Hyster A214 User manual

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 1
Control Valve, Carriage/Attachment ............................................................................................................ 2
Selector Valve................................................................................................................................................. 2
Safety Procedures When Working Near Mast.................................................................................................. 3
Carriage Repair.................................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Disassemble ................................................................................................................................................... 5
Assemble ........................................................................................................................................................ 7
Install ............................................................................................................................................................. 7
Selector Valve................................................................................................................................................. 8
Remove and Disassemble.......................................................................................................................... 8
Clean and Inspect...................................................................................................................................... 8
Assemble.................................................................................................................................................... 8
Install......................................................................................................................................................... 8
Tilt Cylinders Repair ......................................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Disassemble ................................................................................................................................................... 9
Clean .............................................................................................................................................................. 10
Assemble ........................................................................................................................................................ 10
Install ............................................................................................................................................................. 11
Mast Repair........................................................................................................................................................ 11
Remove ........................................................................................................................................................... 11
Disassemble ................................................................................................................................................... 14
Clean and Inspect.......................................................................................................................................... 14
Assemble ........................................................................................................................................................ 16
Install ............................................................................................................................................................. 17
Lift Cylinders Repair ......................................................................................................................................... 19
Description and Operation............................................................................................................................ 19
Remove ........................................................................................................................................................... 20
Disassemble ................................................................................................................................................... 20
Clean and Inspect.......................................................................................................................................... 20
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 22
Mast Operation Check....................................................................................................................................... 23
Lift and Tilt System Leaks Check..................................................................................................................... 23
Lift System..................................................................................................................................................... 23
Tilt System..................................................................................................................................................... 23
Tilt Cylinder Stroke and Backward Tilt Angle Adjustments .......................................................................... 25
Carriage Adjustments........................................................................................................................................ 26
Lift Chain Adjustments................................................................................................................................. 26
Bearing Blocks ............................................................................................................................................... 26
Mast Adjustments.............................................................................................................................................. 26
Bearing Blocks ............................................................................................................................................... 26
Wear Plates .................................................................................................................................................... 26
Troubleshooting.................................................................................................................................................. 28
©2006 HYSTER COMPANY i

4000 SRM 660 Operation
General
This section has the description, operation, and repair procedures for the masts used on this series of lift trucks:
Information on the lift cylinders, lowering control valves, carriage, and tilt cylinders is also described in this
section.
Description
The vertical frames of a mast are called weldments.
See Figure 10. Load rollers and bearing blocks are in-
stalled on the inner and outer weldments. The chan-
nels are the vertical parts of the weldments that have
the tracks for the load rollers and bearing blocks. The
load rollers and bearing blocks guide the weldments
as the mast lifts and lowers.
The mast can tilt forward and backward. Tilt cylin-
ders are installed between the frame of the lift truck
and the outer weldment. The pivot mounts are at the
bottom of the outer weldment and connect the mast
to the lift truck. During the tilt operation the mast
rotatesonthepivotpinsintheframe.
The mast has a carriage. The carriage is a separate
section that moves within the vertical channels of the
inner weldment on load rollers. The forks and fork
positioner cylinders are attached to the carriage.
Operation
The mast has an outer weldment and an inner weld-
ment. See Figure 1. The outer weldment is con-
nected to the lift truck by the pivot pins and the tilt
cylinders. The top of the outer weldment has two sets
of bearing blocks to control movement of the inner
weldment. The inner weldment has two load rollers
and a bearing block on each side. These parts travel
along the channels of the outer weldment and con-
trol the movement between the inner and outer weld-
ments.
The mast has two single-stage lift cylinders. The lift
cylinders are installed at the back of the mast. The
base of each lift cylinder is held to the mount plate at
the bottom of the outer weldment. The hydraulic fit-
ting and external lowering control valve for each lift
cylinder go through a hole in the mount plate. The
cylinder rod of each lift cylinder is held in position at
the top of the inner weldment.
Two lift chains control the movement of the carriage.
The chains are fastened to mounts near the top of
the outer weldment. The chains go up and over the
chain sheaves on the inner weldment and then con-
nect to the carriage. When a load on the carriage
is raised by the lift cylinders, the weight of the load
and carriage assembly is transferred from the car-
riagethroughthechainstotheouterweldment.
When the lift cylinders retract, the weight of the load,
the carriage, and inner weldment push the oil from
the lift cylinders. The oil flows from the lift cylin-
ders, through the lowering control valves, main con-
trol valve, and then to the hydraulic tank.
1

Operation 4000 SRM 660
1. LIFT CYLINDER (2)
2. OUTER WELDMENT
3. INNER WELDMENT
4. CHAIN SHEAVE
5. LIFT CHAIN (2)
6. CARRIAGE
7. BREATHER LINE
8. EXTERNAL LOWERING CONTROL VALVE
9. FROM MAIN CONTROL VALVE
10. TO HYDRAULIC TANK
Figure 1. Mast Operation
CONTROL VALVE,
CARRIAGE/ATTACHMENT
The hydraulic functions for the carriage and attach-
ment are controlled by the auxiliary control valve.
The operator actuates the auxiliary control valve
with switches in the operator’s compartment. The oil
from the auxiliary control valve is used to move the
auxiliary spool in the main control valve. Oil from
the auxiliary spool flows to the selector valves for the
functions at the carriage, such as fork positioners.
When the operator pushes a switch, one solenoid on
the auxiliary control valve and a solenoid on the se-
lector valve are energized at the same time. The so-
lenoid on the auxiliary control valve opens and lets
oil flow through the pilot line to move the auxiliary
spool. The opposite end of the auxiliary spool is open
to drain through the other solenoid on the auxiliary
control valve. When the auxiliary spool moves, it lets
oil from the hydraulic pump flow to the selector valve
as required.
SELECTOR VALVE
A selector valve opens and closes a hydraulic circuit
for one function. See Figure 2. Each valve has one
solenoid that operates one spool. Selector valves are
mounted on a common hydraulic manifold on the car-
riage. The control valve for the carriage and attach-
ment starts and stops the flow of oil to the manifold.
A selector valve lets the oil flow to the cylinder or
cylinders for a specific function. The operator con-
trols the selector valves with separate switches for
each of the hydraulic functions. Each of the switches
operates the control valve and a selector valve at the
same time.
2

4000 SRM 660 Safety Procedures When Working Near Mast
NOTE: PORTS: 1 = LEFT-HAND CYLINDER (ROD END), 2= LEFT-HAND CYLINDER (PISTON END), 3=
RIGHT-HAND CYLINDER (ROD END), 4= RIGHT-HAND CYLINDER (PISTON END). SOLENOIDS: SOLENOID
A(SIDESHIFT), SOLENOID B(RIGHT FORK), SOLENOID C(LEFT FORK).
1. LEFT-HAND CYLINDER (MOVES RIGHT-HAND FORK)
2. RIGHT-HAND CYLINDER (MOVES LEFT-HAND FORK)
3. SELECTOR VALVE
Figure 2. Hydraulic Schematic (Selector Valve)
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• Do NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Do NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make
sure there is no movement in the mast. Make
sure that all parts of the mast that move are
fully lowered.
OR
3

Safety Procedures When Working Near Mast 4000 SRM 660
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving parts
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom of the in-
ner weldment to below the anchor for the tilt
cylinders. See Figure 3.
c. Use a 1/2 inch minimum safety chain with
a hook to fasten the weldments together so
that the inner weldment cannot lower. In-
stallthechainonbothsidesofthemast.
Make sure the hooks are completely engaged
with a link in the chain.
d. Lower the mast until there is tension in the
safety chain. If the engine is running, stop
the engine. Apply the parking brake. In-
stall a DO NOT REMOVE tag on the safety
chain. Put a DO NOT OPERATE tag in the
operator’s compartment.
1. INNER WELDMENT 2. TILT CYLINDERS 3. HOOK
Figure 3. Mast
4

4000 SRM 660 Carriage Repair
Carriage Repair
REMOVE
WARNING
The mast assembly and its components are
heavy. To avoid causing damage or an injury,
a lifting device must be used during all service
procedures. See Table 1 for the approximate
weight of the components.
WARNING
When working on or near the mast see Safety
Procedures When Working Near Mast in this
section.
1. Lower the carriage and forks on blocks so that
the lift chains are loose. See Figure 4.
2. Disconnect the electrical connectors and hy-
draulic lines at the carriage. Put caps on the
open lines.
WARNING
Keep control of the lift chains when discon-
necting them from the carriage. Use wire to
temporarily connect the ends of the lift chains
to a crossmember on the inner weldment.
(Make sure the wire(s) will not break when
raising the inner weldment.) This procedure
will prevent the lift chains from falling and
causing an injury or damage.
3. Remove the pin from each chain anchor at the
carriage. Disconnect the lift chains from the car-
riage. Use wire to connect the ends of the chains
to the inner weldment.
WARNING
When the carriage is not connected to the mast,
it can fall and cause an injury. Make sure that
the carriage has stability and will not fall over
when the inner weldment is raised above the
carriage.
4. Put a weight of approximately 454 kg (1000 lb)
on the forks. This weight on the forks will give
stabilitytothecarriagesothatitwillnotfall
when it is disconnected from the mast.
5. Use the lift cylinders to raise the inner weldment
until it is above the top of the carriage. If the hy-
draulic system cannot be used, connect a lifting
device to the top of the inner weldment. Care-
fully raise the inner weldment until it is above
the top of the carriage.
6. Move the lift truck from the carriage and connect
a lifting device to the carriage. [The carriage can
weigh up to 2270 kg (5000 lb). The forks can
weigh up to 680 kg (1500 lb) each.] Make sure
the carriage has stability.
DISASSEMBLE
1. Remove the fork positioner cylinders, fork pins,
forks, and fork guides or fork carriers. See Fig-
ure4andFigure5.Putthecarriageonblocksso
thattheloadrollersarenotontheground.
2. Remove the load rollers and bearing blocks as
necessary.
3. Remove the selector valves if necessary.
4. Disassemble a fork positioner cylinder as follows:
a. Removetheretainer. Pulltherodassembly
and retainer from the cylinder shell.
b. Remove the nut from the rod and remove the
piston.
c. Remove the seals and O-rings.
d. Clean the cylinder using the same proce-
dures as described for the tilt cylinders.
5

Carriage Repair 4000 SRM 660
NOTE: QUICK DISCONNECT, HOOK-TYPE FORK ARRANGEMENT SHOWN.
1. CARRIAGE
2. BRACKET
3. SHIM
4. BEARING BLOCK
5. LOAD ROLLER
6. SNAP RING
7. BEARING CUP
8. BEARING CONE
9. SEAL
10. SHIM
11. RETAINER
12. FORK PIN
13. SELECTOR VALVE
14. ANCHOR PIN
15. BUSHING
16. FORK CARRIER
17. FORK POSITIONER CYLINDER
Figure 4. Carriage
6

4000 SRM 660 Carriage Repair
1. CYLINDER ROD
2. NUT
3. WEAR RING
4. O-RING
5. PISTON SEAL
6. PISTON
7. GUIDE RING
8. ROD SEAL
9. RETAINER
10. WIPER
11. SHELL
Figure 5. Fork Positioner Cylinder
ASSEMBLE
1. Assemble a fork positioner cylinder as follows
(Figure 4 and Figure 5):
a. Lubricate the seals and O-rings with clean
hydraulic oil. Install the O-ring and backup
ring in the groove of the retainer. Install the
rod seal, guide ring and wiper in the bore of
the retainer. Install the retainer on the rod.
b. Install the O-ring and piston on the rod.
Use Loctite®277 on the threads of the
rod. Tighten the nut for the rod to 990 to
1090 N•m (732 to 805 lbf ft).
c. Install the piston seal and wear ring on the
piston. Install the rod and piston in the shell.
d. Install the retainer.
2. Install the load rollers on the carriage as follows:
a. Lubricate the bearings with multipurpose
grease.
b. Install the load roller on the shaft. Install the
retainer and capscrews. (Do not add shims at
this time.) Tighten the capscrews to 26 N•m
(19 lbf ft).
c. Measure the clearance between the retainer
and the outer bearing. Add shims under
the retainer so that there will be zero clear-
ance. Install the retainer and tighten the
capscrews to 53 N•m (39 lbf ft). Check that
the load roller rotates freely.
3. Install the mounts for the bearing blocks and
tighten the capscrews for the mounts to 53 N•m
(39 lbf ft). Install the bearing blocks and shims
on the mounts. Lubricate the surface of the bear-
ing blocks with multipurpose grease. See Mast
Adjustments, Bearing Blocks at the end of this
section.
INSTALL
1. Use the hydraulic system of the lift truck or a
lifting device to raise the inner weldment. Raise
the inner weldment until it is above the top of
the carriage. Carefully lower the inner weldment
until it engages all of the load rollers.
2. Check the clearance of the bearing blocks. See
Carriage Adjustments, Bearing Blocks in this
section.
3. Connect the lift chains to the chain anchors. In-
stall the pins using new cotter pins.
WARNING
Do not try to move a fork without a lifting de-
vice. The forks can weigh up to 680 kg (1500 lb)
each.
4. Install the fork positioner cylinders and fork
guides or fork carriers. Install the forks and fork
pins. Install the retainers for the fork pins.
5. Connect the electrical connectors and hydraulic
lines as necessary. Check the lift chains as de-
scribed in Carriage Adjustments, Lift Chain Ad-
justments.
7

Carriage Repair 4000 SRM 660
SELECTOR VALVE
Remove and Disassemble
NOTE: The selector valves are installed on the car-
riage.
1. Disconnect the electrical wires at the selector
valve(s). See Figure 4 and Figure 6.
1. SOLENOID
2. CARTRIDGE 3. PLUG AND O-RING 4. VALVE BODY
Figure 6. Selector Valves
2. Disconnect the hydraulic lines at the selector
valve(s).
3. Remove the capscrews that hold the selector
valves to the carriage.
4. Remove the nut and the solenoid coil from the
housing. Remove the spool and O-rings.
Clean and Inspect
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the compressed air path is away
from all personnel. Wear eye protection.
Use solvent to clean the metal parts. Carefully dry
the parts with compressed air. Inspect the other
parts and replace parts that are damaged.
Assemble
1. Lubricate the cartridge with clean hydraulic oil.
See Figure 6. Install the O-rings on the cartridge,
then install the cartridge in the valve body. In-
stall the solenoid coil and nut.
2. Install the O-rings and plugs in the valve body.
3. Install the selector valves together with new
O-rings. Tighten the through bolts.
Install
1. Put the selector valve assembly on the carriage.
Install the capscrews and washers that hold the
valves in position. See Figure 4 and Figure 7.
2. Connect the hydraulic lines to the valve body.
3. Connect the wires to the solenoids.
8

4000 SRM 660 Tilt Cylinders Repair
Figure 7. Selector Valve Wiring
Legend for Figure 7
1. SOLENOID A (SIDESHIFT)
2. SOLENOID B (RIGHT FORK)
3. SOLENOID C (LEFT FORK)
4. SELECTOR VALVE (AUXILIARY FUNCTION)
5. SELECTOR VALVE (AUXILIARY FUNCTION)
6. SELECTOR VALVE (AUXILIARY FUNCTION)
7. SELECTOR VALVE HARNESS
8. SELECTOR VALVE HARNESS (AUXILIARY)
Tilt Cylinders Repair
REMOVE
WARNING
Before removing the tilt cylinder(s), tilt the
mast forward. Use a chain to hold the mast to
the frame and prevent the mast from moving
forward.
1. Disconnect the hydraulic lines at the tilt cylinder.
Install caps on the hydraulic lines and ports.
WARNING
Do not push the pivot pins out of the rod end
with your fingers.
Do not permit the tilt cylinders to drop and
cause damage.
2. Remove the retainers for the pivot pins. Push the
pivot pins out of the rod end with a tool.
3. Use a lifting device to move the tilt cylinders. Re-
move the retainer and pivot pin from the frame
mount. Remove the tilt cylinder.
DISASSEMBLE
1. Remove the rod end from the rod. See Figure 8.
2. Remove the retainer from the shell. Remove the
rod and piston assembly.
3. Disassemble the tilt cylinder as necessary.
9

Tilt Cylinders Repair 4000 SRM 660
1. O-RING
2. SEAL RING
3. PISTON
4. WEAR RING
5. NUT
6. SHELL
7. PLUG
8. ROD
9. BACKUP RING
10. RETAINER
11. WIPER SEAL
12. ROD SEAL
Figure 8. Tilt Cylinder
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Cleanallpartsinsolventand dry with compressed
air.
ASSEMBLE
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean
hydraulic oil.
1. Install the O-ring inside the piston bore. See Fig-
ure 8. Install the piston on the piston rod. Make
sure the O-ring is not damaged. Tighten the nut
on the piston rod to 1500 to 1600 N•m (1100 to
1180 lbf ft).
2. Install the O-ring, seal ring, and wear ring on
thepiston. Thesealringmustbeheatedbefore
installation. After heating, it must be pushed
into its groove using a ring compressor. Let the
seal ring cool and return to its normal shape.
10

4000 SRM 660 Mast Repair
3. Install the O-ring and the backup ring on the out-
side of the retainer. Install the rod seal and wiper
seal in the retainer.
4. Install the retainer on the piston rod. Install
the piston and rod assembly and the retainer in
the cylinder shell. Tighten the retainer to 450 to
550 N•m (330 to 400 lbf ft).
5. Install the plug and O-ring in the port that is not
used.
INSTALL
1. Install the rod end on the rod as described in Tilt
Cylinder Stroke and Backward Tilt Angle Ad-
justments.
2. Usealiftingdevicetomovethetiltcylinders. Put
the tilt cylinder in position on the lift truck. Lu-
bricate the pivot pin, then install it in the frame.
Make sure the grease fitting is toward the out-
side. Install the retainer pin.
3. Install the pivot pin at the mast mount. Install
the retainer pin. Tighten the capscrews for the
retainer pins.
4. Install the relief valves at the rod end ports. Con-
nect the hydraulic lines to the tilt cylinder. See
Figure 9.
5. Operate the tilt cylinders. Check for correct op-
eration and leakage. Adjust the tilt cylinders as
described in Lift and Tilt System Leaks Check.
1. SPRING
2. POPPET
3. SEAT
4. PLUG
5. O-RING
6. BODY
7. GUIDE
Figure 9. Tilt System Relief Valve
Mast Repair
REMOVE
WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not
put any part of your body in or through the
lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Before making any repairs, use blocks and
chains on the inner weldment and carriage so
that they cannot move. Make sure the moving
parts are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
1. Fully lower the inner weldment. See Figure 10
and Figure 14. If the mast must be disassembled,
remove the forks and carriage. If the carriage is
not removed, it must be fastened to a crossmem-
ber on the mast. Use a chain or straps to keep the
carriage from moving when the mast is removed.
2. See Table 1 and connect a lifting device to the lift-
ingeyesatthetopoftheouterweldment.Make
sure the lifting device has the capacity to hold the
mast. Raise the lifting device so that the mast
has stability.
11

Mast Repair 4000 SRM 660
Figure 10. Mast
12

4000 SRM 660 Mast Repair
Legend for Figure 10
1. CHAIN ANCHOR
2. LIFT CHAIN
3. OUTER WELDMENT
4. BRACKET
5. SHIMS
6. BEARING BLOCK
7. WEAR PLATE
8. PLATE
9. RETAINERS
10. SHAFT
11. LIFT CYLINDER
12. LOWERING CONTROL VALVE
13. COVER
14. CHAIN SHEAVE
15. INNER WELDMENT
16. LOAD ROLLER ASSEMBLY
Table 1. Lift Height and Mast Weights
Unit Lift Height Weight
H14.00-20.00XM
(H360-450H) [A214] 2900 mm (114 in.) 3300 kg (7275 lb)
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236] 3650 mm (144 in.) N/A
H14.00-20.00XM
(H360-450H) [A214]
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236]
4500 mm (177 in.) 3800 kg (8378 lb)
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236] 5300 mm (209 in.) N/A
H14.00-20.00XM
(H360-450H) [A214]
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236]
6100 mm (240 in.) 4600 kg (10141 lb)
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236] 6600 mm (260 in.) N/A
H14.00-20.00XM
(H360-450H) [A214]
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236]
6900 mm (272 in.) 5000 kg (11023 lb)
NOTE: The weight of the mast does not include the carriage or attachment.
3. Clean the area around the hydraulic fittings for
the lift cylinders. Disconnect the hydraulic lines
at the bottom of the lift cylinders and put caps on
the open lines.
4. Disconnect the header hoses and electrical cable.
See Figure 15.
5. If the carriage and forks are installed, remove
them as described in the procedures for the Car-
riage Repair.
6. Put the mast in a vertical position. Remove the
capscrews from the mast mounting pins.
7. Raise the mast a small amount with the lifting
device and put small blocks under the tilt cylin-
ders, between the cylinders and the fenders. Re-
move the anchor pins for the tilt cylinders at the
mast.
8. Operatetheliftingdeviceandremovethemast
from the lift truck. Put the mast in a position so
that the crossmembers are facing up.
13

(More Content includes: Brake system,
Capacities, and specifications, Frame,
Hydraulic, System, Industrial battery,
Main control, Valve, Mast repair,
Fasteners, Schematics diagrams,
Steering axle, Steering system, Wire
harness repair And more)
Click Here
Get all the content
after purchase
Thank you very
much.

Mast Repair 4000 SRM 660
DISASSEMBLE
1. Remove the pins for the lift chains at the chain
anchors. See Figure 10 and Figure 11. Remove
the capscrew and washers from the top of each
lift cylinder. Remove the retainers for the lift
cylinders at the top of the outer weldment. Re-
move the capscrew and washers at the bottom
mount for each lift cylinder.
Figure 11. Inner Weldment Removal
2. Slide the inner weldment from the outer weld-
ment approximately 15 cm (6 in.) to disengage
the lift cylinders from the inner weldment. Use
a lifting sling and remove the lift cylinders from
the mount plates at the bottom of the outer weld-
ment. See Lift Cylinders Repair for disassembly
and assembly instructions.
3. Remove the bearing block assemblies at the top
of the outer weldment. Remove the wear plates
from the outer weldment.
4. Slide the inner weldment halfway out of the
outer weldment. Connect a lifting device to the
center of the inner weldment. See Figure 11.
Slide the inner weldment completely out of the
outer weldment.
5. Remove the load rollers as necessary for cleaning
and repair. Remove the bearing blocks.
6. Remove and disassemble the chain sheaves as
necessary for cleaning and repair. See Figure 12.
1. INNER WELDMENT
2. CHAIN SHEAVE
3. SPACER
4. SHIMS
5. PIN
6. RETAINER
7. LOCK PLATE
8. BEARING CUP
9. BEARING CONE
10. SHIELD
Figure 12. Chain Sheave Arrangement
CLEAN AND INSPECT
1. Inspect the 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 load rollers are sealed and lubricated. Lubri-
cate the bearings in the sheaves and load rollers
with multipurpose grease before installation.
The parts of the chain sheaves and load rollers
can be replaced.
14

4000 SRM 660 Mast Repair
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
2. Clean the lift chains with solvent. Inspect the lift
chains for wear or damage. See Figure 13. A lift
chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain
must be replaced. Use a chain scale to measure
the chains. If a chain scale is not available, check
the lift chains with the measurements given in
Figure 13. Lubricate the chains with SAE 30
engine oil. The best procedure is to remove the
chains from the lift truck and soak them in oil.
Pitch
Total Length of 20 Links
(Pitch) of New Chain
Wear Limit
The Maximum Length of
20 Links
44.5 mm (1.75 in.)
50.8 mm (2.00 in.) 889.0 mm (35.0 in.) 1016.0 mm (40.0 in.) 915.7 mm (36.1 in.) 1046.5 mm (41.2 in.)
NOTE: INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON CHAIN WEAR SCALE.
1. CHAIN WEAR SCALE
2. WORN PIN
3. CRACKS
4. EDGE WEAR
5. HOLE WEAR
6. LOOSE LEAVES
7. DAMAGED PIN
8. RUST
Figure 13. Lift Chains Check
15

Mast Repair 4000 SRM 660
WARNING
Never replace just the worn section of a chain.
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains.
3. Inspect the chain anchors and pins. Replace any
parts that are worn or damaged.
4. Clean the mast with steam or solvent.
5. Inspect the sliding and rolling surfaces for dam-
age. Inspect all welds for cracks.
ASSEMBLE
WARNING
DO NOT weld on any part of the mast assem-
bly including the forks or carriage. Get infor-
mation from your dealer for Hyster lift trucks
before welding on the mast.
NOTE: The shims for the bearing blocks and wear
plates keep the inner and outer weldments parallel
and give correct clearance. During assembly, the lo-
cation of the shims will be approximately the same as
they were before disassembly. Check the clearance
and adjust the shims for wear or changes because of
repairs.
1. Install the load rollers as follows (see Figure 10):
a. Lubricate the bearings with multipurpose
grease.
b. Install the load roller on the shaft. Install the
retainer and capscrews. (Do not add shims at
this time.) Tighten the capscrews to 26 N•m
(19 lbf ft).
c. Measure the clearance between the retainer
and the outer bearing. Add shims under
the retainer so that there will be zero clear-
ance. Install the retainer and tighten the
capscrews to 53 N•m (39 lbf ft). Check that
the load roller rotates freely.
2. Install the mounts for the bearing blocks and
tighten the capscrews for the mounts to 53 N•m
(39 lbf ft). Install the bearing blocks and shims
on the inner weldment. Install the bearing
blocks and shims on the outer weldment. In-
stall the nuts and bolts for the bearing blocks.
Lubricate the surface of the bearing blocks with
multipurpose grease.
3. Connect a lifting device to the center of the inner
weldment. See Figure 11. Put the load rollers
into the end of the outer weldment. Slide the in-
ner weldment into the outer weldment until the
inner and outer weldments are aligned.
4. Install the bearing block assemblies at the top
of the outer weldment using the procedures in
Step 2.
5. Lubricate the back of the inner weldment for its
entire length with multipurpose grease. Install
the wear plates and the shims at the back of the
outer weldment.
6. Adjust the bearing blocks and wear plates as de-
scribed in Mast Adjustments.
7. Use a lifting device to install the lift cylinders.
Install the washers and capscrews at the bottom
of the lift cylinders. Push the inner weldment
to engage the rods of the lift cylinders. Install
the capscrews and washers to hold the top of the
cylinder rods in position. Install the retainers for
thecylindersatthetopoftheouterweldment
8. Make sure the lowering control valves are in-
stalled at the bottom of both lift cylinders.
9. Install the chain sheaves as follows:
a. Lubricate the bearings with multipurpose
grease. Install the bearings in the chain
sheave.
b. Install the chain sheave and inner spacer in
the bracket, then install the shaft. Install
spacer and the retainer. (Do not add shims at
this time.) Tighten the capscrews to 26 N•m
(19 lbf ft).
c. Measure the clearance between the bearing
and the outer spacer. Add shims under the
retainersothattherewillbezeroclearance.
Install the retainer and tighten the cap-
screws to 53 N•m (39 lbf ft). Check that the
chain sheave rotates freely.
10. Connect the lift chains to the outer weldment.
Attach wires between the ends of the lift chains
and the crossmember on the inner weldment to
control the lift chains during installation of the
mast.
16

4000 SRM 660 Mast Repair
INSTALL
1. Make sure the bushings and snap rings for the
tilt cylinder pins are installed in the frame and
outer weldment. See Figure 14. Install the tilt
cylinders to the frame mounts. Install the pivot
pins and anchor pins. Make sure the grease fit-
tings are toward the outside of the lift truck.
1. TILT CYLINDER
2. ROD END
3. ANCHOR PIN
4. SPHERICAL
BUSHING
5. PIN
6. GREASE FITTING
7. SNAP RING
8. LIFT TRUCK
FRAME
9. PIVOT PIN
10. CAP
Figure 14. Mast Installation
2. See Table 1 and connect a lifting device to the top
of the mast assembly. Make sure the inner and
outer weldments are fastened together. Make
sure that the chains do not damage any of the
hydraulic lines or other parts.
3. Raise the mast assembly to a vertical position.
Move the mast assembly into position on the lift
truck.
4. Lubricate the mast mounting pins and bush-
ings with multipurpose grease. Install the mast
mounting pins through the frame and into the
mast. Install the caps and nuts and bolts. Make
surethegreasefittingonthecapistoward
the front of the lift truck. Tighten the bolt to
176 N•m (130 lbf ft).
5. Connect the tilt cylinders to the outer weldment.
Install the pivot pins and anchor pins. Make sure
the grease fittings are toward the outside of the
lift truck.
6. Install the carriage and forks as described in the
procedures for the Carriage Repair.
7. Connect the hydraulic lines to the mast assem-
bly. Install connection hoses, header hoses and
electrical cable as shown in Figure 15. If the hose
sheaves for the header hoses were disassembled,
assemble them as follows:
a. Install the sheaves in the bracket. Install the
bolt, spacers, sheaves, and nut. Tighten the
nut until there is no clearance, then tighten
an additional 1/4 turn.
b. Install the three bolts that hold the brackets
together. Tighten the bolts by hand, then
install the nuts and tighten them to 38 N•m
(28 lbf ft).
8. Adjust the lift chains, carriage, and tilt cylinders
as described in Carriage Adjustments and Tilt
Cylinder Stroke and Backward Tilt Angle Ad-
justments.
17

Mast Repair 4000 SRM 660
1. HOSE BRACKET
2. SPACER
3. SHEAVES
4. OUTER WELDMENT
5. SHEAVE BRACKET
6. CABLE CLAMP
7. HOSE CLAMP
8. HEADER HOSE
9. ELECTRICAL CABLE
Figure 15. Header Hose Arrangement
18