FRAMEA1.00-1.50XL (A20-30XL) [C203]

PART NO. 1482603 100 SRM 793

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains 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 repairon 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 PUTTHE 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 partsmust meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed beforeusing 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 fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1Description ......................................................................................................................................................... 1Overhead Guard Repair .................................................................................................................................... 2

Remove ........................................................................................................................................................... 2Install ............................................................................................................................................................. 2

Hood and Seat Assembly Repair ....................................................................................................................... 2Remove ........................................................................................................................................................... 4Install ............................................................................................................................................................. 4

Counterweight Repair ....................................................................................................................................... 4Remove ........................................................................................................................................................... 4Install ............................................................................................................................................................. 5

Hydraulic Tank Repair ...................................................................................................................................... 6Inspect ............................................................................................................................................................ 6Small Leaks, Repair ...................................................................................................................................... 6Large Leaks, Repair ...................................................................................................................................... 6Clean .............................................................................................................................................................. 6

Steam Method............................................................................................................................................ 6Chemical Solution Method........................................................................................................................ 7

Additional Preparations for Repair .............................................................................................................. 7Safety Labels ...................................................................................................................................................... 7Battery Specifications........................................................................................................................................ 10

This section is for the following models:

A1.00-1.50XL (A20-30XL) [C203]

2002 HYSTER COMPANY i

"THEQUALITYKEEPERS"

HYSTERAPPROVEDPARTS

100 SRM 793 Description

GeneralThis section has a description and the service procedures for the parts of the frame. These parts include thecounterweight assembly, overhead guard, hydraulic tank, access panels, and positions for decals.

DescriptionThe frame is a single weldment with mounts forthe counterweight, overhead guard, mast and loadwheels, and the master drive unit. See Figure 1 andFigure 3. The hydraulic tank is part of the frame.The hood panel is composed of two parts, a front andrear panel, that can be opened or removed for accessto the battery compartment, electronic controller,and the traction motor on the master drive unit. Ac-cess panels on each side of the lift truck are removed

by lifting them from the frame. These panels givefurther access and protection to the battery.

The weight of the battery is the main part of thecounterweight system on an electric lift truck. Eachmodel of lift truck has a cast-iron counterweight witha weight necessary for the indicated capacity. A slotin the overhead guard permits removal of the batterywithout removing the overhead guard.

1. OVERHEAD GUARD2. SEAT ASSEMBLY3. HOOD4. OPERATOR RESTRAINT

5. COUNTERWEIGHT6. LEFT SIDE PANEL (SHOWN)7. FRAME8. FLOOR PLATE

Figure 1. Frame Parts

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Hood and Seat Assembly Repair 100 SRM 793

The hydraulic pump motor and the hydraulic tankare under the floor plate in the operator compart-ment. This floor plate is held in position by tabs andcan be removed to give access to hydraulic compo-nents. The control valve is fastened to the front of

the battery compartment. A cover protects the con-trol valve and control linkage. The cover is fastenedin position by machine screws.

Overhead Guard RepairREMOVE

WARNINGThe overhead guard is part of the operator pro-tection system. Do not operate the lift truckwithout the overhead guard correctly fastenedto the lift truck.

1. Remove the battery as described in the sectionPeriodic Maintenance 8000 SRM 798.

2. Remove the two capscrews that hold the rearsupports of the overhead guard to the counter-weight. Slots on either side of the counterweightpermit access to the nuts and washers.

3. Remove the two capscrews that hold the twofront supports of the overhead guard to the cowl.

4. Use a lifting device or have another person giveassistance to lift the overhead guard from the lifttruck.

INSTALL1. Use a lifting device or have another person give

assistance to lift the overhead guard onto the lifttruck.

2. Install and tighten the four capscrews, washers,and nuts that hold the overhead guard to thelift truck. Tighten the capscrews to 66 Nm(48 lbf ft).

3. Install the battery as described in the section Pe-riodic Maintenance 8000 SRM 798.

Hood and Seat Assembly RepairThe hood panels are a cover for the battery, electroniccontroller, and traction motor, and are a battery re-straint. The function of the battery restraint, whenthe hood panels are correctly locked to the frame, isto hold the battery in the battery compartment if anaccident causes the lift truck to tip over. A slidinglatch mechanism on the front hood panel locks thefront panel to the frame for lift truck operation. SeeFigure 2. The sliding latch unlocks the front hoodpanel from the frame so that the hood can be raisedto the open position for access to the battery.

The latch mechanism must operate correctly beforethe lift truck can be operated. The latch must notbe worn and must fully engage the frame. The fronthood panel must be locked in the closed positionwhen the lift truck is operated. If the latch mecha-nism does not lock the hood in the closed position, donot operate the lift truck.

1. HOOD 2. LATCH

Figure 2. Battery Restraint Latch

The rear hood panel can be removed by removing thetwo capscrews that hold the panel in place on the twobrackets. See Figure 3. A handle to disconnect the

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100 SRM 793 Hood and Seat Assembly Repair

battery is located to the right of the operator seat andtoward the back of the front hood panel. This handleis an emergency disconnect that permits the operator

to quickly disconnect the battery while on the seat ofthe lift truck. The hood must be opened to reconnectthe battery.

1. REAR HOOD PANEL2. SEAT3. OPERATOR RESTRAINT4. FRONT HOOD PANEL5. LATCH6. LEFT ACCESS PANEL

7. RIGHT ACCESS PANEL8. FLOOR PLATE9. FENDER - (RIGHT SHOWN)10. VALVE COVER11. COUNTERWEIGHT12. PIN

13. REAR HOOD PANEL BRACKET(1 OF 2 SHOWN)

14. FRONT HOOD PANEL HINGE(1 OF 2 SHOWN)

15. FRONT HOOD PANEL LIFTHANDLE

Figure 3. Hood and Seat Assembly

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Counterweight Repair 100 SRM 793

The hood, seat belt, seat, and seat mount are all partsof the operator restraint system. Checks and adjust-ments for the operator restraint system are describedin the Operating Manual and the section PeriodicMaintenance 8000 SRM 798.

The seat assembly slides on seat rails that are fas-tened to the hood by four capscrews. A lever at theleft front side of the base controls the adjustment ofthe seat to the forward and backward positions.

The optional semi-suspension seat assembly includesan adjustable back support. A knob handle on thelower right side of the seat allows the operator to tiltand adjust the back support portion of the seat to amaximum angle of 3 degrees forward and 12 degreesbackward. A weight adjustment control lever is onthe right side of the seat, on the back support portion.The seat can be adjusted to support a weight rangeof 60 to 120 kg (132 to 264 lb).

All seats have a seat switch installed in the bottomcushion that senses pressure. When the operator isnot on the seat, the seat switch opens and stops theoperation of the lift truck.

REMOVE1. Disconnect the battery connector. See Figure 3.

2. Disconnect the electrical connector to the seatswitch. Remove the four capscrews that fasten

the seat base to the hood. Lift the seat assemblyfrom the hood.

3. Remove the capscrews that fasten the front hoodpanel to the hinges on the frame. Lift the panelfrom the lift truck.

4. Remove the capscrews that fasten the rear hoodpanel to the brackets on the counterweight. Liftthe panel from the lift truck.

INSTALL1. Install the rear hood panel by aligning the two

holes on the panel to the holes on the bracketswhich are located on the counterweight. See Fig-ure 3. Insert and tighten the two capscrews thatjoin the rear hood panel to the counterweight.

2. Place the front hood panel onto the lift truck. Besure the holes on the panel line up with the holeson the hinges found on the frame. Insert andtighten the capscrews to secure the front hoodpanel to the truck frame.

3. Place the seat on the front hood panel and alignthe holes. Set the four capscrews into the holesand tighten as needed. Connect the electricalconnector to the seat switch.

4. Connect the battery connector.

Counterweight RepairREMOVE

WARNINGDo not operate the lift truck if the capscrewsfor the counterweight are not installed. Whenthe capscrews are removed, the counterweightcan fall from the lift truck.

1. Remove the battery. See the section PeriodicMaintenance 8000 SRM 798 for removal of thebattery.

2. Remove the overhead guard as described in Over-head Guard Repair.

3. Remove the rear hood cover and battery connec-tor mounting plate assembly.

WARNINGThe counterweight is very heavy. Make surethe sling, chain, eyebolts, and crane or liftingdevice has the capacity to lift the counter-weight. See Table 1.

4. Install eyebolts in the holes where the overheadguard fastens to the counterweight. See Fig-ure 4. Attach a chain or sling to the eyebolts. Usea crane or other lifting device to hold the weightof the counterweight. Make sure the sling, chain,eyebolts, and crane or lifting device has the ca-pacity to lift the counterweight. See Table 1.

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100 SRM 793 Counterweight Repair

1. COUNTERWEIGHT2. INSTALL EYEBOLTS HERE TO LIFT

COUNTERWEIGHT3. MOUNT HOLES

Figure 4. Counterweight

Table 1. Weight of Counterweights

A1.00XL (A20XL) 504 to 554 kg(1111 to 1222 lb)

A1.25XL (A25XL) 677 to 727 kg(1493 to 1603 lb)

A1.50XL (A30XL) 815 to 865 kg(1797 to 1907 lb)

5. Access to the two capscrews that hold the coun-terweight to the frame is at the bottom inside of

the battery compartment. Access to the nuts isfrom under the counterweight. Remove the twocapscrews, flat washers, lockwashers, and nutsthat hold the counterweight to the frame. Usea crane or lifting device to lift the counterweightaway from the frame.

INSTALL

WARNINGThe counterweight is very heavy. Make surethe sling, chain, eyebolts, and crane or liftingdevice has the capacity to lift the counter-weight. See Table 1.

1. Use a crane to lift the counterweight into posi-tion. The lift points for the counterweight arenot at the center of gravity of the counterweight.Some assistance will be required to engage theattachment points on the frame. The counter-weight engages two vertical plates on the frame.These plates hold the counterweight in positionon the lift truck.

2. Install the two capscrews, flat washers, lock-washers, and nuts that hold the counterweightto the frame. Tighten the capscrews to 320 Nm(236 lbf ft).

3. Disconnect the sling or chain. Remove the eye-bolts from the counterweight.

4. Install the battery.

5. Install the overhead guard as described in Over-head Guard Repair. Install the hood and seat as-sembly.

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Hydraulic Tank Repair 100 SRM 793

Hydraulic Tank RepairINSPECTMake a visual inspection of all sides of the tank. In-spect the welds for cracks and leakage. Check forwet areas, accumulation of dirt, and loose or miss-ing paint caused by leakage. Areas of the tank thatare not easily seen can be checked with an inspectionmirror and a light that is approved for locations withflammable vapors.

SMALL LEAKS, REPAIRUse the following procedure to repair small leaks.

1. Use steam to clean the area around the leak. Re-move all paint and dirt around the leak.

WARNINGDo not use tools that generate sparks, heat, orstatic electricity. The vapors in the tank cancause an explosion.

2. Apply Loctite 290 to the leak. Follow the in-structions of the manufacturer.

LARGE LEAKS, REPAIR1. Use one of the procedures described under Clean

to clean and prepare the tank for repairs.

2. Use acceptable welding practices to repair thetank. See the American National StandardSafety In Welding and Cutting ANSI Z 49.1 -1973.

CLEAN

WARNINGSpecial procedures must be followed whenlarge leaks or other repairs need welding orcutting. All work must be done by authorizedpersonnel. If the tank is cleaned inside a build-ing, make sure there is enough ventilation.See the following manuals for additional infor-mation. Safe Practices for Welding and Cutting Con-

tainers That Have Held Combustibles by theAmerican Welding Society, A6.0-65.

Safety In Welding and Cutting, American Na-tional Standard, ANSI Z 49.1 - 1973.

When cleaning the tank, do not use solutions thatmake dangerous gases at normal temperatures orwhen heated. Wear eye and face protection. Protectthe body from burns.

When cleaning with steam, use a hose with a mini-mum diameter of 19 mm (0.75 in.). Control the pres-sure of the steam by a valve installed at the nozzle ofthe hose. If a metal nozzle is used, it must be made ofa material that does not make sparks. Make an elec-trical connection between the nozzle and the tank.Connect a ground wire to the tank to prevent staticelectricity.

Steam MethodUse the following procedure to clean the tank withsteam.

1. Remove all the parts from the tank. Install thedrain plug.

2. Fill the tank 1/4 full with a solution of water andsodium bicarbonate or sodium carbonate. Mix0.5 kg (1 lb) per 4 liter (1 gal) of water.

3. Mix the solution in the tank using air pressure.Make sure all the surfaces on the inside of thetank are flushed with the solution. Drain thetank.

4. Put steam into the tank until the tank does nothave odors and the metal is hot. Steam vaporsmust come from all the openings.

5. Flush the inside of the tank with boiling water.Make sure all the loose material is removed fromthe inside of the tank.

6. Make an inspection of the inside of the tank. If itis not clean, repeat Step 4 and Step 5 and makeanother inspection. When making inspections,use a light that is approved for locations withflammable vapors.

7. Put plugs in all the openings in the tank. Wait 15minutes; then remove the inlet and outlet plugs.Test a sample of the vapor with a special indi-cator for gas vapors. If the amount of flammablevapors is above the lower flammable limit, repeatthe cleaning procedures.

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100 SRM 793 Safety Labels

Chemical Solution MethodIf the tank cannot be cleaned with steam, use thefollowing procedure.

1. Mix a solution of water and trisodium phosphateor a cleaning compound with an alkali base. Fol-low the instructions given by the manufacturer.

2. Fill the tank with the cleaning solution. Use com-pressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank withhot (boiling) water. Make sure all the cleaningcompound is removed.

4. Make an inspection of the inside of the tank.If the tank is not clean, repeat Step 1 throughStep 3. Make another inspection of the tank.When making inspections, use a light that is ap-proved for locations with flammable vapors.

5. Check the tank for flammable vapors using a spe-cial indicator for gas vapors. If the amount of

flammable vapors is above the lower flammablelimit, repeat the cleaning procedures.

ADDITIONAL PREPARATIONS FORREPAIRIf nitrogen gas or carbon dioxide gas is available, pre-pare the tank for welding using these gases. See themanual Safe Practices for Welding and Cutting Con-tainers That Have Held Combustibles by the Ameri-can Welding Society, A6.0-65. If these gases are notavailable, another method using water can be usedas follows.

1. Fill the tank with water to just below the pointwhere the work will be done. Make sure thespace above the level of the water has a vent.

2. Use acceptable welding practices to repair thetank. See the American National StandardSafety In Welding and Cutting ANSI Z 49.1 -1973.

Safety LabelsWARNING

Safety labels are installed on the lift truck togive information about operation and possiblehazards. It is important that all safety labelsare installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Anychange to the lift truck, the tires, or its equip-ment can change the lifting capacity. The lifttruck must be rated as equipped and the name-plate must show the new capacity rating. Con-tact your dealer for Hyster lift trucks for a re-placement nameplate.

If a label must be replaced, use the following proce-dure to install a new label. See Figure 5.

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the recom-mendations of the manufacturer.

1. Make sure the surface is dry and has no oil orgrease. Do not use solvent on new paint. Cleanthe surface of old paint with a cleaning solvent.

2. Remove the paper from the back of the label. Donot touch the adhesive surface.

3. Carefully hold the label in the correct positionabove the surface. The label cannot be moved af-ter it touches the surface. Make sure that all airis removed from under the label, and the cornersand edges are tight.

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Safety Labels 100 SRM 793

Figure 5. Location of Labels (Sheet 1 of 2)

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100 SRM 793 Safety Labels

Figure 5. Location of Labels (Sheet 2 of 2)

9

Battery Specifications 100 SRM 793

Legend for Figure 5

1. MAST WARNING2. EMERGENCY BATTERY DISCONNECT3. NO RIDER4. PARKBRAKE WARNING5. MAST WARNING6. MAST PINCH POINT WARNING7. OPERATOR RESTRAINT8. CAPACITY PLATE9. MODEL LABEL

10. LOGO - (MAST AND SIDE ACCESS PANELS)11. LOGO - (COUNTERWEIGHT)12. PATENT AND TRADEMARKS13. NAMEPLATE TAG14. HOIST AND TILT15. AUXILIARY FUNCTION - SIDESHIFT16. HYDRAULIC OIL FILL17. OPERATOR WARNING

Battery SpecificationsBattery Size

Minimum/Maximum Maximum Minimum/Maximum

Model

Length Width Height Weight

A1.00XL(A20XL)

486/497 mm(19.1/19.5 in.)

825/830 mm(32.5/32.6 in.)

678 mm(26.7 in.)

450/800 kg(992/1764 lb)

A1.25XL(A25XL)

486/497 mm(19.1/19.5 in.)

825/830 mm(32.5/32.6 in.)

678 mm(26.7 in.)

450/800 kg(992/1764 lb)

A1.50XL(A30XL)

486/497 mm(19.1/19.5 in.)

825/830 mm(32.5/32.6 in.)

678 mm(26.7 in.)

620/800 kg(1367/1764 lb)

The clearance between the battery (lifting eyes) and the hood determines the maximum battery height.NOTE: Minimum gap is 4 mm (0.18 in.) and maximum gap is 18 mm (0.71 in.) for the size of the battery com-partment. The battery specification tables show the maximum size tolerances that will permit the battery tostill fit into the battery compartment. The clearance between the battery lifting eyes and the hood determinesthe minimum battery height.

WARNINGThe battery must fit the battery compartment so the battery restraint system will operate cor-rectly.

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TECHNICAL PUBLICATIONS

100 SRM 793 3/00 Printed in United Kingdom

tocFrameSafety Precautions Maintenance and RepairGeneralDescriptionOverhead Guard RepairRemoveInstall

Hood and Seat Assembly RepairRemoveInstall

Counterweight RepairRemoveInstall

Hydraulic Tank RepairInspectSmall Leaks, RepairLarge Leaks, RepairCleanSteam MethodChemical Solution Method

Additional Preparations for Repair

Safety LabelsBattery Specifications

tablesTable 1. Weight of Counterweights