suitable for:

Mast n40-45frMast n30xmhMast n30xmh2Mast n25xmdr3Mast n30- 40xmr3Mast n50xma3 ... Show all

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