Hyster G005 Operating instructions

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

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

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
•Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•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.
•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 (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Vista®Masts Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Carriages........................................................................................................................................................ 1
Two-Stage Mast With Limited Free-Lift ...................................................................................................... 1
Two-Stage Mast With Full Free-Lift Mast ................................................................................................... 2
Three-Stage Mast With Full Free-Lift ......................................................................................................... 3
Safety Procedures When Working Near Mast.................................................................................................. 5
Forks Replacement ............................................................................................................................................ 7
Remove and Install........................................................................................................................................ 7
Hook Fork .................................................................................................................................................. 7
Remove .................................................................................................................................................. 7
Install..................................................................................................................................................... 7
Pin Fork ..................................................................................................................................................... 8
Remove .................................................................................................................................................. 8
Install..................................................................................................................................................... 8
Carriage Repair.................................................................................................................................................. 8
Remove ........................................................................................................................................................... 8
Sideshift Carriage Repair.................................................................................................................................. 10
Sideshift Carriage (Earlier Designs) ............................................................................................................ 10
Disassemble............................................................................................................................................... 10
Assemble.................................................................................................................................................... 11
Install......................................................................................................................................................... 14
Sideshift Carriage (1993 and Later Design) ................................................................................................ 14
Remove....................................................................................................................................................... 14
Repairs ....................................................................................................................................................... 14
Install......................................................................................................................................................... 14
Weight of Mast Parts ......................................................................................................................................... 17
Two-Stage Mast With Limited Free-Lift Repair .............................................................................................. 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Clean and Inspect.......................................................................................................................................... 19
Assemble ........................................................................................................................................................ 19
Install ............................................................................................................................................................. 21
Two-Stage Mast With Full Free-Lift Repair..................................................................................................... 21
Remove ........................................................................................................................................................... 21
Disassemble ................................................................................................................................................... 21
Clean and Inspect.......................................................................................................................................... 23
Assemble ........................................................................................................................................................ 23
Install ............................................................................................................................................................. 23
Three-Stage Mast With Full Free-Lift.............................................................................................................. 24
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 24
Clean and Inspect.......................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 26
Mast Operation Check....................................................................................................................................... 28
Lift and Tilt System Leak Check ...................................................................................................................... 29
Lift System..................................................................................................................................................... 29
Tilt System..................................................................................................................................................... 29
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment............................................................................ 30
Lift Chain Adjustments ..................................................................................................................................... 30
©2002 HYSTER COMPANY i

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:
[e-mail]

Table of Contents Vista®Masts
TABLE OF CONTENTS (Continued)
Mast Adjustments.............................................................................................................................................. 31
Carriage Adjustment ......................................................................................................................................... 33
Troubleshooting.................................................................................................................................................. 34
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]
ii

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. The lift cylinders and the lowering control valves are described in the section Lift Cylinders 4000
SRM 1354000 YRM 135. The tilt cylinders are described in the section Tilt Cylinders 2100 SRM 103 .
Description and Operation
The vertical frames of a mast are called weldments.
See Figure 1. Channels, load rollers and crossmem-
bers are parts of the weldments. The channels on
each side of the weldment are the support members
of the mast and the tracks for the load rollers. Dur-
ing lifting and lowering a load, large forces are put
on the mast assembly. The load rollers reduce the
friction between the channels when the weldments
move vertically.
Each mast can tilt forward and backward. Tilt
cylinders are installed between the frame of the lift
truck and the outer weldment of the mast. The pivot
mounts at the bottom of the outer weldment connect
the mast to the lift truck. During the tilt operation,
the mast rotates on the pivot pins in the frame.
1. FORKS
2. CARRIAGE
3. LOAD BACKREST
EXTENSION
4. OUTER
WELDMENT
5. INNER WELDMENT
6. LIFT CYLINDER
Figure 1. Mast Components
CARRIAGES
The carriage is a separate section that moves on load
rollers within the vertical channels of the inner weld-
ment. Forks or other types of load handling equip-
ment are attached to the carriage. A load backrest
extension is installed on the carriage.
A sideshift carriage permits the operator to hydrauli-
cally change the lateral position of the load handling
device on the carriage.
TWO-STAGE MAST WITH LIMITED
FREE-LIFT
The Vista Two-Stage mast has two weldments, an
outer weldment and an inner weldment. See Fig-
ure 2. The outer weldment is connected to the lift
truck by the pivot mounts and the tilt cylinders. The
top of the outer weldment has one load roller on each
side. The base of the inner weldment has one load
roller on each side. These load rollers travel along
the channels of the weldments. The angle of the load
rollers permits them to control the forces from the
front, back and sides of the mast. The shims on the
load rollers control the lateral clearance between the
weldments and the load rollers. Strip bearings are
installed at the top of each side of the outer weld-
ment. The strip bearings keep the correct clearance
(forward and backward) between the outer weldment
and the inner weldment.
The two-stage mast has two single stage lift cylin-
ders. The lift cylinders are installed at the back of the
outer weldment. The base of each lift cylinder sits in
a mount at the bottom of the outer weldment. The
hydraulic fitting for each lift cylinder goes through a
hole in the mount. The top of each lift cylinder (cylin-
der rod) fits into a guide at the top of the inner weld-
ment. A bracket on the cylinder shell holds the lift
cylinder in position on the outer weldment. Opera-
tion of the lift cylinders extends and retracts the in-
ner weldment.
1

Description and Operation 4000 SRM 340
1. LIFT CYLINDER (2)
2. LIFT CHAIN
3. OUTER WELDMENT
4. CHAIN SHEAVE
5. INNER WELDMENT
6. CARRIAGE
7. FROM MAIN CONTROL VALVE
8. EXTERNAL LOWERING CONTROL VALVE
9. INTERNAL LOWERING CONTROL VALVE
Figure 2. Two-Stage Mast With Limited
Free-Lift
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. When the lift cylinders ex-
tend, the lift chains transfer the force from the lift
cylinders to the carriage.
When the lift cylinders retract, the weight of the
load, carriage and inner weldment push the oil
from the lift cylinders. The oil flows from the lift
cylinders, through the lowering control valves, main
control valve and then to the hydraulic tank.
TWO-STAGE MAST WITH FULL FREE-LIFT
MAST
The Vista Free-Lift mast has an inner weldment, an
outer weldment and three single stage lift cylinders.
See Figure 3. It is called a free-lift mast because the
carriage can travel to the top of the inner weldment
without increasing mast height. The free-lift mast
has load roller and strip bearing arrangements sim-
ilar to the two-stage mast.
The two main lift cylinders are installed at the back
of the outer weldment. The base of each lift cylin-
der sits in a mount at the bottom of the outer weld-
ment. The hydraulic fitting for each lift cylinder goes
through a hole in the mount. The top of each lift
cylinder (cylinder rod) fits into guides at the top of
the inner weldment.
The free-lift cylinder is installed in the inner weld-
ment. The main lift cylinder on the right side of the
mast and the free-lift cylinder each have an inter-
nal lowering control valve. A single external lower-
ing control valve is connected by tubing to all of the
lift cylinders. Two chain sheaves are installed on the
cylinder rod of the free-lift cylinder. The lift chains
are connected to a mount behind the free-lift cylin-
der. The chains then go over the sheaves and are
connected to the carriage.
The three lift cylinders are connected by hoses and
tubing. To extend the mast, oil from the main control
valve flows to all of the lift cylinders at the same time.
The free-lift cylinder raises first because it lifts the
least amount of weight. The free-lift cylinder raises
the carriage to the top of the inner weldment. After
the free-lift cylinder reaches the end of its stroke, the
main lift cylinders begin to extend and raise the inner
weldment.
2

4000 SRM 340 Description and Operation
1. MAIN LIFT CYLINDER (2)
2. OUTER WELDMENT
3. FREE-LIFT CYLINDER
4. INNER WELDMENT
5. CHAIN SHEAVE
6. LIFT CHAIN
7. CARRIAGE
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 3. Two-Stage Mast With Full Free-Lift
During lowering, the main lift cylinders lower first
because they have a greater load. After the main lift
cylinders have retracted, the free-lift cylinder lowers.
All of the oil from the lift cylinders flows through the
lowering control valves to the hydraulic tank.
THREE-STAGE MAST WITH FULL
FREE-LIFT
The Vista Three-Stage mast has an outer, an inter-
mediate and an inner weldment. See Figure 4. Three
single stage lift cylinders are used on the mast to
raise the carriage and extend the weldments. The
weldments are telescopic and have load roller and
strip bearing arrangements similar to the two-stage
mast. The two main lift cylinders are installed at
the back of the outer weldment. The base of each lift
cylinder is held on a mount at the bottom of the outer
weldment. The hydraulic fittings for the lift cylin-
ders go through holes in the mounts. The top of each
main lift cylinder (cylinder rod) fits into a guide at
the top of the intermediate weldment. The free-lift
cylinder is installed in the inner weldment.
The two main lift chains fasten at one end near the
top of the outer weldment. The lift chains then go
over sheaves at the top of the intermediate weldment
and fasten at the bottom of the inner weldment. The
free-lift chains are connected to a mount behind the
free-lift cylinder. The chains then go over the sheaves
and connect to the carriage.
3

Description and Operation 4000 SRM 340
A. PHASE 2
1. MAIN LIFT CYLINDER (2)
2. OUTER LIFT CHAIN
3. FREE-LIFT CYLINDER
4. INNER LIFT CHAIN
5. INNER WELDMENT
6. INTERMEDIATE WELDMENT
7. OUTER WELDMENT
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 4. Three-Stage Mast With Full Free-Lift
4