MAST

REPAIRS
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 (J40-60Z) [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 (E40-65Z) [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 Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

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

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Mast Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Forks Repair....................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 3
Carriages Repair ................................................................................................................................................ 4
Standard Carriage, Remove.......................................................................................................................... 4
Hang-On Sideshift Carriage, Remove .......................................................................................................... 5
Standard Carriage and Hang-On Sideshift Carriage, Repair..................................................................... 6
Standard Carriage, Install ............................................................................................................................ 6
Hang-On Sideshift Carriage, Install ............................................................................................................ 7
Integral Sideshift Carriage ........................................................................................................................... 7
Remove....................................................................................................................................................... 7
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 9
Install ......................................................................................................................................................... 10
Mast Repair........................................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Two-Stage LFL and Two-Stage FFL Masts, Disassemble ........................................................................... 12
Three-Stage FFL Mast .................................................................................................................................. 19
Disassemble ............................................................................................................................................... 19
Mast and Chains, Clean and Inspect ....................................................................................................... 23
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 24
Three-Stage FFL Mast, Assemble ................................................................................................................ 25
Install ............................................................................................................................................................. 26
Lift Cylinders Repair ......................................................................................................................................... 27
Main Lift Cylinders, Remove ........................................................................................................................ 27
Free-Lift Cylinder, Remove ........................................................................................................................... 28
Lift Cylinders, Disassemble .......................................................................................................................... 28
Lift Cylinders, Assemble ............................................................................................................................... 31
Main Lift Cylinders, Install .......................................................................................................................... 32
Free-Lift Cylinder, Install ............................................................................................................................. 32
Header Hose Arrangements .............................................................................................................................. 33
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 33
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 38
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 39
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 45
Three-Stage FFL Mast, New Hose Install ................................................................................................... 45
Three-Stage FFL Mast, Adjust Hoses After Installation ............................................................................ 56
Header Hose Arrangement................................................................................................................................ 57
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 57
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 61
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 61
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 66
Three-Stage FFL Mast, New Hose Install ................................................................................................... 68
Three-Stage FFL Mast, Adjust Hoses After Install..................................................................................... 76
Lift and Tilt System Leak Check ...................................................................................................................... 77
Lift Cylinders Leak Check ............................................................................................................................ 77
Tilt Cylinders Leak Check ............................................................................................................................ 77
Tilt Cylinders Adjustment................................................................................................................................. 78
Lift Chains Adjustment ..................................................................................................................................... 79

©2003 HYSTER COMPANY i

Table of Contents Mast

TABLE OF CONTENTS (Continued)

Mast Adjustment ............................................................................................................................................... 81
Carriage Adjustment ......................................................................................................................................... 83
Troubleshooting.................................................................................................................................................. 83

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 (J40-60Z) [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 (E40-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]

ii
4000 SRM 522 Safety Procedures When Working Near Mast

General
4000 SRM 521 for the description and operation of
WARNING the masts.
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this NOTE: Hoses have a service life that is determined
section. by application and time. All hoses must be inspected
at the intervals specified in the Maintenance Sched-
This section has the repair procedures for the ule for the hydraulic system. Install a new hose if the
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full hose is worn, damaged, soft or hard, and no longer
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL) flexible. If necessary, make a comparison to a new
masts; and for the sideshift carriages. Carriage hose that is the correct replacement for the hose you
Adjustment and Troubleshooting are at the end of are inspecting.
this section. See the section Mast Description

Safety Procedures When Working Near Mast

The following procedures MUST be used when in- OR
specting or working near the mast. Additional pre-
cautions and procedures can be required when re- • If parts of the mast must be in a raised po-
pairing or removing the mast. sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
WARNING these procedures:
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or 1. Put the mast in a vertical position.
death can result if part of the body is hit by
parts of the mast or the carriage. 2. Raise the mast to align the bottom crossmem-
• Never put any part of the body into or under ber of the weldment that moves in the outer
the mast or carriage unless all parts are com- weldment with a crossmember on the outer
pletely lowered or a safety chain is installed. weldment. On the two-stage and free-lift mast,
Also make sure the power is off and the key the moving part is the inner weldment. On the
is removed. Put a DO NOT OPERATE tag in three-stage mast, it is the intermediate weld-
the operator’s compartment. ment. See Figure 1.
• Be careful of the forks. When the mast is 3. Use a 9.5 mm (3/8 in.) minimum safety chain
raised, the forks can be at a height to cause with a hook to fasten the crossmembers together
an injury. so the movable member cannot lower. Put the
• DO NOT climb on the mast or lift truck at any hook on the back side of the mast. Make sure
time. Use a ladder or personnel lift to work the hook is completely engaged with a link in
on the mast. the chain. Make sure the safety chain does not
• DO NOT use blocks to support the mast weld- touch lift chains or chain sheaves, tubes, hoses,
ments nor to restrain their movement. fittings, or other parts on the mast.
• Mast repairs require disassembly and re-
moval of parts and can require removal of 4. Lower the mast until there is tension in the
the mast or carriage. Follow the repair pro- safety chain and the free-lift cylinder (two-stage
cedures in the correct Service Manual for full free-lift and three-stage masts only) is com-
the mast. pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
WHEN WORKING NEAR THE MAST ALWAYS: REMOVE tag on the safety chain(s).
• Lower the mast and carriage completely.
Push the lift/lower control lever forward and NOTE: After lowering or restraining the mast, shut
make sure there is no movement in the mast. off the power and remove the key. Put a DO NOT
Make sure all parts of the mast that move are OPERATE tag in the operator’s compartment.
fully lowered.

1
Safety Procedures When Working Near Mast 4000 SRM 522

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

1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER
2. INNER WELDMENT 5. FREE-LIFT CYLINDER
3. INTERMEDIATE WELDMENT 6. CROSSMEMBER

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

2
4000 SRM 522 Forks Repair

Forks Repair
The forks are held on the carriage by hooks. The INSTALL
forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the top Move the fork and carriage so the top hook on the
bar carriage. Always check that the latch pins for fork can engage the upper carriage bar. Raise the
the forks keep the forks in position on the carriage. carriage to move the lower hook through the fork re-
Replace damaged latch pins parts. The forks can be moval notch. Slide the fork on the carriage so both
removed from the carriage by aligning the forks with upper and lower hooks engage the carriage bars. En-
the fork removal notch. The fork removal notch is in gage the latch pin with a notch in the upper carriage
the bottom bar of 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.

Figure 3. Carriage and Forks

3
Carriages Repair 4000 SRM 522

Legend for Figure 3

A. EARLIER MODELS B. LATER MODELS
1. FORKS 6. LEVER
2. CARRIAGE 7. WASHER
3. LOAD BACKREST EXTENSION 8. SPRING
4. FORK REMOVAL NOTCH 9. PIN
5. LATCH PIN ASSEMBLY 10. KNOB

Carriages Repair
STANDARD CARRIAGE, REMOVE
1. Put a one-quarter capacity load on the forks. The
load must give the carriage stability so the car-
riage cannot fall when it is disconnected from the
mast.

2. Lower the carriage and forks on blocks so the lift

chains become loose.

3. Remove the load backrest extension.

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
NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
of the lift chains to a part of the mast. Make sure
the chains can move freely when the inner mast 1. CARRIAGE 6. CHAIN PIN
weldment is raised. 2. SNAP RING 7. COTTER PIN
3. SHIM 8. ANCHOR PIN
4. LOAD ROLLER 9. SPACER
WARNING 5. CHAIN ANCHOR
To help prevent possible injury, make sure the
carriage is stable when the inner mast weld- Figure 4. Standard Carriage
ment is above the load rollers of the carriage.
6. Move the lift truck away from the carriage. Com-
5. Use the lift cylinders to raise the inner mast pletely lower the inner mast weldment so it can-
weldment. If the hydraulic system cannot be not move.
used, disconnect the lift cylinders from the inner
7. Connect a lifting device to the carriage. Remove
or intermediate mast weldment. Connect a crane
the load from the forks with another lift truck.
[the capacity of the crane must be at least 681 kg
Lower the carriage to the floor so the load rollers
(1501 lb)] to the top of the inner mast weldment.
are facing up.
Carefully raise the inner mast weldment until it
is above the load rollers of the carriage. 8. If the forks are removed, use a lifting device to
put the carriage on the floor so the load rollers
are up.

4
4000 SRM 522 Carriages Repair

HANG-ON SIDESHIFT CARRIAGE, bracket and cylinder will stay on the standard
REMOVE carriage. Remove the bearings.

1. Lower the carriage completely. Remove the forks

WARNING
and the load backrest extension.
Hydraulic oil is hot after system operation and
2. Connect a crane [the capacity of the crane must can cause burns. Do not disconnect any hy-
be at least 681 kg (1501 lb)] to the lifting eye on draulic lines of the system until the oil for the
the sideshift carriage. See Figure 5. system is cool and the pressure is relieved.

3. Remove the two upper capscrews from the lower 5. Disconnect the hydraulic lines at the sideshift
apron. Slowly loosen the two bottom capscrews, cylinder. Put caps on the open hydraulic lines.
but do not remove them. The slotted holes will al- Remove the cylinder support bracket from the
low the lower apron to move down so the sideshift standard carriage. If necessary, remove the
carriage can be removed. threaded rods and shims in order to remove the
sideshift cylinder.
4. Carefully lift the sideshift carriage from the stan-
dard carriage. The sideshift cylinder support

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 7. UPPER APRON
2. CYLINDER SUPPORT BRACKET 8. BOTTOM BEARING
3. THREADED ROD 9. LOWER APRON
4. SHIM 10. LIFTING EYE
5. SIDESHIFT CYLINDER 11. SHIM STRIP
6. GREASE FITTING

Figure 5. Hang-On Sideshift Carriage

5
Carriages Repair 4000 SRM 522

STANDARD CARRIAGE AND HANG-ON

SIDESHIFT CARRIAGE, REPAIR
NOTE: The carriage can have four or six load rollers.
When the carriage has four load rollers, shims are
used behind all of the load rollers. When the carriage
has six load rollers, shims are installed on the bottom
and middle rollers only.

1. If any of the load rollers must be replaced, make

a note of the location and number of the shims.
Install the shims, load rollers, and snap rings.
See Carriage Adjustment for correct adjustment
of the load rollers.

2. If the carriage aprons have any protruding welds

1. SHELL 5. RETAINER
or damaged notches, repair by grinding, filing, or 2. O-RING 6. WIPER
welding. 3. BACKUP RING 7. PISTON AND ROD
4. ROD SEAL 8. PISTON SEAL
3. The repair procedure for the sideshift cylinder is
as follows (see Figure 5 and Figure 6): Figure 6. Sideshift Cylinder

a. Remove the retainers from the shell. Pull the

rod from the shell. WARNING
Cleaning solvents may be flammable and toxic
b. Replace seals, O-rings, or backup rings as and can cause severe skin irritation. When
necessary. Use the installation guides to pre- using cleaning solvents, always follow the
vent damage to the seals. solvent manufacturer’s recommended safety
precautions.
c. Lubricate all internal parts with clean hy-
draulic oil. d. Clean the retainers and the cylinder rod with
cleaning solvent. Lubricate the new seals
d. Install the piston and rod in the shell. Ap- and O-rings with hydraulic oil.
ply Loctite® 242 to the threads of the retain-
ers. Install the retainers and tighten them to e. Install the seals into the retainer grooves.
27 N•m (20 lbf ft). Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc-
4. Replace the cylinder rod seals as follows: tion of the rod seals. Pressure seals are in-
a. Clamp the cylinder in a soft-jawed vise. DO stalled with the lip toward the pressure
NOT clamp on the cylinder shell. side of the cylinder.

b. With the cylinder rod centered, unscrew the f. Apply a film of hydraulic oil to the inside
retainer from each end of the cylinder. Slide of the retainers. Carefully slide them onto
the retainers off the cylinder rod. the cylinder rod. Tighten the retainers to
165 N•m (122 lbf ft).
NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step f. STANDARD CARRIAGE, INSTALL
c. Remove the seals and O-ring from each re- 1. Use the hydraulic system of the lift truck or a
tainer with a brass O-ring tool. DO NOT crane to raise the inner mast weldment. If the
scratch the grooves. hydraulic system cannot be used, disconnect the
lift cylinders from the inner or intermediate mast

6
4000 SRM 522 Carriages Repair

weldment. Connect a crane [the capacity of the 6. Install the shim strips under the bottom bearing
crane must be at least 681 kg (1501 lb)] to the top strip (be sure the shims are seated between the
of the inner mast weldment. Carefully raise the shim stops) so the bottom bearing strip will just
inner mast weldment until it is above the load clear the lower lip of the standard carriage bar
rollers of the carriage. when the lower apron is brought into position.

2. Move the lift truck toward the carriage until the 7. Make sure the standard carriage is completely
inner mast weldment is aligned with the carriage lowered. Connect a crane [the capacity of the
rollers. Carefully lower the inner mast weldment crane must be at least 908 kg (2002 lb)] to the
until it engages all of the load rollers. lifting eye. Install the sideshift carriage on the
standard carriage. Put blocks under the bottom
3. Check the clearance of the load rollers. See Car- apron of the sideshift carriage so the bottom
riage Adjustment in this section. bearing moves tight against the standard car-
riage when the lifting device is lowered.
4. Connect the lift chains to the chain anchors at the
carriage. Use new cotter pins in the anchor pins. Install the two top capscrews into the sideshift
Adjust the lift chains as described in Carriage carriage. Tighten the capscrews to the following
Adjustment in this section. torque:
• On H/S1.50-1.75XM, H/S2.00XMS (H/S25-
5. Install the backrest on the sideshift carriage.
35XM, H/S40XMS), E1.50-1.75XM (E25-
Tighten the capscrews to 195 N•m (144 lbf ft).
35XM, E25-35XM 2) [D114], E2.00XMS
(E40XMS, E40XM 2S [D114], E1.50-2.00XM
HANG-ON SIDESHIFT CARRIAGE,
(E25-35Z, E40ZS) [E114], H/S2.00-2.75XM
INSTALL (H/S40-55XM), S/E/J2.00-2.50XL (S/E/
1. Install the sideshift cylinder in the cylinder sup- J40-50XL), J1.60-2.00XMT (J30-40XMT),
port bracket. See Figure 5. Use an equal num- J2.00-2.50XM (J40-50XM) [A216], and
ber of shims on both sides of the cylinder to limit J2.00-2.50XM (J40-50Z) [A416] units, tighten
side-to-side movement within the bracket. Maxi- all of the capscrews to 435 N•m (321 lbf ft).
mum movement is 0.6 mm (0.024 in.). Install the • On H/S3.00-3.20XM (H/S60-65XM), J3.00-
threaded rods to hold the cylinder in position and 3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z)
tighten to 18 N•m (159 lbf in). [A416], E2.00-3.20XM (E40-65Z) [G108], and
S/E/J3.00XL (S/E/J60XL) units, tighten all of
2. Install the cylinder support bracket on the stan- the capscrews to 755 N•m (557 lbf ft).
dard carriage. Make sure the bracket is engaged
in the center notch in the top carriage bar. 8. Install the load backrest extension on the
sideshift carriage. Tighten the capscrews to
3. Connect the hydraulic lines to the sideshift cylin- 195 N•m (144 lbf ft).
der. See Figure 5. Lubricate the ends of the cylin-
der rod with multipurpose grease. 9. Remove the lifting device. Lubricate the top
bearings at the grease fittings.
4. Install the top bearing on the cylinder support
bracket. Lubricate only the outer surface of the INTEGRAL SIDESHIFT CARRIAGE
bearing with multipurpose grease.
Remove
5. Connect the top and bottom aprons by installing
the two bottom capscrews. Do NOT tighten the 1. Lower the carriage completely. Remove the forks
capscrews. Lubricate only the outer surface of and the load backrest extension. See Figure 3
the bottom bearing with multipurpose grease. and Figure 7.
Install the bottom bearing in the lower apron.

7
Carriages Repair 4000 SRM 522

NOTE: TWO AND THREE-STAGE FFL IS 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

8
4000 SRM 522 Carriages Repair

WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic lines of the system until the oil for the
system is cool and the pressure is relieved.

2. Disconnect the hydraulic lines at the sideshift

cylinder. Put caps on the open hydraulic lines.

3. Remove the lower mounting hooks.

4. Use a crane with a capacity of at least 450 kg

(992 lb) to lift the outer frame away from the in-
ner frame. Lay the outer frame flat on a pallet or
workbench.

5. If the sideshift cylinder or the bearings are to be

serviced, remove the capscrews and the cylinder
assembly from the inner frame.

Clean and Inspect 1. CYLINDER SHELL 3. O-RING

AND ROD 4. RETAINER
2. SEAL 5. WIPER
1. Inspect the lower mounting hooks for wear. Re-
place the hooks if they are worn beyond the wear Figure 8. Integral Sideshift Cylinder
limit. The wear limit clearance range is 0.8 mm
(1/32 in.) minimum and 1.6 mm (1/16 in.) maxi- Repair
mum. See Figure 7.
1. If any of the load rollers must be replaced, make
2. Clean and inspect the carriage bars for damage a note of the location and number of the shims.
and smoothness. Ensure the bars are parallel Install the shims, load rollers, and snap rings.
and the ends are flush. See Carriage Adjustment for correct adjustment.
3. Clean the bearing areas. Inspect the sideshift 2. If the carriage bars have any protruding welds
bearings for wear as follows: or damaged notches, repair by grinding, filing,
or welding.
a. Remove the upper bearings from the upper
apron. If either upper bearing is worn to 3. Replace the cylinder rod seals as follows:
less than 2.5 mm (3/32 in.) thickness, re-
place both upper bearings by driving the up- a. Clamp the cylinder in a soft-jawed vise. DO
per bearings from the upper apron. NOT clamp on the cylinder shell.

b. Remove the lower bearings from the lower b. With the cylinder rod centered, unscrew the
carriage bar. If either lower bearing is worn retainer from each end of the cylinder. Slide
to less than 2.5 mm (3/32 in.) thickness, re- the retainers off the cylinder rod.
place both lower bearings by prying the lower
bearings from the lower carriage bar. NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step f.
4. Inspect the sideshift cylinder. Replace the en-
tire cylinder assembly if a cylinder rod is bent or c. Remove the seals and O-ring from each re-
scored or if there is damage on the outside of the tainer with a brass O-ring tool. DO NOT
cylinder shell that could impair performance or scratch the grooves.
cause leaks under pressure. See Figure 8.

9
Mast Repair 4000 SRM 522

Proper lower hook clearance requires the upper bear-

WARNING ings be fully seated.
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When 1. If necessary, install the lower sideshift bearings.
using cleaning solvents, always follow the Then install the upper sideshift bearings. Lubri-
solvent manufacturer’s recommended safety cate the upper and lower sideshift bearings with
precautions. chassis grease. See Figure 7.

d. Clean the retainers and the cylinder rod with 2. If necessary, install the sideshift cylinder.
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil. 3. Use a crane with a capacity of at least 450 kg
(992 lb) to install the outer frame on the inner
e. Install the seals into the retainer grooves. frame.
Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc- 4. Install the lower mounting hooks. For proper
tion of the rod seals. Pressure seals are in- sideshift operation, make sure there is 0.8 to
stalled with the lip toward the pressure 1.6 mm (1/32 to 1/16 in.) clearance between the
side of the cylinder. bottom of the hooks and the outer frame.

f. Apply a film of hydraulic oil to the inside 5. Connect the hydraulic lines to the sideshift cylin-
of the retainers. Carefully slide them onto der.
the cylinder rod. Tighten the retainers to 6. Install the backrest on the sideshift carriage.
165 N•m (122 lbf ft). Tighten the capscrews to 195 N•m (144 lbf ft).
Install 7. Install the forks.
NOTE: Use a wood block or a plastic hammer to fully
seat the upper bearings onto the upper carriage bar.

Mast Repair
REMOVE the mast weldments are fastened together. Make
sure the chains will not damage the sheaves, tub-
WARNING ing, or other parts of the mast.
The mast is heavy. The mast can weigh approx-
imately 907.2 kg (2000 lb). Make sure all lift- WARNING
ing devices (hoists, cables, chains, slings, etc.) Hydraulic oil is hot after system operation and
are suitable and of adequate capacity to lift the can cause burns. Do not disconnect any hy-
mast. draulic hoses until the oil in the system is cool.
NOTE: If the mast needs to be disassembled, remove 2. Put a drain pan under the area of the hydraulic
the forks and carriage. If only the lift cylinders need fittings. Disconnect the hydraulic line at the ex-
to be removed for repair, the mast does not need to be ternal lowering control valve on the outer mast
removed from the lift truck. See the procedures for weldment.
Lift Cylinders Repair.

NOTE: The length of the lift chains must be checked WARNING

before the mast is removed. See Step 2 in Mast and Use a driver, NOT your fingers, to push the an-
Chains, Clean and Inspect. chor pins from the clevises on the tilt cylinders.
The cylinder or mast can move and cause seri-
1. Fully lower all of the mast weldments and the ous injury.
carriage. Tilt the mast fully forward. Connect a
crane with a capacity of at least 1600 kg (3527 lb) 3. Remove the cotter pins and anchor pins or the
to the top of the mast using chains. Make sure all capscrews, washers, and anchor pins at the tilt
cylinder mounts on the outer mast weldment.

10
4000 SRM 522 Mast Repair

NOTE: To perform the next two steps, the lift truck 5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-
must be raised. See the Operator Manual or Pe- 35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
riodic Maintenance Manual for your lift truck for E25-35XM 2) (D114), E2.00XMS (E40XMS,
instructions on how to put a lift truck on blocks. E40XM SS (D114), E1.50-2.00XM (E25-35Z,
E40ZS) (E114), and J1.60-2.00XMT (J30-
4. On the H/S2.00-3.20XM (H/S40-65XM), 40XMT), see Figure 10; on S/E/J2.00-3.00XL
E2.00-3.20XM (E40-65XM, E40-65XM 2) (S/E/J40-60XL), see Figure 11; and on J1.60-
(F108), E2.00-3.20XM (E40-65Z) (G108) 2.00XMT (J30-40ZT), see Figure 12, and remove
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), the capscrews that hold the retainer caps to the
and J2.00-3.20XM (J40-60Z) (A416), see Fig- mast mounts.
ure 9, remove the capscrews that hold the outer
mast weldment to the pivot pins at the mounts.

1. RETAINER CAP 6. SHIMS

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

11
Mast Repair 4000 SRM 522

Legend for Figure 12

1. RETAINER CAP 6. NUT
2. LOCKWASHER 7. PIN
3. TILT CYLINDER 8. ROD END
4. OUTER MAST 9. WASHER
WELDMENT 10. CAPSCREW
5. BUSHING

WARNING
The mast is heavy. The mast can weigh approx-
imately 907.2 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.

6. Use the crane to lift the mast assembly from the

lift truck. Put the mast on the floor so the back
of the mast is toward the floor.

TWO-STAGE LFL AND TWO-STAGE FFL

1. RETAINER CAP 5. BUSHING MASTS, DISASSEMBLE
2. SPACER 6. SHIMS
3. TILT CYLINDER 7. PIN
4. OUTER MAST 8. ROD END WARNING
WELDMENT
Hydraulic oil is hot after system operation and
Figure 11. Mast Mounting S/E/J2.00-3.00XL can cause burns. Do not disconnect any hy-
(S/E/J40-60XL) draulic lines of the system until the oil for the
system is cool and the pressure is relieved.

NOTE: If only the lift cylinders need to be removed

and repaired, see the procedures for Lift Cylinders
Repair. When the mast has header hoses, see the
procedures for the Header Hose Arrangements.

1. Clean the area around the hydraulic fittings for

the lift cylinders. Disconnect the fittings at the
lift cylinders and put caps on the open lines.

2. Remove the chains and header hoses. On the

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.

Figure 12. Mast Mounting J1.60-2.00XMT

(J30-40ZT)

12
4000 SRM 522 Mast Repair

disengage the main lift cylinders from the inner

WARNING mast weldment. Remove the main lift cylinders
Be careful when removing or installing snap from the outer mast weldment. See Figure 13
rings. These snap rings can come loose dur- and Figure 14.
ing removal or installation with enough force
to cause an injury. Always use the correct snap 6. Slide the inner mast weldment from the bot-
ring pliers, and wear eye and face protection tom of the outer mast weldment approximately
during removal or installation. 30 cm (12 in.). Remove the strip bearings and
load rollers from the top of the outer mast weld-
3. Remove the nut, bolt, and spacer at the mount ment. Remove the load rollers from the bottom
near the top of each main lift cylinder. Remove of the inner mast weldment. Make a note of each
the snap rings and washers from the top of shim arrangement and load roller location. The
each main lift cylinder. Disconnect the main lift shim arrangements will be approximately the
chains at the mounts. same during assembly.
4. On the H/S2.00-3.20XM (H/S40-65XM),
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), WARNING
E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM The mast is heavy. The mast can weigh ap-
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM proximately 681 kg (1501 lb). Make sure all lift-
(J40-60Z) (A416), and S/E/J2.00-3.00XL ing devices (hoists, cables, chains, slings, etc.)
(S/E/J40-60XL), two-stage FFL mast, disconnect are suitable and of adequate capacity to lift the
the FFL supply tube and remove the hydraulic mast.
fitting from the top of the left-hand main lift
cylinder. NOTE: When replacing the outer channel weldment,
copy the part number and date code information from
On the H/S1.50-1.75XM, H/S2.00XMS (H/S25- the old channel and stamp that information on the
35XM, H/S40XMS), E1.50-1.75XM (E25-35XM, new channel with a letter R at the end to indicate
E25-35XM 2) (D114), E2.00XMS (E40XMS, that it has been replaced.
E40XM 2S) (D114), E1.50-2.00XM (E25-35Z,
E40ZS) (E114), and J1.60-2.00XMT (J30- 7. Slide the inner mast weldment halfway out of
40XMT) two-stage FFL masts, disconnect the the top of the outer mast weldment. Connect a
FFL supply tube and remove the hydraulic fit- crane [the capacity of the crane must be at least
ting from the top of the right-hand main lift 681 kg (1501 lb)] to the center of the inner mast
cylinder. weldment. See Figure 15. 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 weldment can slide when the mast is the inner mast weldment from the outer mast
moved. A weldment that slides can cause in- weldment.
jury.
8. Remove the chain sheaves and disassemble them
5. Slide the inner mast weldment from the outer as necessary for repair and cleaning.
mast weldment approximately 30 cm (12 in.) to

13
Mast Repair 4000 SRM 522

Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)

14
4000 SRM 522 Mast Repair

Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)

15
Mast Repair 4000 SRM 522

Legend for Figure 13

A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z) (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

16
4000 SRM 522 Mast Repair

Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 1 of 2)

17
Mast Repair 4000 SRM 522

Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 2 of 2)

18
4000 SRM 522 Mast Repair

Legend for Figure 14

A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z) (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 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
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
at the bottom of the inner mast weldment. Push
the inner mast weldment toward the bottom of
the mast assembly until the bottom load rollers
can be seen.

WARNING
The weldments can slide when the mast is
moved. A weldment that slides can cause in-
Figure 15. Inner Mast Weldment
jury. Use a crane to turn the mast slowly and
carefully.
THREE-STAGE FFL MAST
4. Remove the strip bearings at the top of the inter-
Disassemble mediate mast weldment. Remove the load rollers
at the bottom of the inner mast weldment. Re-
WARNING move the load rollers at the top of the intermedi-
Hydraulic oil is hot after system operation and ate mast weldment. Make a note of each shim ar-
can cause burns. Do not disconnect any hy- rangement and load roller location. The shim ar-
draulic lines of the system until oil for the sys- rangements will be approximately the same dur-
tem is cool and the pressure is relieved. ing assembly.

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

member. See Figure 16.

19
Mast Repair 4000 SRM 522

8. Slide the intermediate mast weldment from the

WARNING bottom of the outer mast weldment approxi-
The mast is heavy. The mast can weigh ap- mately 30 cm (12 in.). Remove the strip bearings
proximately 681 kg (1501 lb). Make sure all lift- at the top of the outer mast weldment. Remove
ing devices (hoists, cables, chains, slings, etc.) the snap rings and load rollers from both weld-
are suitable and of adequate capacity to lift the ments. Make a note of each shim arrangement
mast. and load roller location. The shim arrangements
will be approximately the same during assembly.
5. Slide the inner mast weldment halfway out of
the top of the intermediate mast weldment. Con-
nect a crane with a capacity of at least 681 kg WARNING
(1501 lb) to the center of the inner mast weld- The mast is heavy. The mast can weigh ap-
ment. See Figure 15. Slide the inner mast weld- proximately 681 kg (1501 lb). Make sure all lift-
ment out of the intermediate mast weldment un- ing devices (hoists, cables, chains, slings, etc.)
til the stub shafts are in the notches of the inter- are suitable and of adequate capacity to lift the
mediate mast weldment. Remove the inner mast mast.
weldment from the intermediate mast weldment.
9. Slide the intermediate mast weldment halfway
out of the top of the outer mast weldment. Con-
WARNING nect a crane with a capacity of at least 681 kg
Be careful when removing or installing snap (1501 lb) to the center of the intermediate mast
rings. These snap rings can come loose dur- weldment. See Figure 15. Slide the intermedi-
ing removal or installation with enough force ate mast weldment out of the outer mast weld-
to cause an injury. Always use the correct snap ment until the stub shafts are in the notches of
ring pliers, and wear eye and face protection the outer mast weldment. Remove the interme-
during removal or installation. diate mast weldment from the outer mast weld-
ment.
6. Remove the snap rings and washers at the top of
the main lift cylinders. Remove the nut, bolt, and 10. Disassemble the chain sheaves as necessary for
spacer at the mount near the top of each main lift repair and cleaning. Remove the hydraulic lines
cylinder. and fittings from the weldments as necessary.
7. Push the intermediate mast weldment to disen-
gage the main lift cylinders. Remove the main
lift cylinders.

20
4000 SRM 522 Mast Repair

Figure 16. Three-Stage, Full Free-Lift Mast (Sheet 1 of 2)

21
Mast Repair 4000 SRM 522

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

(E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z) (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 12. SPRING 20. CHAIN ANCHOR
2. LOAD ROLLER 13. LOWERING CONTROL VALVE 21. INNER MAST WELDMENT
3. SHIM (INTERNAL) 22. FREE-LIFT CYLINDER
4. SNAP RING 14. HOUSING 23. CYLINDER BRACKET
5. O-RING 15. LOWERING CONTROL VALVE 24. CAPSCREW
6. SHIM(S) (EXTERNAL) 25. SPACER
7. STRIP BEARING 16. CHAIN SHEAVE 26. NUT
8. WASHER 17. INTERMEDIATE MAST 27. HOSE
9. MAIN LIFT CYLINDER WELDMENT 28. FLOW CONTROL FITTING
10. LIFT CHAIN 18. FREE-LIFT CYLINDER TUBE
11. STAR WASHER 19. HOSE SHEAVE

Figure 16. Three-Stage, Full Free-Lift Mast (Sheet 2 of 2)

22
4000 SRM 522 Mast Repair

Mast and Chains, Clean and Inspect 5. Clean the mast weldments with steam or solvent.

1. Inspect the chain sheaves and load rollers for

wear or damage. Do NOT use steam to clean the
lift chains, sheaves, or load rollers. The bearings
in the sheaves and load rollers are sealed and lu-
bricated.

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

2. Clean the lift chains with solvent. Remove all

dirt and grease. Inspect the lift chains for wear
or damage. The lift chains must be installed in
the mast and the mast must be installed on the
lift truck before they can be checked for correct
length.

Pitch Total length Wear Limit

WARNING
of 20 links The maximum
Never replace only the worn section of a chain.
(pitch) length of 20
Replace the complete chain. Never replace
of new chain links
only one chain of a chain pair. Replace both
chains. 12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
3. A lift chain becomes longer when it is worn. If
15.9 mm 317.5 mm 327.0 mm
a chain is 3% longer than a new lift chain, the
(0.63 in.) (12.5 in.) (12.9 in.)
lift chain must be replaced. If a chain scale is
19.1 mm 381.0 mm 392.4 mm
available, check the lift chain as shown in Fig-
(0.75 in.) (15.0 in.) (15.4 in.)
ure 17. If a chain scale is not available, measure
25.4 mm 508.0 mm 523.3 mm
20 links of the lift chain. Compare the measure-
(1.00 in.) (20.0 in.) (20.6 in.)
ment with the lengths given in Figure 17. Lubri-
cate the chains with SAE 30 engine oil. The best
procedure is to soak them in engine oil. NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
4. Inspect the chain anchors and pins. Replace any SCALE.
parts that are worn or damaged.
1. CHAIN WEAR SCALE

WARNING Figure 17. Lift Chains Check

Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective cloth- WARNING
ing, gloves, and eye protection. Never expose Incorrect welding procedures can damage the
your skin to steam. structure of the mast or cause wrong operation
of the mast. Obtain information from your Hys-
WARNING ter lift truck dealer before welding on the mast.
Cleaning solvents may be flammable and toxic
6. Inspect the sliding surfaces for wear or damage.
and can cause severe skin irritation. When
Inspect the load roller contact surfaces for wear
using cleaning solvents, always follow the
or damage. Inspect all welds for cracks.
solvent manufacturer’s recommended safety
precautions.

23
Mast Repair 4000 SRM 522

TWO-STAGE LFL AND TWO-STAGE FFL 3. Install the load rollers and shims on both weld-
MAST, ASSEMBLE ments. Check the clearance of the load rollers as
described in Carriage Adjustment.
WARNING 4. To install the main lift cylinders on the two-stage
The mast is heavy. The mast can weigh ap- LFL mast, push the inner mast weldment to en-
proximately 681 kg (1501 lb). Make sure all lift- gage the rods of the lift cylinders. Install the
ing devices (hoists, cables, chains, slings, etc.) washer and snap ring.
are suitable and of adequate capacity to lift the
mast. NOTE: The clearance check and adjustment in either
procedure for Step 5 is only an initial setup. The
NOTE: The shims for the load rollers keep the final check and adjustment is done after the mast is
mast weldments parallel and give correct clearance. installed on the lift truck.
During assembly, the shim arrangement will be ap-
proximately the same as before disassembly. Check 5. To install the main lift cylinders on the two-stage
the clearance and adjust the shims for wear or for FFL mast, perform the following procedure:
changes caused by repairs. The strip bearings are
a. H/S2.00-3.20XM (H/S40-65XM), E2.00-
also adjusted by using shims. See Carriage Adjust-
3.20XM (E40-65XM, E40-65XM 2) (F108),
ment in this section for the adjustment procedures.
E2.00-3.20XM (E40-65Z) (G108), J2.00-
NOTE: When the mast has header hoses, see the pro- 3.20XM (J40-60XM, J40-60XM 2) (A216),
cedures for Header Hose Arrangements. J2.00-3.20XM (J40-60Z) (A416), and
S/E/J2.00-3.00XL (S/E/J40-60XL),: Install
1. Connect a crane with a capacity of at least 681 kg the washers at the top of the right-hand
(1501 lb) to the center of the inner mast weld- cylinder. Push the inner mast weldment to
ment. Fit the stub shafts through the notches in engage the rods of the lift cylinders. Check
the outer mast weldment. Slide the inner mast the clearance at the top of the lift cylinder
weldment into the outer mast weldment so the mounts. Add or remove washers at the
stub shafts are seen at the top and bottom of the right-hand cylinder until it is even with the
weldments. See Figure 13 and Figure 14. left-hand cylinder. Install the snap ring at
the top of the right-hand lift cylinder. Install
2. Install the strip bearings and the shims on the the hydraulic fitting on the left-hand cylin-
outer mast weldment. See Figure 18. Apply der.
chassis lube to the bearing surface. Check the
clearance of the strip bearings as described in b. H/S1.50-2.00XMS (H/S25-40XMS), E1.50-
Carriage Adjustment. 2.00XMS (E25-40XMS, E25-40XM 2S (D114),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
J1.60-2.00XMT (J30-40XMT): Install the
washers at the top of the left-hand cylinder.
Push the inner mast weldment to engage the
rods of the lift cylinders. Check the clearance
at the top of the lift cylinder mounts. Add
or remove washers at the left-hand cylinder
until it is even with the right-hand cylin-
der. Install the snap ring at the top of the
left-hand lift cylinder. Install the hydraulic
fitting on the right-hand cylinder.

6. Install the spacers, nuts, and bolts at the mounts

for the lift cylinders. Tighten the bolts to 53 N•m
(39 lbf ft).

Figure 18. Strip Bearings 7. Install the housing for the lowering control valve
on the outer mast weldment. Tighten the nuts for
the lowering control valve to 18 N•m (13 lbf ft).
Install the lowering control valve in the housing.

24
4000 SRM 522 Mast Repair

Connect the hydraulic lines and fittings between weldment so the stub shafts are seen at the top
the lowering control valve and the main lift cylin- and bottom of both weldments.
ders.
NOTE: The load rollers must be in place before strip
8. On the two-stage LFL mast, install the chain bearing can be shimmed.
sheaves at the inner mast weldment. On the
H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM 2. Install the strip bearings and the shims on the
(E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM channels of the outer mast weldment. See Fig-
(E40-65Z) (G108), J2.00-3.20XM (J40-60XM, ure 18. Apply chassis lube to the bearing sur-
J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z) faces. Check the clearance of the strip bearings
(A416), and S/E/J2.00-3.00XL (S/E/J40-60XL), as described in Carriage Adjustment.
be sure to install both pins that hold the shaft
3. Install the load rollers and the shims on the
for the chain sheave in position. Connect the
outer mast weldment and at the bottom of the
lift chains to the chain anchors at the main lift
intermediate mast weldment. Before doing the
cylinder mounts. Attach wires between the ends
next step, adjust the intermediate mast weld-
of the lift chains and the crossmember to control
ment and check the clearance of the load rollers
the lift chains during mast installation.
as described in Carriage Adjustment.
9. On the two-stage FFL mast:
NOTE: The clearance check and adjustment in Step 4
a. Install the free-lift cylinder in the mounts on is only an initial setup. The final check and adjust-
the inner mast weldment. Install the brack- ment is done after the mast is installed on the lift
ets for the cylinder and tighten the bolts to truck.
53 N•m (39 lbf ft).
4. Install the main lift cylinders. Push the interme-
b. Install the tubing or hoses that connect the diate mast weldment to engage the lift cylinders.
free-lift cylinder to the main lift cylinder. Check the clearance at the top of the lift cylin-
der mounts. Add or remove washers at the top of
c. Connect the free-lift chains to the chain an- the cylinder rods until they are even. Install the
chors at the crossmember. Attach a wire be- snap ring and washer at the top of the lift cylin-
tween the end of the lift chain and the bottom ders.
of the mast to control the lift chain during in-
stallation. 5. Install the housing for the lowering control valve
on the outer mast weldment. Tighten the nuts for
THREE-STAGE FFL MAST, ASSEMBLE the lowering control valve to 18 N•m (13 lbf ft).
Install the lowering control valve in the housing.
NOTE: The shims for the load rollers keep the weld- Connect the hydraulic lines and fittings between
ments parallel and give correct clearance. During as- the lowering control valve and the main lift cylin-
sembly, the shim arrangement will be approximately ders.
the same as before disassembly. Check the clearance
and adjust the shims for wear or for changes caused 6. Install the chain sheaves at the intermedi-
by repairs. The strip bearings are also adjusted by ate mast weldment. On the H/S2.00-3.20XM
using shims. See Carriage Adjustment in this sec- (H/S40-65XM), E2.00-3.20XM (E40-65XM,
tion for the adjustment procedures. E40-65XM 2) (F108), E2.00-3.20XM (E40-65Z)
(G108), J2.00-3.20XM (J40-60XM, J40-60XM 2)
NOTE: When the mast has header hoses, see the pro- (A216), J2.00-3.20XM (J40-60Z) (A416),
cedures for Header Hose Arrangements. S/E/J2.00-3.00XL (S/E/J40-60XL), be sure to
install both pins that hold the shaft for the chain
1. Put the outer mast weldment on the floor with sheave in position.
the mast pivots toward the floor. See Figure 16.
Connect a crane with a capacity of at least 681 kg 7. Install the spacers, washers, nuts, and bolts at
(1501 lb) to the center of the intermediate mast the mounts for the main lift cylinders. Tighten
weldment. Fit the lower stub shafts of the inter- the bolts to 53 N•m (39 lbf ft).
mediate mast weldment into the notches in the
top of the outer mast weldment. Slide the in-
termediate mast weldment into the outer mast

25
Mast Repair 4000 SRM 522

8. Connect a crane with a capacity of at least 681 kg them into the mounts on the mast. On the
(1501 lb) to the center of the inner mast weld- J1.60-2.00XMT (J30-40ZT) lubricate the bush-
ment. Slide the inner mast weldment into the in- ings with chassis lube and install them onto
termediate mast weldment so the stub shafts are the stub shafts at the bottom of the outer mast
seen at the top and bottom of both weldments. weldment.

NOTE: The load rollers must be in place before bear-

ing strips can be shimmed.
WARNING
The mast is heavy. The mast can weigh approx-
9. Install the strip bearings and the shims on the imately 1600 kg (3527 lb). Make sure all lift-
channels of the intermediate mast weldment. ing devices (hoists, cables, chains, slings, etc.)
Apply chassis lube to the bearing surfaces. are suitable and of adequate capacity to lift the
Install the load rollers and the shims on the mast.
intermediate and inner mast weldments. Before
doing the next step, adjust the inner mast weld- CAUTION
ment as described in Carriage Adjustment.
Make sure the chains will not damage the
10. Connect the main lift chains to the chain anchors sheaves, tubing, or other parts of the mast.
at the main lift cylinder mounts. Put the lift
2. Connect a crane with a capacity of at least
chains over the chain sheaves and connect them
1600 kg (3527 lb) to the top of the mast using
to the anchors at the bottom of the inner mast
chains. Make sure all the mast weldments are
weldment.
fastened together. Make sure the chains will not
11. Install the free-lift cylinder in the mounts on damage the sheaves, tubing, or other parts of
the inner mast weldment. Install the brackets the mast.
for the cylinder and tighten the nuts to 38 N•m
3. Use the crane to install the mast assembly:
(28 lbf ft). On the three-stage FFL mast, the
nuts are installed on the bracket side of the a. On the H/S2.00-3.20XM (H/S40-65XM),
free-lift cylinder. E2.00-3.20XM (E40-65XM, E40-65XM 2)
(F108), E2.00-3.20XM (E40-65Z) (G108),
12. Install the hose sheave for the free-lift cylinder.
J2.00-3.20XM (J40-60XM, J40-60XM 2)
Tighten the capscrew for the hose sheave to
(A216), and J2.00-3.20XM (J40-60Z) (A416),
66 N•m (49 lbf ft). Install the hydraulic hose
install the mast on the pivot pins. Install
and tubing for the free-lift cylinder.
the capscrews that hold the mast to the pivot
13. Connect the free-lift chains to the chain anchors pins. Tighten the capscrews to 130 N•m
at the crossmember. Attach a wire between the (96 lbf ft).
end of the lift chain and the bottom of the mast
b. On the H/S1.50-1.75XM, H/S2.00XMS
to control the lift chain during mast installation.
(H/S25-35XM, H/S40XMS), E1.50-1.75XM
(E25-35XM, E25-35XM 2) (D114), E2.00XMS
INSTALL
(40XMS, 40XM SS) (D114), E1.50-2.00XM
1. On the H/S2.00-3.20XM (H/S40-65XM), (E25-35Z, E40ZS) (E114), S/E/J2.00-3.00XL
E2.00-3.20XM (E40-65XM, E40-65XM 2) (S/E/J40-60XL), and J1.60-2.00XMT
(F108), E2.00-3.20XM (E40-65Z) (G108), (J30-40XMT), install the mast on the drive
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), axle. Install the capscrews and bushings
and J2.00-3.20XM (J40-60Z) (A416), lubricate that hold the retainer caps and mast assem-
the pivot pins with chassis lube and install them bly to the drive axle. Tighten the capscrews
into the mounts at the drive axle hanger. On the to 90 N•m (66 lbf ft).
H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM,
c. On the J1.60-2.00XMT (J30-40ZT), install
H/S40XMS), E1.50-1.75XM (E25-35XM,
the mast into the transmission housing
E25-35XM 2) (D114), E2.00XMS (E40XMS,
mounts. Apply HCE-92 adhesive sealant
E40XM 2S) (D114), E1.50-2.00XM (E25-35Z,
(Loctite ™ #290) to capscrew threads. In-
E40ZS) (E114), J1.60-2.00XMT (J30-40XMT);
stall the capscrews, bushing, and retainer
and S/E/J2.00-3.00XL (S/E/J40-60XL), lubri-
cate the bushings with chassis lube and install

26
4000 SRM 522 Lift Cylinders Repair

caps. Tighten the capscrews to 34.8 N•m shown in Figure 19. Apply chassis lube only to
(25.7 lbf ft). the surfaces indicated.

NOTE: Lubricate the anchor pins with chassis grease

before installation.

4. Connect the tilt cylinders to the mast. Install

the anchor pins and/or cotter pins, washers, or
capscrews.

5. Connect the hydraulic line to the lowering control

valve.

6. Install the carriage as described in Carriages Re-

pair.

7. Check the tilt cylinder adjustment as described

in Carriage Adjustment. Operate the mast and
A. UPPER LOAD ROLLERS
check for leaks and correct operation. Check the B. LOWER LOAD ROLLERS
lift chains as described in Carriage Adjustment.
1. LUBRICATE STRIP BEARINGS SURFACES
NOTE: The load rollers and sheaves have sealed bear- WITH CHASSIS LUBE
ings and do not need additional lubrication. 2. LUBRICATE LOAD ROLLER SURFACES WITH
CHASSIS LUBE
8. Lubricate the sliding surfaces and the load roller 3. LOAD ROLLER
surfaces along the full length of the channels as
Figure 19. Mast Lubrication

Lift Cylinders Repair

MAIN LIFT CYLINDERS, REMOVE WARNING
Be careful when removing or installing snap
WARNING rings. These snap rings can come loose dur-
Before working on or near the mast, see Safety ing removal or installation with enough force
Procedures When Working Near Mast in this to cause an injury. Always use the correct snap
section. ring pliers, and wear eye and face protection
during removal or installation.
NOTE: The following procedures are for the removal
of the lift cylinders with the mast installed on the lift 3. Remove the snap ring or fitting at the top of the
truck. lift cylinder that needs to be removed.

1. Remove the carriage as described in the proce-

dures for Carriages Repair. See Figure 13, Fig-
WARNING
ure 14, and Figure 16. Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
2. Raise the mast until it is almost fully extended. draulic hoses until the oil in the system is cool.
Use safety chains to connect the bottom cross-
member of the inner mast weldment (two-stage) 4. Put a drain pan under the area of the hydraulic
or intermediate mast weldment (three-stage) to fittings. Disconnect the hydraulic line at the
the top crossmember of the outer mast weldment. cylinder. Retract the rod into the lift cylinder.
On the three-stage mast, use a safety chain to
5. Remove the nut, bolt, and spacer at the mount.
connect the bottom crossmember to a crossmem-
Disconnect the main lift chain at the mount.
ber on the intermediate or outer mast weldment.
Lower the mast so the safety chains hold the 6. Remove the lift cylinder from the front of the
weight of the weldments. mast. Use a lifting device as necessary.

27
Lift Cylinders Repair 4000 SRM 522

FREE-LIFT CYLINDER, REMOVE 4. Remove the crosshead from the cylinder rod. See
Figure 20. Disassemble the crosshead as neces-
1. Remove the carriage as described in the proce- sary.
dures for Carriages Repair. Lower the mast com-
pletely. See Figure 14 and Figure 16. LIFT CYLINDERS, DISASSEMBLE

WARNING CAUTION
Hydraulic oil is hot after system operation and Carefully disassemble the lift cylinders so the
can cause burns. Do not disconnect any hy- piston rods and sliding surfaces are not dam-
draulic hoses until the oil in the system is cool. aged.
2. Put a drain pan under the area of the hydraulic NOTE: Disassembly of the main lift cylinders and the
fittings. Disconnect the hydraulic line at the free-lift cylinder is similar, but all cylinders cannot be
cylinder. completely disassembled. All of the lift cylinders are
disassembled from the rod end of the cylinder shell.
3. Remove the brackets for the free-lift cylinder. Re-
move the free-lift cylinder. 1. Loosen the retainer with a spanner wrench. Re-
move the retainer from the shell. See Figure 21,
Figure 22, Figure 23, and Figure 24.

2. Pull the rod and piston assembly from the shell.

Drain the hydraulic oil into a container.

3. Remove the retainer from the piston rod. Re-

move and discard the O-rings, seals, and wear
rings.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal or installation.

4. Remove the snap ring, washer, and check valve

from the base of the piston.
NOTE: THE SPACERS ARE ONLY INSTALLED
ON EARLIER H/S2.00-3.20XM (H/S40-65XM), 5. Clean all the parts. Check the sliding surfaces
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), for damage. Repair or replace any damaged
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), AND parts.
S/E/J2.00-3.00XL (S/E/J40-60XL), MODELS. MAKE
A NOTE OF THE NUMBER OF SPACERS IN EACH
LOCATION.
1. LIFT CHAIN 6. BEARING
2. CHAIN SHEAVE 7. PIN
3. CHAIN GUARD 8. FREE-LIFT
4. SNAP RING CYLINDER
5. CROSSHEAD 9. SPACER

Figure 20. Crosshead Assembly, Two-Stage and

Three-Stage FFL Mast

28
4000 SRM 522 Lift Cylinders Repair

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

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

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

(G108), J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.00XM (J40-60Z) (A416), AND S/E/J2.00-3.00XL
(S/E/J40-60XL),

Figure 21. Main Lift Cylinders, Two-Stage Full Free-Lift Mast

29
Lift Cylinders Repair 4000 SRM 522

1. SHELL 9. BACKUP RING

2. SNAP RING 10. ROD
3. WASHER 11. SPACER
4. O-RING 12. O-RING
5. CHECK VALVE 13. WEAR RING
6. PISTON RING 14. RETAINER
(THREE-STAGE 15. SEAL
FFL ONLY) 16. BACKUP RING
7. WEAR RING 17. WIPER
8. SEAL

Figure 22. Main Lift Cylinders, Two-Stage 1. WIPER 8. PISTON SEAL

2. ROD SEAT 9. WEAR RING
Limited Free-Lift and Three-Stage Full 3. RETAINER 10. CHECK VALVE
Free-Lift Mast for H/S1.50-1.75XM, H/S2.00XMS 4. O-RING 11. WASHER
(H/S25-35XM, H/S40XMS), E1.50-1.75XM 5. SPACER 12. SNAP RING
(E25-35XM, E25-35XM 2) (D114), E2.00XMS 6. ROD AND PISTON 13. SHELL
(E40XMS, E40XM 2S) (D114), and E1.50-2.00XM 7. BACKUP RING
(E25-35Z, E40ZS) (E114) Figure 23. Main Lift Cylinders, Two-Stage
Limited Free-Lift and Three-Stage Full
Free-Lift Mast

30
4000 SRM 522 Lift Cylinders Repair

LIFT CYLINDERS, ASSEMBLE washer and the spring are installed correctly. A
wrong installation can cause the load to lower too
fast.
CAUTION
The correct screw and washer must be used
in this location. The wrong parts will cause
leaks or damage the cylinder. See your HYS-
TER lift truck dealer for the correct parts. See
Figure 21 and Figure 24.

1. Lubricate all internal parts of the lift cylinder

with clean hydraulic oil or packing lubricant,
Hyster Part No. 186061. Use new O-rings, seals,
and wear rings.

2. Install the check valve and O-ring in the base of

the piston. Make sure the arrow on the check
valve is toward the base of the piston. Install the
washer and snap ring for the check valve.

CAUTION
A difficult and important step in assembling
lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused
by seal leaks. Do not damage any parts during
assembly.

3. Install the wear ring, piston seal, and backup

ring on to the piston assembly. If a spacer is used,
install it.

4. Carefully push the piston and rod assembly into

the shell.

5. Install the rod seal ring and wiper into the re-
tainer. Install the O-ring and backup ring on the
outside of the retainer.

6. Carefully install the retainer on the piston rod.

1. WIPER 9. WEAR RING
7. Free-lift cylinder only. Remove screw and 2. ROD SEAL 10. SCREW
sealing washer. Pour 150 cc (5 oz) of hydraulic 3. RETAINER 11. SEALING WASHER
oil into the cylinder through the hole. This oil 4. BACKUP RING 12. CHECK VALVE
provides a hydraulic cushion when the cylinder 5. O-RING 13. SHELL
6. ROD AND PISTON 14. WASHER
reaches the top of its stroke. 7. BACKUP RING 15. SNAP RING
8. PISTON SEAL
8. Engage the threads and turn the retainer in the
shell until it is tight. Use the correct spanner. Do Figure 24. Free-Lift Cylinder, Two-Stage Full
NOT hit the retainer with a hammer and driver. Free-Lift and Three-Stage Full Free-Lift Mast
9. Install the lowering control valve. See Figure 13,
Figure 14, and Figure 16. Make sure the special

31
Lift Cylinders Repair 4000 SRM 522

MAIN LIFT CYLINDERS, INSTALL a. Loosen the screws two turns to permit oil to
flow around the threads of the screw.
1. Use a crane with a capacity of at least 1600 kg
(3527 lb) to raise the mast until it is almost fully b. With the forks unloaded and the engine
extended. Use safety chains to connect the bot- speed at idle, raise the carriage using the hy-
tom crossmember of the inner mast weldment draulic control. Raise the carriage 300 mm
(two-stage) or intermediate mast weldment (12 in.) and then stop for ten seconds to
(three-stage) to the top crossmember of the outer reduce the pressure in the cylinder. Repeat
mast weldment. Lower the mast so the safety this procedure until the oil flowing from
chains hold the weight of the weldments. See around the threads is free of air bubbles.
Figure 13, Figure 14, and Figure 16.
c. Stop the carriage at the top of the cylinder
2. Install the lift cylinder in the mount at the bot- stroke. Tighten the screws.
tom of the outer mast weldment. Install the nut,
bolt, and spacer at the mount for the lift cylinder. FREE-LIFT CYLINDER, INSTALL
3. Use a lifting device to lower the inner mast weld- 1. Install the crosshead assembly on the cylinder
ment (two-stage) or intermediate mast weldment rod. Tighten the capscrews for the chain guards
(three-stage) on to the lift cylinder. Install the to 66 N•m (49 lbf ft). See Figure 14, Figure 16,
washers and snap ring at the top of the lift cylin- Figure 20, and Figure 24.
der. See Two-Stage LFL and Two-Stage FFL
Mast, Assemble and Three-Stage FFL Mast, 2. Install the cylinder in the mounts. Install
Assemble procedures for the correct adjustment the brackets and tighten the bolts to 53 N•m
of the lift cylinders. (39 lbf ft). On the three-stage FFL mast, the nuts
are installed on the bracket side of the free-lift
4. Connect the hydraulic line at the base of the lift cylinder. Tighten the nuts to 38 N•m (28 lbf ft).
cylinder. Connect the hydraulic line at the top of
the left-hand main lift cylinder on the full free-lift 3. Connect the hydraulic line at the cylinder.
mast.
4. Install the carriage as described in the proce-
5. Connect the main lift chains as necessary and dures for the Carriages Repair.
adjust them as specified in Carriage Adjustment.

6. Remove the air from the cylinders on the two-

stage FFL. See Figure 21.

32
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 25.
E2.00-3.20XM (E40-65Z) (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)
60Z) (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 25.
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 25.
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 26.
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 27 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 carriage height must be correct before the mast. See Safety Procedures When Working
header hoses can be adjusted. See Lift Chains Ad- Near Mast in this section for additional proce-
justment for the carriage adjustment procedure. dures for the installation of safety chains.

1. Mark each hose with a single letter: A, B, C, or

D.

33
Header Hose Arrangements 4000 SRM 522

Figure 25. Header Hose Measurement, Two-Stage Limited Free-Lift Mast

34
4000 SRM 522 Header Hose Arrangements

Legend for Figure 25

* 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 (E40-65Z) (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

35
Header Hose Arrangements 4000 SRM 522

Figure 26. Header Hoses, Two-Stage Limited Free-Lift Mast

36
4000 SRM 522 Header Hose Arrangements

Legend for Figure 26

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. SPECIAL WASHER 7. COWL HOSES
2. HOSE SHEAVE 8. BOTTOM CLAMP
3. HOSE GUARD 9. HEADER HOSES
4. WASHER 10. BRACKET, UPPER
5. CAPSCREW 11. BRACKET, CARRIAGE
6. CLAMP (TOP OF LIFT CYLINDER) 12. CLAMPS

1. HOOK 2. SHACKLE

Figure 27. Safety Chain Installation, Two-Stage Limited Free-Lift Mast

37
Header Hose Arrangements 4000 SRM 522

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: 1. Loosen the clamps and pull (if the hoses are
loose) or push (if the hoses are tight) on the
a. Put the mast in a vertical position.
hoses so that they move 30 mm (1.2 in.). Tighten
b. Raise the carriage approximately 300 mm the hardware to 8 N•m (71 lbf in). See Figure 25,
(12 in.). Figure 26, and Figure 27.

c. Use a 3/8 inch minimum safety chain with a 2. With no load on the forks, check the header hose
hook. Attach one end of the chain around all adjustment by operating the mast through the
the top crossmembers. Make sure the hook is full lift cycle two times. When properly adjusted,
completely engaged with a link in the chain. the hoses will not be so tight that they compress
when they pass over the sheaves nor will they be
d. Attach a shackle to the lifting eye on the car- so loose that they touch the load backrest or any
riage. Install the chain through the shackle. crossmember that is next to a sheave. If neces-
Make sure the hook is completely engaged sary, repeat Step 1 until the hoses are properly
with a link in the chain. Make sure the adjusted.
safety chain does not touch lift chains, chain
sheaves, tubes, hoses, fittings, or other parts
of the mast.

38
4000 SRM 522 Header Hose Arrangements

TWO-STAGE FFL MAST, NEW HOSE 7. Put the clamps over the hoses and attach the
INSTALL clamps to the lower bracket (do NOT tighten the
hardware).
WARNING NOTE: To make the alignment of dimension E easier,
Before working on or near the mast, see Safety use a crane with a capacity of at least 908 kg (2002 lb)
Procedures When Working Near Mast in this to raise the carriage high enough to install a safety
section. chain.
NOTE: This procedure is for the four-function option. 8. Align mark E at the bottom of the clamp. Tighten
The three-function option will have hoses A and B the hardware to 8 N•m (71 lbf in).
only.
9. Install the hose guards at the free-lift crosshead.
NOTE: The carriage height must be correct before the Tighten the capscrews that mount the guards to
header hoses can be adjusted. See Lift Chains Ad- 66 N•m (49 lbf ft).
justment for the carriage adjustment procedure.
NOTE: The proper hose alignment is shown in Fig-
1. Mark each hose with a single letter: A, B, C, or ure 30.
D.
10. Apply a spray lubricant onto the hoses in the area
2. Use a calculator to calculate dimension E. See that will contact the channels. Make sure the
Figure 28. hoses are properly aligned in the channels. Put
the clamps over the hoses and attach the clamps
3. Clamp the end of the hose (the smaller fitting) to the channels. Tighten the hardware to 8 N•m
that attaches to the carriage in a vise (do NOT (71 lbf in). See Figure 30.
clamp on the threads), pull on the other end until
the hose is straight. Do NOT apply enough force 11. Connect the header hoses (10, C, and D) to the
to stretch the hose. See Figure 28. cowl hoses. Connect the header hoses (10, A, and
B) to the tubes.
4. Mark the hoses with dimension E [all measure-
ments are made from the carriage end of the hose 12. Use the rubber clamps and strap clamps to at-
(the smaller fitting)]. See Figure 28. tach the hoses to the main lift cylinders. Make
sure the cowl hoses do not stretch or fold while
5. Attach the hoses to the carriage bracket with tilting the mast fully forward and backward.
clamp. See Figure 29.

6. Put the header hoses over the free-lift chains.

39
Header Hose Arrangements 4000 SRM 522

Figure 28. Header Hose Measurement, Two-Stage Full Free-Lift Mast

40
4000 SRM 522 Header Hose Arrangements

Legend for Figure 28

* Metric Formulas (All Dimensions are in Millimeters)

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
Step 3. Dimension E = 3284.7 + 303
Step 4. Dimension E = 3587.7
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
Dimension G (3 Function) for Lift Heights of 3082 mm to 5482 mm:
(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
Dimension G (4 Function) for Lift Heights of 3082 mm to 5482 mm:
(1.991 × Y) + (0.985 × Z) 1046

* Inch Formulas (All Dimensions are in Inches)

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
Step 4. Dimension E = 141.34
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4
(1.982 × Y) + (0.985 × Z) 31.531
Dimension G (3 Function) for Lift Heights of 121.3 to 215.8
(1.991 × Y) + (0.985 × Z) 36.125
Dimension G (4 Function) for Lift Heights of 97.7 to 117.4
(1.982 × Y) + (0.985 × Z) 34.156
Dimension G (4 Function) for Lift Heights of 121.3 to 218.8
(1.991 × Y) + (0.985 × Z) 41.156
*All measurements are made with mast vertical and fully lowered.

41
Header Hose Arrangements 4000 SRM 522

Legend for Figure 28 (Continued)

* Metric Formulas (All Dimensions are in Millimeters)

Class III Mast Type
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.
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2360 mm to 2960 mm:
(1.981 × Y) + (0.985 × Z) 851
Dimension G (3 Function) for Lift Heights of 3060 mm 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
Dimension G (4 Function) for Lift Heights of 3060 mm to 5360 mm:
(1.991 × Y) + (0.985 × Z) 1100

* Inch Formulas (All Dimensions are in Inches)

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.
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 92.9 to 116.5
(1.981 × Y) + (0.985 × Z) 33.500
Dimension G (3 Function) for Lift Heights of 120.5 to 211.0
(1.991 × Y) + (0.985 × Z) 38.281
Dimension G (4 Function) for Lift Heights of 92.9 to 116.5
(1.981 × Y) + (0.985 × Z) 36.156
Dimension G (4 Function) for Lift Heights of 120.5 to 211.0
(1.991 × Y) + (0.985 × Z) 43.312
*All measurements are made with mast vertical and fully lowered.

1. DIMENSION G 5. HOSE
2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. TOP OUTER CHANNEL

42
4000 SRM 522 Header Hose Arrangements

NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE CHANNEL 8. TUBE 15. BOTTOM CLAMP 21. STUBSHAFT
2. COWL HOSES 9. FITTING 16. HOSE GUIDE 22. SHEAVE
3. HEADER HOSES 10. CLAMP 17. SNAP RING 23. WASHER
4. STRAP CLAMP 11. BRACKET 18. CAPSCREW 24. WASHER
5. CLAMP 12. LOWER BRACKET (THREE-FUNCTION) 25. NUT
6. CLAMP 13. CAPSCREW 19. CAPSCREW
7. FITTING 14. CARRIAGE (FOUR-FUNCTION)
BRACKET 20. HOSE GUARD

Figure 29. Header Hoses, Two-Stage Full Free-Lift Mast

43
Header Hose Arrangements 4000 SRM 522

Figure 30. Header Hose Alignment, Two-Stage Full Free-Lift Mast

44
4000 SRM 522 Header Hose Arrangements

13. With no load on the forks, operate the mast NOTE: The carriage height must be correct before the
through the full lift cycle two times. With the header hoses can be adjusted. See Lift Chains Ad-
mast at full lift height, attach clamp at the bot- justment for the carriage adjustment procedure.
tom of the hose loop on the third and/or fourth
function hoses. This action allows the hoses to 1. Mark each hose with a single letter: A, B, C, or
fit properly in the hose channel. D.

14. With no load on the forks, check the header hose 2. Use a calculator to calculate the dimensions E
adjustment by operating the mast through the and G. See Figure 31.
full lift cycle two times. When properly adjusted,
3. Clamp the end of the hose (the smaller fitting)
the hoses will not be so tight that they compress
that attaches to the carriage in a vise (do NOT
when they pass over the sheaves nor will they
clamp on the threads), pull on the other end until
be so loose that they touch the load backrest or
the hose is straight. Do NOT apply enough force
any crossmember that is next to a sheave. If the
to stretch the hose. See Figure 31.
hoses require additional adjustment, see Two-
Stage FFL Mast, Adjust Hoses After Installation. 4. Mark all the hoses with dimensions E and G (all
measurements are made from the carriage end of
TWO-STAGE FFL MAST, ADJUST HOSES the hose [the smaller fitting]). See Figure 31.
AFTER INSTALLATION
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 32.
hoses so that they move 15 mm (0.6 in.). Tighten
the hardware to 8 N•m (71 lbf in). See Figure 28, NOTE: The hoses cross each other in two locations.
Figure 29, Figure 30, and Figure 34. The proper hose alignment is shown in Figure 33.

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 32 and
full lift cycle two times. When properly adjusted, Figure 33. 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 34 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.

NOTE: This procedure is for the four-function option.

The three-function option will have hoses A and B
only.

45
Header Hose Arrangements 4000 SRM 522

Figure 31. Header Hose Measurement, Three-Stage Full Free-Lift Mast

46
4000 SRM 522 Header Hose Arrangements

Legend for Figure 31

* Metric Formulas (All Dimensions are in Millimeters)

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
Step 4. Dimension E = 5368.0
** 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
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
Dimension G for Lift Heights of 6260 mm to 8510 mm:
(1.965 × Y) + (0.985 × Z) 65

* Inch Formulas (All Dimensions are in Inches)

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
Step 4. Dimension E = 216.42
** For Lift Heights of 146.1 to 240.6. For Lift Heights of 246.5 To 335.0, Use 33.156
Dimension G Calculations are Similar to Dimension E
Dimension G for Lift Heights of 146.1 to 240.6
(1.965 × Y) + (0.985 × Z) 2.562
Dimension G for Lift Heights of 246.5 to 335.0
(1.965 × Y) + (0.985 × Z) 2.562
*All measurements are made with mast vertical and fully lowered.

47
Header Hose Arrangements 4000 SRM 522

Legend for Figure 31 (Continued)

* Metric Formulas (All Dimensions are in Millimeters)

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
II Mast - Metric Formula.
Dimension G Calculations are Similar to Dimension E
Dimension G for Lift Heights of 3518 mm to 5918 mm:
(1.965 × Y) + (0.985 × Z) 65
Dimension G for Lift Heights of 6068 mm to 8318 mm:
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842

* Inch Formulas (All Dimensions are in Inches)

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
Dimension G Calculations are Similar to Dimension E
Dimension G for Lift Heights of 138.5 to 233.0
(1.965 × Y) + (0.985 × Z) 2.562
Dimension G for Lift Heights of 238.9 to 327.5
(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
*All measurements are made with mast vertical and fully lowered.

1. DIMENSION G 5. TOP OUTER CHANNEL

2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. HOSE

48
4000 SRM 522 Header Hose Arrangements

Figure 32. Header Hoses, Three-Stage Full Free-List Mast

49
Header Hose Arrangements 4000 SRM 522

Legend for Figure 32

NOTE: THREE-FUNCTION MAST SHOWN.

1. CAPSCREW 13. LOWER HOSE GUIDE
2. HOSE GUARD 14. NUT
3. SNAP RING 15. BOTTOM CLAMP
4. HOSE GUIDE 16. HEADER HOSES
5. FREE-LIFT CYLINDER CROSSHEAD 17. FREE-LIFT CHAIN
6. WASHER 18. CLAMP
7. SPACER 19. COWL HOSES
8. HOSE SHEAVE 20. UPPER BRACKET
9. HOSE GUARD 21. CARRIAGE BRACKET
10. CLAMP 22. CLAMP
11. LOWER BRACKET 23. STUBSHAFT
12. HOSE RESTRAINT

50
4000 SRM 522 Header Hose Arrangements

Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)

51
Header Hose Arrangements 4000 SRM 522

Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 2 of 3)

52
4000 SRM 522 Header Hose Arrangements

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

Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 3 of 3)

53
Header Hose Arrangements 4000 SRM 522

8. SAFETY CHAIN INSTALLATION WHEN

WARNING THE CARRIAGE IS RAISED:
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or a. Put the mast in a vertical position.
death can result if part of the body is hit by
parts of the mast or the carriage. b. Raise the carriage approximately 300 mm
• Never put any part of the body into or under (12 in.).
the mast or carriage unless all parts are com- c. Use a 3/8 inch minimum safety chain with a
pletely lowered or a safety chain is installed. hook. Attach one end of the chain around all
Also make sure that the power is off, the key the top crossmembers. Make sure the hook is
is removed, and the parking brake is applied. completely engaged with a link in the chain.
Put a DO NOT OPERATE tag in the operator’s
compartment. d. Attach a shackle to the lifting eye on the car-
• Be careful of the forks. When the mast is riage. Install the chain through the shackle.
raised, the forks can be at a height to cause Make sure the hook is completely engaged
an injury. with a link in the chain. Make sure the
• DO NOT climb on the mast or lift truck at any safety chain does not touch lift chains, chain
time. Use a ladder or personnel lift to work sheaves, tubes, hoses, fittings, or other parts
on the mast. of the mast.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement. e. Lower the crane until there is tension in the
• Mast repairs require disassembly and re- safety chain. Make sure both hooks are prop-
moval of parts and can require removal of erly engaged before working on the mast. In-
the mast or carriage. Follow the repair pro- stall a DO NOT REMOVE tag on the safety
cedures in the correct Service Manual for chain.
the mast.

Figure 34. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 1 of 2)

54
4000 SRM 522 Header Hose Arrangements

1. HOOK 2. SHACKLE

Figure 34. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 2 of 2)

9. SAFETY CHAIN INSTALLATION WHEN e. Attach the other end of the chain around
THE INNER CHANNEL IS RAISED: the lower crossmember of the inner channel.
Make sure the hook is completely engaged
a. Put the mast in a vertical position. with a link in the chain.
b. The mast must be full lowered. f. Lower the crane until there is tension in the
safety chain. Make sure both hooks are prop-
c. Attach a crane to the top crossmember of the
erly engaged before working on the mast. In-
inner channel. Raise the inner channel ap-
stall a DO NOT REMOVE tag on the safety
proximately 600 mm (24 in.).
chain.
d. Use a 3/8 inch minimum safety chain with a
10. Align the mark for dimension E at the bottom
hook. Attach one end of the chain around the
of the clamp to create the proper hose tension.
top crossmember of the outer channel. Make
Tighten the hardware to 8 N•m (71 lbf in). In-
sure the hook is completely engaged with a
stall the hose guards. Tighten the capscrews that
link in the chain.
mount the guards to 66 N•m (49 lbf ft).

55
Header Hose Arrangements 4000 SRM 522

11. Position the hoses at the hose sheave. See Fig- any crossmember that is next to a sheave. If the
ure 32 and Figure 33. The hose sheave and hose hoses require additional adjustment, see Three-
guard must be installed on to the hose before they Stage FFL Mast, Adjust Hoses After Installation.
are attached to the mast. Tighten the hardware
to 53 N•m (39 lbf ft). THREE-STAGE FFL MAST, ADJUST
HOSES AFTER INSTALLATION
12. Put the clamps over the hoses and attach the
clamps to the upper brackets. Do NOT tighten 1. If the tension of the hoses is correct between the
the hardware. carriage and the clamp at the lower bracket, go
to Step 2. If the tension of the hoses is not cor-
NOTE: To make the alignment of dimension G easier, rect, loosen the clamps and pull (if the hoses are
use a crane with a capacity of at least 908 kg (2002 lb) loose) or push (if the hoses are tight) on the hoses
to raise the inner channel high enough to install a so that they move 15 mm (0.6 in.). Tighten the
safety chain as shown in Figure 34. hardware to 8 N•m (71 lbf in). See Figure 30,
13. Align mark G on hoses A and D at the bottom Figure 31, Figure 32, and Figure 33.
edge of clamp to create the proper tension. Align 2. If the tension of the hoses is correct between the
mark G on hoses B and C at the top edge of clamp clamp at the upper bracket and the clamp at the
to create the proper tension. Tighten the hard- lower bracket, go to Step 3. If the tension of the
ware to 8 N•m (71 lbf in). hoses is not correct, loosen the clamps and pull
14. Install the hose restraints. (if the hoses are too loose) or push (if the hoses
are too tight) on the hoses so that they move
15. Connect the header hoses to the cowl hoses. 15 mm (0.6 in.) plus the amount the hoses were
moved in Step 1. Tighten the hardware to 8 N•m
16. Use the rubber clamps and strap clamps to at- (71 lbf in).
tach the hoses to the main lift cylinders. Make
sure the hoses do NOT stretch or fold while tilt- 3. With no load on the forks, check the header hose
ing the mast fully forward and backward. adjustment by operating the mast through the
full lift cycle two times. When properly adjusted,
17. With no load on the forks, check the header hose the hoses will not be so tight that they compress
adjustment by operating the mast through the when they pass over the sheaves nor will they be
full lift cycle two times. When properly adjusted, so loose that they touch the load backrest or any
the hoses will not be so tight that they compress crossmember that is next to a sheave. If neces-
when they pass over the sheaves nor will they sary, repeat Step 1 and Step 2 until the hoses are
be so loose that they touch the load backrest or properly adjusted.

56
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 carriage height must be correct before the
J1.60-2.00XMT (J30-40XMT), and J1.60-2.00XMT header hoses can be adjusted. See Lift Chains Ad-
(J30-40ZT) models. justment for the carriage adjustment procedure.

NOTE: Hoses have a service life that is determined by 1. Mark each hose with a single letter: A, B, C, or
application and time. All hoses must be inspected at D. See Figure 27, Figure 35, and Figure 36.
the intervals specified in the Maintenance Sched-
2. Use a calculator to calculate dimension E. See
ule for the hydraulic system. Install a new hose if the
Figure 35.
hose is worn, damaged, soft or hard, and no longer
flexible. If necessary, make a comparison to a new 3. Clamp the end of the hose (the smaller fitting)
hose that is the correct replacement for the hose you that attaches to the carriage in a vise (do NOT
are inspecting. clamp on the threads), and pull on the other end
until the hose is straight. Do NOT apply enough
Some lift trucks have auxiliary hydraulic equipment
force to stretch the hose. See Figure 35.
that is attached to the carriage. Examples of aux-
iliary equipment are a sideshift carriage or a roll 4. Mark all the hoses with dimension E (all mea-
clamp. These auxiliary functions require arrange- surements are made from the carriage end of the
ments of header hoses for their operation. hose [the smaller fitting]). See Figure 35.

TWO-STAGE LFL MAST, NEW HOSE 5. Attach the hoses to the carriage brackets with
INSTALL the clamps. See Figure 36.

6. Place the hoses at the location of the hose sheave.

WARNING The hose sheave and stub shaft must be assem-
Before working on or near the mast, see Safety bled on to the hose before they are attached to
Procedures When Working Near Mast in this the mast. Tighten the mounting hardware to
section. 66 N•m (49 lbf ft).

57
Header Hose Arrangement 4000 SRM 522

Figure 35. Header Hose Measurement, Two-Stage Limited Free-Lift Mast

58
4000 SRM 522 Header Hose Arrangement

Legend for Figure 35

* Metric Formulas (All Dimensions are in Millimeters)

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

* Inch Formulas (All Dimensions are in Inches)

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
Step 3. Dimension E = 84.0
*All measurements are made with mast vertical and fully lowered.

1. DIMENSION E 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE 6. GROUND LEVEL

59
Header Hose Arrangement 4000 SRM 522

Figure 36. Header Hoses, Two-Stage Limited Free-Lift Mast

60
4000 SRM 522 Header Hose Arrangement

Legend for Figure 36

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. HOSES, HEADER 12. NUT
2. CLAMP, STRAP 13. CAPSCREW
3. FITTINGS 14. CLAMP
4. CAPSCREW 15. WASHER
5. BRACKET, CARRIAGE 16. CAPSCREW
6. SPACER 17. CAPSCREW
7. NUT 18. CLAMP
8. BRACKET, UPPER 19. CLAMP
9. STUBSHAFT 20. HOSE, COWL
10. SHEAVE 21. CLAMP
11. WASHER

7. Put the clamps over the hoses and attach the when they pass over the sheaves nor will they be
clamps to the upper brackets. Do NOT tighten so loose that they touch the load backrest or any
the hardware. crossmember that is next to a sheave. If neces-
sary, repeat Step 1 until the hoses are properly
NOTE: To make the alignment of dimension E easier, adjusted.
use a crane with a capacity of at least 908 kg (2002 lb)
to raise the carriage high enough to install a safety TWO-STAGE FFL MAST, NEW HOSE
chain as shown in Figure 27. INSTALL
8. Align mark E at the bottom of the clamps.
Tighten the hardware to 8 N•m (71 lbf in). WARNING
Before working on or near the mast, see Safety
9. Connect the header hoses to the cowl hoses. Procedures When Working Near Mast in this
10. Use the rubber clamps and hose clamps to attach section.
the hoses to the main lift cylinders. Make sure NOTE: This procedure is for the four-function option.
the hoses do NOT stretch or fold while tilting the The three-function option will have hoses A and B
mast fully forward and backward. only.
11. With no load on the forks, check the header hose NOTE: The carriage height must be correct before the
adjustment by operating the mast through the header hoses can be adjusted. See Lift Chains Ad-
full lift cycle two times. When properly adjusted, justment for the carriage adjustment procedure.
the hoses will not be so tight that they compress
when they pass over the sheaves nor will they 1. Mark each hose with a single letter: A, B, C,
be so loose that they touch the load backrest or or D. See Figure 34, Figure 37, Figure 38, and
any crossmember that is next to a sheave. If the Figure 39.
hoses require additional adjustment, see Two-
Stage LFL Mast, Adjust Hoses After Installation. 2. Use a calculator to calculate dimension E. See
Figure 37.
TWO-STAGE LFL MAST, ADJUST HOSES
3. Clamp the end of the hose (the smaller fitting)
AFTER INSTALLATION that attaches to the carriage in a vise (do NOT
1. Loosen the clamps and pull (if the hoses are clamp on the threads), and pull on the other end
loose) or push (if the hoses are tight) on the until the hose is straight. Do NOT apply enough
hoses so they move 30 mm (1.2 in.). Tighten the force to stretch the hose. See Figure 37.
hardware to 8 N•m (71 lbf in). See Figure 27,
4. Mark all the hoses with dimension E (all mea-
Figure 35, and Figure 36.
surements are made from the carriage end of the
2. With no load on the forks, check the header hose hose [the smaller fitting]). See Figure 37.
adjustment by operating the mast through the
5. Attach the hoses to the carriage bracket with
full lift cycle two times. When properly adjusted,
clamps. See Figure 38.
the hoses will not be so tight that they compress

61
Header Hose Arrangement 4000 SRM 522

Figure 37. Header Hose Measurement, Two-Stage Full Free-Lift Mast

62
4000 SRM 522 Header Hose Arrangement

Legend for Figure 37

* Metric Formulas (All Dimensions are in Millimeters)

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
Step 3. Dimension E = 3284.7 + 303
Step 4. Dimension E = 3587.7
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
Dimension G (3 Function) for Lift Heights of 3082 mm to 5482 mm:
(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
Dimension G (4 Function) for Lift Heights of 3082 mm to 5482 mm:
(1.991 × Y) + (0.985 × Z) 1046

* Inch Formulas (All Dimensions are in Inches)

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
Step 4. Dimension E = 141.34
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 31.531
Dimension G (3 Function) for Lift Heights of 121.3 to 215.8:
(1.991 × Y) + (0.985 × Z) 36.125
Dimension G (4 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 34.156
Dimension G (4 Function) for Lift Heights of 121.3 to 215.8:
(1.991 × Y) + (0.985 × Z) 41.156
*All measurements are made with mast vertical and fully lowered.

63
Header Hose Arrangement 4000 SRM 522

Legend for Figure 37 (Continued)

* Metric Formulas (All Dimensions are in Millimeters)

Class III Mast Type
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.
Dimension G Calculations Are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2360 mm to 2960 mm:
(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
Dimension G (4 Function) for Lift Heights of 3060 mm to 5360 mm:
(1.991 × Y) + (0.985 × Z) 1100

* Inch Formulas (All Dimensions are in Inches)

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.
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 92.9 to 116.5:
(1.981 × Y) + (0.985 × Z) 33.500
Dimension G (3 Function) for Lift Heights of 120.5 to 211.0:
(1.991 × Y) + (0.985 × Z) 38.281
Dimension G (4 Function) for Lift Heights of 92.9 to 116.5:
(1.981 × Y) + (0.985 × Z) 36.156
Dimension G (4 Function) for Lift Heights of 120.5 to 211.0:
(1.991 × Y) + (0.985 × Z) 41.156
*All measurements are made with mast vertical and fully lowered.

1. DIMENSION G 5. HOSE
2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. TOP OUTER CHANNEL

64
4000 SRM 522 Header Hose Arrangement

Figure 38. Header Hoses, Two-Stage Full Free-Lift Mast

65
Header Hose Arrangement 4000 SRM 522

Legend for Figure 38

NOTE: THREE-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. CHANNEL 14. CARRIAGE BRACKET
2. COWEL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
6. CLAMP 19. CAPSCREW
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUBSHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN

6. Put the header hoses over the free-lift chains. mast at full lift height, attach clamp at the bot-
tom of the hose loop on the third and/or fourth
7. Put the clamps over the header hoses and at- function hoses. This action allows the hoses to
tach the clamps to the free-lift bracket. (DO NOT fit properly in the hose channel.
tighten the hardware.)
13. With no load on the forks, check the header hose
NOTE: To make the alignment of dimension E easier, adjustment by operating the mast through the
use a crane with a capacity at least 908 kg (2002 lb) full lift cycle two times. When properly adjusted,
to raise the carriage high enough to install a safety the hoses will not be so tight that they compress
chain as shown in Figure 34. when they pass over the sheaves nor will they
be so loose that they touch the load backrest or
8. Align mark E at the bottom of the clamp. Tighten
any crossmember that is next to a sheave. If the
the hardware to 8 N•m (71 lbf in).
hoses require additional adjustment, see Two-
NOTE: The proper hose alignment is shown in Fig- Stage FFL Mast, Adjust Hoses After Installation.
ure 39.
TWO-STAGE FFL MAST, ADJUST HOSES
9. Apply a spray lubricant on the hoses in the area AFTER INSTALLATION
that will contact the channels. Make sure the
hoses are properly aligned in the channels. Put 1. Loosen the clamps and pull (if the hoses are
the clamps over the hoses and attach the clamps loose) or push (if the hoses are tight) on the
to the channels. Tighten the hardware to 8 N•m hoses so they move 15 mm (0.6 in.). Tighten the
(71 lbf in). See Figure 38. hardware to 8 N•m (71 lbf in). See Figure 34,
Figure 37, Figure 38, and Figure 39.
10. Connect the header hoses (4, C, and D) to the
cowl hoses. Connect the header hoses (4, A, and 2. With no load on the forks, check the header hose
B) to the tubes. adjustment by operating the mast through the
full lift cycle two times. When properly adjusted,
11. 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 cowl hoses do NOT stretch or fold while so loose that they touch the load backrest or any
tilting the mast fully forward and backward. crossmember that is next to a sheave. If neces-
sary, repeat Step 1 until the hoses are properly
12. With no load on the forks, operate the mast adjusted.
through the full lift cycle two times. With the

66
4000 SRM 522 Header Hose Arrangement

Figure 39. Header Hose Alignment, Two-Stage Full Free-Lift Mast

67
Header Hose Arrangement 4000 SRM 522

THREE-STAGE FFL MAST, NEW HOSE NOTE: To make the alignment of dimension E easier,
INSTALL use a crane with a capacity of at least 908 kg (2002 lb)
to raise the carriage high enough to attach a safety
chain as shown in Figure 34.
WARNING
Before working on or near the mast, see Safety 7. Align the mark for dimension E at the bottom
Procedures When Working Near Mast in this of the clamp to create the proper hose tension.
section. Tighten the hardware to 8 N•m (71 lbf in). In-
stall the hose guards. Tighten the capscrews that
NOTE: This procedure is for the four-function option. mount the guards to 66 N•m (49 lbf ft).
The three-function option will have hoses A and B
only. 8. Position the hoses at the hose sheave. See Fig-
ure 41 and Figure 42. The hose sheave and stub-
NOTE: The carriage height must be correct before the shaft must be installed on the hose before they
header hoses can be adjusted. See Lift Chains Ad- are attached to the mast. Tighten the hardware
justment for the carriage adjustment procedure. to 53 N•m (39 lbf ft).
1. Mark each hose with a single letter: A, B, C, 9. Put the clamps over the hoses and attach the
or D. See Figure 34, Figure 40, Figure 41, and clamps to the upper brackets. (DO NOT tighten
Figure 42. the hardware.)
2. Use a calculator to calculate the dimensions E NOTE: To make the alignment of dimension G easier,
and G. See Figure 40. use a crane to raise the inner channel high enough to
3. Clamp the end of the hose (the smaller fitting) install a safety chain as shown in Figure 34.
that attaches to the carriage in a vise (do NOT 10. Align mark G on hoses A and D at the bottom
clamp on the threads), and pull on the other end edge of clamp to create the proper tension. Align
until the hose is straight. Do NOT apply enough mark G on hoses B and C at the top edge of clamp
force to stretch the hose. See Figure 40. to create the proper tension. Tighten the hard-
4. Mark the all the hoses with dimensions E and ware to 8 N•m (71 lbf in).
G (all measurements are made from the carriage 11. Install the clamps.
end of the hose [the smaller fitting]). See Fig-
ure 40. 12. Connect the header hoses to the cowl hoses.
5. Attach the hoses to the carriage bracket with 13. Use the rubber clamps and strap clamps to at-
clamps. See Figure 41. Apply spray lubricant tach the hoses to the main lift cylinders. Make
to the surface of the hose guide that contacts the sure the hoses do not stretch or fold while tilting
hoses. the mast fully forward and backward.
6. Place the hoses over the top of the free-lift 14. With no load on the forks, check the header hose
chains and under the hose guides. See Figure 41 adjustment by operating the mast through the
and Figure 42. Attach the hose guides to the full lift cycle two times. When properly adjusted,
lower crossmember and tighten the mounting the hoses will not be so tight that they compress
hardware to 33 N•m (24 lbf ft). Make sure the when they pass over the sheaves nor will they
bracket is between the crossmember and the be so loose that they touch the load backrest or
hose guide. Put the clamps over the hoses and any crossmember that is next to a sheave. If the
attach the clamps to the free-lift bracket. (DO hoses require additional adjustment, see Three-
NOT tighten the hardware.) Stage FFL Mast, Adjust Hoses After Install.

68
4000 SRM 522 Header Hose Arrangement

Figure 40. Header Hose Measurement, Three-Stage Full Free-Lift Mast

69
Header Hose Arrangement 4000 SRM 522

Legend for Figure 40

* Metric Formulas (All Dimensions are in Millimeters)

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
Step 4. Dimension E = 5368.0
** 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
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
Dimension G for Lift Heights of 6260 mm to 8510 mm:
(1.965 × Y) + (0.985 × Z) 65

* Inch Formulas (All Dimensions are in Inches)

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
Step 4. Dimension E = 216.42
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
Dimension G Calculations are Similar to Dimension E
Dimension G for Lift Heights of 146.1 to 240.6:
(1.965 × Y) + (0.985 × Z) 2.562
Dimension G for Lift Heights of 246.5 to 335.0:
(1.965 × Y) + (0.985 × Z) 2.562
*All measurements are made with mast vertical and fully lowered.

70
4000 SRM 522 Header Hose Arrangement

Legend for Figure 40 (Continued)

* Metric Formulas (All Dimensions are in Millimeters)

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
II Mast - Metric Formula.
Dimension G Calculations are Similar to Dimension E
Dimension G for Lift Heights of 3518 mm to 5918 mm:
(1.965 × Y) + (0.985 × Z) 65
Dimension G for Lift Heights of 6068 mm to 8318 mm:
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842

* Inch Formulas (All Dimensions are in Inches)

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
Dimension G Calculations are similar to Dimension E
Dimension G for Lift Heights of 138.5 to 233.0:
(1.965 × Y) + (0.985 × Z) 2.562
Dimension G for Lift Heights of 238.9 to 327.5:
(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.
*All measurements are made with mast vertical and fully lowered.

1. DIMENSION G 5. TOP OUTER CHANNEL

2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. HOSE

71
Header Hose Arrangement 4000 SRM 522

Figure 41. Header Hoses, Three-Stage Full Free-Lift Mast

72
4000 SRM 522 Header Hose Arrangement

Legend for Figure 41

NOTE: THREE-FUNCTION MAST SHOWN.

A. OLD STYLE
1. CAPSCREW 14. NUT
2. HOSE GUARD 15. CLAMP
3. SNAP RING 16. HEADER HOSES
4. HOSE GUIDE 17. FREE-LIFT CHAINS
5. FREE-LIFT CYLINDER CROSSHEAD 18. CLAMP
6. WASHER 19. COWL HOSES
7. SPACER 20. UPPER BRACKET
8. SHEAVE 21. CARRIAGE BRACKET
9. HOSE GUARD 22. CLAMP
10. CLAMP 23. STUBSHAFT
11. FREE-LIFT BRACKET 24. LOCK NUT
12. LOWER BRACKET 25. STRAP CLAMP
13. HOSE GUIDE

73
Header Hose Arrangement 4000 SRM 522

Figure 42. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)

74
4000 SRM 522 Header Hose Arrangement

Figure 42. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 2 of 3)

75
Header Hose Arrangement 4000 SRM 522

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

Figure 42. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 3 of 3)

THREE-STAGE FFL MAST, ADJUST go to Step 2. If the tension of the hoses is wrong,
HOSES AFTER INSTALL loosen the clamps and pull (if the hoses are loose)
or push (if the hoses are tight) on the hoses so
1. If the tension of the hoses is correct between the they move 15 mm (0.6 in.). Tighten the hardware
carriage and the clamp at the free-lift bracket,

76
4000 SRM 522 Lift and Tilt System Leak Check

to 8 N•m (71 lbf in). See Figure 34, Figure 40, 3. With no load on the forks, check the header hose
Figure 41, and Figure 42. adjustment by operating the mast through the
full lift cycle two times. When properly adjusted,
2. If the tension of the hoses is correct between the the hoses will not be so tight that they compress
clamp at the upper bracket and the clamp at the when they pass over the sheaves nor will they be
free-lift bracket, go to Step 3. If the tension of the so loose that they touch the load backrest or any
hoses is wrong, loosen the clamps and pull (if the crossmember that is next to a sheave. If neces-
hoses are too loose) or push (if the hoses are too sary, repeat Step 1 and Step 2 until the hoses are
tight) on the hoses so they move 15 mm (0.6 in.), properly adjusted.
plus the amount the hoses were moved in Step 1.
Tighten the hardware to 8 N•m (71 lbf in).

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

77
Tilt Cylinders Adjustment 4000 SRM 522

Tilt Cylinders Adjustment

c. Slowly tilt the mast backward until one rod
WARNING end just contacts the spacer. Add shims to
When the tilt cylinders have tilt limit spacers, fill the gap at the opposite rod end until both
make sure they are installed during installa- rod ends contact the spacers within 0.5 mm
tion procedures. Without the tilt limit spacers, (0.02 in.).
the mast can tilt too much and cause an acci-
dent or serious injury. d. After the adjustments are complete, tighten
the capscrews on the rod ends.
Check the tilt cylinder stroke by slowly tilting the
mast fully forward and backward several times. Both e. Tilt the mast fully backward and measure
tilt cylinders must stop their stroke at the same time. the tilt angle. (See the nameplate for tilt
Adjust the rod ends as shown in Figure 43, Figure 44, angles.) If necessary, add an equal number
and Figure 45. There must be no twist in the mast of shims to both rods for the correct angle.
weldments.

1. Adjust the stroke of the tilt cylinders WITHOUT

tilt limit spacers as follows:

a. Adjust the rod ends to 15 mm (0.6 in.) for all

tilt cylinders shown in Figure 43, and 32 mm
(1.25 in.) for all tilt cylinders shown in Fig-
ure 45.

b. Slowly tilt the mast backward until one

cylinder rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Mea-
sure the distance from the end of cylinder to
the back end of the rod end. Use a wrench
and turn the cylinder rod IN until the dimen-
sion starts to decrease, then stop. Repeat
this procedure until both cylinder rods stop
at the same position within 1 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 NOTE: THE END OF THE ROD IS EVEN WITH THE
equally for the correct angle. FRONT FACE OF THE ROD END.

2. Adjust the stroke of the tilt cylinders WITH tilt 1. MAST 3. TILT CYLINDER
limit spacers as follows: 2. ROD ENDS

a. Adjust the rod ends to 15 mm (0.6 in.) for all Figure 43. Tilt Cylinder Adjustment
tilt cylinders as shown in Figure 44. H/S1.50-1.75XM (H/S25-35XM), H/S2.00XMS
(H/S40XMS), E1.50-1.75XM (E25-35XM,
b. Slowly tilt the mast forward until one cylin- E25-35XM 2) (D114), and E2.00XMS (E40XMS,
der rod stops. On the opposite cylinder, E40XM 2S) (D114), and E1.50-2.00XM (E25-35Z,
loosen the capscrews on the rod end. Use E40ZS) (E114)
a wrench and turn the cylinder rod IN as
necessary. Repeat this procedure until both
cylinder rods stop at the same position
within 1 mm (0.04 in.).

78
4000 SRM 522 Lift Chains Adjustment

1. MAST 4. TILT LIMIT SPACER 1. MAST 3. TILT CYLINDER

2. ROD END 5. TILT CYLINDER 2. ROD ENDS
3. SHIMS
Figure 45. Tilt Cylinder Adjustment
Figure 44. 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
(E40-65Z) (G108), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z)
(A416), and S/E/J2.00-3.00XL (S/E/J40-60XL)

Lift Chains Adjustment

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

79
Lift Chains Adjustment 4000 SRM 522

1. When adjusting the lift chains on forklift trucks carriage bar is above the floor level as shown in
equipped with either pin- or hook-type forks in- Table 1.
stalled, go to Step 2. If the forklift truck is nor-
mally equipped with a hook-type carriage and Table 1. Hook-Type Carriage Chain Adjustment
has an attachment without forks, go to Step 3.
If the forklift truck is normally equipped with a Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)
pin-type carriage and has an attachment without Class IV 133.5 ±3 mm (5.26 ±0.12 in.)
forks, go to Step 4.

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.

2. Adjust the chain anchors which support the car-

riage until the bottom of the fork heel is 6 ±3 mm
(0.24 ±0.12 in.) above the floor level. See Fig-
ure 46.

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

Figure 47. Lift Chain Adjustment, Hook-Type

Carriage

4. See Figure 48. Adjust the chain anchors, which

1. TILT MAST FULLY BACKWARD support the carriage, until the center line of the
2. CARRIAGE ROLLER fork pin is above the floor level as shown in Ta-
3. FORK ble 2.
4. CARRIAGE ROLLER MUST NOT EXTEND
MORE THAN 34 mm (1.3 in.) BELOW INNER Table 2. Pin-Type Carriage Chain Adjustment
MAST CHANNEL.

Figure 46. Lift Chain Adjustment, Hook- or H70/80, 90XLS 545 ±3 mm (21.5 ±0.12 in.)
Pin-Type Forks H90-110XL 708 ±3 mm (27.87 ±0.12 in.)
3. See Figure 47. Adjust the chain anchors which H135-155XL 907 ±3 mm (35.71 ±0.12 in.)
support the carriage until the bottom of the lower

80
4000 SRM 522 Mast Adjustment

Legend for Figure 48

1. LOAD BACK REST
2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR

Figure 48. Lift Chain Adjustment, Pin-Type

Carriage

Mast Adjustment
NOTE: Shims are installed on both sides of the load b. Use shims to adjust the load rollers so there
rollers. Do not add or remove shims from the stub is zero clearance between the load roller and
shafts. To change the position of the roller on the the channel at the point of tightest fit.
stub shaft, move the shims from one side of the load
roller to the other. c. The number of shims under a load roller
must be approximately the same as the stub
During assembly, the shim arrangement will be ap- shaft in the opposite side of the weldment.
proximately the same as before disassembly. Check The weldments will be approximately in the
the clearance and adjust for wear or change due to center.
repairs.
2. Adjust the load rollers on the mast as follows:
1. The load rollers control the alignment of the mast
weldments. The alignment conditions are given a. Use a pry bar to move the mast weldments
on a list below, with the most important condition from side to side to measure the amount of
first. See Figure 49. movement. Repeat this step in a minimum
of three different positions (top, middle, bot-
a. The mast weldments must be parallel to each tom) of the mast weldments.
other.

81
Mast Adjustment 4000 SRM 522

b. Separate the mast weldments and change Change shims to keep the distance equal be-
the shim arrangements as needed. Assemble tween the top and bottom of the mast weld-
the mast weldments. Slide the mast weld- ments. Make sure the weldments are paral-
ment all the way to the top and bottom to find lel within 1.5 mm (0.06 in.).
the tightest fit.
3. Adjust the strip bearings. Insert shims between
c. Repeat Step a and Step b until there is zero the strip bearing and the channel. Adjust the
clearance at the point of tightest fit. strip bearings so the maximum clearance at the
point of tightest fit is 0.8 mm (0.031 in.). See
d. Measure the distance between the channels Figure 18.
of the mast weldments on the top and bottom.

A. TOP VIEW C. CARRIAGE FRONT VIEW

B. MAST FRONT VIEW
1. MAST WELDMENT (CHANNEL) 6. PARALLEL, EQUAL SPACE WITHIN 1.5 mm
2. LOAD ROLLER (0.06 in.)
3. SNAP RING 7. ADJUST LOAD ROLLERS FOR ZERO
4. SHIMS CLEARANCE
5. STUB SHAFT

Figure 49. Mast and Carriage Adjustments

82
4000 SRM 522 Troubleshooting

Carriage Adjustment
1. Install the load rollers on the carriage. Install 3. Remove the carriage from the mast. Adjust the
the shims for the rollers in the same sequence on shim arrangement for each load roller for clear-
the stub shaft as before disassembly. When the ance between the load roller and the inner mast
carriage has six load rollers, there are no shims weldment. Repeat Step 1 and Step 2 until there
under the top load rollers. See Mast and Car- is zero clearance at the point of tightest fit.
riage Adjustments.
4. Keep the shim arrangement between the middle
and bottom load rollers on the same side of the
WARNING carriage approximately equal. Also keep the
The mast is heavy. The mast can weigh approx- shim arrangement on each side of the carriage
imately 681 kg (1501 lb). Make sure all lifting approximately equal. The carriage must be
devices (hoists, cables, chains, slings, etc.) are parallel with the inner mast weldment within
suitable and of adequate capacity to lift the mo- ±1.5 mm (±0.06 in.).
tor.

2. Use a crane to raise the carriage up the inner

mast weldment. Find the tightest fit between the
load rollers and the inner mast weldment.

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.

83
Troubleshooting 4000 SRM 522

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

84
 TECHNICAL PUBLICATIONS

4000 SRM 522 11/03 (3/03)(5/01)(5/96)(11/94)(7/94)(2/94)(11/93)(4/93) Printed in U.S.A.