Hyster AP20Z Service Manual
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Hyster AP20Z Service Manual

Hyster AP20Z Service Manual

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Hyster A254 (AP20Z) Forklift

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Summary of Contents for Hyster AP20Z

  • Page 1 Hyster A254 (AP20Z) Forklift...
  • Page 2 MAST REPAIR (S/N A615) AP20Z [A254] PART NO. 4131893 4000 SRM 1916...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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 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 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 7: Table Of Contents

    Remove ................................6 Disassemble .................................8 Clean and Inspect ............................. 15 Assemble ................................15 Install .................................20 Mast Adjustments ..............................21 Lateral Mast Adjustment ..........................21 Vertical Mast Adjustment ..........................23 This section is for the following models: (AP20Z) [A254] ©2015 HYSTER COMPANY...
  • Page 8 "THE QUALITY KEEPERS" HYSTER APPROVED PARTS...

  • Page 9: General

    4000 SRM 1916 General General Operator Compartment 0100SRM1915 WARNING Lift Cylinders 2100SRM1914 DO NOT operate an aerial work platform that needs repairs. If a repair is necessary, put a DO Electrical System 2200SRM1913 NOT OPERATE tag on the control handle. Remove the key from the key switch.

  • Page 10: Working Near Power Lines

    General 4000 SRM 1916 WORKING NEAR POWER LINES Table 1. Minimum Safety Approach Distance (MSAD) DANGER Approach Distances For Qualified Employees - Alternating Current The lift is NOT insulated for use near electrical power lines and DOES NOT provide protection Voltage Range Minimum Approach from contact with or close proximity to any...
  • Page 11 4000 SRM 1916 Special Precautions 5. Discharge the capacitors in the controllers by CAUTION connecting a 200-ohm, 2-watt resistor across the lift controller’s negative (B−) and positive To avoid controller damage: (B+) terminals. Wait at least 20 seconds to be 1.

  • Page 12: Description

    Special Precautions 4000 SRM 1916 Legend for Figure 3 1. B- TERMINAL 2. JUMPER LEADS 3. 200-OHM, 2-WATT RESISTOR 4. B+ TERMINAL Figure 3. Traction Controller Description The mast used on the aerial work platform covered ment). See Figure 4. One main lift cylinder is used in this manual is a five stage mast with four mast to raise and lower the aerial work platform.
  • Page 13 4000 SRM 1916 Description 1. FIRST INTERMEDIATE MAST WELDMENT 4. FOURTH INTERMEDIATE MAST WELDMENT 2. SECOND INTERMEDIATE MAST WELDMENT 5. CARRIAGE WELDMENT 3. THIRD INTERMEDIATE MAST WELDMENT 6. LIFT CYLINDER Figure 4. Mast Weldments...

  • Page 14: Mast Repair

    Mast Repair 4000 SRM 1916 Mast Repair REMOVE 8. Turn off all power to aerial work platform by disconnecting the battery and discharging the capacitors. See the Special Precautions section WARNING for procedures to discharge the capacitors. The mast and carriage assemblies, and their com- 9.
  • Page 15 4000 SRM 1916 Mast Repair NOTE: PARTS OF MAST OMITTED FOR CLARITY. 1. NUT 8. BRACKET 2. WASHER 9. FIRST INTERMEDIATE MAST WELDMENT 3. SPRING 10. SECOND INTERMEDIATE MAST WELDMENT 4. FIRST PHASE CABLE 11. THIRD INTERMEDIATE MAST WELDMENT 5. SECOND PHASE CABLE 12.

  • Page 16: Disassemble

    Mast Repair 4000 SRM 1916 DISASSEMBLE NOTE: Remove self-tapping screws with hand tools and not power tools. The use of power tools can strip the self-tapping screws and damage them. 1. Remove threaded end of fourth phasing cable from bracket on carriage weldment. See Fig- ure 5.
  • Page 17 4000 SRM 1916 Mast Repair 1. LIFT BUTTON 7. CAPSCREWS 2. LOWER BUTTON 8. WIRE HARNESS CABLE 3. LOWER CONTROL PANEL 9. ROUND BELT PULLEY 4. MAST SIGNAL CABLE 10. HYDRAULIC TUBE CONNECTION (EXCESS 5. SPRING FLOW PROTECTOR) 6. BRACKET 11.
  • Page 18 Mast Repair 4000 SRM 1916 A. TOP OF MAST B. BOTTOM OF MAST 1. CHAIN ANCHOR 5. CHAIN RETAINER BLOCK 2. CHAIN ANCHOR PIN 6. LIFT CHAIN 3. COTTER PIN 7. SAIL COVER BRACKET 4. LIFT CYLINDER Figure 8. Disconnecting First Set of Lift Chains...
  • Page 19 4000 SRM 1916 Mast Repair A. OUTSIDE VIEW B. INSIDE VIEW 1. MAST SLIDER BLOCKS 3. SELF-TAPPING SCREWS 2. SETSCREWS Figure 9. Mast Slider Blocks Removal...
  • Page 20 Mast Repair 4000 SRM 1916 NOTE: SOME COMPONENTS OF MAST OMITTED FOR CLARITY. NOTE: IN ILLUSTRATION B, TOP VIEW OF MAST, CHAIN ANCHOR PINS MUST FACE OUTBOARD SIDE OF MAST DURING INSTALLATION, AS SHOWN ABOVE. A. BOTTOM VIEW OF MAST B.
  • Page 21 4000 SRM 1916 Mast Repair 12. Remove two cotter pins and two chain anchor 24. Using lifting device, lift third intermediate pins, and disconnect lift chains from chain re- mast weldment up and slide it off of second in- tainer block at top of fourth intermediate mast termediate mast weldment.
  • Page 22 Mast Repair 4000 SRM 1916 NOTE: CHAIN SHEAVES AND CABLE PULLEY ON FOURTH INTERMEDIATE MAST WELDMENT SHOWN. CHAIN SHEAVES AND CABLE PULLEYS ON ALL OTHER INTERMEDIATE MAST WELDMENTS ARE SIMI- LAR. A. TOP OF MAST B. BOTTOM OF MAST 1. SNAP RING 3.

  • Page 23: Clean And Inspect

    Some parts may be damaged by welding. To pre- Figure 12. vent an injury, always get authorization from your dealer for Hyster aerial work platforms before 5. Install washer on outside of cable pulley only. welding on the mast or mast components.

  • Page 24: Install

    Mast Repair 4000 SRM 1916 WARNING Use a lifting device to move mast weldments to prevent serious injury. Each mast weldment weighs approximately 68 kg (150 lb). 7. Using a lifting device, lift second intermediate mast weldment and slide it through mast slider blocks on top of first intermediate mast weld- ment to the position shown in Figure 13.
  • Page 25 4000 SRM 1916 Mast Repair 16. Install mast slider blocks with self-tapping NOTE: Apply Loctite® Blue 242 Threadlocker to screws into the top and bottom of second inter- setscrew threads prior to installation. mediate mast weldment. Tighten self-tapping 25. Install four setscrews (two on each slider block) screws to 2.1 N•m (18.6 lbf in).
  • Page 26 Mast Repair 4000 SRM 1916 28. Install two chain anchors to chain retainer 38. Install two lift chains, with a length of blocks in the bottom of third intermediate mast 1924.05 mm (75 3/4 in.), to two chain anchors weldment with four nuts and two pins. See Fig- with two chain anchor pins and two cotter pins.
  • Page 27 4000 SRM 1916 Mast Repair 49. Install phasing cable pulley to stubshaft on bot- tom of fourth intermediate mast weldment. In- stall washer on outside of pulley. 50. Install snap rings to outside of both round belt pulley and phasing cable pulley. See Figure 11. NOTE: Do not adjust setscrews at this moment.

This manual is also suitable for:

A254

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