FOUR-STAGE MAST

S40-60XM [D187];
E45-65XM, E45-65XM 2 [F108];
E45-65Z [G108]

PART NO. 897644 4000 SRM 563

 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!
Four-Stage Mast Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Carriages ........................................................................................................................................................ 1
Mast Mounts .................................................................................................................................................. 2
Mast................................................................................................................................................................ 2
Description................................................................................................................................................. 2
Operation ................................................................................................................................................... 3
Forks Repair....................................................................................................................................................... 6
Remove ........................................................................................................................................................... 6
Install ............................................................................................................................................................. 6
Safety Procedures When Working Near Mast.................................................................................................. 8
Carriage Repair.................................................................................................................................................. 11
Remove ........................................................................................................................................................... 11
Standard Carriage..................................................................................................................................... 11
Sideshift Carriage ..................................................................................................................................... 11
Repairs ........................................................................................................................................................... 12
Install ............................................................................................................................................................. 13
Standard Carriage..................................................................................................................................... 13
Sideshift Carriage ..................................................................................................................................... 13
Mast Repair........................................................................................................................................................ 14
Remove ........................................................................................................................................................... 14
Disassemble ................................................................................................................................................... 14
Clean and Inspect .......................................................................................................................................... 15
Assemble ........................................................................................................................................................ 16
Install ............................................................................................................................................................. 19
Lift Cylinders Repair ......................................................................................................................................... 22
Remove ........................................................................................................................................................... 22
Main Lift Cylinders ................................................................................................................................... 22
Free-Lift Cylinders.................................................................................................................................... 22
Disassemble ................................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 26
Main Lift Cylinder..................................................................................................................................... 26
Free-Lift Cylinder ..................................................................................................................................... 27
Header Hose Arrangements .............................................................................................................................. 28
Header Hoses, Install .................................................................................................................................... 28
Lift and Tilt System Leaks Check..................................................................................................................... 35
Lift Cylinders Leaks Check........................................................................................................................... 35
Tilt Cylinders Leaks Check........................................................................................................................... 35
Tilt Cylinders Adjustment................................................................................................................................. 36
Lift Chain Adjustments ..................................................................................................................................... 36
Mast Adjustments.............................................................................................................................................. 38
Carriage Adjustments........................................................................................................................................ 40
Troubleshooting.................................................................................................................................................. 41

This section is for the following models:

S40-60XM [D187];
E45-65XM, E45-65XM 2 [F108];
E45-65Z [G108]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
4000 SRM 563
General
This section has the description and repair proce-
dures for the four-stage, full free-lift (FFL) mast,
and the carriages. Checks, adjustments, and trou-
bleshooting information are at the end of this section.
The mast is used to lift a load vertically. The mast
has two movements controlled by hydraulic cylin-
ders: forward and backward tilt, and the lifting and
lowering of the mast weldments and carriage. The
outer weldment can move on the pivot pins at the
mast mounts. The operation of the tilt cylinders
causes the mast to tilt forward and backward. The
Description
CARRIAGES
The carriage is a part of the mast assembly and
moves within the channels of the inner mast. See
Figure 1. Forks or other types of load handling
equipment are attached to the carriage. A load
A. CARRIAGE
1. LOAD BACKREST
2. STANDARD CARRIAGE
3. FORKS
4. FORK REMOVAL NOTCH
5. TOP BUSHING
Figure 1. Carriage and Forks
Description
tilt cylinders are fastened between the frame of the
lift truck and the outer weldment of the mast. Hy-
draulic lift cylinders are installed vertically on the
mast weldments. The lift cylinders and lift chains
raise and lower the weldments and the carriage. The
hydraulic operation of the lift cylinders and tilt cylin-
ders is described in the section Main Control Valve
2000 SRM 562 for lift truck models E45-65XM,
E45-65XM 2 (F108) and E45-65Z (G108) and Main
Control Valve 2000 SRM 516 for S40-65XM (D187)
trucks.
backrest extension is attached to the carriage and
adds support for a load that has multiple pieces. The
sideshift carriage lets the operator move the forks
and load from side to side. This function makes it
easier for the operator to align the forks with a load
or align the load with a stack.
B. SIDESHIFT CARRIAGE
6. TOP BAR
7. BOTTOM BUSHING
8. BOTTOM BAR
9. SIDESHIFT CYLINDER
10. CYLINDER MOUNTING BRACKET
1
Description 4000 SRM 563

The sideshift carriage hangs on the fork bars of the

standard carriage. Special bushings fit between the
sideshift carriage and the fork bars. A sideshift cylin-
der is installed on a bracket that fits on the standard
carriage. The sideshift cylinder moves the sideshift
carriage on the standard carriage.

MAST MOUNTS
The mast can tilt forward and backward. See Fig-
ure 14. Tilt cylinders are fastened between the frame
of the lift truck and the outer mast of the mast to
change the angle of the mast and forks. Pivot pins
are installed in the drive axle hangers. The pivot
pins rotate in bushings in the hangers. The outer
mast has mounts that fit on the pivot pins. Cap-
screws hold the mast to the pivot pins.

MAST
Description
The full free-lift, four-stage mast has four mast up-
rights: outer, inter#2, inter#3, and inner. See Fig-
ure 2. Two single-stage main lift cylinders and a
free-lift cylinder are used to raise the carriage and
extend the mast uprights. It is called a full free-lift
mast because the carriage can travel to the top of the
inner mast without extending the inner mast.

Legend for Figure 2

1. OUTER MAST
2. INTER#2 MAST
3. INTER#3 MAST
4. INNER MAST
5. FREE-LIFT CHAINS
6. FREE-LIFT CYLINDER
7. MAIN LIFT CYLINDER
8. MAIN LIFT CHAIN #1
(MAIN LIFT CHAIN #2 NOT SHOWN)

Figure 2. Four-Stage Mast

2
4000 SRM 563 Description

The mast uprights are telescopic and use load rollers
and strip bearings to keep them in alignment. The
load rollers are installed at the top of the outer, in-
ter#2, and inter#3 masts. Load rollers are also used
at the bottom of the inter#2, inter#3, and the inner
mast. These load rollers travel along the flanges of
the masts. The angle of the load rollers permits them
to control the forces from the front, back, and sides
of the mast. The strip bearings are installed at the
top of the outer, inter#2, and inter#3 masts and help
keep the correct clearance between the masts. The
load rollers and strip bearings are adjustable with
shims.
The two main lift cylinders are installed at the back
of the outer mast. The base of each lift cylinder sits
in a mount at the bottom crossmember of the outer
mast. The top of each main lift cylinder (cylinder rod)
fits into a guide at the top crossmember of the inter#2
mast. The free-lift cylinder is installed to the inner
mast. The free-lift and left-hand main lift cylinder
has an internal (secondary) lowering control valve.
A single external (primary) lowering control valve is
connected by tubing and hoses to all of the lift cylin-
ders.
mast. After the free-lift cylinder reaches the end of
its stroke, the main lift cylinders begin to extend. As
the main lift cylinders extend, the inter#2 mast is
raised by the lift cylinders. The inter#3 and inner
masts are raised by the lift chains. See Figure 4.
The left-hand lift cylinder has a small amount of oil
below the piston. The free-lift cylinder has a small
amount of oil above the piston. This oil provides a hy-
draulic cushion during operation. See Figure 5 and
Figure 6. 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 oil from the lift cylinders flows
through the lowering control valves to the hydraulic
tank.

One set of main lift chains is connected to mounts

that are near the top of the outer mast. The lift
chains then go over sheaves at the top of the inter#2
mast and fasten at the bottom of the inter#3 mast.

Another set of main lift chains is connected to mounts

that are near the top of the inter#2 mast. The lift
chains then go over sheaves at the top of the inter#3
mast and fasten at the bottom of the inner mast.

The free-lift chains connect at one end of the cross-

member for the free-lift cylinder. Two chain sheaves
are installed on a crosshead on the cylinder rod of the
free-lift cylinder. The chains then go over sheaves on
the crosshead and connect to the carriage.
1. MAIN LIFT CYLINDER (LEFT-HAND)
Operation 2. FREE-LIFT CYLINDER
3. MAIN LIFT CYLINDER (RIGHT-HAND)
The three hydraulic cylinders are connected by hoses 4. LOWERING CONTROL VALVE (INTERNAL)
and tubing as shown in Figure 3. To extend the mast, 5. LOWERING CONTROL VALVE (EXTERNAL)
6. TO/FROM MAIN CONTROL VALVE
oil from the main control valve flows to all cylinders
at the same time. The free-lift cylinder extends first Figure 3. Hydraulic Schematic
because it lifts the least amount of weight. The free-
lift cylinder raises the carriage to the top of the inner

3
Description 4000 SRM 563

Figure 4. Mast Operation

4
4000 SRM 563 Description

Legend for Figure 4

A. LOWERED C. FULLY RAISED
B. FREE-LIFT
1. MAIN LIFT CYLINDER 7. CARRIAGE
2. OUTER MAST 8. FORK
3. INTER#2 MAST 9. MAIN LIFT CHAIN #1
4. INTER#3 MAST 10. MAIN LIFT CHAIN #2
5. FREE-LIFT CYLINDER 11. FREE-LIFT CHAIN
6. INNER MAST

1. CYLINDER ROD 5. PISTON

2. CYLINDER SHELL 6. INTERNAL CHECK
3. LARGE ORIFICE VALVE
4. SMALL ORIFICE
NOTE: LEFT-HAND LIFT CYLINDER SHOWN.
Figure 6. Free-Lift Cylinder Operation
1. CYLINDER ROD 5. HYDRAULIC PORT
2. CYLINDER SHELL 6. ORIFICE There is hydraulic oil on the rod side of the piston.
3. PISTON 7. PISTON SEAL There are two orifices in the cylinder rod, one larger
4. INTERNAL CHECK 8. CUSHION RING than the other. As the cylinder rod extends, the hy-
VALVE draulic oil on the rod side flows to the base of the
cylinder through the larger orifice and the internal
Figure 5. Main Lift Cylinder Operation
check valve. When the cylinder rod extends to the
As the main lift cylinders retract, hydraulic oil flows last 25 mm (1.0 in.) of its stroke, the retainer at the
out of the cylinders through the hydraulic port. Dur- top of the cylinder closes the larger orifice. Now, the
ing the last 20 mm (0.8 in.) of the stroke, the hy- remainder of the hydraulic oil must flow through the
draulic oil must flow out through the small orifice. small orifice to the internal check valve. This action
This action causes the cylinder rod to move much increases the hydraulic pressure so that the main lift
more slowly at the end of the stroke. This cushion cylinders begin to extend. At the end of the free-lift
effect prevents a sudden stop at the end of the lower- stroke the oil flow through the small orifice gives a
ing sequence, making a smoother lowering operation. cushion effect for the free-lift cylinder. At the end of
the free-lift stroke the oil flow through the small ori-
fice gives a cushion effect for the free-lift cylinder.

5
Forks Repair
Forks Repair
WARNING
Before working on or near the mast, read
Safety Procedures When Working Near Mast.
See Figure 10.
The forks are held on the carriage by one of two types
of hooks and lock pin assemblies (see Figure 7 and
Figure 8.) The forks are kept in position by latches
that fit through the top fork hooks and into slots in
the top carriage bar. The forks can be removed from
the carriage by aligning the forks with the fork re-
moval notch. See Figure 9. The fork removal notch
is in the bottom crossmember of the carriage. Always
check that latches for the forks keep the forks in po-
sition on the carriage. Replace damaged latch parts.
1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
Figure 7. Hook Fork Removal
6
4000 SRM 563
REMOVE
WARNING
Do not try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (100 to 250 lb).
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance. Slide hook
fork to fork removal notch on carriage. See Figure 9.
Lower fork onto blocks so bottom hook of fork moves
through fork removal notch. See Figure 7. Lower
carriage farther so top hook of fork is disengaged
from top carriage bar. Move carriage away from fork,
or use lifting device to move fork away from carriage.
INSTALL
WARNING
Do not try to install a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (100 to 250 lb).
Move fork and carriage so top hook on fork can
engage upper carriage bar. Raise carriage to move
lower hook through fork removal notch. Slide fork
on carriage so both upper and lower hooks engage
carriage. Engage lock pin with notch in top carriage
bar.
4000 SRM 563 Forks Repair

A. OLD STYLE LOCK PIN ASSEMBLY B. NEW STYLE LOCK PIN ASSEMBLY
1. FORK 6. WEDGE
2. LOCK PIN 7. KNOB
3. SPRING 8. LEVER
4. WASHER 9. COTTER PIN
5. WASHER 10. LOCK PIN ASSEMBLY

Figure 8. Fork Lock Pin Assembly

7
Safety Procedures When Working Near Mast
Figure 9. Forks Check
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery and put a tag or lock on the bat-
tery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height difficult
to see. Be aware of fork height to aviod in-
jury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
8
4000 SRM 563
Legend for Figure 9
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION "X")
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93
8. FORK REMOVAL NOTCH
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Ac-
tivate the lift/lower controls and make sure
there is no movement in the mast. Make sure
that all parts of the mast that move are fully
lowered.
OR
• If parts of the mast must be in a raised po-
sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put mast in vertical position.
4000 SRM 563
2. Raise mast to align bottom crossmember of weld-
ment that moves in outer weldment with cross-
member on outer weldment. On the two-stage
and free-lift mast, the moving part is the inner
weldment. On the three-stage mast, it is the in-
termediate weldment. On the four-stage mast, it
is the inter#2 weldment. See Figure 10.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side
of mast. Make sure hook is completely engaged
with a link in the chain. Make sure safety chain
does not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
4. Lower mast until there is tension in safety chain
and free-lift cylinder (two-stage full free-lift,
Safety Procedures When Working Near Mast
three-stage, and four-stage) is completely re-
tracted. If running, turn the power OFF. Apply
the parking brake. Install a DO NOT REMOVE
tag on the safety chain(s).
5. Install another safety chain (3/8-inch minimum)
between the top or bottom crossmember of the
carriage (6) and a crossmember on the outer
weldment.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and remove
key. Put a DO NOT OPERATE tag in the operator’s
compartment. Disconnect battery and put a tag or
lock on battery connector.
9
Safety Procedures When Working Near Mast 4000 SRM 563

Figure 10. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts

10
4000 SRM 563 Carriage Repair

Legend for Figure 10

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER WELDMENT 5. FREE-LIFT CYLINDER
2. INNER WELDMENT 6. CROSSMEMBER
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. HOOK 8. INTER#2 WELDMENT

Carriage Repair
REMOVE WARNING
When disconnecting the lift chains, keep con-
Standard Carriage
trol of the ends. Use wire to temporarily
1. Put a one-quarter capacity load on forks. The connect the ends of the lift chains to the mast.
load must give the carriage stability so the car- This procedure will prevent the lift chains
riage cannot fall when it is disconnected from the from falling from the sheaves and causing an
mast. See Figure 8 and Figure 11. injury or damage.

2. Lower carriage and forks on blocks so lift chains
become loose.
3. Remove pin from each chain anchor at carriage.
Disconnect lift chains from carriage. Use wire to
connect ends of lift chains to a part of the mast.
Make sure chains can move freely when inner
weldment is raised.

WARNING
Make sure that the carriage has stability when
the inner weldment is above the load rollers of
the carriage.

4. Use lift cylinders to raise inner weldment. If the

hydraulic system cannot be used, connect crane
to top of inner weldment. Carefully raise inner
weldment until it is above load rollers of carriage.

5. Move lift truck away from carriage. Completely

lower inner weldment so it cannot move.

6. Connect lifting device to carriage. Remove load

from forks with another lift truck. Lower car-
riage to floor so load rollers are up.

7. If forks are removed, use lifting device to put car-

riage on floor so load rollers are up.
1. CARRIAGE 5. CHAIN ANCHOR
2. SNAP RING 6. CHAIN PIN Sideshift Carriage
3. SHIM 7. COTTER PIN
4. LOAD ROLLER 8. ANCHOR PIN 1. Lower carriage completely and remove forks.

Figure 11. Carriage 2. Connect lifting device to lifting eye on sideshift

carriage. The sideshift carriage weighs approxi-
mately 200 kg (441 lb).

11
Carriage Repair 4000 SRM 563

1. TOP BUSHING 6. BOTTOM CARRIAGE BAR

2. CYLINDER MOUNTING BRACKET 7. BOTTOM BUSHING
3. SHIM 8. TOP CARRIAGE BAR
4. SIDESHIFT CYLINDER 9. GREASE FITTING
5. LIFTING EYE 10. BOLT

Figure 12. Sideshift Carriage

3. Remove two upper capscrews from bottom car-
riage bar. Slowly loosen two bottom capscrews,
but do not remove them. The slotted holes will al-
low the bottom carriage bar to move down so that
the sideshift carriage can be removed. Carefully
lift sideshift carriage from standard carriage.
The sideshift cylinder mounting bracket and
cylinder will stay on the standard carriage. Re-
move bushings. See Figure 12.
4. Disconnect hydraulic lines at sideshift cylinder.
Put caps on open lines. Remove cylinder mount-
ing bracket from carriage. If necessary, remove
threaded rods and shims to remove sideshift
cylinder.
REPAIRS
1. If any of the load rollers must be replaced, make
a note of location and number of shims. See
Figure 11. Install shims, load rollers, and snap
rings. See Carriage Adjustments for correct ad-
justment of load rollers.
NOTE: The carriage has six load rollers. The shims
are installed on the bottom four rollers only.
2. Repair sideshift cylinder as follows (see Fig-
ure 13):
a. Remove retainers from shell. Pull rod from
shell.
b. Replace seals, O-rings, or backup rings as
necessary.
c. Lubricate all internal parts with clean hy-
draulic oil.
d. Install piston and rod in shell. Apply Loctite®
242 to threads of retainers. Install retainers
and tighten them to 27 N•m (20 lbf ft).

12
4000 SRM 563 Carriage Repair

Sideshift Carriage
1. Install sideshift cylinder in bracket. See Fig-
ure 12. Use equal number of shims on both
sides of cylinder to limit side-to-side movement
within bracket. Maximum movement is 0.6 mm
(0.024 in.). Install bolts and nuts to hold cylinder
in position. Tighten nuts to 26 N•m (19 lbf ft).

2. Install cylinder mounting bracket on standard

carriage, making sure it is engaged with notch
in top carriage bar. Connect hydraulic lines to
sideshift cylinder. Put grease on ends of cylinder
rod.

3. Install top bushing on mounting bracket. Lubri-

1. SHELL 5. RETAINER cate outer surface of bushing with multipurpose
2. O-RING 6. WIPER
3. BACKUP RING 7. PISTON AND ROD grease.
4. ROD SEAL 8. PISTON SEAL
4. Connect top and bottom carriage bars by in-
Figure 13. Sideshift Cylinder stalling two bottom capscrews. Do not tighten
capscrews. Lubricate outer surface of bottom
INSTALL bushing with multipurpose grease. Install bot-
tom bushing in bottom carriage bar.
Standard Carriage
5. Make sure standard carriage is completely low-
1. Use hydraulic system of lift truck or crane to ered. Connect lifting device to lifting eye. Install
raise inner weldment. If hydraulic system can- sideshift carriage on standard carriage. Put
not be used, connect crane to top of inner weld- blocks under bottom bar of sideshift carriage so
ment. Carefully raise inner weldment until it bottom bushing moves tight against standard
is above load rollers of carriage. Move lift truck carriage.
toward carriage until inner weldment is aligned
with carriage rollers. Carefully lower inner weld- 6. Install two top capscrews into sideshift carriage.
ment until it engages all load rollers. On E45-55XM, E45-55XM 2 (F108), E45-55Z
(G108), and S40-50XM (D187) units, tighten
2. Check clearance of load rollers. See Carriage Ad- all capscrews to 435 N•m (320 lbf ft). On
justments in this section. E60-65XM, E60-65XM 2 (F108), E60-65Z (G108),
and S55-65XM (D187) units, tighten all cap-
3. Connect lift chains to chain anchors at carriage. screws to 755 N•m (557 lbf ft). Remove lifting
Use new cotter pins in anchor pins. Adjust lift device. Lubricate top bushing at grease fittings.
chains as described in Lift Chain Adjustments in
this section.

13
Mast Repair 4000 SRM 563

Mast Repair
REMOVE
NOTE: If the mast must be disassembled, remove
forks and carriage as described in Carriage Repair.
If only the lift cylinders need to be removed, see the
procedures for Lift Cylinders Repair.

1. Before removing mast, check length of lift chains.

See the procedures in Clean and Inspect.

2. Fully lower all mast weldments and carriage.

Tilt mast fully forward. Use chains and connect
a crane to top of mast. Make sure all weldments
are fastened together. Make sure chains will
not damage sheaves, tubing, or other parts of
mast. Make sure crane has a capacity of at least
1600 kg (3500 lb).

3. Put drain pan under the area of hydraulic fit-

tings. Disconnect hydraulic line at external low-
ering control valve on outer weldment.

WARNING
Use a driver, not your fingers, to push the an-
chor pins from the rod ends on the tilt cylin-
ders. The cylinder or mast can move and cause
serious injury.

4. Remove cotter pins and anchor pins at tilt cylin-
der mounts on mast. See Figure 14.
5. Remove capscrews that hold mast to pivot pins
at mounts.
6. Use crane to lift mast assembly from lift truck.
Put mast on floor so back of mast is toward floor.
DISASSEMBLE
NOTE: If only the lift cylinders need to be removed
and repaired, see the procedures for Lift Cylinders
Repair. When the mast has header hoses, see the
procedures for the Header Hose Arrangements.
1. Disconnect and remove hydraulic lines for free-
lift cylinder. Remove brackets for free-lift cylin-
der. Remove free-lift cylinder. Disconnect free-
lift chains at crossmember. See Figure 17 and
Figure 18.
1. PIVOT PIN
2. DRIVE AXLE HANGER (MAST MOUNT)
3. TILT CYLINDER
4. OUTER WELDMENT
Figure 14. Mast Mounting
2. Disconnect lift chains at bottom of inner weld-
ment and top of inter#2 weldment. Remove lift
chains. Push inner weldment toward bottom of
mast assembly until bottom load rollers are seen.
See Figure 17 and Figure 18.
3. Remove strip bearings at top of inter#3 weld-
ment. Remove load rollers at bottom of inner
weldment. Remove load rollers at top of inter#3
weldment. Make a note of each shim arrange-
ment and load roller location. The shim arrange-
ments will be approximately the same during as-
sembly.

14
4000 SRM 563
4. Slide inner weldment halfway out of top of in-
ter#3 weldment. Connect crane to center of in-
ner weldment. See Figure 15. Slide inner weld-
ment out until stub shafts are in notches of in-
ter#3 weldment. Remove inner weldment from
inter#3 weldment.
Figure 15. Weldment Removal
5. Disconnect lift chains at bottom of inter#3 weld-
ment and top of outer weldment. Remove lift
chains. Push inter#3 weldment toward bottom of
mast assembly until bottom load rollers are seen.
6. Remove strip bearings and spacers at top of in-
ter#2 weldment. Remove load rollers at bottom of
inter#3 weldment. Remove load rollers at top of
inter#2 weldment. Make a note of each shim ar-
rangement and load roller location. The shim ar-
rangements will be approximately the same dur-
ing assembly.
7. Slide inter#3 weldment halfway out of top of in-
ter#2 weldment. Connect crane to center of in-
ter#3 weldment. See Figure 15. Slide inter#3
weldment out until stub shafts are in notches of
inter#2 weldment. Remove inter#3 weldment.
8. Disconnect hydraulic lines at top and bottom of
lift cylinders. Disconnect balance line at top of
right-hand lift cylinder.
9. Remove snap rings and washers at top of main
lift cylinders. Remove nut, bolt, and spacer at
mount near top of each main lift cylinder.
10. Push inter#2 weldment to disengage lift cylin-
ders. Remove main lift cylinders. Keep shims
from top of right-hand lift cylinder with cylinder.
Mast Repair
11. Slide inter#2 weldment from bottom of outer
weldment approximately 30 cm (12 in.). Remove
strip bearings at top of outer weldment. Remove
snap rings and load rollers from both weldments.
Make a note of each shim arrangement and load
roller location. The shim arrangements will be
approximately the same during assembly.
12. Slide inter#2 weldment halfway out of top of
outer weldment. Connect crane to center of
inter#2 weldment. See Figure 15. Slide inter#2
out of outer weldment until stub shafts are in
notches of outer weldment. Remove inter#2
weldment from outer weldment.
13. Disassemble chain sheaves as necessary for re-
pair and cleaning. Remove hydraulic lines and
fittings from weldments as necessary.
CLEAN AND INSPECT
CAUTION
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated.
1. Inspect chain sheaves and load rollers for wear
or damage.
WARNING
Cleaning solvents can be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
2. Clean lift chains with solvent. Remove all dirt
and grease. Inspect lift chains for wear or dam-
age. The lift chains must be installed on the mast
before they can be checked for length. A lift chain
becomes longer when it is worn. If a chain is
3% longer than a new lift chain, a new set of lift
chains must be installed. If a chain scale is avail-
able, check lift chain as shown in Figure 16. If a
chain scale is not available, measure 20 links of
lift chain. Compare measurement with lengths
given in Figure 16. Lubricate chains with SAE
30 engine oil. The best procedure is to soak the
lift chains in engine oil.
15
Mast Repair 4000 SRM 563

crane to center of inter#2 weldment. Fit lower

WARNING stub shafts of inter#2 weldment into notches in
Never replace just the worn section of a chain. top of outer weldment. Slide inter#2 weldment
Install the complete chain. Never replace just into outer weldment so stub shafts are seen at
one chain of a chain pair. Install new chains in top and bottom of both weldments.
pairs.
2. Install strip bearings and shims on channels of
3. Inspect chain anchors and pins. Install new outer weldment. See Figure 19. Apply grease to
parts for old parts that are worn or damaged. bearing surfaces.

WARNING
Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective
clothing and gloves. Never expose your skin to
steam.

WARNING
Cleaning solvents can be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.

4. Clean mast weldments with steam or solvent.

WARNING
Incorrect welding procedures can cause dam-
age to the structure of the mast. Get informa-
tion from your Hyster lift truck dealer before
welding on the mast. Pitch Wear Limit
Total length
The
5. Inspect sliding surfaces for wear or damage. In- of 20 links
maximum
spect load roller contact surfaces for wear or dam- (pitch) of new
length of 20
age. Inspect all welds for cracks. chain
links

ASSEMBLE 12.7 mm 254.0 mm 261.6 mm

(0.50 in.) (10.0 in.) (10.3 in.)
NOTE: The shims for the load rollers keep the weld- 15.9 mm 317.5 mm 327.0 mm
ments parallel and give correct clearance. During as- (0.63 in.) (12.5 in.) (12.9 in.)
sembly, the shim arrangement will be approximately 19.1 mm 381.0 mm 392.4 mm
the same as before disassembly. Check clearance and (0.75 in.) (15.0 in.) (15.5 in.)
adjust shims for wear or for changes caused by re- 25.4 mm 508.0 mm 523.3 mm
pairs. The strip bearings are also adjusted by using (1.00 in.) (20.0 in.) (20.6 in.)
shims. See Mast Adjustments in this section for the
adjustment procedures. NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
NOTE: When the mast has header hoses, see the pro- SCALE.
cedures for the Header Hose Arrangements.
1. CHAIN WEAR SCALE
1. Put outer weldment on floor with mast pivots to-
ward floor. See Figure 17 and Figure 18. Connect Figure 16. Lift Chains Check

16
4000 SRM 563 Mast Repair

3. Install load rollers and shims on outer weldment step, adjust inter#3 weldment as described in
and at bottom of inter#2 weldment. Before do- Mast Adjustments.
ing the next step, adjust inter#2 weldment as
described in Mast Adjustments. Install chain 9. Connect lift chains to chain anchors at outer
sheaves, shims, and snap rings on inter#2 weld- weldment. Put lift chains over chain sheaves on
ment. inter#2 weldment and connect them to anchors
at bottom of inter#3 weldment.
4. Install main lift cylinders in mounts at bottom
of outer weldment. Push inter#2 weldment to 10. Connect crane to center of inner weldment. Slide
engage lift cylinders. Check clearance at top of weldment into inter#3 weldment so stub shafts
lift cylinder mounts. Add or remove shims at top are seen at top and bottom of both weldments.
of left-hand cylinder rod until both cylinders are
11. Install strip bearings and shims on channels of
even. Install keeper at top of right-hand cylinder.
inter#3 weldment. Apply grease to bearing sur-
Install snap ring and washer at top of lift cylin-
faces. Install load rollers and shims on inter#3
ders. Install nuts, bolts, and spacers at lift cylin-
and inner weldments. Before doing the next step,
der mounts on outer weldment. Tighten nuts to
adjust inner weldment as described in Mast Ad-
53 N•m (39 lbf ft).
justments.
5. Install housing for lowering control valve on
12. Connect lift chains to chain anchors at top of
outer weldment. Tighten nuts for lowering con-
inter#2 weldment. Put lift chains over chain
trol valve to 18 N•m (13 lbf ft). Install lowering
sheaves on inter#3 weldment and connect them
control valve in housing. Connect hydraulic
to anchors at bottom of inner weldment.
lines and fittings between lowering control valve
and main lift cylinders. 13. Install free-lift cylinder in mounts on inner weld-
ment. Install brackets for cylinder and tighten
6. Install chain sheaves and snap rings on inter#3
nuts and bolts.
weldment.
14. Install hose sheave for free-lift cylinder. Install
7. Connect crane to center of inter#3 weldment.
hydraulic hose and tubing that connect free-lift
Slide weldment into inter#2 weldment so stub
cylinder to right-hand lift cylinder. Install bal-
shafts are seen at top and bottom of both weld-
ance line between two main lift cylinders.
ments.
15. Connect free-lift chains to chain anchors at inner
8. Install strip bearings and shims on channels of
crossmember. Attach wire between other end of
inter#2 weldment. Apply grease to bearing sur-
lift chain and bottom of mast to control free-lift
faces. Install load rollers and shims on inter#2
chain during installation of mast.
and inter#3 weldments. Before doing the next

17
Mast Repair 4000 SRM 563

Figure 17. Outer and Inter#2 Weldments

18
4000 SRM 563 Mast Repair

Legend for Figure 17

1. OUTER WELDMENT 10. WASHER
2. O-RING 11. NUT
3. SHIM(S) 12. INTER#2 WELDMENT
4. STRIP BEARING 13. SNAP RING
5. LIFT CHAIN 14. SHIMS
6. SPACER 15. LOAD ROLLER
7. ANCHOR PIN 16. BEARING
8. COTTER PIN 17. CHAIN SHEAVE
9. CHAIN ANCHOR

INSTALL 5. Connect hydraulic line to lowering control valve.

1. Lubricate pivot pins and install them into 6. Install carriage as described in the procedures for
mounts at drive axle hanger. See Figure 14. the Carriage Repair.

2. Connect crane to top of mast using chains. Make
sure all weldments are fastened together. Make
sure chains will not damage sheaves, tubing, or
other parts of mast. Make sure crane has a ca-
pacity of at least 1600 kg (3500 lb).
3. Use crane to install mast assembly on pivot pins.
Install capscrews that hold mast to pivot pins.
Tighten capscrews to 90 N•m (66 lbf ft).
4. Connect tilt cylinders to mast. Install anchor pin
and cotter pin.
7. Check tilt cylinder adjustment as described in
Tilt Cylinders Adjustment. Operate mast and
check for leaks and correct operation. Check lift
chains as described in Lift Chain Adjustments.
NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
8. Lubricate sliding surfaces and load roller sur-
faces along full length of channels as shown in
Figure 20. Apply lubricant only to surfaces indi-
cated.

19
Mast Repair 4000 SRM 563

Figure 18. Inter#3 and Inner Weldments

20
4000 SRM 563 Mast Repair

Legend for Figure 18

1. SNAP RING 10. SHIMS
2. BEARING 11. COTTER PIN
3. CHAIN SHEAVE 12. NUT
4. INTER#3 WELDMENT 13. WASHER
5. O-RING 14. CHAIN ANCHOR
6. SHIM(S) 15. ANCHOR PIN
7. STRIP BEARING 16. LIFT CHAIN
8. INNER WELDMENT 17. FREE-LIFT CHAIN
9. LOAD ROLLER

Figure 19. Strip Bearings

A. LOWER LOAD ROLLERS

B. UPPER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER

Figure 20. Lubricate Mast

21
Lift Cylinders Repair 4000 SRM 563

Lift Cylinders Repair

REMOVE 4. Put drain pan under the area of the hydraulic
fittings. Disconnect hydraulic lines at cylinder.
Main Lift Cylinders Retract rod into lift cylinder.

5. Remove nut, bolt, and spacer at mounts.

WARNING
Before working on or near the mast, see Safety 6. Use lifting device as necessary to remove lift
Procedures When Working Near Mast. See Fig- cylinder from mast. Keep shims from top of
ure 10. left-hand cylinder with cylinder.

NOTE: The following procedures are for the removal
of the lift cylinders with the mast installed on the lift
truck.
1. Remove carriage as described in the procedures
for the Carriage Repair. See Figure 17 and Fig-
ure 24.
2. Raise mast until it is almost fully extended. Use
safety chain to connect middle crossmember of
inter#2 weldment to top crossmember on outer
weldment. Lower mast so safety chain holds the
weight of the weldments.
3. On left-hand lift cylinder, remove snap ring from
top of cylinder rod. On right-hand lift cylinder,
remove spacer and retainer from cylinder rod.
Free-Lift Cylinders
1. Remove carriage as described in the procedures
for the Carriage Repair. Lower mast completely.
See Figure 17.
2. Put drain pan under the area of the hydraulic
fittings. Disconnect hydraulic line at cylinder.
3. Move chains from chain sheaves. Remove clamp
and bracket for free-lift cylinder. Remove free-lift
cylinder.
4. Remove crosshead from cylinder rod. Disassem-
ble crosshead as necessary. See Figure 21.

Legend for Figure 21

1. HOSE 10. PIN
2. HOSE SHEAVE 11. CROSSHEAD
3. STUB SHAFT WELDMENT 12. ALIGNMENT PIN
4. WASHER 13. FREE-LIFT CYLINDER
5. CAPSCREW 14. STRAP
6. CHAIN GUARD 15. TUBE SPACER
7. SPACER 16. BRACKET
8. CHAIN SHEAVE 17. LOWERING CONTROL VALVE FITTING
9. SNAP RING 18. BEARING

22
4000 SRM 563 Lift Cylinders Repair

Figure 21. Crosshead and Free-Lift Cylinder Assembly

23
Lift Cylinders Repair
DISASSEMBLE
CAUTION
Carefully disassemble the lift cylinders so that
the piston rods and sliding surfaces are not
damaged.
NOTE: Disassembly of the main lift cylinders and the
free-lift cylinder is similar. All of the lift cylinders are
disassembled from the rod end of the cylinder shell.
1. Loosen retainer with spanner. See Figure 22 and
Figure 23.
2. On the main lift cylinders, do the following:
a. Pull retainer and rod and piston assembly
from shell. Drain hydraulic oil into a con-
tainer.
b. Remove piston from rod. Remove retainer
from rod. See Figure 22.
3. On the free-lift cylinder, do the following:
a. Remove retainer from shell.
b. Pull rod and piston assembly from shell.
Drain hydraulic oil into container. See Fig-
ure 23.
4. Remove and discard O-rings, seals, and wear
rings.
5. On left-hand lift cylinder and free-lift cylinder,
remove snap ring, washer, and check valve from
base of piston.
6. Clean all parts. Check sliding surfaces for dam-
age. Repair or install new parts as necessary.
ASSEMBLE
NOTE: Assembly of the main lift cylinders and the
free-lift cylinder is similar. All of the lift cylinders
are assembled from the rod end of the cylinder shell.
1. Lubricate all internal parts of lift cylinder with
clean hydraulic oil or packing lubricant, Hyster
24
4000 SRM 563
Part No. 186061. Use new O-rings, seals, and
wear rings. See Figure 22 and Figure 23.
2. On the main lift cylinders, do the following:
a. Install rod wiper and rod seal in retainer. In-
stall O-ring on outside of retainer. Install re-
tainer on rod.
b. Install O-ring and backup ring on piston for
right-hand cylinder. If a spacer is used, in-
stall it on rod. Install piston in rod. Tighten
piston to 170 to 200 N•m (125 to 150 lbf ft).
3. Install check valve and O-ring in base of pis-
ton of free-lift cylinder and left-hand lift cylinder.
Make sure arrow on check valve is toward base
of piston. Install washer and snap ring for check
valve. See Figure 22.
CAUTION
A difficult and important step in assembling
lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused
by seal leaks. Do not damage any parts during
assembly.
4. Install backup ring, piston seal, and wear ring
onto piston. On the main lift cylinders, install
seal ring.
5. Carefully push piston and rod assembly into
shell.
6. Before installing retainer, pour 150 cc (5 oz) of
hydraulic oil into free-lift cylinder shell.
7. On the free-lift cylinder, install rod wiper and rod
seal in retainer. Install O-ring and backup ring
on outside of retainer. See Figure 23.
8. Carefully engage threads and tighten retainer
in shell. Use a correct spanner. Do not hit re-
tainer with a hammer and driver. Tighten re-
tainer on free-lift cylinder to 475 to 540 N•m (350
to 400 lbf ft). Tighten retainer on main cylinder
to 340 to 410 N•m (250 to 300 lbf ft).
4000 SRM 563 Lift Cylinders Repair

A. RIGHT-HAND LIFT CYLINDER B. LEFT-HAND LIFT CYLINDER

1. ROD 6. SPACER 11. SEAL RING
2. WIPER 7. BACKUP RING 12. SHELL
3. ROD SEAL 8. PISTON 13. CHECK VALVE
4. RETAINER 9. PISTON SEAL 14. WASHER
5. O-RING 10. WEAR RING 15. SNAP RING

Figure 22. Main Lift Cylinders

25
Lift Cylinders Repair 4000 SRM 563

Legend for Figure 23

1. WIPER 7. PISTON SEAL
2. ROD SEAL 8. WEAR RING
3. RETAINER 9. CHECK VALVE
4. BACKUP RING 10. WASHER
5. O-RING 11. SNAP RING
6. ROD AND PISTON 12. SHELL

9. Install lowering control valve in port at base

of left-hand, main lift cylinder. See Figure 24.
Make sure special washer and spring are in-
stalled correctly. The special washer is next
to the cylinder shell. A wrong installation can
cause the load to lower too fast.

10. Install fitting at base of free-lift cylinder. This is

a special fitting that limits flow of the hydraulic
oil.

INSTALL
Main Lift Cylinder
1. Use lifting device to raise mast until it is al-
most fully extended. See Figure 10, Figure 17,
and Figure 24. Use safety chains to connect bot-
tom crossmember of inter#2 weldment to cross-
member on outer weldment. Use safety chains
between other weldments so they cannot move.
Lower mast so safety chains hold weight of weld-
ments.

2. Install lift cylinder in mount at bottom of outer

weldment. Install nut, bolt, and spacer at mount
for lift cylinder. Tighten nut to 53 N•m (39 lbf ft).

3. Install shims at top of left-hand cylinder. Use

lifting device to lower inter#2 weldment onto lift
cylinders. See the Mast Repair, Assemble proce-
dures for the correct adjustment of the lift cylin-
ders. Install snap ring at top of left-hand lift
cylinder. Install retainer, fittings, and tube at
top of right-hand lift cylinder. Tighten nuts for
retainer to 33 N•m (24 lbf ft).

4. Connect hydraulic lines at lift cylinders. Connect

hydraulic line at tube on right-hand lift cylinder.

5. Install balance line between main lift cylinders.

6. Connect main lift chains as necessary and adjust

them as specified in Lift Chain Adjustments.

Figure 23. Free-Lift Cylinder

26
4000 SRM 563 Lift Cylinders Repair

1. BALANCE LINE 7. HOUSING

2. SNAP RING 8. HOSE
3. SHIM 9. LOWERING CONTROL VALVE
4. FITTING AND O-RING 10. RIGHT-HAND MAIN LIFT CYLINDER
5. LEFT-HAND MAIN LIFT CYLINDER 11. SPACER
6. LOWERING CONTROL VALVE FITTING 12. RETAINER

Figure 24. Main Lift Cylinders Installation

Free-Lift Cylinder 2. Install cylinder in mounts. Install brackets,

1. Make sure alignment pin is in position, then
install crosshead mount on cylinder rod. See
Figure 17 and Figure 21. Tighten capscrew for
mount to 435 N•m (320 lbf ft). Install chain
sheaves and nylon spacers in mount. Install
shaft through sheaves. Install chain guard on
mount, making sure shaft is in correct position.
Tighten capscrews for chain guard to 38 N•m
(28 lbf ft).
spacers, bolts, and nuts. Tighten bolts at bottom
bracket to 53 N•m (39 lbf ft). Tighten nuts at
top clamp to 38 N•m (28 lbf ft).
3. Connect hydraulic line at cylinder.
4. Install carriage as described in the procedures for
the Carriage Repair.

27
Header Hose Arrangements
Header Hose Arrangements
NOTE: Before installing the header hoses, make sure
you know the lift height of the mast. The tension on
the header hoses is adjusted according to lift height.
The lift height is on the nameplate of the lift truck
and on the right-hand side of the outer weldment.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage.
Examples of these auxiliary functions are a sideshift
carriage or a roll clamp. These auxiliary functions
require header hoses for their operation.
HEADER HOSES, INSTALL
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast. See Fig-
ure 10.
NOTE: This procedure is for the four-function option.
The three-function option will have hoses "A" and "B"
only.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chain Adjust-
ments for the carriage adjustment procedure.
NOTE: If the header hoses were removed, use this
procedure to install the Type "A" or Type "B" header
hoses. See Table 1. If the mast components have not
been assembled, assemble the mast as described in
the previous procedure.
1. Raise carriage so free-lift chains are not tight.
See Figure 25, Figure 26, and Figure 27. Raise
inner channel so main-lift chains are not tight.
Install chains to prevent inner channel and car-
riage from moving. The chains must not be in the
path of the header hose.
2. Install all hose sheaves loosely. Do not tighten
capscrews and nuts until header hoses are in-
stalled.
3. Make sure replacement header hose is correct
part number for your mast assembly. Make sure
header hoses are straight on a flat surface. Mark
header hose at points "E" and "G" (mm) as shown
28
4000 SRM 563
in Table 1. Measure from end of hose with small
fitting.
4. Loosely assemble hose sheaves as shown in Fig-
ure 26:
a. Put coating of multipurpose grease on stub
shafts before assembly.
b. The nuts for the sheave capscrew (axle) must
be on the inside of each assembly.
c. Do NOT tighten any nuts or capscrews. They
must be loose to allow installation of hoses on
hose sheave.
5. Install plate at middle hose clamp and tighten
capscrews to 8 N•m (6 lbf ft).
6. Install bottom hose clamps as shown in Fig-
ure 25. Put some grease on bottom of brack-
ets so hoses can slip to equalize the pressure.
Tighten capscrews and nuts of bracket to 18 N•m
(13 lbf ft). Do NOT tighten capscrews and nuts
for strap clamps at this time.
7. If the crosshead of the free-lift cylinder does not
have hose guides, remove chain guard brackets,
chains, and chain sheaves. Install hose guides
(flare toward outside) and snap rings to chain
sheaves. Install free-lift sheaves, chains, and
chain guard brackets as shown in Figure 25 and
Figure 27.
8. Install hoses over free-lift cylinder with marks
"E" aligned with top edge of clamp of middle hose
clamp assemblies. Tighten capscrews and nuts
of clamps to 8 N•m (6 lbf ft).
9. Pass hoses under lower hose clamps and install
strap clamps on hoses. Align marks "G" to bot-
toms of lower hose clamps. Tighten capscrews
and nuts of strap clamps to 18 N•m (13 lbf ft).
10. Install hoses on hose sheaves (Figure 25) with
loops long enough to install on floating hose
sheaves. Tighten axle capscrews and nuts of
sheaves to 53 N•m (39 lbf ft).
4000 SRM 563 Header Hose Arrangements

1. CARRIAGE 5. FRONT HOSE SHEAVES

2. MAST ASSEMBLY 6. MIDDLE HOSE SHEAVES
3. CHAIN AND HOSE SHEAVES AT FREE-LIFT 7. MIDDLE HOSE CLAMP
CYLINDER 8. CABLE MOUNT BLOCKS
4. REAR HOSE SHEAVES 9. BOTTOM HOSE CLAMP ASSEMBLIES

A B C D = HOSES

Figure 25. Hose Sheaves and Routing

29
Header Hose Arrangements 4000 SRM 563

Figure 26. Header Hoses

30
4000 SRM 563 Header Hose Arrangements

Legend for Figure 26

1. CARRIAGE CLAMP 16. TUBE
2. WASHER 17. ROLLER
3. HOSE SHEAVE 18. CABLE ROLLER
4. STUB SHAFT 19. CABLE ASSEMBLY
5. STUB SHAFT WELDMENT 20. NUT
6. SNAP RING 21. BLOCK
7. HOSE GUIDE 22. PIN
8. C-D CLAMP 23. COTTER PIN
9. PLATE 24. HEADER HOSE
10. A-B CLAMP 25. HOSE MOUNT
11. HOSE BRACKET 26. HOSE CLAMP
12. GUIDE BRACKET 27. C-D CLAMP
13. STRAP 28. SPRING
14. HOSE GUARD 29. SPACER
15. STUB SHAFT

11. Partially assemble floating sheaves as shown in
Figure 25 and Figure 26. Install loops of hoses
under sheaves. Then install roller guide assem-
blies over hoses and between hose guards. See
Figure 25 and Figure 27. Tighten roller guide
capscrews and nuts to 8 N•m (6 lbf ft).
12. Fasten looped ends of cables of floating sheaves
to cable mount blocks. Use pins, washers, and
cotter pins to fasten cable loops. See Figure 26.
If necessary, install mount blocks on bottom
crossmember of intermediate channel using
capscrews and washers. Tighten capscrews to
18 N•m (13 lbf ft).
13. Make sure cables are in grooves of idler wheels
and under formed feature of hose guards of float-
ing sheaves. Install ends of cables in brackets so
there is spring tension on cables. Make sure axle
capscrews and nuts of sheaves are tightened to
53 N•m (39 lbf ft).
14. Slowly operate hydraulic system so lift chains
are tight. Remove chains that fasten carriage
and channel weldment. Slowly raise carriage us-
ing hydraulic system. Make sure hoses move
through all sheaves correctly.
15. Slowly operate mast through a few cycles to
make sure hoses track correctly. Tighten strap
clamps at bottom hose clamps to 18 N•m
(13 lbf ft). Fasten hose assemblies to main
cylinders using hose clamps and screw clamps
as shown in Figure 25 and Figure 26.

31
Header Hose Arrangements 4000 SRM 563

Figure 27. Header Hose Arrangement

32
4000 SRM 563 Header Hose Arrangements

Legend for Figure 27

A. BACK VIEW B. SIDE VIEW
1. HOSE SHEAVE NO. 1 6. GUIDE BRACKET
2. HOSE SHEAVE NO. 2 7. C-D CLAMP
3. FLOATING SHEAVE ASSEMBLY 8. C-D CLAMP
4. A-B CLAMP 9. A-B CLAMP
5. CABLE MOUNT 10. FREE-LIFT CROSSHEAD

33
Header Hose Arrangements 4000 SRM 563

Table 1. Standard Four-Stage Hose Dimensions

Channel
Lift Height Length Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
4839 190.5 1735 1351 53.2 4750 187.0
5143 202.5 1811 1426 56.1 4971 195.7
5450 214.6 1888 1501 59.1 5192 204.4
5754 226.5 1964 1576 62.1 5414 213.1
6058 238.5 2040 1651 65.0 5635 221.9
6364 250.6 2141 1751 68.9 5930 233.5
6670 262.6 2243 1851 72.9 6225 245.1
6977 274.7 2345 1951 76.8 6520 256.7
7274 286.4 2446 2051 80.8 6815 268.3
7583 298.5 2548 2151 84.7 7110 279.9
7886 310.5 2649 2251 88.6 7405 291.6
8192 322.5 2751 2351 92.6 7701 303.2
8496 334.5 2853 2452 96.5 7996 314.8
8799 346.4 2954 2552 100.5 8291 326.4
9108 358.6 3056 2652 104.4 8586 338.0

"E" = (0.985 × channel length in mm) 358.2 "G" = (2.095 × channel length in mm) 291.0

34
4000 SRM 563 Lift and Tilt System Leaks Check

Lift and Tilt System Leaks Check

LIFT CYLINDERS LEAKS CHECK 4. If carriage does not move, open gate valve and
check movement again. If carriage lowers when
WARNING gate valve is open, check for leaks in hydraulic
lines and fittings. If no leaks are found, main
During the test procedures for the hydraulic
control valve can be worn or damaged. Remove
system, use chains to fasten the load to the car-
load from forks.
riage to prevent it from falling. Keep all people
away from the lift truck during the tests.
TILT CYLINDERS LEAKS CHECK
Do not try to find hydraulic leaks by putting
1. Put capacity load on forks. Use safety chain to
your hand on hydraulic components under
hold load to carriage. Raise load approximately
pressure. Hydraulic oil can be injected into
2.5 m (8 ft). Put mast in vertical position.
the body by the pressure.
2. Measure distance that rod for tilt cylinder ex-
1. Operate hydraulic system. Put capacity load on
tends from shell. Check distance the rod moves
forks. Use safety chain to hold load to carriage.
in five or ten minutes. The maximum tilt rate
Raise and lower load several times. Lower load
with the oil at 20 C (68 F) is 1.0 mm/min (0.04 in./
and tilt mast forward and backward several
min). The maximum tilt rate with the oil at 60 C
times. Check for leaks.
(140 F) is 6.8 mm/min (0.30 in./min).
2. Raise carriage and load 1 m (3 ft). If carriage
3. If the tilt rate is greater than the specifications,
slowly lowers when control valve is in NEU-
lower mast and remove load from forks. Install
TRAL position, there are leaks in hydraulic
gate valve between port at front of tilt cylinder
system. The maximum speed the carriage is
and hydraulic line. Put load on forks again.
allowed to lower is 50 mm (2 in.) per 10 minutes
Close valve. Tilt mast forward just past vertical
when hydraulic oil is 30 C (90 F). If oil tem-
position. If mast continues to tilt slowly forward,
perature is 70 C (160 F), the maximum speed
seals on piston are leaking.
the carriage can lower is 150 mm (6 in.) per 10
minutes. 4. If mast does not move, open gate valve and check
movement again. If mast moves forward when
3. Check lift cylinders for internal leaks. Remove
gate valve is open, check for leaks in hydraulic
load from forks. Install gate valve in supply line
lines and fittings. If no leaks are found, main
between main control valve and mast. Put capac-
control valve can be worn or damaged. Remove
ity load on forks again. Raise carriage 1 m (3 ft).
load from forks when checks are complete.
Close gate valve. If carriage or mast weldments
lower slowly, seals in lift cylinders have leaks.

35
Lift Chain Adjustments 4000 SRM 563

Tilt Cylinders Adjustment

WARNING
When the tilt cylinders have tilt limit spacers,
make sure they are installed during installa-
tion procedures. Without the tilt limit spacers,
the mast can tilt too much and cause an acci-
dent or serious injury.

Check tilt cylinder stroke by slowly tilting mast fully

forward and backward several times. Both tilt cylin-
ders must stop their stroke at the same time. Ad-
just rod ends to dimension A for all tilt cylinders as
shown in Figure 28. There must be no twist in the
mast weldments. Adjust tilt cylinders as follows:

1. Slowly tilt mast forward until one cylinder rod

stops. On opposite cylinder, loosen capscrews on
rod end. Use a wrench and turn cylinder rod IN
as necessary. Repeat this procedure until both
cylinder rods stop at the same position within
1 mm (0.04 in.).

2. Slowly tilt mast backward until one rod end just

contacts spacer. Add shims to fill gap at oppo- A. DIMENSION A = 15 mm (0.60 in.)
site rod end until both rod ends contact spacers
within 0.5 mm (0.02 in.). 1. MAST
2. ROD END
3. After adjustments are complete, tighten cap- 3. SHIMS
screws on rod ends. 4. TILT LIMIT SPACER
5. TILT CYLINDER
4. Tilt mast fully backward and measure tilt angle.
Figure 28. Tilt Cylinder Adjustments
(See nameplate for tilt angles.) If necessary, add
an equal number of shims to both rods for the
correct angle.

Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section
Never allow anyone under a raised carriage.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.
During test procedures for the hydraulic sys-
tem, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel
away from the lift truck during the tests.
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of the
chain set. Check tension by pushing on both chains
at the same time.
• The chain length will be correct.
• The chains must travel freely through the complete
cycle.
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain
anchors are completely engaged. Make sure that all

36
4000 SRM 563 Lift Chain Adjustments

of the adjustment is not removed from the chain an- the floor level as shown in Table 2. Also, see Fig-
chors. The chain anchors must be able to move on ure 30.
their mounting.
Table 2. Hook type Carriage Chain Adjustment
1. When adjusting the lift chains on forklift trucks
equipped with either pin or hook type forks in- Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)
stalled, go to Step 2. If the forklift truck is nor-
Class IV 133.5 ±3 mm (5.26 ±0.12 in.)
mally equipped with a hook type carriage and
has an attachment without forks go to Step 3.
If the forklift truck is normally equipped with a
pin type carriage and has an attachment without
forks go to Step 4.

NOTE: Prior to performing adjustment procedures

make sure that the forklift truck is parked on a level
surface and that the mast is in the vertical position.

2. Adjust the chain anchors which support the car-

riage until the bottom of the fork heel is 6 ±3 mm
(0.24 ±0.12 in.) above the floor level. See Fig-
ure 29.

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR

Figure 30. Lift Chain Adjustment, Hook-Type

Carriage

4. Adjust chain anchors which support carriage un-

til the centerline of the fork pin is above the floor
level as shown in Table 3. Also, see Figure 31.

Table 3. Pin-Type Carriage Chain Adjustment

1. MAST
2. CARRIAGE
3. FORK H70-80, 90XLS 545 ±3 mm (21.5 ±0.12 in.)
4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
ABOVE FLOOR LEVEL. H90-110XL 708 ±3 mm (27.87 ±0.12 in.)
H135-155XL 907 ±3 mm (35.71 ±0.12 in.)
Figure 29. Lift Chain Adjustment, Hook or
Pin-Type Forks

3. Adjust chain anchors which support carriage un-

til the bottom of the lower carriage bar is above

37
Mast Adjustments 4000 SRM 563

Legend for Figure 31

1. LOAD BACKREST
2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR

Figure 31. Lift Chain Adjustment, Pin-Type

Carriage

Mast Adjustments
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub
shafts. To change the position of the roller on the
stub shaft, move the shims from one side of the load
roller to the other.
During assembly, the shim arrangement will be ap-
proximately the same as before disassembly. Check
the clearance and adjust for wear or change because
of repairs.
1. The load rollers control the alignment of the
weldments. The alignment conditions are given
on a list below with the most important condition
first. See Figure 32.
a. The weldments must be parallel to each
other.
b. Use shims to adjust load rollers so there is
zero clearance between load roller and chan-
nel at point of tightest fit.
c. The number of shims under a load roller
must be approximately the same as the stub
shaft in the opposite side of the weldment.
The weldments will be approximately in the
center.

38
4000 SRM 563 Mast Adjustments

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST WELDMENTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND WELDMENTS, AND TO GIVE ZERO CLEARANCE
AT POINT OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW
B. MAST FRONT VIEW
1. CHANNEL 8. EQUAL SPACE ±1.5 mm (0.060 in.)
2. LOAD ROLLER 9. PARALLEL
3. STUB SHAFT 10. PUT SPACER ON OUTSIDE OF TOP LOAD
4. SNAP RING ROLLER, UNDER SNAP RING
5. SHIMS 11. SHIM FOR ZERO CLEARANCE AT POINT OF
6. PARALLEL TIGHTEST FIT
7. ZERO CLEARANCE AT POINT OF TIGHTEST FIT

Figure 32. Mast Adjustments

2. Do the following steps to adjust the mast load
rollers:
a. Use a crowbar to move weldments from side
to side to measure movement. Measure
movement in a minimum of three different
positions of weldments.
b. Separate mast weldments and change shim
arrangements as required. Assemble weld-
ments. Slide weldment all the way to the top
and bottom to find the tightest fit.
c. Repeat Step a and Step b until there is zero
clearance at the point of the tightest fit.

39
Carriage Adjustments
d. Measure distance between channels of weld-
ments on top and bottom. Change shims
to keep distance equal between top and bot-
tom so mast weldments are parallel. Also
make sure the weldments are parallel within
1.5 mm (0.060 in.).
1. STRIP BEARING
2. LOAD ROLLER
3. WELDMENT
Figure 33. Strip Bearings Arrangement
Carriage Adjustments
1. Install six load rollers on carriage. See Figure 32.
Install shims for rollers in the same sequence on
stub shaft before disassembly.
2. Use lifting device to raise carriage up the inner
channel. Find the point of tightest fit between
load rollers and inner channels.
3. Remove carriage from mast. Adjust shim ar-
rangement for each roller for clearance between
roller and inner channel. Repeat Step 1 and
Step 2 until there is zero clearance at the point
of tightest fit.
40
4000 SRM 563
3. Adjust strip bearings. See Figure 33. Insert
shims under strip bearing. Adjust clearance un-
til there is less than 0.8 mm (0.030 in.) at the
tightest fit. See Figure 32.
4. SHIMS
5. O-RING
4. Keep shim arrangement on each side of carriage
approximately equal. Also keep shim arrange-
ment on each side of carriage approximately
equal. The carriage must run parallel with the
inner weldment within +1.5 mm (0.060 in.).
CAUTION
Too much grease will cause the rollers to slide
and wear flat areas on the rollers.
5. After adjustment, lubricate channels with a thin
layer of grease. Adjust hydraulic hoses and
make sure connections are correct if the carriage
is equipped with hydraulic attachments.
4000 SRM 563 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Slow or no movement of lift Insufficient oil. Check hydraulic system oil level.
or tilt cylinders.

Air is in the hydraulic system. Remove air from hydraulic system.

The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.

Restriction in the hydraulic lines. Repair hydraulic lines.

Cylinder seals are damaged. Repair cylinders.

Load is greater than capacity. Reduce load.

Linkage is disconnected or damaged. Repair and adjust linkage for control

levers.

Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).

justed correctly or is damaged.

Large leaks between spool and bore. Replace valve section.

Spool is not fully extended or re- Adjust linkage to spool.

tracted.

Rough movement of the mast Air is in the hydraulic system. Remove air from hydraulic system.
assembly.

Lift cylinder(s) is damaged. Repair cylinder(s).

Mast weldments are damaged or not Repair or adjust mast weldments.

aligned.

Mast weldments are not lubricated Lubricate mast correctly.

correctly.

Lift or tilt cylinders retract Check valve for the lift spool is dam- Replace check valve.
when the spool is in the aged.
NEUTRAL position.

Cylinder seals have leaks. Repair lift cylinders.

Hydraulic lines have leaks. Repair or tighten lines or fittings.

Leaks between the lift spool and the Replace valve section.
bore.

41
Troubleshooting 4000 SRM 563

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Tilt cylinders extend when Cylinder seal have leaks. Repair tilt cylinders.
the tilt spool is in the NEU-
TRAL position.

Oil leaks between control valve spool Replace valve section.

and bore.

Hydraulic lines have leaks. Repair or tighten lines or fittings.

42
 TECHNICAL PUBLICATIONS

4000 SRM 563 4/05 (11/03)(12/96)(2/95) Printed in U.S.A.