Hyster A380 User manual

Hyster A380 (H40XT, H50XT, H60XT) Forklift Service
Repair Manual

MAST REPAIR
(S/N A387, A389, A397, A399)
TWO-STAGE LFL AND THREE-
STAGE FFL MAST
H2.0-3.0XT (H40-60XT) [A380]
PART NO. 4150993 4000 SRM 1999

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2016 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Safety Procedures When Working Near Mast .......................................................................................................3
Fork Replacement ................................................................................................................................................... 5
Standard Carriage and Integral Sideshift Carriage .........................................................................................5
Remove ............................................................................................................................................................5
Install ..............................................................................................................................................................7
Checks .............................................................................................................................................................7
Fork Positioner Carriage ....................................................................................................................................8
Remove ............................................................................................................................................................8
Install ..............................................................................................................................................................9
Checks ...........................................................................................................................................................10
Carriages Repair, Two-Stage LFL Mast ..............................................................................................................11
Standard Carriage ............................................................................................................................................11
Remove ..........................................................................................................................................................11
Clean and Inspect .........................................................................................................................................12
Install ............................................................................................................................................................13
Integral Sideshift Carriage ...............................................................................................................................14
Remove ..........................................................................................................................................................14
Disassemble .................................................................................................................................................. 16
Clean and Inspect .........................................................................................................................................16
Assemble ....................................................................................................................................................... 18
Install ............................................................................................................................................................18
Fork Positioner Carriage ..................................................................................................................................18
Remove ..........................................................................................................................................................18
Clean and Inspect .........................................................................................................................................20
Install ............................................................................................................................................................20
Fork Positioner Hydraulic Hose Adjustment ..............................................................................................22
Two-Stage LFL Mast Repair ................................................................................................................................ 23
Mast With Serial Numbers A389 and A399 ....................................................................................................23
Remove ..........................................................................................................................................................25
Disassemble .................................................................................................................................................. 28
Clean and Inspect .........................................................................................................................................32
Assemble ....................................................................................................................................................... 34
Install ............................................................................................................................................................35
Header Hoses ................................................................................................................................................36
Remove ......................................................................................................................................................36
Installation ............................................................................................................................................... 36
Adjustment ...............................................................................................................................................41
Carriages Repair, Three-Stage FFL Mast ...........................................................................................................41
Standard Carriage ............................................................................................................................................41
Remove ..........................................................................................................................................................41
Clean and Inspect .........................................................................................................................................43
Install ............................................................................................................................................................43
Integral Sideshift Carriage ...............................................................................................................................44
Remove ..........................................................................................................................................................44
Disassemble .................................................................................................................................................. 46
Clean and Inspect .........................................................................................................................................46
Assemble ....................................................................................................................................................... 48
Install ............................................................................................................................................................48
Fork Positioner Carriage ..................................................................................................................................48
Table of Contents
i

TABLE OF CONTENTS (Continued)
Remove ..........................................................................................................................................................48
Clean and Inspect .........................................................................................................................................51
Install ............................................................................................................................................................51
Fork Positioner Hydraulic Hose Adjustment ..............................................................................................53
Three-Stage FFL Mast Repair ..............................................................................................................................54
Mast With Serial Numbers A387 And A397 ................................................................................................... 54
Remove ..........................................................................................................................................................56
Disassemble .................................................................................................................................................. 59
Clean and Inspect .........................................................................................................................................67
Assemble ....................................................................................................................................................... 70
Install ............................................................................................................................................................71
Header Hose Installation and Adjustment ................................................................................................. 72
Remove ......................................................................................................................................................72
Installation ............................................................................................................................................... 73
Adjustment ...............................................................................................................................................80
Carriage Adjustments ...........................................................................................................................................81
Lift Chains Adjustment ........................................................................................................................................ 82
Lift Trucks Equipped with Forks ................................................................................................................ 83
Lift Trucks Equipped with Hook-Type Carriage and Attachment Without Forks ...................................83
Mast Adjustments .................................................................................................................................................84
Load Roller, Adjust ...........................................................................................................................................84
Mast Side Kicking, Adjust ................................................................................................................................86
Hydraulic Quick Disconnect Hoses ......................................................................................................................86
Disconnecting Attachment Hydraulic Quick Disconnect Hoses .....................................................................86
Lift Trucks Equipped With E-Hydraulic Controls ......................................................................................86
Lift Trucks Equipped With Manual Hydraulic Controls ............................................................................87
Connecting Attachment Hydraulic Quick Disconnect Hoses .........................................................................87
Lift Trucks Equipped With E-Hydraulic Controls ......................................................................................87
Lift Trucks Equipped With Manual Hydraulic Controls ............................................................................88
This section is for the following models:
H2.0-3.0XT (H40-60XT) [A380]
Table of Contents
ii

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General
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
manual.
NOTE: Hoses have a service life that is determined
by application and time. Install a new hose if the
hose is leaking, worn through, or damaged. A hose
has been damaged if the hose cover is cracked,
exposing the braiding, or if the hose has been
kinked or crushed, or if the hose is no longer
flexible. Install a new hose if the hose has been
tensioned beyond the adjustment range. If
necessary, make a comparison to a new hose that is
the correct replacement for the hose you are
inspecting.
This section contains the repair procedures for the
Two-Stage, Limited Free-Lift (LFL) mast with
serial numbers A389 and A399 and the Three-
Stage, Full Free-Lift (FFL) mast with serial
numbers A387 and A397. The mast serial number
is located on the right side of the outer mast. Other
information about the mast can also be found in
this area. See Figure 1.
Procedures to repair the carriage, replace the forks,
and adjust the lift chains, carriage, and mast are
also covered in this manual.
4000 SRM 1999 General
1

NOTE: THE MAST AND TEXT SHOWN IN ABOVE ILLUSTRATION ARE FOR ILLUSTRATIVE PURPOSES
ONLY. YOUR MAST AND TEXT MAY BE DIFFERENT, BUT THE TEXT IS FOUND IN THE SAME LOCATION.
1. MAST SERIAL NUMBER SERIES
2. MANUFACTURING PLANT
3. PRODUCTION SEQUENCE
4. MAST LIFT HEIGHT (IN MILLIMETERS)
5. MAST ASSEMBLY PART NUMBER
Figure 1. Mast Serial Number Location
Additional information concerning the mast may be
included in other sections when the information is
closely related to other systems. Sections may
include:
Cylinder Repair 2100SRM1994
Periodic Maintenance 8000SRM2000
General 4000 SRM 1999
2

Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast. See the correct Serv-
ice Manual section for the specific mast being re-
paired.
WARNING
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when
repairing or removing the mast. See the correct
Service Manual section for the specific mast be-
ing repaired.
•Never put any part of the body into or under
the mast or carriage unless all parts are
completely lowered or a safety chain is in-
stalled. Also make sure that the power is off
and the key is removed. Put a DO NOT OP-
ERATE tag in the operator's compartment.
Disconnect the battery on electric lift trucks
and put a tag or lock on the battery connec-
tor.
•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
weldments or 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 proce-
dures in the correct Service Manual for the
mast.
WHEN WORKING NEAR THE MAST ALWAYS:
•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
•If parts of the mast must be in a raised posi-
tion, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put mast in vertical position.
2. Raise mast to align bottom crossmember of
weldment that moves in the outer weldment
with a crossmember on the outer weldment. On
the two-stage and free-lift mast, the moving
part is the inner weldment. On the three-stage
mast, it is the intermediate weldment. See Fig-
ure 2.
3. Use a 3/8 inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
hook on the back side of the mast. Make sure
the hook is completely engaged with a link in
the chain. Make sure the safety chain does not
touch lift chains or chain sheaves, tubes, hoses,
fittings, or other parts on the mast.
4. Lower mast until there is tension in the safety
chain and the free-lift cylinder (three-stage) is
completely retracted. If running, stop the en-
gine. Apply parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
5. Install another safety chain (3/8 inch mini-
mum) between the top or bottom crossmember
of the carriage and a crossmember on the outer
weldment. See Figure 2.
NOTE: Apply parking brake. After lowering or re-
straining the mast, shut off power and remove key.
Put a DO NOT OPERATE tag in the operator's
compartment. Disconnect battery on electric lift
trucks and put a tag or lock on battery connector.
4000 SRM 1999 Safety Procedures When Working Near Mast
3

A. TWO-STAGE LFL MAST B. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 2. Two-Stage LFL and Three-Stage FFL Masts
Safety Procedures When Working Near Mast 4000 SRM 1999
4

Fork Replacement
STANDARD CARRIAGE AND INTEGRAL
SIDESHIFT CARRIAGE
On lift trucks equipped with a standard carriage or
an integral sideshift carriage, the forks are held on
the carriage by hooks. Forks are held in position by
pins that fit through the top fork hooks and into
slots in top carriage bar.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that pins for
forks keep forks in position on carriage. Replace
damaged fork pin parts.
Remove
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 50 to 98 kg (110 to 216 lb).
NOTE: Forks are to be replace in sets by trained
personnel only. DO NOT replace forks individually.
1. Slide fork to fork removal notch on bottom bar
of carriage. See Figure 3.
2. Lower fork onto blocks (see Figure 4), so bottom
hook of fork moves through fork removal notch.
3. Lower carriage further so top hook of fork is
disengaged from top carriage bar. See Figure 3.
4. Move carriage away from fork or use a lifting
device to move fork away from carriage.
4000 SRM 1999 Fork Replacement
5

1. LOAD BACKREST
2. CARRIAGE
3. FORK(S)
4. KNOB
5. PIN RETAINER
6. SPRING
7. PIN (FORK LATCH)
8. FORK REMOVAL NOTCH
9. LOWER HOOK
10. UPPER HOOK
Figure 3. Carriage and Forks
Figure 4. Hook Fork, Remove
Legend for Figure 4
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Fork Replacement 4000 SRM 1999
6

Install
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 50 to 98 kg (110 to 216 lb).
NOTE: Forks are to be replace in sets by trained
personnel only. DO NOT replace forks individually.
1. Move fork and carriage so top hook of fork can
engage upper carriage bar. See Figure 4.
2. Raise carriage to move bottom hook of fork
through fork removal notch.
3. Slide fork on carriage so both upper and lower
hooks engage carriage bars. See Figure 3.
4. Install latch pin in top hook and notch in upper
carriage bar. See Figure 3.
Checks
WARNING
Never repair damaged forks by heating or weld-
ing. Forks are made of tempered steel using spe-
cial procedures. Always replace damaged forks as
a pair.
Inspect forks for cracks and wear. Check alignment
of fork tips. The difference in height of fork tips
must be less than three percent of the length of the
forks. See Table 1 and Figure 5.
Some applications may require closer alignment. If
forks do not meet specification, they both must be
replaced. Check for smooth and proper operation of
the fork lock pins. Repair or replace any damaged
or broken fork lock pins or components and lubri-
cate, as necessary. See Figure 5.
Table 1. Fork Tip Alignment
Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip Difference*
mm (in.) mm (in.)
914 (36) 27.4 (1.08)
1000 (39.5) 30 (1.20)
1016 (40) 30.5 (1.20)
1067 (42) 32 (1.25)
1100 (43) 33 (1.30)
1200 (47) 36 (1.40)
1207 (47.5) 36.2 (1.43)
1219 (48) 36.5 (1.43)
1372 (54) 41.1 (1.62)
1524 (60) 45.7 (1.80)
1829 (72) 54.9 (2.20)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.
4000 SRM 1999 Fork Replacement
7

A. HEEL OF FORK (MUST BE 90% OF DIMEN-
SION B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE
Figure 5. Fork Checks
FORK POSITIONER CARRIAGE
NOTE: The fork positioner can be removed from
the integral sideshift carriage with integral side-
shift carriage on or off the mast. In the steps below,
the fork positioner is removed with integral side-
shift carriage on the mast. If integral sideshift car-
riage must be removed from mast first, go to sec-
tion Carriages Repair, Two-Stage LFL Mast or
Carriages Repair, Three-Stage FFL Mast for
removal procedures.
Forks used on an integral sideshift carriage equip-
ped with a fork positioner attachment, are held in
position with fork carriers (inner and outer) that
slide along the fork positioner cylinder. Forks are
removed from carriage by aligning forks with fork
removal notch. Fork removal notch is in the bottom
bar of carriage. See Figure 6.
1. OUTER FORK CARRIER
2. CAPSCREWS
3. INNER FORK CARRIER
4. FORK POSITIONER CYLINDER
Figure 6. Fork Carrier Components
Remove
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 50 to 98 kg (110 to 216 lb).
CAUTION
Remove fork latch pins (7, Figure 3) if adding a
fork positioner attachment. Damage to forks and
other carriage components can occur if fork latch
pins are not removed prior to using attachment.
NOTE: Forks are to be replace in sets by trained
personnel only. DO NOT replace forks individually.
1. Lower carriage and remove four capscrews from
fork carriers. Slide inner fork carriers down cyl-
inder shell to remove forks. See Figure 7.
2. Slide fork to fork removal notch in bottom bar
of carriage. See Figure 7.
3. Lower forks onto blocks (see Figure 4) so bot-
tom hook of fork moves through fork removal
notch. Lower carriage further so top hook of
fork is disengaged from top carriage bar.
Fork Replacement 4000 SRM 1999
8

4. Move carriage away from fork or use a lifting
device to move fork away from carriage.
NOTE: FORK POSITIONER AND INTEGRAL SIDESHIFT CARRIAGE FOR THREE-STAGE FFL MAST
SHOWN. REMOVAL OF FORKS FROM TWO-STAGE LFL MAST IS SIMILAR.
1. OUTER FORK CARRIER
2. FORKS
3. INNER FORK CARRIER
4. OUTER FRAME
5. FORK POSITIONER
6. CAPSCREWS
7. FORK REMOVAL NOTCH
Figure 7. Fork Positioner Fork Removal
Install
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 50 to 98 kg (110 to 216 lb).
CAUTION
Remove fork latch pins (7, Figure 3) if adding a
fork positioner attachment. Damage to forks and
other carriage components can occur if fork latch
pins are not removed prior to using attachment.
NOTE: Forks are to be replace in sets by trained
personnel only. DO NOT replace forks individually.
1. Move fork and carriage so top hook of fork can
engage upper carriage bar. See Figure 4.
2. Raise carriage to move bottom hook of fork
through fork removal notch. See Figure 7.
3. Slide fork on carriage so both upper and lower
hooks engage carriage bars. See Figure 4.
4. Move fork into place on outer fork carrier. Se-
cure inner fork carrier to outer fork carrier us-
ing four capscrews. Tighten capscrew to
35 N•m (25 lbf ft). See Figure 7.
4000 SRM 1999 Fork Replacement
9

Checks
WARNING
Never repair damaged forks by heating or weld-
ing. Forks are made of tempered steel using spe-
cial procedures. Always replace damaged forks as
a pair.
Inspect forks for cracks and wear. Check the align-
ment of fork tips. The difference in height of fork
tips must be less than three percent of the length of
the forks. See Table 2 and Figure 8.
Some applications may require closer alignment. If
forks do not meet specification, they both must be
replaced. Repair or replace any damaged or broken
fork components and lubricate, as necessary. See
Figure 8.
Table 2. Fork Tip Alignment
Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip Difference*
mm (in.) mm (in.)
914 (36) 27.4 (1.08)
1000 (39.5) 30 (1.20)
1016 (40) 30.5 (1.20)
1067 (42) 32 (1.25)
1100 (43) 33 (1.30)
1200 (47) 36 (1.40)
1207 (47.5) 36.2 (1.43)
1219 (48) 36.5 (1.43)
1372 (54) 41.1 (1.62)
1524 (60) 45.7 (1.80)
1829 (72) 54.9 (2.20)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.
Fork Replacement 4000 SRM 1999
10

Figure 8. Fork Checks
Legend for Figure 8
A. HEEL OF FORK (MUST BE 90% OF DIMEN-
SION B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE
Carriages Repair, Two-Stage LFL Mast
STANDARD CARRIAGE
Remove
1. Remove forks. See Fork Replacement section
for procedures.
2. Remove four capscrews and load backrest from
carriage. See Figure 9.
3. Connect a lifting device to the carriage. Lift car-
riage so that lift chains become loose.
1. CAPSCREW
2. WASHER
3. NUT
4. CARRIAGE
5. LOAD BACKREST
Figure 9. Load Backrest, Remove
4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast
11

WARNING
When disconnecting the lift chains, keep control
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 and caus-
ing an injury or damage.
1. Remove chain pin from each chain anchor at
the carriage. Disconnect lift chains from car-
riage. Use wire to connect the ends of lift chains
to a part of the mast. Make sure chains can
move freely when inner mast is raised. See Fig-
ure 10.
WARNING
To help prevent possible injury, make sure the
carriage is stable and will not fall over when the
inner mast is raised above the load rollers of the
carriage.
2. Use lift cylinders to raise inner mast. If hy-
draulic system cannot be used, disconnect lift
cylinders from inner mast. See the Cylinder
Repair manual listed in the General section of
this manual for procedures.
3. Connect a crane with a capacity of at least
700 kg (1550 lb), to top of inner mast. Carefully
raise inner mast until it is above the load roll-
ers of the carriage. Install safety chains to se-
cure mast in its extended position and discon-
nect the crane. See Safety Procedures When
Working Near Mast.
4. Move lift truck away from carriage. Completely
lower inner mast so it cannot move.
NOTE: BOTTOM AND MIDDLE LOAD ROLLER
COMPONENTS ARE THE SAME.
1. SNAP RING
2. ANCHOR PIN
3. COTTER PIN
4. CHAIN ANCHOR
5. CHAIN PIN
6. LOAD ROLLER
7. SPACER
8. SHIM
9. STANDARD CARRIAGE
Figure 10. Standard Carriage Components
Clean and Inspect
NOTE: Shims are installed on the bottom and mid-
dle load rollers only.
1. If load rollers must be replaced, make a note of
the location and number of shims. Install
shims, load rollers, and snap rings. See Car-
riage Adjustments section for correct adjust-
ment of the load rollers.
Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999
12

WARNING
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.
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using clean-
ing solvents, always follow the recommendations
of the manufacturer.
CAUTION
DO NOT use cleaning solvent, compressed air, or
steam to clean lift chain sheaves or load rollers.
The bearings in the lift chain sheaves and load
rollers are sealed and lubricated. Cleaning sol-
vent, compressed air, and steam can damage the
load roller bearings.
2. Clean any oil, grease, dirt, and other debris
from carriage frame. Use a cleaning solvent and
compressed air to dry.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast. Consult a Resident Service Engineer-
ing through the Contact Management System be-
fore welding on the mast.
3. If carriage bars have any protruding welds or
damaged notches, repair by grinding, filing, or
welding.
4. Clean and inspect the chain anchors and chain
anchor pins. Check chain anchors and anchor
pins for wear and serviceability. Discard worn
or unserviceable chain anchors and chain an-
chor pins. Discard used cotter pins. See Fig-
ure 10.
Install
1. Move the lift truck towards the carriage until
inner mast is aligned with carriage rollers. If
inner mast has been raised and secured using a
crane and safety chains, connect the crane,
raise inner mast, and remove safety chains.
Carefully lower inner mast until it engages all
of the load rollers. Disconnect the crane, if at-
tached, and reconnect lift cylinders. See the
Cylinder Repair manual listed in the General
section of this manual for procedures.
2. Check the clearance of the load rollers. See Car-
riage Adjustments section for procedures.
NOTE: Use new cotter pins each time chain pins
are removed.
3. Connect lift chains to chain anchors at the car-
riage. Install cotter pins in chain pins. Adjust
lift chains as described in Lift Chains Adjust-
ment.
4. Install load backrest on carriage. Tighten cap-
screws to 195 N•m (144 lbf ft).
5. Install forks. See Fork Replacement for proce-
dures.
4000 SRM 1999 Carriages Repair, Two-Stage LFL Mast
13

INTEGRAL SIDESHIFT CARRIAGE
Remove
1. Lower carriage completely. Remove forks. See
Fork Replacement for removal procedures.
2. Remove four capscrews and load backrest from
carriage. See Figure 9.
WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy-
draulic system prior to disconnecting hydraulic
hoses.
3. Relieve hydraulic pressure to the sideshift cyl-
inder by moving sideshift lever in both direc-
tions several times.
WARNING
Always wear the proper protective equipment in-
cluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
WARNING
Never check for leaks by putting hands on hy-
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.
NOTE: Tag hydraulic lines and fittings prior to dis-
connecting to aid in connecting during installation.
4. Disconnect hydraulic hoses from sideshift cylin-
der. Put caps and plugs on open lines and cylin-
der ports. See Figure 11.
1. HOSE FITTINGS
2. HOSES
3. INTEGRAL SIDESHIFT CYLINDER
Figure 11. Integral Sideshift Carriage Hydraulic
Hose Connections
5. Remove lower mounting hooks by removing
four capscrews securing hooks. See Figure 12.
6. Remove integral sideshift cylinder from car-
riage. See the Cylinder Repair manual listed
in the General section of this manual for proce-
dures.
7. Insert a M12 x 1.75 lifting eye in hole on top of
outer frame. Use a crane with a capacity of at
least 78 kg (172 lb) to lift outer frame away
from inner frame. Lay outer frame flat on a pal-
let or work bench. See Figure 13.
Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999
14