Hyster G005 Service & Repair Manual
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Hyster G005 Service & Repair Manual

Hyster G005 Service & Repair Manual

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Hyster G005 (H70XL, H80XL, H90XL, H100XL,
H110XL, H90XLS) Forklift

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Summary of Contents for Hyster G005

  • Page 1 Hyster G005 (H70XL, H80XL, H90XL, H100XL, H110XL, H90XLS) Forklift...
  • Page 2 VISTA MASTS ® DESCRIPTION AND REPAIRS FOR LIFT TRUCKS WITH 3,500 TO 6,000 KG (7,000 TO 12,000 LB) CAPACITIES H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL) [C098] PART NO. 897122 4000 SRM 340...
  • Page 3 • 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 4: Table Of Contents

    Disassemble ..............................Clean and Inspect ............................Assemble ................................ Install ................................Mast Operation Check ............................Lift and Tilt System Leak Check ........................Lift System..............................Tilt System ..............................Tilt Cylinder Stroke and Backward Tilt Angle Adjustment................Lift Chain Adjustments ............................. ©2002 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more 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 please write to me: admin@servicemanualperfect.com...
  • Page 6 Table of Contents Vista Masts ® TABLE OF CONTENTS (Continued) Mast Adjustments.............................. Carriage Adjustment ............................Troubleshooting..............................This section is for the following models: H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL) [C098]...

  • Page 7: General

    4000 SRM 340 Description and Operation General ® This section has the description, operation, and repair procedures for the Vista masts for the 3,500 to 6,000 kg (7,000 to 12,000 lb) capacity lift trucks. Information on the different types of sideshift carriages is also in- cluded.

  • Page 8: Two-Stage Mast With Full Free-Lift Mast

    Description and Operation 4000 SRM 340 Two lift chains control the movement of the carriage. The chains are fastened to mounts near the top of the lift cylinder shells. The chains go up and over the chain sheaves on the inner weldment and then connect to the carriage.

  • Page 9: Three-Stage Mast With Full Free-Lift

    4000 SRM 340 Description and Operation 1. MAIN LIFT CYLINDER (2) 6. LIFT CHAIN 2. OUTER WELDMENT 7. CARRIAGE 3. FREE-LIFT CYLINDER 8. FROM MAIN CONTROL VALVE 4. INNER WELDMENT 9. EXTERNAL LOWERING CONTROL VALVE 5. CHAIN SHEAVE 10. INTERNAL LOWERING CONTROL VALVE Figure 3.
  • Page 10 Description and Operation 4000 SRM 340 A. PHASE 2 1. MAIN LIFT CYLINDER (2) 6. INTERMEDIATE WELDMENT 2. OUTER LIFT CHAIN 7. OUTER WELDMENT 3. FREE-LIFT CYLINDER 8. FROM MAIN CONTROL VALVE 4. INNER LIFT CHAIN 9. EXTERNAL LOWERING CONTROL VALVE 5.

  • Page 11: Safety Procedures When Working Near Mast

    4000 SRM 340 Safety Procedures When Working Near Mast The three lift cylinders are connected by hoses and cylinders extend the intermediate weldment, the in- tubing. To extend the mast, oil from the main con- ner weldment is extended by the lift chains. trol valve flows to all cylinders at the same time.
  • Page 12 Safety Procedures When Working Near Mast 4000 SRM 340 A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST 1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER 2. INNER WELDMENT 5. FREE-LIFT CYLINDER 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER Figure 5. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts...

  • Page 13: Forks Replacement

    4000 SRM 340 Forks Replacement Forks Replacement The identification of a fork describes how the fork is [66 to 183 kg (145 to 402 lb) for a hook fork] and connected to the carriage. The series of lift trucks [128 to 226 kg (281 to 498 lb) for a pin fork]. that use this mast normally have hook forks.

  • Page 14: Pin Fork

    Carriage Repair 4000 SRM 340 Pin Fork Remove Put blocks under forks and lower carriage. When weight of forks have been removed from fork pin, re- move load backrest extension. The load backrest ex- tension holds the fork pin in the carriage. Slide fork pin from its mount in the carriage and through the eye of the fork.
  • Page 15 4000 SRM 340 Carriage Repair 1. Lower carriage and forks on blocks so lift chains WARNING become loose. See Figure 9 and Figure 12. Make sure that the carriage has stability and will not fall over when the inner weldment is WARNING raised above the load rollers of the carriage.

  • Page 16: Sideshift Carriage Repair

    Disconnect sideshift cylinder at carriage and at DESIGNS) apron. Remove sideshift cylinder. See Figure 10, The earlier Hyster Company designs of sideshift car- Figure 11, Figure 12, and Figure 13. riages for this mast are shown in Figure 12 and Fig- 2.

  • Page 17: Assemble

    4000 SRM 340 Sideshift Carriage Repair Legend for Figure 10 1. RETAINER 8. BACKUP RING 2. COVER 9. O-RING 3. WIPER 10. ROD 4. ROD SEAL 11. PISTON 5. SNAP RING 12. PISTON SEAL 6. CAPSCREW 13. NUT 7. RETAINING RING 14.
  • Page 18 Sideshift Carriage Repair 4000 SRM 340 Figure 12. Sideshift Carriages...
  • Page 19 4000 SRM 340 Sideshift Carriage Repair Legend for Figure 12 A. H3.50-4.00XL-5 (H70-80XL) C. BACK OF CARRIAGE B. FACE OF CARRIAGE D. H4.00XL-6, H4.50-5.00XL (H90-100XL) 1. CARRIAGE 8. SIDE ROLLER 2. APRON 9. CHAIN ANCHOR (FREE-LIFT AND 3. SIDESHIFT CYLINDER THREE-STAGE MAST) 4.

  • Page 20: Install

    Sideshift Carriage Repair 4000 SRM 340 Install bracket and cylinder will stay on the standard carriage. Remove bushings. 1. Use hydraulic system of lift truck or a lifting de- vice to raise inner weldment. Raise inner weld- 4. Disconnect hydraulic lines at sideshift cylinder. ment until it is above the load rollers of the car- Put caps on open lines.
  • Page 21 4000 SRM 340 Sideshift Carriage Repair 1. STANDARD CARRIAGE 5. BOTTOM BUSHING 2. TOP BAR, SIDESHIFT CARRIAGE 6. SIDESHIFT CYLINDER 3. TOP BUSHING 7. BOTTOM BARS, SIDESHIFT CARRIAGE 4. CYLINDER MOUNT BRACKET Figure 14. Sideshift Carriage (1993 and Later Design) 5.

This manual is also suitable for:

H70xlH80xlH90xlH100xlH110xlH90xls

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