Mast Repair - (07-2010) - Us-En

MAST REPAIRS
2- AND 3-STAGE MASTS

H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM 2S) [D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897507 4000 SRM 522

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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mast Repairs Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Safety Procedures When Working Near Mast.................................................................................................... 2
Fork Repair .......................................................................................................................................................... 4
Remove ............................................................................................................................................................. 4
Install ............................................................................................................................................................... 4
Carriages Repair .................................................................................................................................................. 6
Standard Carriage, Remove............................................................................................................................ 6
Hang-On Sideshift Carriage, Remove ............................................................................................................ 6
Standard Carriage and Hang-On Sideshift Carriage, Repair....................................................................... 8
Standard Carriage, Install .............................................................................................................................. 9
Hang-On Sideshift Carriage, Install ............................................................................................................ 10
Integral Sideshift Carriage ........................................................................................................................... 10
Remove....................................................................................................................................................... 10
Clean and Inspect...................................................................................................................................... 14
Repair......................................................................................................................................................... 15
Install ......................................................................................................................................................... 16
Mast Repair........................................................................................................................................................ 17
Remove ........................................................................................................................................................... 17
Two-Stage LFL and Two-Stage FFL Masts, Disassemble ........................................................................... 20
Three-Stage FFL Mast .................................................................................................................................. 27
Disassemble ............................................................................................................................................... 27
Mast and Chains, Clean and Inspect ....................................................................................................... 31
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 32
Three-Stage FFL Mast, Assemble ................................................................................................................ 33
Install ............................................................................................................................................................. 34
Lift Cylinders Repair ......................................................................................................................................... 36
Main Lift Cylinders, Remove ........................................................................................................................ 36
Free-Lift Cylinder, Remove ........................................................................................................................... 36
Cylinders, Disassemble ................................................................................................................................. 37
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder ........................................................... 37
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.............................................................. 39
Two-Stage Limited Free-Lift Mast and
Three-Stage Full Free-Lift Mast, Main Lift Cylinders for Lift Trucks
H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM 2) (D114), E2.00XMS (E40XMS, E40XM 2S) (D114), and E1.50-2.00XM (E25-35Z,
E40ZS) (E114)............................................................................................................................................ 39
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift Mast, Main Lift Cylinders .......... 40
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mast, Free-Lift Cylinder ................... 41
Clean and Inspect .......................................................................................................................................... 42
Cylinders, Assemble ...................................................................................................................................... 42
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder ........................................................... 42
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.............................................................. 43
Three-Stage Full Free-Lift Mast, Main Lift Cylinders for Lift Trucks
H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM 2) (D114), E2.00XMS (E40XMS, E40XM 2S) (D114), and E1.50-2.00XM (E25-35Z,
E40ZS) (E114)............................................................................................................................................ 44
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift Mast, Main Lift Cylinders .......... 45
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mast, Free-Lift Cylinder ................... 45
Main Lift Cylinders, Install .......................................................................................................................... 46
Free-Lift Cylinder, Install ............................................................................................................................. 46
©2010 HYSTER COMPANY i

Table of Contents Mast Repairs
TABLE OF CONTENTS (Continued)

Header Hose Arrangements .............................................................................................................................. 47
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 47
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 52
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 53
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 59
Three-Stage FFL Mast, New Hose Install ................................................................................................... 59
Three-Stage FFL Mast, Adjust Hoses After Installation ............................................................................ 70
Header Hose Arrangement................................................................................................................................ 71
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 71
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 75
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 76
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 82
Three-Stage FFL Mast, New Hose Install ................................................................................................... 82
Three-Stage FFL Mast, Adjust Hoses After Install..................................................................................... 91
Lift and Tilt System Leak Check ...................................................................................................................... 92
Lift Cylinders Leak Check ............................................................................................................................ 92
Tilt Cylinders Leak Check ............................................................................................................................ 92
Tilt Cylinders Adjustment................................................................................................................................. 93
Lift Chains Adjustment ..................................................................................................................................... 95
Mast Adjustment ............................................................................................................................................... 97
Carriage Adjustment ......................................................................................................................................... 99
Troubleshooting................................................................................................................................................ 100
This section is for the following models:
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];

E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM 2S) [D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]
ii
4000 SRM 522 General
General
NOTE: For models J1.60-2.00XMT (J30-40ZT)
WARNING [J160], refer to Mast Repairs, 2-, 3-, and 4-Stage
Before working on or near the mast, see Safety Masts 4000 SRM 1148 for information on Four-Stage
Procedures When Working Near Mast in this masts.
section.
NOTE: Hoses have a service life that is determined by
This section has the repair procedures for the application and time. All hoses must be inspected at
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full the intervals specified in the Maintenance Schedule
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL) for the hydraulic system. Install a new hose if the
masts; and for the sideshift carriages. Carriage hose is worn, damaged, soft or hard, and no longer
Adjustment and Troubleshooting are at the end of flexible. If necessary, make a comparison to a new
this section. See the section Mast, Description hose that is the correct replacement for the hose you
4000 SRM 521 for the description and operation of are inspecting.
the masts.
1
Safety Procedures When Working Near Mast 4000 SRM 522
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- WHEN WORKING NEAR THE MAST ALWAYS:
specting or working near the mast. Additional pre- • Lower the mast and carriage completely.
cautions and procedures can be required when re- Push the lift/lower control lever forward and
pairing or removing the mast. make sure there is no movement in the mast.
Make sure all parts of the mast that move are
fully lowered.
WARNING
Mast parts are heavy and can move. Distances OR
between parts are small. Serious injury or
death can result if part of the body is hit by • If parts of the mast must be in a raised po-
parts of the mast or the carriage. sition, install a safety chain to restrain the
• Never put any part of the body into or under moving parts of the mast. Connect moving
the mast or carriage unless all parts are com- parts to a part that does not move. Follow
pletely lowered or a safety chain is installed. these procedures:
Also make sure the power is off and the key
is removed. Put a DO NOT OPERATE tag in 1. Put the mast in a vertical position.
the operator’s compartment. 2. Raise the mast to align the bottom crossmember
• Be careful of the forks. When the mast is of the mast upright that moves in the outer mast
raised, the forks can be at a height to cause upright with a crossmember on the outer mast
an injury. upright. On the two-stage and free-lift mast, the
• DO NOT climb on the mast or lift truck at any moving part is the inner mast upright. On the
time. Use a ladder or personnel lift to work three-stage mast, it is the intermediate mast up-
on the mast. right. See Figure 1.
• DO NOT use blocks to support the mast up-
rights nor to restrain their movement. 3. Use a 9.50 mm (.37 in.) minimum safety chain
• Mast repairs require disassembly and re- with a hook to fasten the crossmembers together
moval of parts and can require removal of so the movable member cannot lower. Put the
the mast or carriage. Follow the repair pro- hook on the back side of the mast. Make sure
cedures in the correct Service Manual for the hook is completely engaged with a link in
the mast. the chain. Make sure the safety chain does not
touch lift chains or chain sheaves, tubes, hoses,
fittings, or other parts on the mast.
4. Lower the mast until there is tension in the

safety chain and the free-lift cylinder (two-stage
full free-lift and three-stage masts only) is com-
pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
NOTE: After lowering or restraining the mast, shut

off the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment.
2
4000 SRM 522 Safety Procedures When Working Near Mast
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST

1. OUTER MAST UPRIGHT 4. HOOK 6. CROSSMEMBER
2. INNER MAST UPRIGHT 5. FREE-LIFT CYLINDER 7. CROSSMEMBER
3. INTERMEDIATE MAST
UPRIGHT
Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
3
Fork Repair 4000 SRM 522
Fork Repair
The forks are held on the carriage by hooks. The INSTALL
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage. Move the fork and carriage so the top hook on the
Always check that the pins for the forks keep the fork can engage the upper carriage bar. Raise the
forks in position on the carriage. Replace damaged carriage to move the lower hook through the fork re-
fork pin parts. The forks can be removed from the moval notch. Slide the fork on the carriage so both
carriage by aligning the forks with the fork removal upper and lower hooks engage the carriage bars. En-
notch. The fork removal notch is in the bottom bar of gage the latch pin with a notch in the upper carriage
the carriage. bar.
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 (99 to 254 lb).
A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car-
riage further so the top hook of the fork is disengaged 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
from the top carriage bar. Move the carriage away
from the fork or use a lifting device to move the fork Figure 2. Hook Fork Removal
away from the carriage.
4
4000 SRM 522 Fork Repair
A. EARLIER MODELS B. LATER MODELS

1. FORKS 5. LATCH PIN ASSEMBLY 8. SPRING
2. CARRIAGE 6. LEVER 9. PIN
3. LOAD BACKREST EXTENSION 7. WASHER 10. KNOB
4. FORK REMOVAL NOTCH
Figure 3. Carriage and Forks
5
Carriages Repair 4000 SRM 522
Carriages Repair
STANDARD CARRIAGE, REMOVE 7. Connect a lifting device to the carriage. Remove
the load from the forks with another lift truck.
1. Put a one-quarter capacity load on the forks. The Lower the carriage to the floor so the load rollers
load must give the carriage stability so the car- are facing up.
riage cannot fall when it is disconnected from the
mast. 8. If the forks are removed, use a lifting device to
put the carriage on the floor so the load rollers
2. Lower the carriage and forks on blocks so the lift are up.
chains become loose.
3. Remove the load backrest.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pin from each chain anchor at the

carriage. See Figure 4. Disconnect the lift chains
from the carriage. Use wire to connect the ends
of the lift chains to a part of the mast. Make sure
the chains can move freely when the inner mast
is raised.
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast is above
the load rollers of the carriage.
NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
5. Use the lift cylinders to raise the inner or inter-
mediate mast. If the hydraulic system cannot be 1. CARRIAGE 6. CHAIN PIN
2. SNAP RING 7. COTTER PIN
used, disconnect the lift cylinders from the in-
3. SHIM 8. ANCHOR PIN
ner or intermediate mast. Connect a crane [the 4. LOAD ROLLER 9. SPACER
capacity of the crane must be at least 681 kg 5. CHAIN ANCHOR
(1501 lb)] to the top of the inner mast. Carefully
raise the inner mast until it is above the load Figure 4. Standard Carriage
rollers of the carriage.
HANG-ON SIDESHIFT CARRIAGE,
6. Move the lift truck away from the carriage. Com- REMOVE
pletely lower the inner mast so it cannot move.
1. Lower the carriage completely. Remove the forks
and the load backrest extension.
6
4000 SRM 522 Carriages Repair
A. HYDRAULIC CONNECTIONS - TWO-STAGE, B. HYDRAULIC CONNECTIONS - TWO-STAGE,

FULL FREE-LIFT AND THREE-STAGE, FULL LIMITED FREE-LIFT
FREE-LIFT
1. TOP BEARING 4. SHIM 8. BOTTOM BEARING
2. CYLINDER SUPPORT 5. SIDESHIFT CYLINDER 9. LOWER APRON
BRACKET 6. GREASE FITTING 10. LIFTING EYE
3. THREADED ROD 7. UPPER APRON 11. SHIM STRIP
Figure 5. Hang-On Sideshift Carriage
7
2. Connect a crane [the capacity of the crane must STANDARD CARRIAGE AND HANG-ON
be at least 681 kg (1501 lb)] to the lifting eye on SIDESHIFT CARRIAGE, REPAIR
the sideshift carriage. See Figure 5.
NOTE: The carriage can have four or six load rollers.
3. Remove the two upper capscrews from the lower When the carriage has four load rollers, shims are
apron. Slowly loosen the two bottom capscrews, used behind all of the load rollers. When the carriage
but do not remove them. The slotted holes will al- has six load rollers, shims are installed on the bottom
low the lower apron to move down so the sideshift and middle rollers only.
carriage can be removed.
1. If any of the load rollers must be replaced, make
4. Carefully lift the sideshift carriage from the stan- a note of the location and number of the shims.
dard carriage. The sideshift cylinder support Install the shims, load rollers, and snap rings.
bracket and cylinder will stay on the standard See Carriage Adjustment for correct adjustment
carriage. Remove the bearings. of the load rollers.
2. If the carriage aprons have any protruding welds

WARNING
or damaged notches, repair by grinding, filing, or
Always wear the proper protective equipment welding.
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor- 3. The repair procedure for the sideshift cylinder is
oughly wash oil from exposed areas of skin as as follows (see Figure 5 and Figure 6):
soon as possible.
a. Remove the retainers from the shell. Pull the
The hydraulic oil is hot at normal operating rod from the shell.
temperatures. Be careful when draining the
oil. b. Replace seals, O-rings, or backup rings as
necessary. Use the installation guides to pre-
Never check for leaks by putting hands on vent damage to the seals.
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected c. Lubricate all internal parts with clean hy-
into the skin. draulic oil.
d. Install the piston and rod in the shell. Ap-

CAUTION ply Loctite® 242 to the threads of the retain-
Protect the hydraulic system from dirt and ers. Install the retainers and tighten them to
contaminants when servicing the hydraulic 27 N•m (20 lbf ft).
system.
5. Disconnect the hydraulic lines at the sideshift

cylinder. Put caps on the open hydraulic lines.
Remove the cylinder support bracket from the
standard carriage. If necessary, remove the
threaded rods and shims in order to remove the
sideshift cylinder.
8
e. Install the seals into the retainer grooves.

Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc-
tion of the rod seals. Pressure seals are in-
stalled with the lip toward the pressure
side of the cylinder.
f. Apply a film of hydraulic oil to the inside

of the retainers. Carefully slide them onto
the cylinder rod. Tighten the retainers to
165 N•m (122 lbf ft).
STANDARD CARRIAGE, INSTALL

1. Use the hydraulic system of the lift truck or a
crane to raise the inner mast. If the hydraulic
1. SHELL 5. RETAINER
2. O-RING 6. WIPER system cannot be used, disconnect the lift cylin-
3. BACKUP RING 7. PISTON AND ROD ders from the inner or intermediate mast. See
4. ROD SEAL 8. PISTON SEAL Lift Cylinders section. Connect a crane [the
capacity of the crane must be at least 681 kg
Figure 6. Sideshift Cylinder (1501 lb)] to the top of the inner mast. Carefully
raise the inner mast until it is above the load
4. Replace the cylinder rod seals as follows:
rollers of the carriage. Install safety chains to
a. Clamp the cylinder in a soft-jawed vise. DO secure the mast in its extended position and dis-
NOT clamp on the cylinder shell. connect the crane. See Safety Procedures When
Working Near Mast.
b. With the cylinder rod centered, unscrew the
retainer from each end of the cylinder. Slide 2. Move the lift truck toward the carriage until the
the retainers off the cylinder rod. inner mast is aligned with the carriage rollers.
If the inner mast has been raised and secured
NOTE: If new retainers that are already assembled using a crane and safety chains, connect the
with seals are being installed, proceed to Step f. crane, raise the inner mast, and remove the
safety chains. Carefully lower the inner mast
c. Remove the seals and O-ring from each re- until it engages all of the load rollers. Discon-
tainer with a brass O-ring tool. DO NOT nect the crane, if attached, and reconnect the lift
scratch the grooves. cylinders. See the Lift Cylinders section.
3. Check the clearance of the load rollers. See Car-

WARNING
riage Adjustment in this section.
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When NOTE: Use new cotter pins each time the anchor pins
using cleaning solvents, always follow the are removed.
solvent manufacturer’s recommended safety
precautions. 4. Connect the lift chains to the chain anchors at
the carriage. Install the cotter pins in the an-
d. Clean the retainers and the cylinder rod with chor pins. Adjust the lift chains as described in
cleaning solvent. Lubricate the new seals Carriage Adjustment in this section.
and O-rings with hydraulic oil.
5. Install the backrest on the sideshift carriage.
Tighten the capscrews to 195 N•m (144 lbf ft).
6. Install the forks. See Fork Repair.
9
HANG-ON SIDESHIFT CARRIAGE, standard carriage. Put blocks under the bottom
INSTALL apron of the sideshift carriage so the bottom
bearing moves tight against the standard car-
1. Install the sideshift cylinder in the cylinder sup- riage when the lifting device is lowered.
port bracket. See Figure 5. Use an equal num-
ber of shims on both sides of the cylinder to limit Install the two top capscrews into the sideshift
side-to-side movement within the bracket. Maxi- carriage. Tighten the capscrews to the following
mum movement is 0.6 mm (0.024 in.). Install the torque:
threaded rods to hold the cylinder in position and • On H/S1.50-1.75XM, H/S2.00XMS (H/S25-
tighten to 18 N•m (159 lbf in). 35XM, H/S40XMS), E1.50-1.75XM (E25-
35XM, E25-35XM 2) [D114], E2.00XMS
2. Install the cylinder support bracket on the stan- (E40XMS, E40XM 2S [D114], E1.50-2.00XM
dard carriage. Make sure the bracket is engaged (E25-35Z, E40ZS) [E114], H/S2.00-2.75XM
in the center notch in the top carriage bar. (H/S40-55XM), S/E/J2.00-2.50XL (S/E/
J40-50XL), J1.60-2.00XMT (J30-40XMT),
3. Connect the hydraulic lines to the sideshift cylin- J2.00-2.50XM (J40-50XM) [A216], and
der. See Figure 5. Lubricate the ends of the cylin- J2.00-2.50XM (J40-50Z) [A416] units, tighten
der rod with multipurpose grease. all of the capscrews to 435 N•m (321 lbf ft).
• On H/S3.00-3.20XM (H/S60-65XM), J3.00-
4. Install the top bearing on the cylinder support
3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z)
bracket. Lubricate only the outer surface of the
[A416], E2.00-3.20XM (E45-65Z) [G108], and
bearing with multipurpose grease.
S/E/J3.00XL (S/E/J60XL) units, tighten all of
5. Connect the top and bottom aprons by installing the capscrews to 755 N•m (557 lbf ft).
the two bottom capscrews. DO NOT tighten the
8. Install the load backrest extension on the
capscrews. Lubricate only the outer surface of
sideshift carriage. Tighten the capscrews to
the bottom bearing with multipurpose grease.
195 N•m (144 lbf ft).
Install the bottom bearing in the lower apron.
9. Remove the lifting device. Lubricate the top
6. Install the shim strips under the bottom bearing
bearings at the grease fittings.
strip (be sure the shims are seated between the
shim stops) so the bottom bearing strip will just
INTEGRAL SIDESHIFT CARRIAGE
clear the lower lip of the standard carriage bar
when the lower apron is brought into position.
Remove
7. Make sure the standard carriage is completely
1. Lower the carriage completely. Remove the forks
lowered. Connect a crane [the capacity of the
and the load backrest extension. See Fork Repair
crane must be at least 908 kg (2002 lb)] to the
and Figure 7 Figure 8 or Figure 9.
lifting eye. Install the sideshift carriage on the
10
NOTE: TWO- AND THREE-STAGE FFL ARE SHOWN.

1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN
2. OUTER FRAME 10. HAIRPIN 18. LOAD ROLLER
3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS
4. UPPER BEARING 12. LUBE FITTING 20. SPACER
5. LOWER BEARING 13. PIN 21. SNAP RING
6. LOWER HOOK 14. CHAIN ANCHOR 22. SPACER
7. CAPSCREW 15. SNAP RING
8. WASHER 16. PIN
Figure 7. Integral Sideshift Carriage
11
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

7. CAPSCREW 15. SNAP RING 23. FORK REMOVAL NOTCH
8. WASHER 16. PIN
Figure 8. Integral Sideshift Carriage for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)
12
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

7. CAPSCREW 15. SNAP RING 23. FORK REMOVAL NOTCH
8. WASHER 16. PIN
Figure 9. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001)
13
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
The hydraulic oil is hot at normal operating

temperatures. Be careful when draining the
oil.
Never check for leaks by putting hands on

Hydraulic oil under pressure can be injected
into the skin.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
system. 1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
NOTE: Tag hydraulic lines prior to disconnecting to MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
insure correct connection during installation.
Figure 10. Lower Mounting Hooks Wear Limit
2. Disconnect the hydraulic lines at the sideshift and Clearance Adjustment
cylinder. Put caps on the open hydraulic lines.
2. Clean and inspect the carriage bars for damage
3. Remove the lower mounting hooks by removing and smoothness. Ensure the bars are parallel
the four capscrews securing the hooks. and the ends are flush.
4. Remove two hairpins, two pins, and sideshift 3. Clean the bearing areas. Inspect the sideshift
cylinder from the carriage. See Figure 7. bearings for wear as follows:
5. Use a crane with a capacity of at least 450 kg a. Remove the upper bearings from the upper
(992 lb) to lift the outer frame away from the in- apron. If either upper bearing is worn to less
ner frame. Lay the outer frame flat on a pallet or than 2.5 mm (0.1 in.) thickness, replace both
workbench. upper bearings by driving the upper bearings
from the upper apron.
Clean and Inspect
b. Remove the lower bearings from the lower
1. Inspect the lower mounting hooks for wear. Re- carriage bar. If either lower bearing is worn
place the hooks if they are worn beyond the wear to less than 2.5 mm (0.1 in.) thickness, re-
limit. The wear limit clearance range is 0.76 mm place both lower bearings by prying the lower
(0.03 in.) minimum and 1.52 mm (0.06 in.) max- bearings from the lower carriage bar.
imum. See A in Figure 10.
4. Inspect the sideshift cylinder. Replace the en-
tire cylinder assembly if a cylinder rod is bent or
scored or if there is damage on the outside of the
cylinder shell that could impair performance or
cause leaks under pressure. See Figure 11.
14
b. Unscrew the retainer from the cylinder.

Slide the retainer off the cylinder rod.
c. Clamp the other end of the cylinder in a

vise between the hydraulic fitting and the
retainer on the same end.
d. Unscrew the retainer from the cylinder.
NOTE: If new retainers that are already assembled

with seals are being installed, proceed to Step h.
e. Remove and discard the seals and O-ring

from each retainer with a brass O-ring tool.
DO NOT scratch the grooves.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
1. CYLINDER SHELL 3. O-RING solvent manufacturer’s recommended safety
AND ROD 4. RETAINER precautions.
2. SEAL 5. WIPER
f. Clean the retainers and the cylinder rod with
Figure 11. Integral Sideshift Cylinder
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
Repair
g. Install the seals into the retainer grooves.
NOTE: Drain the oil from the cylinder before under-
Form the seals into a "kidney" shape to ease
taking any repairs.
placement into the groove. Note the direc-
1. If any of the load rollers must be replaced, make tion of the rod seals. Pressure seals are in-
a note of the location and number of the shims. stalled with the lip toward the pressure
Install the shims, load rollers, and snap rings. side of the cylinder.
See Carriage Adjustment for correct adjustment.
h. Apply a film of hydraulic oil to the inside of
the retainers.
WARNING
Improper welding procedures can damage the i. Clamp one end of the cylinder in a vise be-
structure of the mast or cause incorrect func- tween the hydraulic fitting and the end.
tion of the mast. Consult your Hyster lift truck
j. Screw the retainer into the cylinder. Tighten
dealer for more information before welding on
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
the mast.
k. Clamp the other end of the cylinder in a vise
2. If the carriage bars have any protruding welds
between the hydraulic fitting and the end.
or damaged notches, repair by grinding, filing,
or welding. l. Slide the retainer onto the cylinder rod.
Screw the retainer into the cylinder. Tighten
3. Replace the cylinder rod seals as follows:
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
a. Clamp one end of the cylinder in a vise be-
tween the hydraulic fitting and the retainer
on the same end.
15
Install 3. Use a crane with a capacity of at least 450 kg

(992 lb) to install the outer frame on the inner
NOTE: Use a wood block or a plastic hammer to fully frame.
seat the upper bearings onto the upper carriage bar.
Proper lower hook clearance requires the upper bear- 4. Install the lower mounting hooks using four cap-
ings be fully seated. screws. Tighten to 165 ±15 N•m (120 ±12 lbf ft).
For proper sideshift operation, make sure there
1. If necessary, install the lower sideshift bearings. is 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
Then install the upper sideshift bearings. Lubri- between the bottom of the hooks and the outer
cate the upper and lower sideshift bearings with frame. See B in Figure 10.
chassis grease. See Figure 7 .
5. Connect the hydraulic lines, as noted during re-
NOTE: The pin, located on the left top of the cylinder moval, to the sideshift cylinder.
looking from the front of the carriage, is for align-
ment purposes and to prevent the cylinder from 6. Install the backrest on the sideshift carriage.
rolling to the front or to the back. Tighten the capscrews to 195 N•m (144 lbf ft).
2. Install sideshift cylinder onto the carriage with 7. Install the forks.
the pin in the up position. Install two pins and
two hairpins. See Figure 7.
16
4000 SRM 522 Mast Repair
Mast Repair
REMOVE 2. Put a drain pan under the area of the hydraulic
fittings. Disconnect the hydraulic line at the ex-
WARNING ternal lowering control valve on the outer mast
weldment.
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.) WARNING
are suitable and of adequate capacity to lift the Use a driver, NOT your fingers, to push the an-
mast. chor pins from the clevises on the tilt cylinders.
The cylinder or mast can move and cause seri-
NOTE: If the mast needs to be disassembled, remove ous injury.
the forks and carriage. If only the lift cylinders need
to be removed for repair, the mast does not need to be 3. Remove the cotter pins and anchor pins or the
removed from the lift truck. See the procedures for capscrews, washers, and anchor pins at the tilt
Lift Cylinders Repair. cylinder mounts on the outer mast weldment.
NOTE: The length of the lift chains must be checked NOTE: To perform the next two steps, the lift truck
before the mast is removed. See Step 2 in Mast and must be raised. See the Operating Manual or Pe-
Chains, Clean and Inspect. riodic Maintenance Manual for your lift truck for
instructions on how to put a lift truck on blocks.How
1. Fully lower all of the mast weldments and the to Put Lift Truck on Blocks
carriage. Tilt the mast fully forward. Connect a
crane with a capacity of at least 1600 kg (3527 lb) 4. On the H/S2.00-3.20XM (H/S40-65XM),
to the top of the mast using chains. Make sure all E2.00-3.20XM (E40-65XM, E40-65XM 2)
the mast weldments are fastened together. Make (F108), E2.00-3.20XM (E45-65Z) (G108)
sure the chains will not damage the sheaves, tub- J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
ing, or other parts of the mast. and J2.00-3.20XM (J40-65Z) (A416), see Fig-
ure 12, remove the capscrews that hold the outer
mast weldment to the pivot pins at the mounts.
WARNING
Always wear the proper protective equipment 5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-
including eye protection and petroleum-resis- 35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
tant gloves when handling hydraulic oil. Thor- E25-35XM 2) (D114), E2.00XMS (E40XMS,
oughly wash oil from exposed areas of skin as E40XM SS (D114), E1.50-2.00XM (E25-35Z,
soon as possible. E40ZS) (E114), and J1.60-2.00XMT (J30-
40XMT), see Figure 13; on S/E/J2.00-3.00XL
The hydraulic oil is hot at normal operating (S/E/J40-60XL), see Figure 14; and on J1.60-
temperatures. Be careful when draining the 2.00XMT (J30-40ZT), see Figure 15, and remove
oil. the capscrews that hold the retainer caps to the
mast mounts.
CAUTION
contaminants when servicing the hydraulic
system.
17
Mast Repair 4000 SRM 522
1. SPACER 7. O-RING 1. RETAINER CAP 6. SHIMS

2. TILT CYLINDER 8. PIVOT PIN 2. SPACER 7. PIN
3. OUTER MAST 9. DRIVE AXLE 3. TILT CYLINDER 8. ROD END
WELDMENT HANGER (MAST 4. OUTER MAST 9. O-RING
4. SHIMS MOUNT) WELDMENT 10. CAPSCREW
5. PIN 10. COTTER PIN 5. BUSHING 11. FLAT WASHER
6. ROD END
Figure 13. Mast Mounting H/S1.50-1.75XM,
Figure 12. Mast Mounting H/S2.00-3.20XM H/S2.00XMS (H/S25-35XM, H/S40XMS),
(H/S40-65XM), E2.00-3.20XM (E40-65XM, E1.50-1.75XM (E25-35XM, E25-35XM 2) (D114),
E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z) E2.00XMS (E40XMS, E40XM 2S (D114),
(G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
(A216), and J2.00-3.20XM (J40-65Z) (A416), J1.60-2.00XMT (J30-40XMT)
18
1. RETAINER CAP 5. BUSHING

2. SPACER 6. SHIMS
3. TILT CYLINDER 7. PIN
4. OUTER MAST 8. ROD END
WELDMENT
1. RETAINER CAP 6. NUT
Figure 14. Mast Mounting S/E/J2.00-3.00XL 2. LOCKWASHER 7. PIN
(S/E/J40-60XL) 3. TILT CYLINDER 8. ROD END
4. OUTER MAST 9. WASHER
WELDMENT 10. CAPSCREW
5. BUSHING
Figure 15. Mast Mounting J1.60-2.00XMT

(J30-40ZT)
19
WARNING WARNING
The mast is heavy. The mast can weigh ap- Be careful when removing or installing snap
proximately 907 kg (2000 lb). Make sure all lift- rings. These snap rings can come loose dur-
ing devices (hoists, cables, chains, slings, etc.) ing removal or installation with enough force
are suitable and of adequate capacity to lift the to cause an injury. Always use the correct snap
mast. ring pliers, and wear eye and face protection
during removal or installation.
6. Use the crane to lift the mast assembly from the
lift truck. Put the mast on the floor so the back 3. Remove the nut, bolt, and spacer at the mount
of the mast is toward the floor. near the top of each main lift cylinder. Remove
the snap rings and washers from the top of
TWO-STAGE LFL AND TWO-STAGE FFL each main lift cylinder. Disconnect the main lift
MASTS, DISASSEMBLE chains at the mounts.
4. On the H/S2.00-3.20XM (H/S40-65XM),

WARNING E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108),
Always wear the proper protective equipment E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
including eye protection and petroleum-resis- (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
tant gloves when handling hydraulic oil. Thor- (J40-65Z) (A416), and S/E/J2.00-3.00XL
oughly wash oil from exposed areas of skin as (S/E/J40-60XL), two-stage FFL mast, disconnect
soon as possible. the FFL supply tube and remove the hydraulic
fitting from the top of the left-hand main lift
Completely lower forks to relieve hydraulic cylinder.
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-
hoses. 35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM 2) (D114), E2.00XMS (E40XMS,
The hydraulic oil is hot at normal operating E40XM 2S) (D114), E1.50-2.00XM (E25-35Z,
temperatures. Be careful when draining the E40ZS) (E114), and J1.60-2.00XMT (J30-
oil. 40XMT) two-stage FFL masts, disconnect the
FFL supply tube and remove the hydraulic fit-
CAUTION ting from the top of the right-hand main lift
Protect the hydraulic system from dirt and cylinder.
system. WARNING
NOTE: If only the lift cylinders need to be removed The mast weldment can slide when the mast is
and repaired, see the procedures for Lift Cylinders moved. A weldment that slides can cause in-
Repair. When the mast has header hoses, see the jury.
procedures for the Header Hose Arrangements. 5. Slide the inner mast weldment from the outer
1. Clean the area around the hydraulic fittings for mast weldment approximately 30 cm (12 in.) to
the lift cylinders. Disconnect the fittings at the disengage the main lift cylinders from the inner
lift cylinders and put caps on the open lines. mast weldment. Remove the main lift cylinders
from the outer mast weldment. See Figure 16
2. Remove the chains and header hoses. On the and Figure 17.
two-stage FFL mast, remove the brackets and
disconnect the hydraulic line for the free-lift
cylinder. Remove the free-lift cylinder. Discon-
nect the free-lift chains at the crossmember.
20
6. Slide the inner mast weldment from the bot- the old channel and stamp that information on the
tom of the outer mast weldment approximately new channel with a letter R at the end to indicate
30 cm (12 in.). Remove the strip bearings and that it has been replaced.
load rollers from the top of the outer mast weld-
ment. Remove the load rollers from the bottom 7. Slide the inner mast weldment halfway out of
of the inner mast weldment. Make a note of each the top of the outer mast weldment. Connect a
shim arrangement and load roller location. The crane [the capacity of the crane must be at least
shim arrangements will be approximately the 681 kg (1501 lb)] to the center of the inner mast
same during assembly. weldment. See Figure 18. Slide the inner mast
weldment out of the outer mast weldment until
the mast stub shafts of the inner mast weldment
WARNING are in the notches of the outer channels. Remove
The mast is heavy. The mast can weigh ap- the inner mast weldment from the outer mast
proximately 681 kg (1501 lb). Make sure all lift- weldment.
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the 8. Remove the chain sheaves and disassemble them
mast. as necessary for repair and cleaning.
NOTE: When replacing the outer channel weldment,

copy the part number and date code information from
21
Figure 16. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)
22
Figure 16. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)
23
Legend for Figure 16

A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416), AND
S/E/J2.00-3.00XL (S/E/J40-60XL), SHOWN.
B. MODELS H/S1.50-2.00XMS (H/S25-40XMS), E1.50-2.00XMS (E25-40XMS, E25-40XM 2S) (D114),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), AND J1.60-2.00XMT (J30-40XMT) SHOWN.
C. OLDER MODELS.
1. OUTER MAST WELDMENT 14. STAR WASHER
2. LOAD ROLLER 15. HOUSING
3. SHIM 16. LOWERING CONTROL VALVE (EXTERNAL)
4. SNAP RING 17. INNER MAST WELDMENT
5. O-RING 18. PIN (2)
6. SHIM(S) 19. SPACER
7. STRIP BEARING 20. CHAIN SHEAVE
8. WASHER 21. PIN
9. MAIN LIFT CYLINDER 22. CAPSCREW
10. MAIN LIFT CHAIN 23. NUT
11. CHAIN ANCHOR 24. HOSE
12. LOWERING CONTROL VALVE (INTERNAL) 25. PLUG
13. SPRING
24
Figure 17. Two-Stage, Full Free-Lift Mast (Sheet 1 of 2)
25
Figure 17. Two-Stage, Full Free-Lift Mast (Sheet 2 of 2)
26

C. OLDER MODELS.
1. OUTER MAST WELDMENT 15. LOWERING CONTROL VALVE (EXTERNAL)
2. LOAD ROLLER 16. INNER MAST WELDMENT
3. SHIM 17. FREE-LIFT CHAIN
4. SNAP RING 18. CHAIN ANCHOR
5. O-RING 19. FREE-LIFT CYLINDER
6. SHIM(S) 20. CYLINDER BRACKET
7. STRIP BEARING 21. HOSE
8. WASHER 22. CROSSHEAD
9. LEFT-HAND MAIN LIFT CYLINDER 23. CHAIN GUARD
10. RIGHT-HAND MAIN LIFT CYLINDER 24. PLUG
11. STAR WASHER 25. CAPSCREW
12. SPRING 26. SPACER
13. LOWERING CONTROL VALVE (INTERNAL) 27. NUT
14. HOUSING 28. TUBE
CAUTION
system.
1. Disconnect the main free-lift chains at the cross-

member. See Figure 19.
2. Disconnect and remove the hydraulic lines for

the main free-lift cylinder. Remove the brackets
for the main free-lift cylinder. Remove the main
free-lift cylinder.
3. Disconnect the main lift chains from the chain

anchors near the top of the main lift cylinders.
Disconnect the other end of the main lift chains
Figure 18. Inner Mast Weldment
at the bottom of the inner mast weldment. Push
the inner mast weldment toward the bottom of
THREE-STAGE FFL MAST
the mast assembly until the bottom load rollers
Disassemble can be seen.
WARNING WARNING
Always wear the proper protective equipment The weldments can slide when the mast is
including eye protection and petroleum-resis- moved. A weldment that slides can cause in-
tant gloves when handling hydraulic oil. Thor- jury. Use a crane to turn the mast slowly and
oughly wash oil from exposed areas of skin as carefully.
soon as possible. 4. Remove the strip bearings at the top of the inter-
Completely lower forks to relieve hydraulic mediate mast weldment. Remove the load rollers
pressure before disassembling any part of the
lift pump or disconnecting any hoses.
Hydraulic oil is hot at normal operating tem-

peratures. Be careful when draining the oil.
27
at the bottom of the inner mast weldment. Re-

move the load rollers at the top of the intermedi- WARNING
ate mast weldment. Make a note of each shim ar- Be careful when removing or installing snap
rangement and load roller location. The shim ar- rings. These snap rings can come loose dur-
rangements will be approximately the same during removal or installation with enough force
ing assembly. to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection
WARNING
The mast is heavy. The mast can weigh ap- 6. Remove the snap rings and washers at the top of
proximately 681 kg (1501 lb). Make sure all lift- the main lift cylinders. Remove the nut, bolt, and
ing devices (hoists, cables, chains, slings, etc.) spacer at the mount near the top of each main lift
are suitable and of adequate capacity to lift the cylinder.
mast.
7. Push the intermediate mast weldment to disen-
5. Slide the inner mast weldment halfway out of gage the main lift cylinders. Remove the main
the top of the intermediate mast weldment. Con- lift cylinders.
nect a crane with a capacity of at least 681 kg
(1501 lb) to the center of the inner mast weld- 8. Slide the intermediate mast weldment from the
ment. See Figure 18. Slide the inner mast weld- bottom of the outer mast weldment approxi-
ment out of the intermediate mast weldment un- mately 30 cm (12 in.). Remove the strip bearings
til the stub shafts are in the notches of the inter- at the top of the outer mast weldment. Remove
mediate mast weldment. Remove the inner mast the snap rings and load rollers from both weld-
weldment from the intermediate mast weldment. ments. Make a note of each shim arrangement
and load roller location. The shim arrangements
will be approximately the same during assembly.
28
Figure 19. Three-Stage, Full Free-Lift Mast (Sheet 1 of 2)
29

C. OLDER MODELS.
1. OUTER MAST WELDMENT 11. STAR WASHER 19. HOSE SHEAVE
2. LOAD ROLLER 12. SPRING 20. CHAIN ANCHOR
3. SHIM 13. LOWERING CONTROL VALVE 21. INNER MAST WELDMENT
4. SNAP RING (INTERNAL) 22. FREE-LIFT CYLINDER
5. O-RING 14. HOUSING 23. CYLINDER BRACKET
6. SHIM(S) 15. LOWERING CONTROL VALVE 24. CAPSCREW
7. STRIP BEARING (EXTERNAL) 25. SPACER
8. WASHER 16. CHAIN SHEAVE 26. NUT
9. MAIN LIFT CYLINDER 17. INTERMEDIATE MAST 27. HOSE
10. LIFT CHAIN WELDMENT 28. FLOW CONTROL FITTING
18. FREE-LIFT CYLINDER TUBE
Figure 19. Three-Stage, Full Free-Lift Mast (Sheet 2 of 2)
30
WARNING WARNING
The mast is heavy. The mast can weigh ap- Never replace only the worn section of a chain.
proximately 681 kg (1501 lb). Make sure all lift- Replace the complete chain. Never replace
ing devices (hoists, cables, chains, slings, etc.) only one chain of a chain pair. Replace both
are suitable and of adequate capacity to lift the chains.
mast.
3. A lift chain becomes longer when it is worn. If
9. Slide the intermediate mast weldment halfway a chain is 3% longer than a new lift chain, the
out of the top of the outer mast weldment. Con- lift chain must be replaced. If a chain scale is
nect a crane with a capacity of at least 681 kg available, check the lift chain as shown in Fig-
(1501 lb) to the center of the intermediate mast ure 20. If a chain scale is not available, measure
weldment. See Figure 18. Slide the intermedi- 20 links of the lift chain. Compare the measure-
ate mast weldment out of the outer mast weldment with the lengths given in Figure 20. Lubri-
ment until the stub shafts are in the notches of cate the chains with SAE 30 engine oil. The best
the outer mast weldment. Remove the interme- procedure is to soak them in engine oil.
diate mast weldment from the outer mast weld-
ment. 4. Inspect the chain anchors and pins. Replace any
parts that are worn or damaged.
10. Disassemble the chain sheaves as necessary for
repair and cleaning. Remove the hydraulic lines
WARNING
and fittings from the weldments as necessary.
Be careful when cleaning with steam. Steam
Mast and Chains, Clean and Inspect can cause serious burns. Wear protective cloth-
ing, gloves, and eye protection. Never expose
1. Inspect the chain sheaves and load rollers for your skin to steam.
wear or damage. DO NOT use steam to clean the
lift chains, sheaves, or load rollers. The bearings Cleaning solvents may be flammable and toxic
in the sheaves and load rollers are sealed and lu- and can cause severe skin irritation. When
bricated. using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
WARNING
Cleaning solvents may be flammable and toxic 5. Clean the mast weldments with steam or solvent.
and can cause severe skin irritation. When
using cleaning solvents, always follow the WARNING
solvent manufacturer’s recommended safety Incorrect welding procedures can damage the
precautions. structure of the mast or cause wrong operation
2. Clean the lift chains with solvent. Remove all of the mast. Obtain information from your Hys-
dirt and grease. Inspect the lift chains for wear ter lift truck dealer before welding on the mast.
or damage. The lift chains must be installed in 6. Inspect the sliding surfaces for wear or damage.
the mast and the mast must be installed on the Inspect the load roller contact surfaces for wear
lift truck before they can be checked for correct or damage. Inspect all welds for cracks.
length.
31
During assembly, the shim arrangement will be ap-

proximately the same as before disassembly. Check
the clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. See Carriage Adjust-
ment in this section for the adjustment procedures.
NOTE: When the mast has header hoses, see the pro-
cedures for Header Hose Arrangements.
1. Connect a crane with a capacity of at least 681 kg

(1501 lb) to the center of the inner mast weld-
ment. Fit the stub shafts through the notches in
the outer mast weldment. Slide the inner mast
weldment into the outer mast weldment so the
stub shafts are seen at the top and bottom of the
weldments. See Figure 16 and Figure 17.
2. Install the strip bearings and the shims on the

outer mast weldment. See Figure 21. Apply
chassis lube to the bearing surface. Check the
Pitch Total length Wear Limit clearance of the strip bearings as described in
of 20 links The maximum Carriage Adjustment.
(pitch) length of 20
of new chain links
12.7 mm (0.5 in.) 254.0 mm 261.6 mm

15.9 mm (0.6 in.) (10.0 in.) (10.3 in.)
19.1 mm (0.8 in.) 317.5 mm 327.0 mm
25.4 mm (1.0 in.) (12.5 in.) (12.9 in.)
381.0 mm 392.4 mm
(15.0 in.) (15.4 in.)
508.0 mm 523.3 mm
(20.0 in.) (20.6 in.)
NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
1. CHAIN WEAR SCALE Figure 21. Strip Bearings
Figure 20. Lift Chains Check 3. Install the load rollers and shims on both weld-
ments. Check the clearance of the load rollers as
TWO-STAGE LFL AND TWO-STAGE FFL described in Carriage Adjustment.
MAST, ASSEMBLE
4. To install the main lift cylinders on the two-stage
LFL mast, push the inner mast weldment to en-
WARNING
gage the rods of the lift cylinders. Install the
The mast is heavy. The mast can weigh ap- washer and snap ring.
proximately 681 kg (1501 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.) NOTE: The clearance check and adjustment in either
are suitable and of adequate capacity to lift the procedure for Step 5 is only an initial setup. The
mast. final check and adjustment is done after the mast is
installed on the lift truck.
NOTE: The shims for the load rollers keep the
mast weldments parallel and give correct clearance.
32
5. To install the main lift cylinders on the two-stage for the chain sheave in position. Connect the
FFL mast, perform the following procedure: lift chains to the chain anchors at the main lift
cylinder mounts. Attach wires between the ends
a. H/S2.00-3.20XM (H/S40-65XM), E2.00- of the lift chains and the crossmember to control
3.20XM (E40-65XM, E40-65XM 2) (F108), the lift chains during mast installation.
E2.00-3.20XM (E45-65Z) (G108), J2.00-
3.20XM (J40-60XM, J40-60XM 2) (A216), 9. On the two-stage FFL mast:
J2.00-3.20XM (J40-65Z) (A416), and
S/E/J2.00-3.00XL (S/E/J40-60XL),: Install a. Install the free-lift cylinder in the mounts on
the washers at the top of the right-hand the inner mast weldment. Install the brack-
cylinder. Push the inner mast weldment to ets for the cylinder and tighten the bolts to
engage the rods of the lift cylinders. Check 53 N•m (39 lbf ft).
the clearance at the top of the lift cylinder
b. Install the tubing or hoses that connect the
mounts. Add or remove washers at the
free-lift cylinder to the main lift cylinder.
right-hand cylinder until it is even with the
left-hand cylinder. Install the snap ring at c. Connect the free-lift chains to the chain an-
the top of the right-hand lift cylinder. Install chors at the crossmember. Attach a wire be-
the hydraulic fitting on the left-hand cylin- tween the end of the lift chain and the bottom
der. of the mast to control the lift chain during in-
stallation.
b. H/S1.50-2.00XMS (H/S25-40XMS), E1.50-
2.00XMS (E25-40XMS, E25-40XM 2S (D114),
THREE-STAGE FFL MAST, ASSEMBLE
E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
J1.60-2.00XMT (J30-40XMT): Install the NOTE: The shims for the load rollers keep the weld-
washers at the top of the left-hand cylinder. ments parallel and give correct clearance. During as-
Push the inner mast weldment to engage the sembly, the shim arrangement will be approximately
rods of the lift cylinders. Check the clearance the same as before disassembly. Check the clearance
at the top of the lift cylinder mounts. Add and adjust the shims for wear or for changes caused
or remove washers at the left-hand cylinder by repairs. The strip bearings are also adjusted by
until it is even with the right-hand cylin- using shims. See Carriage Adjustment in this sec-
der. Install the snap ring at the top of the tion for the adjustment procedures.
left-hand lift cylinder. Install the hydraulic
fitting on the right-hand cylinder. NOTE: When the mast has header hoses, see the pro-
cedures for Header Hose Arrangements.
6. Install the spacers, nuts, and bolts at the mounts
for the lift cylinders. Tighten the bolts to 53 N•m 1. Put the outer mast weldment on the floor with
(39 lbf ft). the mast pivots toward the floor. See Figure 19.
Connect a crane with a capacity of at least 681 kg
7. Install the housing for the lowering control valve (1501 lb) to the center of the intermediate mast
on the outer mast weldment. Tighten the nuts for weldment. Fit the lower stub shafts of the inter-
the lowering control valve to 18 N•m (13 lbf ft). mediate mast weldment into the notches in the
Install the lowering control valve in the housing. top of the outer mast weldment. Slide the in-
Connect the hydraulic lines and fittings between termediate mast weldment into the outer mast
the lowering control valve and the main lift cylin- weldment so the stub shafts are seen at the top
ders. and bottom of both weldments.
8. On the two-stage LFL mast, install the chain NOTE: The load rollers must be in place before strip
sheaves at the inner mast weldment. On the bearing can be shimmed.
H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM
(E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM 2. Install the strip bearings and the shims on the
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM, channels of the outer mast weldment. See Fig-
J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) ure 21. Apply chassis lube to the bearing sur-
(A416), and S/E/J2.00-3.00XL (S/E/J40-60XL), faces. Check the clearance of the strip bearings
be sure to install both pins that hold the shaft as described in Carriage Adjustment.
33
3. Install the load rollers and the shims on the doing the next step, adjust the inner mast weld-
outer mast weldment and at the bottom of the ment as described in Carriage Adjustment.
intermediate mast weldment. Before doing the
next step, adjust the intermediate mast weld-
ment and check the clearance of the load rollers
CAUTION
as described in Carriage Adjustment. Install the chain anchor pins with the cotter
pins opposite from nearby hydraulic hoses to
NOTE: The clearance check and adjustment in Step 4 prevent damage. DO NOT reuse cotter pins.
is only an initial setup. The final check and adjust- Install new cotter pin with the legs bent back
ment is done after the mast is installed on the lift against the chain anchor pin to minimize expo-
truck. sure.
4. Install the main lift cylinders. Push the interme- 10. Connect the main lift chains to the chain anchors
diate mast weldment to engage the lift cylinders. at the main lift cylinder mounts. Put the lift
Check the clearance at the top of the lift cylin- chains over the chain sheaves and connect them
der mounts. Add or remove washers at the top of to the anchors at the bottom of the inner mast
the cylinder rods until they are even. Install the weldment.
snap ring and washer at the top of the lift cylin-
ders. 11. Install the free-lift cylinder in the mounts on
the inner mast weldment. Install the brackets
5. Install the housing for the lowering control valve for the cylinder and tighten the nuts to 38 N•m
on the outer mast weldment. Tighten the nuts for (28 lbf ft). On the three-stage FFL mast, the
the lowering control valve to 18 N•m (13 lbf ft). nuts are installed on the bracket side of the
Install the lowering control valve in the housing. free-lift cylinder.
Connect the hydraulic lines and fittings between
the lowering control valve and the main lift cylin- 12. Install the hose sheave for the free-lift cylinder.
ders. Tighten the capscrew for the hose sheave to
66 N•m (49 lbf ft). Install the hydraulic hose
6. Install the chain sheaves at the intermedi- and tubing for the free-lift cylinder.
ate mast weldment. On the H/S2.00-3.20XM
(H/S40-65XM), E2.00-3.20XM (E40-65XM, 13. Connect the free-lift chains to the chain anchors
E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z) at the crossmember. Attach a wire between the
(G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) end of the lift chain and the bottom of the mast
(A216), J2.00-3.20XM (J40-65Z) (A416), to control the lift chain during mast installation.
S/E/J2.00-3.00XL (S/E/J40-60XL), be sure to
install both pins that hold the shaft for the chain INSTALL
sheave in position. 1. On the H/S2.00-3.20XM (H/S40-65XM),
7. Install the spacers, washers, nuts, and bolts at E2.00-3.20XM (E40-65XM, E40-65XM 2)
the mounts for the main lift cylinders. Tighten (F108), E2.00-3.20XM (E45-65Z) (G108),
the bolts to 53 N•m (39 lbf ft). J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
and J2.00-3.20XM (J40-65Z) (A416), lubricate
8. Connect a crane with a capacity of at least 681 kg the pivot pins with chassis lube and install them
(1501 lb) to the center of the inner mast weld- into the mounts at the drive axle hanger. On the
ment. Slide the inner mast weldment into the in- H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM,
termediate mast weldment so the stub shafts are H/S40XMS), E1.50-1.75XM (E25-35XM,
seen at the top and bottom of both weldments. E25-35XM 2) (D114), E2.00XMS (E40XMS,
E40XM 2S) (D114), E1.50-2.00XM (E25-35Z,
NOTE: The load rollers must be in place before bear- E40ZS) (E114), J1.60-2.00XMT (J30-40XMT);
ing strips can be shimmed. and S/E/J2.00-3.00XL (S/E/J40-60XL), lubri-
cate the bushings with chassis lube and install
9. Install the strip bearings and the shims on the them into the mounts on the mast. On the
channels of the intermediate mast weldment. J1.60-2.00XMT (J30-40ZT) lubricate the bush-
Apply chassis lube to the bearing surfaces. ings with chassis lube and install them onto
Install the load rollers and the shims on the the stub shafts at the bottom of the outer mast
intermediate and inner mast weldments. Before weldment.
34
NOTE: Lubricate the anchor pins with chassis grease

WARNING before installation.
The mast is heavy. The mast can weigh approx-
imately 1600 kg (3527 lb). Make sure all lift- 4. Connect the tilt cylinders to the mast. Install
ing devices (hoists, cables, chains, slings, etc.) the anchor pins and/or cotter pins, washers, or
are suitable and of adequate capacity to lift the capscrews.
mast.
5. Connect the hydraulic line to the lowering control
valve.
CAUTION
Make sure the chains will not damage the 6. Install the carriage as described in Carriages Re-
sheaves, tubing, or other parts of the mast. pair.
2. Connect a crane with a capacity of at least 7. Check the tilt cylinder adjustment as described
1600 kg (3527 lb) to the top of the mast using in Carriage Adjustment. Operate the mast and
chains. Make sure all the mast weldments are check for leaks and correct operation. Check the
fastened together. Make sure the chains will not lift chains as described in Carriage Adjustment.
damage the sheaves, tubing, or other parts of
the mast. NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
3. Use the crane to install the mast assembly:
8. Lubricate the sliding surfaces and the load roller
a. On the H/S2.00-3.20XM (H/S40-65XM), surfaces along the full length of the channels as
E2.00-3.20XM (E40-65XM, E40-65XM 2) shown in Figure 22. Apply chassis lube only to
(F108), E2.00-3.20XM (E45-65Z) (G108), the surfaces indicated.
J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216), and J2.00-3.20XM (J40-65Z) (A416),
install the mast on the pivot pins. Install
the capscrews that hold the mast to the pivot
pins. Tighten the capscrews to 130 N•m
(96 lbf ft).
b. On the H/S1.50-1.75XM, H/S2.00XMS

(H/S25-35XM, H/S40XMS), E1.50-1.75XM
(E25-35XM, E25-35XM 2) (D114), E2.00XMS
(40XMS, 40XM SS) (D114), E1.50-2.00XM
(E25-35Z, E40ZS) (E114), S/E/J2.00-3.00XL
(S/E/J40-60XL), and J1.60-2.00XMT
(J30-40XMT), install the mast on the drive
axle. Install the capscrews and bushings
A. UPPER LOAD ROLLERS
that hold the retainer caps and mast assem- B. LOWER LOAD ROLLERS
bly to the drive axle. Tighten the capscrews
to 90 N•m (66 lbf ft). 1. LUBRICATE STRIP BEARINGS SURFACES
WITH CHASSIS LUBE
c. On the J1.60-2.00XMT (J30-40ZT), install 2. LUBRICATE LOAD ROLLER SURFACES WITH
the mast into the transmission housing CHASSIS LUBE
3. LOAD ROLLER
mounts. Apply HCE-92 adhesive sealant
(Loctite ™ #290) to capscrew threads. In- Figure 22. Mast Lubrication
stall the capscrews, bushing, and retainer
caps. Tighten the capscrews to 34.8 N•m
(25.7 lbf ft).
35
Lift Cylinders Repair 4000 SRM 522
Lift Cylinders Repair

MAIN LIFT CYLINDERS, REMOVE FREE-LIFT CYLINDER, REMOVE
1. Remove the carriage as described in the proce-
WARNING dures for Carriages Repair. Lower the mast com-
Before working on or near the mast, see Safety pletely. See Figure 17 and Figure 19.
Procedures When Working Near Mast in this
section.
WARNING
NOTE: The following procedures are for the removal Hydraulic oil is hot after system operation and
of the lift cylinders with the mast installed on the lift can cause burns. Do not disconnect any hy-
truck. draulic hoses until the oil in the system is cool.
1. Remove the carriage as described in the proce- 2. Put a drain pan under the area of the hydraulic
dures for Carriages Repair. See Figure 16, Fig- fittings. Disconnect the hydraulic line at the
ure 17, and Figure 19. cylinder.
2. Raise the mast until it is almost fully extended. 3. Remove the brackets for the free-lift cylinder. Re-
Use safety chains to connect the bottom cross- move the free-lift cylinder.
member of the inner mast (two-stage) or interme-
diate mast (three-stage) to the top crossmember 4. Remove the crosshead from the cylinder rod. See
of the outer mast. On the three-stage mast, use a Figure 23. Disassemble the crosshead as neces-
safety chain to connect the bottom crossmember sary.
to a crossmember on the intermediate or outer
mast. Lower the mast so the safety chains hold
the weight of the mast uprights.
WARNING
Be careful when removing or installing snap
rings. Snap rings can eject with enough force
to cause injury. Always use the correct snap
ring pliers and wear eye and face protection
3. Remove the snap ring or fitting at the top of the

lift cylinder that needs to be removed.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic hoses until the oil in the system is cool.
4. Put a drain pan under the area of the hydraulic

fittings. Disconnect the hydraulic line at the
cylinder. Retract the rod into the lift cylinder.
5. Remove the nut, bolt, and spacer at the mount.

Disconnect the main lift chain at the mount.
6. Remove the lift cylinder from the front of the

mast. Use a lifting device as necessary.
36
4000 SRM 522 Lift Cylinders Repair
CYLINDERS, DISASSEMBLE
Two-Stage Full Free-Lift Mast, Right-Hand
Main Lift Cylinder
CAUTION
Carefully disassemble the lift cylinders so the
piston rods and sliding surfaces are not dam-
aged.
NOTE: Disassembly of the main lift cylinders and the

free-lift cylinder is similar, but not all cylinders can
be completely disassembled. All cylinders are disas-
sembled from the rod end of the cylinder shell.
1. Loosen the gland with a spanner wrench. Re-

move the gland from the shell and rod. See Fig-
ure 24.
NOTE: THE SPACERS ARE ONLY INSTALLED 2. Remove wiper, backup ring, rod seal, wear ring,
ON EARLIER H/S2.00-3.20XM (H/S40-65XM), O-ring, and backup ring from gland. See Fig-
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), ure 24.
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), AND
3. Pull the rod and piston assembly from the shell.
S/E/J2.00-3.00XL (S/E/J40-60XL), MODELS. MAKE
See Figure 24. Drain the hydraulic oil into a con-
A NOTE OF THE NUMBER OF SPACERS IN EACH
tainer.
LOCATION.
1. LIFT CHAIN 6. BEARING 4. Remove the piston from the rod. See Figure 24.
2. CHAIN SHEAVE 7. PIN
3. CHAIN GUARD 8. FREE-LIFT 5. Remove and discard the wear ring from the pis-
4. SNAP RING CYLINDER ton. See Figure 24.
5. CROSSHEAD 9. SPACER
Figure 23. Crosshead Assembly, Two-Stage and WARNING

Three-Stage FFL Mast Be careful when removing or installing snap
6. If present, remove the snap ring, washer, and

check valve from the base of the piston. Remove
and discard the O-ring from the check valve. See
Figure 24.
7. If present, remove the screw and sealing washer

from the shell. See Figure 24.
37
A. RIGHT-HAND CYLINDER B. LEFT-HAND CYLINDER

1. SHELL 8. WEAR RING
2. ROD 9. PISTON RING
3. WIPER 10. SCREW*
4. ROD SEAL 11. SEALING WASHER*
5. GLAND 12. WEAR RING
6. BACKUP RING 13. PISTON
7. O-RING
*
H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z) (G108),
J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.00XM (J40-65Z) (A416), AND S/E/J2.00-3.00XL (S/E/J40-
60XL),
Figure 24. Main Lift Cylinders, Two-Stage Full Free-Lift Mast
38
Two-Stage Full Free-Lift Mast, Left-Hand Two-Stage Limited Free-Lift Mast and
Main Lift Cylinder Three-Stage Full Free-Lift Mast, Main Lift
Cylinders for Lift Trucks
CAUTION H/S1.50-1.75XM, H/S2.00XMS
Carefully disassemble the lift cylinders so the (H/S25-35XM, H/S40XMS), E1.50-1.75XM
piston rods and sliding surfaces are not dam- (E25-35XM, E25-35XM 2) (D114), E2.00XMS
aged. (E40XMS, E40XM 2S) (D114), and
1. Loosen the gland with a spanner wrench. Re- E1.50-2.00XM (E25-35Z, E40ZS) (E114)
ure 24. CAUTION
2. Remove wiper, backup ring, rod seal, wear ring, Carefully disassemble the lift cylinders so the
O-ring, and backup ring from gland. See Fig- piston rods and sliding surfaces are not dam-
ure 24. Discard the rod seal, wear ring, and aged.
O-ring.
3. Pull the rod and piston assembly from the shell. move the gland from the shell and rod and piston
See Figure 24. Drain the hydraulic oil into a con- assembly. See Figure 25.
tainer.
2. Remove wiper, backup ring, rod seal, O-ring, and
4. Remove the piston from the rod. See Figure 24. wear ring from gland. See Figure 25. Discard the
rod seal, O-ring, and wear ring.
5. Remove the piston ring and wear ring from the
piston. See Figure 24. Discard the wear ring. 3. Pull the rod and piston assembly from the shell.
See Figure 25. Drain the hydraulic oil into a con-
tainer.
WARNING
Be careful when removing or installing snap 4. Remove the spacer from the rod. See Figure 25.
to cause injury. Always use the correct snap 5. Remove the piston ring from the piston. See Fig-
ring pliers and wear eye and face protection ure 25.
during removal or installation. 6. Remove the wear ring, seal, and backup ring
6. If present, remove the snap ring, washer, and from the piston. See Figure 25. Discard the
check valve from the base of the piston. Remove wear ring and seal.
and discard the O-ring from the check valve. See
Figure 24. WARNING
7. If present, remove the screw and sealing washer
from the shell. See Figure 24.
7. Remove the snap ring, washer, and check valve

from the base of the piston. Remove and discard
the O-ring from the check valve. See Figure 25.
39

Three-Stage Full Free-Lift Mast, Main Lift
Cylinders
CAUTION
Carefully disassembly the lift cylinders so the
aged.

ure 26.
2. Remove the wiper, rod seal, and O-ring from the

gland. See Figure 26. Discard the rod seal and
O-ring.
3. Remove the rod and piston assembly from the

shell. See Figure 26.
4. Remove the spacer from the rod. See Figure 26.
5. Remove the wear ring, piston seal, and backup

ring from the piston. See Figure 26. Discard the
wear ring and piston seal.
1. SHELL 9. BACKUP RING

2. SNAP RING 10. ROD AND PISTON WARNING
3. WASHER 11. SPACER Be careful when removing or installing snap
4. O-RING 12. O-RING rings. Snap rings can eject with enough force
5. CHECK VALVE 13. WEAR RING
6. PISTON RING 14. GLAND to cause injury. Always use the correct snap
(THREE-STAGE 15. ROD SEAL ring pliers and wear eye and face protection
FFL ONLY) 16. BACKUP RING during removal or installation.
7. WEAR RING 17. WIPER
8. SEAL 6. Remove the snap ring, washer(s), and check
valve from the base of the piston. Remove and
Figure 25. Main Lift Cylinders, Two-Stage discard the O-ring from the check valve. See
Limited Free-Lift and Three-Stage Full Figure 26.
Free-Lift Mast for H/S1.50-1.75XM, H/S2.00XMS
(H/S25-35XM, H/S40XMS), E1.50-1.75XM
(E25-35XM, E25-35XM 2) (D114), E2.00XMS
(E40XMS, E40XM 2S) (D114), and E1.50-2.00XM
(E25-35Z, E40ZS) (E114)
40
Two-Stage Full Free-Lift Mast and

Three-Stage Full Free-Lift Mast, Free-Lift
Cylinder
CAUTION
Carefully disassembly the lift cylinders so the
aged.

ure 27.
2. Remove the wiper, rod seal, O-ring, and backup

ring from the gland. See Figure 27. Discard the
rod seal and O-ring.
3. Remove the rod and piston assembly from the

shell. See Figure 27.
4. Remove the wear ring, piston seal, and backup

ring from the piston. See Figure 27. Discard the
wear ring and piston seal.
WARNING
5. Remove the snap ring, washer, and check valve

from the base of the piston. Remove and discard
the O-ring from the check valve. See Figure 27.
1. WIPER 8. PISTON SEAL
2. ROD SEAL 9. WEAR RING 6. Remove the screw and sealing washer from the
3. GLAND 10. CHECK VALVE shell. See Figure 27.
4. O-RING 11. WASHER
5. SPACER 12. SNAP RING
6. ROD AND PISTON 13. SHELL
7. BACKUP RING
Figure 26. Main Lift Cylinders, Two-Stage

Limited Free-Lift and Three-Stage Full
Free-Lift Mast
41
Compressed air can move particles so they

cause injury tot he user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
CAUTION
DO NOT allow cleaning solvent to come in con-
tact with rubber components, as it will damage
those components.
1. Clean all metal parts in solvent and dry with

compressed air.
2. Inspect the gland for damage to the threads and

the seal surfaces. Replace if damaged.
3. Inspect the piston for any damage tot he seal sur-

faces. Replace piston if damaged.
4. Inspect the rod for damage to the rod surface and

ensure that the rod is not bent. Replace rod if
damaged.
5. Inspect the inner surface of the shell for damage.

Replace cylinder assembly if damaged.
CYLINDERS, ASSEMBLE
Two-Stage Full Free-Lift Mast, Right-Hand
Main Lift Cylinder
CAUTION
1. WIPER 9. WEAR RING A difficult and important step in assembling
2. ROD SEAL 10. SCREW lift cylinders is the correct installation of the
3. GLAND 11. SEALING WASHER seals. Most lift cylinder maintenance is caused
4. BACKUP RING 12. CHECK VALVE
5. O-RING 13. SHELL by seal leaks. Do not damage any parts during
6. ROD AND PISTON 14. WASHER assembly.
7. BACKUP RING 15. SNAP RING
8. PISTON SEAL 1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil or packing lubricant,
Figure 27. Free-Lift Cylinder, Two-Stage Full Hyster Part No. 186061. Use NEW O-rings,
Free-Lift and Three-Stage Full Free-Lift Mast seals, and wear rings.
CLEAN AND INSPECT

CAUTION
The correct screw and sealing washer must
WARNING
be used in this location. The wrong parts will
Cleaning solvents can be flammable and toxic cause leaks or damage the cylinder. See your
and can cause skin irritation. When using HYSTER lift truck dealer for the correct parts.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 2. If required, install the sealing washer and screw
dures. into the shell. See Figure 24. Tighten the screw
to 6 to 8 N•m (53 to 71 lbf in).
42
Two-Stage Full Free-Lift Mast, Left-Hand

WARNING
Main Lift Cylinder
to cause injury. Always use the correct snap CAUTION
ring pliers and wear eye and face protection A difficult and important step in assembling
during removal or installation. lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused
NOTE: To prevent damage to sealing surfaces, use by seal leaks. Do not damage any parts during
brass tools when installing seals and O-rings. assembly.
3. If present, install a new O-ring onto the check 1. Lubricate all internal parts of the lift cylinder
valve. Install the check valve, washer, and snap with clean hydraulic oil or packing lubricant,
ring into the base of the piston. Make sure the Hyster Part No. 186061. Use NEW O-rings,
arrow on the check valve is toward the base of seals, and wear rings.
the piston. See Figure 24.
4. Install a new wear ring onto the piston. See Fig- CAUTION
ure 24. The correct screw and sealing washer must
be used in this location. The wrong parts will
5. Install the piston onto the rod. See Figure 24.
cause leaks or damage the cylinder. See your
Tighten piston to 70 to 200 N•m (125 to
HYSTER lift truck dealer for the correct parts.
148 lbf ft).
2. If required, install the sealing washer and screw
6. Carefully install the rod and piston assembly into
into the shell. See Figure 24. Tighten the screw
the shell. See Figure 24.
to 6 to 8 N•m (53 to 71 lbf in).
CAUTION WARNING
Use caution when installing seals over the Be careful when removing or installing snap
threads of the gland. Sharp edges of the rings. Snap rings can eject with enough force
thread can damage the seals. to cause injury. Always use the correct snap
NOTE: To prevent damage to sealing surfaces, use ring pliers and wear eye and face protection
brass tools when installing seals and O-rings. during removal or installation.
7. Install the backup ring, new O-ring, new wear 3. If check valve is required, install a new O-ring
ring, new rod seal, backup ring, and wiper onto onto the check valve then install the check valve,
the gland. See Figure 24. washer, and snap ring into the base of the piston.
Make sure the arrow on the check valve is toward
8. Carefully install the gland onto the rod and pis- the base of the piston. See Figure 24.
ton assembly in the shell. See Figure 24.
4. Install a new wear ring and the piston ring onto
9. Engage the threads and turn the gland in the the piston. See Figure 24.
shell until it is tight. Use the correct span-
ner, tighten gland to 340 to 400 N•m (251 to 5. Install the piston onto the rod. See Figure 24.
302 lbf ft). DO NOT hit the gland with a ham- Tighten the piston to 170 to 200 N•m (125 to
mer and driver to tighten. 148 lbf ft).
10. Install the lowering control valve. See Figure 16, 6. Carefully install the rod and piston assembly into
Figure 17, and Figure 19. Make sure the special the shell. See Figure 24.
washer and the spring are installed correctly. In-
correct installation can cause the load to lower
too fast.
43
CAUTION WARNING
Use caution when installing seals over the Be careful when removing or installing snap
threads of the gland. Sharp edges of the rings. Snap rings can eject with enough force
thread can damage the seals. to cause injury. Always use the correct snap
7. Install the backup ring, new O-ring, new wear during removal or installation.
ring, new rod seal, backup ring, and wiper onto
the gland. See Figure 24. 2. Install a new O-ring onto the check valve then in-
stall the check valve, washer, and snap ring into
8. Carefully install the gland onto the rod and pis- the base of the piston. Make sure the arrow on
ton assembly in the shell. See Figure 24. the check valve is toward the base of the piston.
See Figure 25.
9. Engage the threads and turn the gland in the
shell until it is tight. Use the correct span- 3. Install the backup ring, new seal, and new wear
ner, tighten gland to 340 to 410 N•m (251 to ring onto the piston. See Figure 25.
302 lbf ft). DO NOT hit the gland with a ham-
mer and driver to tighten. 4. Install the piston ring onto the piston. See Fig-
ure 25.
10. Install the lowering control valve. See Figure 16,
Figure 17, and Figure 19. Make sure the special 5. Install the spacer onto the rod. See Figure 25.
correct installation can cause the load to lower 6. Carefully install the rod and piston assembly into
too fast. the shell. See Figure 25.
Two-Stage Limited Free-Lift Mast and CAUTION

Three-Stage Full Free-Lift Mast, Main Lift Use caution when installing seals over the
Cylinders for Lift Trucks threads of the gland. Sharp edges of the
H/S1.50-1.75XM, H/S2.00XMS thread can damage the seals.
(H/S25-35XM, H/S40XMS), E1.50-1.75XM 7. Install a new wear ring, new O-ring, new rod
(E25-35XM, E25-35XM 2) (D114), E2.00XMS seal, backup ring, and wiper onto the gland. See
(E40XMS, E40XM 2S) (D114), and Figure 25.
E1.50-2.00XM (E25-35Z, E40ZS) (E114) 8. Carefully install the gland onto the rod and pis-
CAUTION
A difficult and important step in assembling
shell until it is tight. Use the correct span-
lift cylinders is the correct installation of the
ner, tighten gland to 340 to 410 N•m (251 to
seals. Most lift cylinder maintenance is caused
by seal leaks. Do not damage any parts during
mer and driver to tighten.
assembly.
10. Install the lowering control valve. See Figure 16,
1. Lubricate all internal parts of the lift cylinder
Figure 17, and Figure 19. Make sure the special
with clean hydraulic oil or packing lubricant,
Hyster Part No. 186061. Use NEW O-rings,
seals, and wear rings.
too fast.
44
Two-Stage Limited Free-Lift Mast and 9. Install the lowering control valve. See Figure 16,
Three-Stage Full Free-Lift Mast, Main Lift Figure 17, and Figure 19. Make sure the special
Cylinders washer and the spring are installed correctly. In-
too fast.
CAUTION
A difficult and important step in assembling Two-Stage Full Free-Lift Mast and
lift cylinders is the correct installation of the Three-Stage Full Free-Lift Mast, Free-Lift
seals. Most lift cylinder maintenance is caused Cylinder
by seal leaks. Do not damage any parts during
assembly.
CAUTION
1. Lubricate all internal parts of the lift cylinder A difficult and important step in assembling
with clean hydraulic oil or packing lubricant, lift cylinders is the correct installation of the
Hyster Part No. 186061. Use NEW O-rings, seals. Most lift cylinder maintenance is caused
seals, and wear rings. by seal leaks. Do not damage any parts during
assembly.
WARNING
1. Lubricate all internal parts of the lift cylinder
Be careful when removing or installing snap with clean hydraulic oil or packing lubricant,
rings. Snap rings can eject with enough force Hyster Part No. 186061. Use NEW O-rings,
to cause injury. Always use the correct snap seals, and wear rings.
CAUTION
2. Install a new O-ring onto the check valve then The correct screw and sealing washer must
install the check valve, washer(s), and snap ring be used in this location. The wrong parts will
into the base of the piston. Make sure the arrow cause leaks or damage the cylinder. See your
on the check valve is toward the base of the pis- HYSTER lift truck dealer for the correct parts.
ton. See Figure 26.
2. Install the sealing washer and screw into the
3. Install the backup ring, new piston seal, and new shell. See Figure 27. Tighten the screw to 6 to
wear ring onto the piston. See Figure 26. 8 N•m (53 to 71 lbf in).
4. Install the spacer onto the rod. See Figure 26.
WARNING
5. Carefully install the rod and piston assembly into Be careful when removing or installing snap
the shell. See Figure 26. rings. Snap rings can eject with enough force
CAUTION ring pliers and wear eye and face protection
Use caution when installing seals over the during removal or installation.
threads of the gland. Sharp edges of the 3. Install a new O-ring onto the check valve then in-
thread can damage the seals. stall the check valve, washer, and snap ring into
6. Install new O-ring, new rod seal, and wiper onto the base of the piston. Make sure the arrow on
the gland. See Figure 26. the check valve is toward the base of the piston.
See Figure 27.
7. Carefully install the gland onto the rod and pis-
ton assembly in the shell. See Figure 26. 4. Install the backup ring, new piston seal, and new
wear ring onto the piston. See Figure 27.
shell until it is tight. Use the correct span- 5. Carefully install the rod and piston assembly into
ner, tighten gland to 340 to 410 N•m (251 to the shell. See Figure 27.
mer and driver to tighten.
45
the lift cylinder. Install the washers and snap

CAUTION ring at the top of the lift cylinder. See Two-Stage
Use caution when installing seals over the LFL and Two-Stage FFL Mast, Assemble and
threads of the gland. Sharp edges of the Three-Stage FFL Mast, Assemble procedures for
thread can damage the seals. the correct adjustment of the lift cylinders.
6. Install the backup ring, new O-ring, new rod seal, 4. Connect the hydraulic line at the base of the lift
and wiper onto the gland. See Figure 27. cylinder. Connect the hydraulic line at the top of
the left-hand main lift cylinder on the full free-lift
7. Carefully install the gland onto the rod and pis- mast.
5. Connect the main lift chains as necessary and
8. Remove screw and sealing washer. Pour 150 cc adjust them as specified in Carriage Adjustment.
(5 oz) of hydraulic oil into the cylinder through
the hole. This oil provides a hydraulic cushion 6. Remove the air from the cylinders on the two-
when the cylinder reaches the top of its stroke. stage FFL. See Figure 24.
Install the screw and sealing washer. Tighten
screw to 6 N•m (53 lbf in). a. Loosen the screws two turns to permit oil to
flow around the threads of the screw.
shell until it is tight. Use the correct span- b. With the forks unloaded and the engine
ner, tighten gland to 340 to 410 N•m (251 to speed at idle, raise the carriage using the hy-
302 lbf ft). DO NOT hit the gland with a ham- draulic control. Raise the carriage 300 mm
mer and driver to tighten. (12 in.) and then stop for ten seconds to
reduce the pressure in the cylinder. Repeat
10. Install the lowering control valve. See Figure 16, this procedure until the oil flowing from
Figure 17, and Figure 19. Make sure the special around the threads is free of air bubbles.
correct installation can cause the load to lower c. Stop the carriage at the top of the cylinder
too fast. stroke. Tighten the screws.
MAIN LIFT CYLINDERS, INSTALL FREE-LIFT CYLINDER, INSTALL

1. Use a crane with a capacity of at least 1600 kg 1. Install the crosshead assembly on the cylinder
(3527 lb) to raise the mast until it is almost fully rod. Tighten the capscrews for the chain guards
extended. Use safety chains to connect the bot- to 66 N•m (49 lbf ft). See Figure 17, Figure 19,
tom crossmember of the inner mast (two-stage) Figure 23, and Figure 27.
or intermediate mast (three-stage) to the top
2. Install the cylinder in the mounts. Install
crossmember of the outer mast. Lower the mast
the brackets and tighten the bolts to 53 N•m
so the safety chains hold the weight of the mast
(39 lbf ft). On the three-stage FFL mast, the nuts
uprights. See Figure 16, Figure 17, and Fig-
are installed on the bracket side of the free-lift
ure 19.
cylinder. Tighten the nuts to 38 N•m (28 lbf ft).
2. Install the lift cylinder in the mount at the bot-
3. Connect the hydraulic line at the cylinder.
tom of the outer mast. Install the nut, bolt, and
spacer at the mount for the lift cylinder. 4. Install the carriage as described in the proce-
dures for the Carriages Repair.
3. Use a lifting device to lower the inner mast (two-
stage) or intermediate mast (three-stage) on to
46
4000 SRM 522 Header Hose Arrangements
Header Hose Arrangements

NOTE: This is for H/S2.00-3.20XM (H/S40-65XM), 2. Use a calculator to calculate dimension E. See
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), Figure 28.
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-60XM, J40-60 2) (A216), J2.00-3.20XM (J40- 3. Clamp the end of the hose (the smaller fitting)
65Z) (A416), and S/E/J2.00-3.00XL (S/E/J40-60XL) that attaches to the carriage in a vise (do not
models. clamp on the threads), pull on the other end until
the hose is straight. Do not apply enough force to
NOTE: Hoses have a service life that is determined by stretch the hose. See Figure 28.
application and time. All hoses must be inspected at
the intervals specified in the Maintenance Schedule 4. Mark the hoses with dimension E [all measure-
for the hydraulic system. Install a new hose if the ments are made from the carriage end of the hose
hose is worn, damaged, soft or hard, and no longer (the smaller fitting)]. See Figure 28.
flexible. If necessary, make a comparison to a new
5. Attach the hoses to the carriage bracket with the
hose that is the correct replacement for the hose you
clamps. See Figure 29.
are inspecting.
6. Place the hoses at the location of the hose
Some lift trucks have auxiliary hydraulic equipment
sheave. The hose sheave and guard must be as-
that is attached to the carriage. Examples of aux-
sembled onto the hose before they are attached
iliary equipment are a sideshift carriage or a roll
to the mast. Tighten the mounting hardware to
clamp. These auxiliary functions require arrange-
66 N•m (49 lbf ft).
ments of header hoses for their operation.
7. Put the clamps over the hoses and attach the
TWO-STAGE LFL MAST, NEW HOSE clamps to the brackets. (Do NOT tighten the
INSTALL hardware.)
NOTE: To make the alignment of dimension E easier,

WARNING
use a crane with a capacity of at least 908 kg (2002 lb)
Before working on or near the mast, see Safety to raise the carriage high enough to install a safety
Procedures When Working Near Mast in this chain. See Figure 30 and Step 8 and Step 9.
section.
8. The following procedures must be used when in-
NOTE: This procedure is for the four-function option. stalling safety chains for the header hose instal-
The three-function option will have hoses A and B lation. Additional precautions and procedures
only. can be required when repairing or removing the
NOTE: The lift chains and carriage height must be mast. See Safety Procedures When Working
correctly adjusted before the header hoses can be ad- Near Mast in this section for additional proce-
justed. See the section Lift Chains Adjustment for dures for the installation of safety chains.
adjustment procedures.
1. Mark each hose with a single letter: A, B, C, or

D.
47
Header Hose Arrangements 4000 SRM 522
Figure 28. Header Hose Measurement, Two-Stage Limited Free-Lift Mast
48
* Metric Formulas (All Dimensions are in Millimeters)

@ Dimension E = (0.985 × Z) + (0.985 × Y) + 244
# Dimension E = (0.985 × Z) + (0.985 × Y) + 220
% Dimension E = (0.985 × Z) + (0.985 × Y) + 283
Example: Dimension E = (0.985 × Z) + (0.985 × Y) + 244
Step 1. Dimension E = (0.985 × 135) + (0.985 × 2290) + 244
Step 2. Dimension E = 133 + 2255.7 + 244
Step 3. Dimension E = 2388.7 + 244
Step 4. Dimension E = 2633
* Inch Formulas (All Dimensions are in Inches)

@ Dimension E = (0.985 × Z) + (0.985 × Y) + 9.6
# Dimension E = (0.985 × Z) + (0.985 × Y) + 8.7
% Dimension E = (0.985 × Z) + (0.985 × Y) + 11.1
Example: Dimension E = (0.985 × Z) + (0.985 × Y) + 9.6
Step 1. Dimension E = (0.985 × 5.3) + (0.985 × 90.0) + 9.6
Step 2. Dimension E = 5.2 + 88.7 + 9.6
Step 3. Dimension E = 93.9 + 9.6
Step 4. Dimension E = 103.5
*All measurements are made with mast vertical and fully lowered.
@H2.00-2.50XM (H40-50XM)
#H3.00-3.20XM (H60-65XM), J2.00-3.00XL (J40-60XL)
%E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z) (G108), and S/E2.00-3.00XL
(S/E40-60XL)
1. DIMENSION E 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE 6. GROUND LEVEL
49
Figure 29. Header Hoses, Two-Stage Limited Free-Lift Mast
50

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. SPECIAL WASHER 6. CLAMP (TOP OF LIFT 10. BRACKET, UPPER
2. HOSE SHEAVE CYLINDER) 11. BRACKET, CARRIAGE
3. HOSE GUARD 7. COWL HOSES 12. CLAMPS
4. WASHER 8. BOTTOM CLAMP
5. CAPSCREW 9. HEADER HOSES
1. HOOK 2. SHACKLE
Figure 30. Safety Chain Installation, Two-Stage Limited Free-Lift Mast
51
e. Lower the crane until there is tension in the

WARNING safety chain. Make sure both hooks are prop-
Mast parts are heavy and can move. Distances erly engaged before working on the mast. In-
between parts are small. Serious injury or stall a DO NOT REMOVE tag on the safety
death can result if part of the body is hit by chain.
parts of the mast or the carriage.
• Never put any part of the body into or under 10. Align mark E at the bottom of the clamp. Tighten
the mast or carriage unless all parts are com- the hardware to 8 N•m (71 lbf in).
pletely lowered or a safety chain is installed.
Also make sure that the power is off, the key 11. Connect the header hoses to the cowl hoses.
is removed, and the parking brake is applied. 12. Use the rubber clamps and strap clamps to at-
• Put a DO NOT OPERATE tag in the operator’s tach the hoses to the main lift cylinders. Make
compartment. sure the cowl hoses do not stretch or fold while
• Be careful of the forks. When the mast is tilting the mast fully forward and backward.
raised, the forks can be at a height to cause
an injury. 13. With no load on the forks, check the header hose
• DO NOT climb on the mast or lift truck at any adjustment by operating the mast through the
time. Use a ladder or personnel lift to work full lift cycle two times. When properly adjusted,
on the mast. the hoses will not be so tight that they compress
• DO NOT use blocks to support the mast weld- when they pass over the sheaves nor will they
ments nor to restrain their movement. be so loose that they touch the load backrest or
• Mast repairs require disassembly and re- any crossmember that is next to a sheave. If the
moval of parts and can require removal of hoses require additional adjustment, see Two-
the mast or carriage. Follow the repair pro- Stage LFL Mast, Adjust Hoses After Installation.
cedures in the correct Service Manual for
the mast. TWO-STAGE LFL MAST, ADJUST HOSES
9. SAFETY CHAIN INSTALLATION WHEN
AFTER INSTALLATION
THE CARRIAGE IS RAISED: NOTE: The lift chains and carriage height must be
correctly adjusted before the header hoses can be ad-
a. Put the mast in a vertical position.
justed. See the section Lift Chains Adjustment for
b. Raise the carriage approximately 300 mm adjustment procedures.
(12 in.).
1. Loosen the clamps and pull (if the hoses are
c. Use a 3/8 inch minimum safety chain with a loose) or push (if the hoses are tight) on the
hook. Attach one end of the chain around all hoses so that they move 30 mm (1.2 in.). Tighten
the top crossmembers. Make sure the hook is the hardware to 8 N•m (71 lbf in). See Figure 28,
completely engaged with a link in the chain. Figure 29, and Figure 30.
d. Attach a shackle to the lifting eye on the car- 2. With no load on the forks, check the header hose
riage. Install the chain through the shackle. adjustment by operating the mast through the
Make sure the hook is completely engaged full lift cycle two times. When properly adjusted,
with a link in the chain. Make sure the the hoses will not be so tight that they compress
safety chain does not touch lift chains, chain when they pass over the sheaves nor will they be
sheaves, tubes, hoses, fittings, or other parts so loose that they touch the load backrest or any
of the mast. crossmember that is next to a sheave. If neces-
sary, repeat Step 1 until the hoses are properly
adjusted.
52
TWO-STAGE FFL MAST, NEW HOSE 6. Put the header hoses over the free-lift chains.
INSTALL
7. Put the clamps over the hoses and attach the
clamps to the lower bracket (do NOT tighten the
WARNING hardware).
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this NOTE: To make the alignment of dimension E easier,
section. use a crane with a capacity of at least 908 kg (2002 lb)
to raise the carriage high enough to install a safety
NOTE: This procedure is for the four-function option. chain.
The three-function option will have hoses A and B
only. 8. Align mark E at the bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in).
NOTE: The lift chains and carriage height must be
correctly adjusted before the header hoses can be ad- 9. Install the hose guards at the free-lift crosshead.
justed. See the section Lift Chains Adjustment for Tighten the capscrews that mount the guards to
adjustment procedures. 66 N•m (49 lbf ft).
1. Mark each hose with a single letter: A, B, C, or NOTE: The proper hose alignment is shown in Fig-
D. ure 33.
2. Use a calculator to calculate dimension E. See 10. Apply a spray lubricant onto the hoses in the area
Figure 31. that will contact the channels. Make sure the
hoses are properly aligned in the channels. Put
3. Clamp the end of the hose (the smaller fitting) the clamps over the hoses and attach the clamps
that attaches to the carriage in a vise (do NOT to the channels. Tighten the hardware to 8 N•m
clamp on the threads), pull on the other end until (71 lbf in). See Figure 33.
the hose is straight. Do NOT apply enough force
to stretch the hose. See Figure 31. 11. Connect the header hoses (10, C, and D) to the
cowl hoses. Connect the header hoses (10, A, and
4. Mark the hoses with dimension E [all measure- B) to the tubes.
ments are made from the carriage end of the hose
(the smaller fitting)]. See Figure 31. 12. Use the rubber clamps and strap clamps to at-
tach the hoses to the main lift cylinders. Make
5. Attach the hoses to the carriage bracket with sure the cowl hoses do not stretch or fold while
clamp. See Figure 32. tilting the mast fully forward and backward.
53
Figure 31. Header Hose Measurement, Two-Stage Full Free-Lift Mast
54

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2482 mm to 2982 mm:
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156

Class III Mast Type
55
Dimension E = (0.492 × Y) + (0.985 × Z) + 269

The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
II Mast - Metric Formula.
(1.981 × Y) + (0.985 × Z) 851
(1.991 × Y) + (0.985 × Z) 972
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 43.312
1. DIMENSION G 5. HOSE
2. DIMENSION E 6. BOTTOM OUTER CHANNEL
4. TOP OUTER CHANNEL
NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE CHANNEL 12. LOWER BRACKET 21. STUBSHAFT
2. COWL HOSES 13. CAPSCREW 22. SHEAVE
3. HEADER HOSES 14. CARRIAGE BRACKET 23. WASHER
4. STRAP CLAMP 15. BOTTOM CLAMP 24. WASHER
5. CLAMP 16. HOSE GUIDE 25. NUT
6. CLAMP 17. SNAP RING
7. FITTING 18. CAPSCREW
8. TUBE (THREE-FUNCTION)
9. FITTING 19. CAPSCREW
10. CLAMP (FOUR-FUNCTION)
11. BRACKET 20. HOSE GUARD
56
Figure 32. Header Hoses, Two-Stage Full Free-Lift Mast
57
Figure 33. Header Hose Alignment, Two-Stage Full Free-Lift Mast
58
13. With no load on the forks, operate the mast NOTE: This procedure is for the four-function option.
through the full lift cycle two times. With the The three-function option will have hoses A and B
mast at full lift height, attach clamp at the bot- only.
tom of the hose loop on the third and/or fourth
function hoses. This action allows the hoses to NOTE: The lift chains and carriage height must be
fit properly in the hose channel. correctly adjusted before the header hoses can be ad-
14. With no load on the forks, check the header hose adjustment procedures.
adjustment by operating the mast through the
full lift cycle two times. When properly adjusted, 1. Mark each hose with a single letter: A, B, C, or
the hoses will not be so tight that they compress D.
when they pass over the sheaves nor will they
2. Use a calculator to calculate the dimensions E
be so loose that they touch the load backrest or
and G. See Figure 34.
any crossmember that is next to a sheave. If the
hoses require additional adjustment, see Two- 3. Clamp the end of the hose (the smaller fitting)
Stage FFL Mast, Adjust Hoses After Installation. that attaches to the carriage in a vise (do NOT
clamp on the threads), pull on the other end until
TWO-STAGE FFL MAST, ADJUST HOSES the hose is straight. Do NOT apply enough force
AFTER INSTALLATION to stretch the hose. See Figure 34.
NOTE: The lift chains and carriage height must be 4. Mark all the hoses with dimensions E and G (all
correctly adjusted before the header hoses can be ad- measurements are made from the carriage end of
justed. See the section Lift Chains Adjustment for the hose [the smaller fitting]). See Figure 34.
5. Attach the hoses to the carriage bracket with
1. Loosen the clamps and pull (if the hoses are clamp. Apply grease to the surface of the hose
loose) or push (if the hoses are tight) on the guide that contacts the hoses. See Figure 35.
hoses so that they move 15 mm (0.6 in.). Tighten
the hardware to 8 N•m (71 lbf in). See Figure 31, NOTE: The hoses cross each other in two locations.
Figure 32, Figure 33, and Figure 37. The proper hose alignment is shown in Figure 36.
2. With no load on the forks, check the header hose 6. Place the hoses over the top of the free-lift chains
adjustment by operating the mast through the and under the hose guides. See Figure 35 and
full lift cycle two times. When properly adjusted, Figure 36. Put the clamps over the hoses and
the hoses will not be so tight that they compress attach the clamps to the lower bracket (do NOT
when they pass over the sheaves nor will they be tighten the hardware).
so loose that they touch the load backrest or any
crossmember that is next to a sheave. If neces- NOTE: To make the alignment of dimension E easier,
sary, repeat Step 1 until the hoses are properly use a crane with a capacity of at least 908 kg (2002 lb)
adjusted. to raise the carriage high enough to attach a safety
chain. See Figure 37 and Step 7, Step 8, and Step 9.
THREE-STAGE FFL MAST, NEW HOSE 7. The following procedures MUST be used when
INSTALL installing safety chains for the header hose
installation. Additional precautions and pro-
WARNING cedures can be required when repairing or re-
Before working on or near the mast, see Safety moving the mast. See Safety Procedures When
Procedures When Working Near Mast in this Working Near Mast in this section for additional
section. procedures for installation of safety chains.
59
Figure 34. Header Hose Measurement, Three-Stage Full Free-Lift Mast
60

Class II Mast Types
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, Use 842
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class II Mast Types
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 to 240.6. For Lift Heights of 246.5 To 335.0, Use 33.156
Dimension G for Lift Heights of 146.1 to 240.6
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
61

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, Use 33.156
1. DIMENSION G 5. TOP OUTER CHANNEL

4. HOSE
NOTE: THREE-FUNCTION MAST SHOWN.

1. CAPSCREW 8. HOSE SHEAVE 16. HEADER HOSES
2. HOSE GUARD 9. HOSE GUARD 17. FREE-LIFT CHAIN
3. SNAP RING 10. CLAMP 18. CLAMP
4. HOSE GUIDE 11. LOWER BRACKET 19. COWL HOSES
5. FREE-LIFT CYLINDER 12. HOSE RESTRAINT 20. UPPER BRACKET
CROSSHEAD 13. LOWER HOSE GUIDE 21. CARRIAGE BRACKET
6. WASHER 14. NUT 22. CLAMP
7. SPACER 15. BOTTOM CLAMP 23. STUBSHAFT
62
Figure 35. Header Hoses, Three-Stage Full Free-List Mast
63
Figure 36. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)
64
65
A. HOSE A F. FORKS
B. HOSE B G. FRONT VIEW
C. HOSE C H. LEFT-HAND CYLINDER
D. HOSE D I. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
E. ALIGN MARK G ON HOSES A AND D AT J. REAR VIEW
BOTTOM OF THIS CLAMP. ALIGN MARK G ON K. RIGHT-HAND CYLINDER
HOSES B AND C AT BOTTOM OF THIS CLAMP.
1. FREE-LIFT SHEAVE 6. BOTTOM CROSSMEMBER, INNER CHANNEL
2. HOSE 7. RETAINER
3. HOSE GUIDE 8. FREE-LIFT CYLINDER
4. HOSE GUIDE 9. CYLINDER GUARD
5. HOSE
66
d. Attach a shackle to the lifting eye on the car-

WARNING riage. Install the chain through the shackle.
Mast parts are heavy and can move. Distances Make sure the hook is completely engaged
between parts are small. Serious injury or with a link in the chain. Make sure the
death can result if part of the body is hit by safety chain does not touch lift chains, chain
parts of the mast or the carriage. sheaves, tubes, hoses, fittings, or other parts
• Never put any part of the body into or under of the mast.
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. e. Lower the crane until there is tension in the
Also make sure that the power is off, the key safety chain. Make sure both hooks are prop-
is removed, and the parking brake is applied. erly engaged before working on the mast. In-
Put a DO NOT OPERATE tag in the operator’s stall a DO NOT REMOVE tag on the safety
compartment. chain.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause 9. SAFETY CHAIN INSTALLATION WHEN
an injury. THE INNER CHANNEL IS RAISED:
• DO NOT climb on the mast or lift truck at any a. Put the mast in a vertical position.
time. Use a ladder or personnel lift to work
on the mast. b. The mast must be full lowered.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement. c. Attach a crane to the top crossmember of the
• Mast repairs require disassembly and re- inner channel. Raise the inner channel ap-
moval of parts and can require removal of proximately 600 mm (24 in.).
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for d. Use a 3/8 inch minimum safety chain with a
the mast. hook. Attach one end of the chain around the
top crossmember of the outer channel. Make
8. SAFETY CHAIN INSTALLATION WHEN sure the hook is completely engaged with a
THE CARRIAGE IS RAISED: link in the chain.
a. Put the mast in a vertical position. e. Attach the other end of the chain around
the lower crossmember of the inner channel.
b. Raise the carriage approximately 300 mm Make sure the hook is completely engaged
(12 in.). with a link in the chain.
c. Use a 3/8 inch minimum safety chain with a f. Lower the crane until there is tension in the
hook. Attach one end of the chain around all safety chain. Make sure both hooks are prop-
the top crossmembers. Make sure the hook is erly engaged before working on the mast. In-
completely engaged with a link in the chain. stall a DO NOT REMOVE tag on the safety
chain.
67
Figure 37. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 1 of 2)
68
1. HOOK 2. SHACKLE
Figure 37. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 2 of 2)
69
10. Align the mark for dimension E at the bottom THREE-STAGE FFL MAST, ADJUST
of the clamp to create the proper hose tension. HOSES AFTER INSTALLATION
Tighten the hardware to 8 N•m (71 lbf in). In-
stall the hose guards. Tighten the capscrews that NOTE: The lift chains and carriage height must be
mount the guards to 66 N•m (49 lbf ft). correctly adjusted before the header hoses can be ad-
11. Position the hoses at the hose sheave. See Fig- adjustment procedures.
ure 35 and Figure 36. The hose sheave and hose
guard must be installed on to the hose before they 1. If the tension of the hoses is correct between the
are attached to the mast. Tighten the hardware carriage and the clamp at the lower bracket, go
to 53 N•m (39 lbf ft). to Step 2. If the tension of the hoses is not cor-
rect, loosen the clamps and pull (if the hoses are
12. Put the clamps over the hoses and attach the loose) or push (if the hoses are tight) on the hoses
clamps to the upper brackets. Do NOT tighten so that they move 15 mm (0.6 in.). Tighten the
the hardware. hardware to 8 N•m (71 lbf in). See Figure 33,
Figure 34, Figure 35, and Figure 36.
NOTE: To make the alignment of dimension G easier,
use a crane with a capacity of at least 908 kg (2002 lb) 2. If the tension of the hoses is correct between the
to raise the inner channel high enough to install a clamp at the upper bracket and the clamp at the
safety chain as shown in Figure 37. lower bracket, go to Step 3. If the tension of the
hoses is not correct, loosen the clamps and pull
13. Align mark G on hoses A and D at the bottom
(if the hoses are too loose) or push (if the hoses
edge of clamp to create the proper tension. Align
are too tight) on the hoses so that they move
mark G on hoses B and C at the top edge of clamp
15 mm (0.6 in.) plus the amount the hoses were
to create the proper tension. Tighten the hard-
moved in Step 1. Tighten the hardware to 8 N•m
ware to 8 N•m (71 lbf in).
(71 lbf in).
14. Install the hose restraints.
3. With no load on the forks, check the header hose
15. Connect the header hoses to the cowl hoses. adjustment by operating the mast through the
full lift cycle two times. When properly adjusted,
16. Use the rubber clamps and strap clamps to at- the hoses will not be so tight that they compress
tach the hoses to the main lift cylinders. Make when they pass over the sheaves nor will they be
sure the hoses do NOT stretch or fold while tilt- so loose that they touch the load backrest or any
ing the mast fully forward and backward. crossmember that is next to a sheave. If neces-
sary, repeat Step 1 and Step 2 until the hoses are
17. With no load on the forks, check the header hose properly adjusted.
the hoses will not be so tight that they compress
hoses require additional adjustment, see Three-
Stage FFL Mast, Adjust Hoses After Installation.
70
4000 SRM 522 Header Hose Arrangement
Header Hose Arrangement

NOTE: This is the Header Hose Arrangement NOTE: This procedure is for the four-function option.
for H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, The three-function option will have hoses A and B
H/S40XMS), E1.50-1.75XM (E25-35XM, E25- only.
35XM 2) (D114), E2.00XMS (E40XMS, E40XM 2S)
(D114), E1.50-2.00XM (E25-35Z, E40ZS) (E114), NOTE: The lift chains and carriage height must be
J1.60-2.00XMT (J30-40XMT), and J1.60-2.00XMT correctly adjusted before the header hoses can be ad-
(J30-40ZT) models. justed. See the section Lift Chains Adjustment for
NOTE: Hoses have a service life that is determined by
application and time. All hoses must be inspected at 1. Mark each hose with a single letter: A, B, C, or
the intervals specified in the Maintenance Sched- D. See Figure 30, Figure 38, and Figure 39.
ule for the hydraulic system. Install a new hose if the
2. Use a calculator to calculate dimension E. See
hose is worn, damaged, soft or hard, and no longer
Figure 38.
flexible. If necessary, make a comparison to a new
hose that is the correct replacement for the hose you 3. Clamp the end of the hose (the smaller fitting)
are inspecting. that attaches to the carriage in a vise (do NOT
clamp on the threads), and pull on the other end
Some lift trucks have auxiliary hydraulic equipment
until the hose is straight. Do NOT apply enough
that is attached to the carriage. Examples of aux-
force to stretch the hose. See Figure 38.
iliary equipment are a sideshift carriage or a roll
clamp. These auxiliary functions require arrange- 4. Mark all the hoses with dimension E (all mea-
ments of header hoses for their operation. surements are made from the carriage end of the
hose [the smaller fitting]). See Figure 38.
TWO-STAGE LFL MAST, NEW HOSE
INSTALL 5. Attach the hoses to the carriage brackets with
the clamps. See Figure 39.
WARNING 6. Place the hoses at the location of the hose sheave.
Before working on or near the mast, see Safety The hose sheave and stub shaft must be assem-
Procedures When Working Near Mast in this bled on to the hose before they are attached to
section. the mast. Tighten the mounting hardware to
66 N•m (49 lbf ft).
71
Header Hose Arrangement 4000 SRM 522
Figure 38. Header Hose Measurement, Two-Stage Limited Free-Lift Mast
72

Dimension E = (Y + Z + 204) × 0.98
Example: Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98
Step 2. Dimension E = 2179 × 0.98
Step 3. Dimension E = 2135

Dimension E = (Y + Z + 8.0) × 0.98
Example: Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98
Step 2. Dimension E = 85.7 × 0.98
1. DIMENSION E 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
73
Figure 39. Header Hoses, Two-Stage Limited Free-Lift Mast
74

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. HOSES, HEADER 8. BRACKET, UPPER 15. WASHER
2. CLAMP, STRAP 9. STUBSHAFT 16. CAPSCREW
3. FITTINGS 10. SHEAVE 17. CAPSCREW
4. CAPSCREW 11. WASHER 18. CLAMP
5. BRACKET, CARRIAGE 12. NUT 19. CLAMP
6. SPACER 13. CAPSCREW 20. HOSE, COWL
7. NUT 14. CLAMP 21. CLAMP
7. Put the clamps over the hoses and attach the TWO-STAGE LFL MAST, ADJUST HOSES
clamps to the upper brackets. Do NOT tighten AFTER INSTALLATION
the hardware.
NOTE: To make the alignment of dimension E easier, correctly adjusted before the header hoses can be ad-
use a crane with a capacity of at least 908 kg (2002 lb) justed. See the section Lift Chains Adjustment for
to raise the carriage high enough to install a safety adjustment procedures.
chain as shown in Figure 30.
8. Align mark E at the bottom of the clamps. loose) or push (if the hoses are tight) on the
Tighten the hardware to 8 N•m (71 lbf in). hoses so they move 30 mm (1.2 in.). Tighten the
hardware to 8 N•m (71 lbf in). See Figure 30,
9. Connect the header hoses to the cowl hoses.
Figure 38, and Figure 39.
10. Use the rubber clamps and hose clamps to attach
the hoses to the main lift cylinders. Make sure
the hoses do NOT stretch or fold while tilting the
mast fully forward and backward.
11. With no load on the forks, check the header hose when they pass over the sheaves nor will they be
adjustment by operating the mast through the so loose that they touch the load backrest or any
full lift cycle two times. When properly adjusted, crossmember that is next to a sheave. If neces-
the hoses will not be so tight that they compress sary, repeat Step 1 until the hoses are properly
when they pass over the sheaves nor will they adjusted.
hoses require additional adjustment, see Two-
Stage LFL Mast, Adjust Hoses After Installation.
75
TWO-STAGE FFL MAST, NEW HOSE 3. Clamp the end of the hose (the smaller fitting)
INSTALL that attaches to the carriage in a vise (do NOT
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this 4. Mark all the hoses with dimension E (all mea-
section. surements are made from the carriage end of the
hose [the smaller fitting]). See Figure 40.
NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B 5. Attach the hoses to the carriage bracket with
only. clamps. See Figure 41.
NOTE: The lift chains and carriage height must be 6. Put the header hoses over the free-lift chains.
justed. See the section Lift Chains Adjustment for 7. Put the clamps over the header hoses and at-
adjustment procedures. tach the clamps to the free-lift bracket. (DO NOT
tighten the hardware.)
1. Mark each hose with a single letter: A, B, C,
or D. See Figure 37, Figure 40, Figure 41, and NOTE: To make the alignment of dimension E easier,
Figure 42. use a crane with a capacity at least 908 kg (2002 lb)
to raise the carriage high enough to install a safety
2. Use a calculator to calculate dimension E. See chain as shown in Figure 37.
Figure 40.
8. Align mark E at the bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in).
76
Figure 40. Header Hose Measurement, Two-Stage Full Free-Lift Mast
77

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
Dimension G (4 Function) for Lift Heights of 2482 mm to 2982 mm
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156

Class III Mast Type
78
Dimension E = (0.492 × Y) + (0.985 × Z) + 269

The Calculation For Dimension E For Class III Mast Is The Same As Class II Mast. See Class
Dimension G Calculations Are Similar to Dimension E
(1.981 × Y) + (0.985 × Z) 851
Dimension G (3 Function) for Lift Heights of 3060mm to 5360 mm:
(1.991 × Y) + (0.985 × Z) 972
Dimension G (4 Function) for Lift Heights of 2360 mm to 2960 mm
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 41.156
1. DIMENSION G 5. HOSE
4. TOP OUTER CHANNEL
79
Figure 41. Header Hoses, Two-Stage Full Free-Lift Mast
80

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. CHANNEL 10. CLAMP 19. CAPSCREW
2. COWEL HOSES 11. BRACKET 20. HOSE GUARD
3. HEADER HOSES 12. FREE-LIFT BRACKET 21. STUBSHAFT
4. STRAP CLAMP 13. FREE-LIFT CHAIN 22. FITTING
5. CLAMP 14. CARRIAGE BRACKET 23. SPACER
6. CLAMP 15. LOWER CLAMP 24. WASHER
7. FITTING 16. HOSE GUIDE 25. NUT
8. TUBE 17. SNAP RING
9. FITTING 18. CLIP
NOTE: The proper hose alignment is shown in Fig- 12. With no load on the forks, operate the mast
ure 42. through the full lift cycle two times. With the
mast at full lift height, attach clamp at the bot-
9. Apply a spray lubricant on the hoses in the area tom of the hose loop on the third and/or fourth
that will contact the channels. Make sure the function hoses. This action allows the hoses to
hoses are properly aligned in the channels. Put fit properly in the hose channel.
the clamps over the hoses and attach the clamps
to the channels. Tighten the hardware to 8 N•m 13. With no load on the forks, check the header hose
(71 lbf in). See Figure 41. adjustment by operating the mast through the
10. Connect the header hoses (4, C, and D) to the the hoses will not be so tight that they compress
cowl hoses. Connect the header hoses (4, A, and when they pass over the sheaves nor will they
B) to the tubes. be so loose that they touch the load backrest or
11. Use the rubber clamps and strap clamps to at-
hoses require additional adjustment, see Two-
Stage FFL Mast, Adjust Hoses After Installation.
sure the cowl hoses do NOT stretch or fold while
tilting the mast fully forward and backward.
81
TWO-STAGE FFL MAST, ADJUST HOSES THREE-STAGE FFL MAST, NEW HOSE
AFTER INSTALLATION INSTALL
WARNING
justed. See the section Lift Chains Adjustment for Before working on or near the mast, see Safety
adjustment procedures. Procedures When Working Near Mast in this
section.
loose) or push (if the hoses are tight) on the NOTE: This procedure is for the four-function option.
hoses so they move 15 mm (0.6 in.). Tighten the The three-function option will have hoses A and B
hardware to 8 N•m (71 lbf in). See Figure 37, only.
Figure 40, Figure 41, and Figure 42.
2. With no load on the forks, check the header hose correctly adjusted before the header hoses can be ad-
adjustment by operating the mast through the justed. See the section Lift Chains Adjustment for
full lift cycle two times. When properly adjusted, adjustment procedures.
1. Mark each hose with a single letter: A, B, C,
when they pass over the sheaves nor will they be
or D. See Figure 37, Figure 43, Figure 44, and
Figure 45.
crossmember that is next to a sheave. If neces-
sary, repeat Step 1 until the hoses are properly 2. Use a calculator to calculate the dimensions E
adjusted. and G. See Figure 43.
3. Clamp the end of the hose (the smaller fitting)

that attaches to the carriage in a vise (do NOT
4. Mark the all the hoses with dimensions E and

G (all measurements are made from the carriage
end of the hose [the smaller fitting]). See Fig-
ure 43.
5. Attach the hoses to the carriage bracket with

clamps. See Figure 44. Apply spray lubricant
to the surface of the hose guide that contacts the
hoses.
6. Place the hoses over the top of the free-lift

chains and under the hose guides. See Figure 44
and Figure 45. Attach the hose guides to the
lower crossmember and tighten the mounting
hardware to 33 N•m (24 lbf ft). Make sure the
bracket is between the crossmember and the
hose guide. Put the clamps over the hoses and
attach the clamps to the free-lift bracket. (DO
NOT tighten the hardware.)
82
Figure 42. Header Hose Alignment, Two-Stage Full Free-Lift Mast
83
Figure 43. Header Hose Measurement, Three-Stage Full Free-Lift Mast
84

Class II Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
Dimension G Calculations are similar to Dimension E
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class II Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
Dimension G for Lift Heights of 146.1 to 240.6:
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
85

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Dimension G Calculations are similar to Dimension E
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.
1. DIMENSION G 5. TOP OUTER CHANNEL

4. HOSE

A. OLD STYLE
1. CAPSCREW 9. HOSE GUARD 18. CLAMP
2. HOSE GUARD 10. CLAMP 19. COWL HOSES
3. SNAP RING 11. FREE-LIFT BRACKET 20. UPPER BRACKET
4. HOSE GUIDE 12. LOWER BRACKET 21. CARRIAGE BRACKET
5. FREE-LIFT CYLINDER 13. HOSE GUIDE 22. CLAMP
CROSSHEAD 14. NUT 23. STUBSHAFT
6. WASHER 15. CLAMP 24. LOCK NUT
7. SPACER 16. HEADER HOSES 25. STRAP CLAMP
8. SHEAVE 17. FREE-LIFT CHAINS
86
Figure 44. Header Hoses, Three-Stage Full Free-Lift Mast
87
88
89
A. HOSE A G. LEFT-HAND CYLINDER

B. HOSE B H. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
C. HOSE C I. REAR VIEW
D. HOSE D J. RIGHT-HAND CYLINDER
E. FRONT VIEW K. FORKS
F. ALIGN G ON HOSES A AND D AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES B AND C AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. FREE-LIFT CYLINDER
2. HOSE 5. CYLINDER GUARD
3. BOTTOM CROSSMEMBER, INNER CHANNEL
90
NOTE: To make the alignment of dimension E easier, THREE-STAGE FFL MAST, ADJUST
use a crane with a capacity of at least 908 kg (2002 lb) HOSES AFTER INSTALL
to raise the carriage high enough to attach a safety
chain as shown in Figure 37. NOTE: The lift chains and carriage height must be
7. Align the mark for dimension E at the bottom justed. See the section Lift Chains Adjustment for
of the clamp to create the proper hose tension. adjustment procedures.
Tighten the hardware to 8 N•m (71 lbf in). In-
stall the hose guards. Tighten the capscrews that 1. If the tension of the hoses is correct between the
mount the guards to 66 N•m (49 lbf ft). carriage and the clamp at the free-lift bracket,
go to Step 2. If the tension of the hoses is wrong,
8. Position the hoses at the hose sheave. See Fig- loosen the clamps and pull (if the hoses are loose)
ure 44 and Figure 45. The hose sheave and stub- or push (if the hoses are tight) on the hoses so
shaft must be installed on the hose before they they move 15 mm (0.6 in.). Tighten the hardware
are attached to the mast. Tighten the hardware to 8 N•m (71 lbf in). See Figure 37, Figure 43,
to 53 N•m (39 lbf ft). Figure 44, and Figure 45.
9. Put the clamps over the hoses and attach the 2. If the tension of the hoses is correct between the
clamps to the upper brackets. (DO NOT tighten clamp at the upper bracket and the clamp at the
the hardware.) free-lift bracket, go to Step 3. If the tension of the
hoses is wrong, loosen the clamps and pull (if the
NOTE: To make the alignment of dimension G easier,
hoses are too loose) or push (if the hoses are too
use a crane to raise the inner channel high enough to
tight) on the hoses so they move 15 mm (0.6 in.),
install a safety chain as shown in Figure 37.
plus the amount the hoses were moved in Step 1.
10. Align mark G on hoses A and D at the bottom Tighten the hardware to 8 N•m (71 lbf in).
edge of clamp to create the proper tension. Align
mark G on hoses B and C at the top edge of clamp
to create the proper tension. Tighten the hard-
ware to 8 N•m (71 lbf in).
11. Install the clamps. when they pass over the sheaves nor will they be
12. Connect the header hoses to the cowl hoses. crossmember that is next to a sheave. If neces-
sary, repeat Step 1 and Step 2 until the hoses are
13. Use the rubber clamps and strap clamps to at- properly adjusted.
sure the hoses do not stretch or fold while tilting
the mast fully forward and backward.

hoses require additional adjustment, see Three-
Stage FFL Mast, Adjust Hoses After Install.
91
Lift and Tilt System Leak Check 4000 SRM 522
Lift and Tilt System Leak Check

LIFT CYLINDERS LEAK CHECK lowers when the gate valve is open, check for
leaks in the hydraulic lines and fittings. If no
WARNING leaks are found, the main control valve can be
worn or damaged. Remove the load from the
During the test procedures for the hydraulic
forks.
system, use chains to fasten the load to the car-
riage to prevent it from falling. Keep all people
away from the lift truck during the tests.
TILT CYLINDERS LEAK CHECK
1. Put a capacity load on the forks. Slowly tilt the
Do NOT try to find hydraulic leaks by putting
mast forward. If the mast continues to slowly
your hand on hydraulic components under
tilt forward when the control valve is in the neu-
pressure. Hydraulic oil can be injected into
tral position, there are leaks inside the hydraulic
the body by the pressure.
system. The maximum speed that the mast is
1. Operate the hydraulic system. Put a capacity allowed to tilt forward when there are internal
load on the forks, and raise and lower the load leaks in the lift system is 13 mm (0.5 in.) per
several times. Lower the load and tilt the mast 10 minutes (measured at rod in the tilt cylinder).
forward and backward several times. Check for The maximum speed is measured when the hy-
leaks. draulic oil is 30 C (86 F). If the oil temperature
is 70 C (158 F), the maximum speed is 39 mm
2. Raise the carriage and load 1 m (3 ft). If the car- (1.5 in.) per 10 minutes.
riage slowly lowers when the control valve is in
the neutral position, there are leaks in the hy- 2. If the leak rate is greater than the specifications,
draulic system. The maximum speed that the remove the load from the mast. Install a gate
carriage is allowed to lower is 50 mm (2 in.) per valve between the port at the front of the tilt
10 minutes when the hydraulic oil is 30 C (86 F). cylinder and the hydraulic line. Put the load on
If the oil temperature is 70 C (158 F), the max- the forks again. Close the gate valve. If the mast
imum speed the carriage can lower is 150 mm tilts slowly forward, the cylinder seals are leak-
(6 in.) per 10 minutes. ing.
3. Check the lift cylinders for internal leaks. Re- 3. If the mast does not move, open the gate valve
move the load from the forks. Install a gate valve and check the movement again. If the mast
in the supply line between the main control valve moves forward when the gate valve is open,
and the mast. Put a capacity load on the forks check for leaks in the hydraulic lines and fit-
again. Raise the carriage 1 m (3 ft). Close the tings. If no leaks are found, the main control
gate valve. If the carriage or mast weldments valve can be worn or damaged. Remove the load
lower slowly, the seals in the lift cylinders have from the forks when the checks are complete.
leaks.
4. If the carriage does not move, open the gate valve

and check the movement again. If the carriage
92
4000 SRM 522 Tilt Cylinders Adjustment
Tilt Cylinders Adjustment

cylinder rods stop at the same position
WARNING within 1.00 mm (0.04 in.).
When the tilt cylinders have tilt limit spacers,
make sure they are installed during installa- c. Slowly tilt the mast backward until one rod
tion procedures. Without the tilt limit spacers, end just contacts the spacer. Add shims to
the mast can tilt too much and cause an acci- fill the gap at the opposite rod end until both
dent or serious injury. rod ends contact the spacers within 0.50 mm
(0.02 in.).
Check the tilt cylinder stroke by slowly tilting the
mast fully forward and backward several times. Both d. After the adjustments are complete, tighten
tilt cylinders must stop their stroke at the same time. the capscrews on the rod ends.
Adjust the rod ends as shown in Figure 46, Figure 47,
and Figure 48. There must be no twist in the mast e. Tilt the mast fully backward and measure
weldments. the tilt angle. (See the nameplate for tilt
angles.) If necessary, add an equal number
1. Adjust the stroke of the tilt cylinders WITHOUT of shims to both rods for the correct angle.
tilt limit spacers as follows:
a. Adjust the rod ends to 15 mm (0.6 in.) for

all tilt cylinders shown in Figure 46, and
32.00 mm (1.25 in.) for all tilt cylinders
shown in Figure 48.
b. Slowly tilt the mast backward until one

cylinder rod stops. On the opposite cylin-
der, loosen the capscrews on the rod end.
Measure the distance from the end of cylin-
der to the back end of the rod end. Use a
wrench and turn the cylinder rod IN un-
til the dimension starts to decrease, then
stop. Repeat this procedure until both cylin-
der rods stop at the same position within
1.00 mm (0.04 in.). After the adjustments
are complete, tighten the capscrews on the
rod ends.
c. Tilt the mast fully backward and measure

the tilt angle. (See the nameplate for tilt
angles.) If necessary, adjust both rod ends
equally for the correct angle.
NOTE: THE END OF THE ROD IS EVEN WITH THE
2. Adjust the stroke of the tilt cylinders WITH tilt FRONT FACE OF THE ROD END.
limit spacers as follows:
1. MAST 3. TILT CYLINDER
a. Adjust the rod ends to 15.0 mm (0.6 in.) for 2. ROD ENDS
all tilt cylinders as shown in Figure 47.
Figure 46. Tilt Cylinder Adjustment for
b. Slowly tilt the mast forward until one cylin- H/S1.50-1.75XM (H/S25-35XM), H/S2.00XMS
der rod stops. On the opposite cylinder, (H/S40XMS), E1.50-1.75XM (E25-35XM,
loosen the capscrews on the rod end. Use E25-35XM 2) (D114), and E2.00XMS (E40XMS,
a wrench and turn the cylinder rod IN as E40XM 2S) (D114), and E1.50-2.00XM (E25-35Z,
necessary. Repeat this procedure until both E40ZS) (E114)
93
Tilt Cylinders Adjustment 4000 SRM 522
1. MAST 4. TILT LIMIT SPACER 1. MAST 3. TILT CYLINDER

2. ROD END 5. TILT CYLINDER 2. ROD ENDS
3. SHIMS
Figure 48. Tilt Cylinder Adjustment
Figure 47. Tilt Cylinder Adjustment J1.60-2.00XMT (J30-40ZT)
H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM
(E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z)
(A416), and S/E/J2.00-3.00XL (S/E/J40-60XL)
94
4000 SRM 522 Lift Chains Adjustment
Lift Chains Adjustment

2. Adjust the chain anchors that support the car-
WARNING riage, until the bottom of the fork heel is 12.0
When working on or near the mast, see Safety +3.0/ 6.0 mm (0.47 +0.12/ 0.24 in.) above the
Procedures When Working Near Mast in this floor level. See Figure 49.
section.
3. See Figure 50. Adjust the chain anchors that
During test procedures for the hydraulic sys- support the carriage, until the bottom of the
tem, fasten the load to the carriage with chains lower carriage bar is above the floor level as
to prevent it from falling. Keep all personnel shown in Table 1.
away from the lift truck during the tests.
Table 1. Hook-Type Carriage Chain Adjustment
Never allow anyone under a raised carriage.
DO NOT put any part of your body in or Class II and III 88.5 +3.0/ 6.0 mm
through the lift mechanism unless all parts (3.50 +0.12/ 0.24 in.)
of the mast are completely lowered and the
engine is STOPPED. Class IV 139.5 +3.0/ 6.0 mm
(5.50 +0.12/ 0.24 in.)
Never check for leaks by putting hands on
Hydraulic oil under pressure can be injected
into the skin.
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 the threads on the nuts of the chain an-
chors are completely engaged. Make sure the chain
anchors are not adjusted too tight. The chain anchors
must be able to move on their mounting.
1. When adjusting the lift chains on forklift trucks 1. TILT MAST FULLY BACKWARD
equipped with either pin or hook-type forks in- 2. CARRIAGE ROLLER
stalled, go to Step 2. If the forklift truck is nor- 3. FORK
4. CARRIAGE ROLLER MUST NOT EXTEND
mally equipped with a hook-type carriage and
MORE THAN 34.0 mm (1.3 in.) BELOW INNER
has an attachment without forks, go to Step 3. MAST CHANNEL.
If the forklift truck is normally equipped with a
pin-type carriage and has an attachment without Figure 49. Lift Chain Adjustment, Hook- or
forks, go to Step 4. Pin-Type Forks
NOTE: Prior to performing adjustment procedures,

make sure the forklift truck is parked on a level sur-
face and the mast is in the vertical position.
95
Lift Chains Adjustment 4000 SRM 522
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 50. Lift Chain Adjustment, Hook-Type

Carriage
4. See Figure 51. Adjust the chain anchors, which

support the carriage, until the center line of the
fork pin is above the floor level as shown in Ta-
ble 2.
Table 2. Pin-Type Carriage Chain Adjustment
H70/80, 90XLS 551.0 +3.0/ 6.0 mm 1. LOAD BACK REST

(21.7 +0.12/ 0.24 in.) 2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
H90-110XL 714.0 +3.0/ 6.0 mm
(28.12 +0.12/ 0.24 in.) Figure 51. Lift Chain Adjustment, Pin-Type
H135-155XL 913.0 +3.0/ 6.0 mm Carriage
(36.0 +3.0/ 6.0 in.)
96
4000 SRM 522 Mast Adjustment
Mast Adjustment
NOTE: Shims are installed on both sides of the load 2. Adjust the load rollers on the mast as follows:
rollers. DO NOT add or remove shims from the stub
shafts. To change the position of the roller on the a. Use a pry bar to move the mast weldments
stub shaft, move the shims from one side of the load from side to side to measure the amount of
roller to the other. movement. Repeat this step in a minimum
of three different positions (top, middle, bot-
During assembly, the shim arrangement will be ap- tom) of the mast weldments.
proximately the same as before disassembly. Check
the clearance and adjust for wear or change due to b. Separate the mast weldments and change
repairs. the shim arrangements as needed. Assemble
the mast weldments. Slide the mast weld-
1. The load rollers control the alignment of the mast ment all the way to the top and bottom to find
weldments. The alignment conditions are given the tightest fit.
on a list below, with the most important condition
first. See Figure 52. c. Repeat Step a and Step b until there is zero
clearance at the point of tightest fit.
a. The mast weldments must be parallel to each
other. d. Measure the distance between the channels
of the mast weldments on the top and bottom.
b. Use shims to adjust the load rollers so there Change shims to keep the distance equal be-
is zero clearance between the load roller and tween the top and bottom of the mast weld-
the channel at the point of tightest fit. ments. Make sure the weldments are paral-
lel within 1.50 mm (0.06 in.).
c. The number of shims under a load roller
must be approximately the same as the stub 3. Adjust the strip bearings. Insert shims between
shaft in the opposite side of the weldment. the strip bearing and the channel. Adjust the
The weldments will be approximately in the strip bearings so the maximum clearance at the
center. point of tightest fit is 0.80 mm (0.03 in.). See
Figure 21.
97
Mast Adjustment 4000 SRM 522
NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO PROVIDE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO PROVIDE ZERO CLEAR-
ANCE AT POINT OF TIGHTEST FIT.
A. TOP VIEW B. MAST FRONT VIEW C. CARRIAGE FRONT VIEW
1. CHANNEL 8. EQUAL SPACE ±1.5 mm 12. CARRIAGE LATERAL
2. LOAD ROLLER (0.060 in.) MOVEMENT 2.5 mm (0.10 in.)
3. STUB SHAFT 9. PARALLEL TO CHANNEL 13. CHECK CARRIAGE LATERAL
4. SNAP RING ±1.5 mm (0.060 in.) MOVEMENT HERE
5. SHIMS 10. PUT SPACER ON OUTSIDE OF
6. PARALLEL TO CHANNEL TOP LOAD ROLLER, UNDER
±1.5 mm (0.060 in.) SNAP RING
7. ZERO CLEARANCE AT POINT 11. SHIM FOR ZERO CLEARANCE
OF TIGHTEST FIT AT POINT OF TIGHTEST FIT
Figure 52. Mast and Carriage Adjustments
98
4000 SRM 522 Carriage Adjustment
Carriage Adjustment
1. Install the load rollers on the carriage. Install 4. Check lateral movement of carriage:
the shims for the rollers in the same sequence on
the stub shaft as before disassembly. When the a. Fully lower carriage to ground.
carriage has six load rollers, there are no shims
b. Place hand or small pry bar between top of
under the top load rollers. See Mast and Car-
carriage side plate and the inner channel
riage Adjustments.
flange. See Figure 52.
WARNING c. Move carriage back and forth and check

The mast is heavy. The mast can weigh approx- movement.
imately 681 kg (1501 lb). Make sure all lifting d. Carriage lateral movement must not be
devices (hoists, cables, chains, slings, etc.) are greater than 2.5 mm (0.10 in.).
suitable and of adequate capacity to lift the mo-
tor. e. If carriage lateral movement is greater than
2.5 mm (0.10 in.), add or remove shims and
2. Use a crane to raise the carriage up the inner repeat Step a through Step d until correct
mast weldment. Find the tightest fit between the movement is achieved.
load rollers and the inner mast weldment.
5. Keep the shim arrangement between the middle
3. Remove the carriage from the mast. Adjust the and bottom load rollers on the same side of the
shim arrangement for each load roller for clear- carriage approximately equal. Also keep the
ance between the load roller and the inner mast shim arrangement on each side of the carriage
weldment. Repeat Step 1 and Step 2 until there approximately equal. The carriage must be
is zero clearance at the point of tightest fit. parallel with the inner mast weldment within
±1.50 mm (±0.06 in.).
99
Troubleshooting 4000 SRM 522
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
No movement of the lift or Linkage at the control valve is dis- Connect and adjust linkage.
tilt cylinders. connected.
No oil or not enough oil in the hy- Fill tank. Check for leaks.
draulic tank.
Relief valve is not set correctly. Adjust or install new relief valve.
Hydraulic pump does not operate or Repair or install new pump.

has damage.
Slow movement of the lift or No oil or not enough oil to the lift Fill tank. Check for leaks.
tilt cylinders. cylinders.
Cylinders have internal or external Repair leaks. Install new parts.

leaks.
Relief valve is not set correctly. Adjust or install new relief valve.
There is a restriction in a hydraulic Remove restriction. Install new

line. parts.
Load is more than capacity. Reduce load.
Hydraulic control linkage is incor- Adjust the load.

rectly adjusted.
Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec-
assembly. tions or breaks in lines.
Lift cylinder(s) is damaged. Repair or install new lift cylinder.
Mast weldments are damaged or not Align weldments. Install new parts.
aligned.
Mast weldments are not lubricated Correct lubrication.

correctly.
100
TECHNICAL PUBLICATIONS
4000 SRM 522 7/10 (10/09)(5/04)(11/03)(3/03)(5/01)(5/96)(11/94)(7/94)(2/94)(11/93)(4/93) Printed in U.S.A.

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MAST REPAIRS

2- AND 3-STAGE MASTS

PART NO. 897507 4000 SRM 522

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2010 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];

Safety Procedures When Working Near Mast

4. Lower the mast until there is tension in the

NOTE: After lowering or restraining the mast, shut

A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST

Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts

A fork can be removed from the carriage for replace-

A. EARLIER MODELS B. LATER MODELS

Figure 3. Carriage and Forks

3. Remove the load backrest.

4. Remove the pin from each chain anchor at the

A. HYDRAULIC CONNECTIONS - TWO-STAGE, B. HYDRAULIC CONNECTIONS - TWO-STAGE,

Figure 5. Hang-On Sideshift Carriage

2. If the carriage aprons have any protruding welds

d. Install the piston and rod in the shell. Ap-

5. Disconnect the hydraulic lines at the sideshift

e. Install the seals into the retainer grooves.

f. Apply a film of hydraulic oil to the inside

STANDARD CARRIAGE, INSTALL

3. Check the clearance of the load rollers. See Car-

6. Install the forks. See Fork Repair.

NOTE: TWO- AND THREE-STAGE FFL ARE SHOWN.

Figure 7. Integral Sideshift Carriage

NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

The hydraulic oil is hot at normal operating

Never check for leaks by putting hands on

b. Unscrew the retainer from the cylinder.

c. Clamp the other end of the cylinder in a

d. Unscrew the retainer from the cylinder.

NOTE: If new retainers that are already assembled

e. Remove and discard the seals and O-ring

Install 3. Use a crane with a capacity of at least 450 kg

1. SPACER 7. O-RING 1. RETAINER CAP 6. SHIMS

1. RETAINER CAP 5. BUSHING

Figure 15. Mast Mounting J1.60-2.00XMT

4. On the H/S2.00-3.20XM (H/S40-65XM),

NOTE: When replacing the outer channel weldment,

Figure 16. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)

Figure 16. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)

Legend for Figure 16

Figure 17. Two-Stage, Full Free-Lift Mast (Sheet 1 of 2)

Figure 17. Two-Stage, Full Free-Lift Mast (Sheet 2 of 2)

Legend for Figure 17

1. Disconnect the main free-lift chains at the cross-

2. Disconnect and remove the hydraulic lines for

3. Disconnect the main lift chains from the chain

Hydraulic oil is hot at normal operating tem-

at the bottom of the inner mast weldment. Re-

Figure 19. Three-Stage, Full Free-Lift Mast (Sheet 1 of 2)

A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM

Figure 19. Three-Stage, Full Free-Lift Mast (Sheet 2 of 2)