Hyster E3.50-5.50XL3 Operating instructions

Hyster C098 (E70XL3, E80XL3, E100XL3, E120XL3) Forklift

MASTS
DESCRIPTION AND REPAIRS
E3.50-5.50XL3(E70-120XL3)[C098];
S3.50-5.50XM (S70-120XM) [E004];
H3.50-5.50XM (H70-120XM) [K005]
PART NO. 1466163 4000 SRM 736

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!

Masts Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Carriages........................................................................................................................................................ 1
Two-Stage Mast With Limited Free-Lift ...................................................................................................... 1
Two-Stage Mast With Full Free-Lift ............................................................................................................ 2
Three-Stage Mast With Full Free-Lift ......................................................................................................... 3
Safety Procedures When Working Near Mast.................................................................................................. 5
Fork Replacement .............................................................................................................................................. 7
Remove ........................................................................................................................................................... 8
Install ............................................................................................................................................................. 8
Carriage Repair.................................................................................................................................................. 9
Remove ........................................................................................................................................................... 9
Sideshift Carriage Repair.................................................................................................................................. 10
Remove ........................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Assemble ........................................................................................................................................................ 10
Install ............................................................................................................................................................. 11
Two-Stage Mast with Limited Free-Lift Repair............................................................................................... 12
Remove - H3.50-5.50XM (H70-120XM) Model Lift Trucks.......................................................................... 12
Remove - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL3(E70-120XL3) Model Lift Trucks................... 12
Disassemble ................................................................................................................................................... 12
Clean and Inspect.......................................................................................................................................... 16
Assemble ........................................................................................................................................................ 17
Install - H3.50-5.50XM (H70-120XM) Lift Truck Models............................................................................ 18
Install - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL3(E70-120XL3) Lift Truck Models..................... 20
Two-Stage Mast with Full Free-Lift Repair ..................................................................................................... 22
Remove ........................................................................................................................................................... 22
Disassemble ................................................................................................................................................... 22
Clean and Inspect.......................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 24
Three-Stage Mast With Full Free-Lift Repair.................................................................................................. 26
Remove ........................................................................................................................................................... 26
Disassemble ................................................................................................................................................... 26
Clean and Inspect.......................................................................................................................................... 29
Assemble ........................................................................................................................................................ 29
Install ............................................................................................................................................................. 31
Mast Operation Check....................................................................................................................................... 35
Lift and Tilt System Leak Check ...................................................................................................................... 35
Lift System..................................................................................................................................................... 35
Tilt System..................................................................................................................................................... 36
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment............................................................................ 37
Lift Chain Adjustments..................................................................................................................................... 38
Mast Adjustments.............................................................................................................................................. 41
Carriage Adjustment ......................................................................................................................................... 43
Troubleshooting.................................................................................................................................................. 43
©2002 HYSTER COMPANY i

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Table of Contents Masts
TABLE OF CONTENTS (Continued)
This section is for the following models:
E3.50-5.50XL3(E70-120XL3) [C098];
S3.50-5.50XM (S70-120XM) [E004];
H3.50-5.50XM (H70-120XM) [K005]
ii

4000 SRM 736 Description and Operation
General
This section contains the description, operation, and repair procedures for the masts. Information on sideshift
carriage is also included in the section.
Description and Operation
Vertical frames of a mast are called weldments. See
Figure 1. Channels, load rollers, and crossmembers
are parts of the weldments. Channels on each side
of the weldment are support members of the mast
and tracks for load rollers. While lifting and lowering
a load, large forces are put on the mast assembly.
Load rollers reduce the friction between the channels
when the weldments move vertically.
1. FORKS
2. CARRIAGE
3. LOAD BACKREST
EXTENSION
4. OUTER
WELDMENT
5. INNER WELDMENT
6. LIFT CYLINDER
Figure 1. Mast Components
The mast can tilt forward and backward. Tilt cylin-
ders are installed between the frame of the lift truck
and outer weldment of the mast. For H3.50-5.50XM
(H70-120XM) lift trucks, the pivot mounts at the bot-
tom of the outer weldment connect the mast to the
lift truck. During tilt operation, the mast rotates on
pivot pins in the frame.
For S3.50-5.50XM and E3.50-5.50XL3(E70-120XL3)
model lift trucks, mast mounting hangers are at-
tached to the drive axle and connect the mast to the
lift truck. During tilt operation, the mast rotates on
the drive axle.
CARRIAGES
The carriage is a separate section that moves on load
rollers within vertical channels of the inner weld-
ment. Forks or other types of load handling equip-
ment are attached to the carriage. A load backrest
extension is installed on the carriage.
A sideshift carriage permits the operator to hydrauli-
cally change the lateral position of the load handling
device on the carriage.
TWO-STAGE MAST WITH LIMITED
FREE-LIFT
The two-stage mast with limited free-lift (LFL) has
two weldments, an outer weldment and an inner
weldment. See Figure 2. Outer weldment is con-
nected to the lift truck by pivot mounts and tilt
cylinders. The top of the outer weldment and the
base of the inner weldment have one load roller on
each side. These load rollers travel along channels
of the weldments. The angle of the load rollers per-
mits them to control the forces from the front, back,
and sides of the mast. Shims on the load rollers
control lateral clearance between weldments and
load rollers. Strip bearings are installed at the top of
each side of the outer weldment. Strip bearings keep
correct clearance (forward and backward) between
outer weldment and inner weldments.
1

Description and Operation 4000 SRM 736
1. LIFT CYLINDER (2)
2. LIFT CHAIN
3. OUTER
WELDMENT
4. CHAIN SHEAVE
5. INNER WELDMENT
6. CARRIAGE
7. FROM MAIN
CONTROL VALVE
8. EXTERNAL
LOWERING
CONTROL VALVE
9. INTERNAL
LOWERING
CONTROL VALVE
Figure 2. Two-Stage Mast With Limited
Free-Lift
The two-stage mast with limited free-lift has two sin-
gle-stage lift cylinders. Lift cylinders are installed at
the back of the outer weldment. The base of each lift
cylinder is held on a mount at the bottom of the outer
weldment by brackets. The top of each lift cylinder
(cylinder rod) fits into a guide at the top of the inner
weldment. A clamp holds the top of the lift cylinder
in position on the outer weldment. Operation of lift
cylinders extends and retracts the inner weldment.
Two lift chains control the movement of the carriage.
Chains are fastened to mounts near the top of the
outer weldment. The chains go up and over chain
sheaves on inner weldment and then connect to
the carriage. When lift cylinders extend, lift chains
transfer the force from lift cylinders to the carriage.
When lift cylinders retract, weight of the load, car-
riage, and inner weldment push oil from the lift cylin-
ders. Oil flows from lift cylinders, through lowering
control valves, main control valve, and then to the
hydraulic tank.
TWO-STAGE MAST WITH FULL FREE-LIFT
The two-stage mast with full free-lift (FFL) has an
inner weldment, an outer weldment, and three sin-
gle-stage lift cylinders. See Figure 3. It is called a
free-lift mast because the carriage can travel to the
top of the inner weldment without increasing mast
height. The free-lift mast has load roller and strip
bearing arrangements similar to the two-stage mast
with limited free-lift.
Two main lift cylinders are installed at the back of
the outer weldment. The base of each lift cylinder
sits in a mount at the bottom of the outer weldment.
The hydraulic fitting for each lift cylinder goes
through a hole in the mount. The top of each lift
cylinder (cylinder rod) fits into guides at the top of
the inner weldment.
Free-lift cylinder is installed in the inner weldment.
Main lift cylinder on the right side of the mast and
the free-lift cylinder each have an internal lower-
ing control valve. A single external lowering con-
trol valve is connected by tubing to all lift cylinders.
Two chain sheaves are installed on the cylinder rod
of the free-lift cylinder. Lift chains are connected to a
mount behind the free-lift cylinder. The chains then
go over the sheaves and are connected to the carriage.
Three lift cylinders are connected by hoses and tub-
ing. To extend the mast, oil from main control valve
flows to all lift cylinders at the same time. Free-lift
cylinder raises first because it lifts the least amount
of weight. Free-lift cylinder raises the carriage to the
top of the inner weldment. After the free-lift cylinder
reaches the end of its stroke, main lift cylinders be-
gin to extend and raise the inner weldment.
2

4000 SRM 736 Description and Operation
1. MAIN LIFT CYLINDER (2)
2. OUTER WELDMENT
3. FREE-LIFT CYLINDER
4. INNER WELDMENT
5. CHAIN SHEAVE
6. LIFT CHAIN
7. CARRIAGE
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 3. Two-Stage Mast With Full Free-Lift
During lowering, main lift cylinders lower first be-
cause they have a greater load. After main lift cylin-
ders have retracted, free-lift cylinder lowers. All oil
from the lift cylinders flows through the lowering
control valves to the hydraulic tank.
THREE-STAGE MAST WITH FULL
FREE-LIFT
The three-stage mast with full free-lift (FFL) has an
outer, an intermediate, and an inner weldment. See
Figure 4. Three single-stage lift cylinders are used
to raise the carriage and extend weldments. Weld-
ments are telescopic and have load roller and strip
bearing arrangements similar to the two-stage mast.
Two main lift cylinders are installed at the back of
the outer weldment. The base of each lift cylinder
is held on a mount at the bottom of the outer weld-
ment by brackets. The top of each main lift cylinder
(cylinderrod)fitsintoaguideatthetopofthein-
termediate weldment. A clamp holds the top of the
lift cylinder in position on the outer weldment. The
free-lift cylinder is installed in the inner weldment
andheldinpositionbytwoclamps.
3

Description and Operation 4000 SRM 736
A. PHASE 1 B. PHASE 2
1. MAIN LIFT CYLINDER (2)
2. OUTER LIFT CHAIN
3. FREE-LIFT CYLINDER
4. INNER LIFT CHAIN
5. INNER WELDMENT
6. INTERMEDIATE WELDMENT
7. OUTER WELDMENT
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 4. Three-Stage Mast With Full Free-Lift
Two main lift chains fasten at one end near the top
of the outer weldment. The lift chains then go over
sheaves at the top of the intermediate weldment and
fasten at the bottom of the inner weldment. Free-
lift chains are connected to a mount behind the free-
lift cylinder. Chains then go over the sheaves and
connect to the carriage.
Three lift cylinders are connected by hoses. To extend
mast, oil from main control valve flows to all cylin-
ders at the same time. Free-lift cylinder raises first
because it lifts the least amount of weight. Free-lift
cylinder raises the carriage to the top of the inner
weldment. After free-lift cylinder reaches the end of
its stroke, the main lift cylinders begin to extend. As
main lift cylinders extend intermediate weldment,
inner weldment is extended by lift chains.
During lowering, main lift cylinders lower first be-
cause they have a greater load. After the main lift
cylinders have retracted, free-lift cylinder lowers. All
oil from lift cylinders flows through the lowering con-
trol valves to the hydraulic tank.
4

4000 SRM 736 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery on electric lift trucks and put a
tag or lock on the battery connector.
• 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. Usealadderorpersonnellifttowork
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:
• 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 po-
sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power and remove
the key. Put a DO NOT OPERATE tag in the oper-
ator’s compartment. Disconnect the battery on elec-
tric lift trucks and put a tag or lock on the battery
connector.
1. Put mast in a vertical position.
2. Raise mast to align the bottom crossmember of
the 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,
itistheintermediateweldment.SeeFigure5.
3. Use a 3/8 inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side
of the mast. Make sure hook is completely en-
gaged with a link in the chain. Make sure safety
chain does not touch lift chains or chain sheaves,
tubes, hoses, fittings, or other parts on the mast.
4. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (free-lift,
three-stage, and four-stage masts only) is com-
pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
5. Install another safety chain (3/8 inch minimum)
between the top or bottom crossmember of the
carriage and a crossmember on the outer weld-
ment.
5

Safety Procedures When Working Near Mast 4000 SRM 736
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 5. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
6

4000 SRM 736 Fork Replacement
Fork Replacement
The identification of a fork describes how the fork is
connected to the carriage. The series of lift trucks covered in this section have hook type forks. See Fig- ure 6.
A. OLD STYLE LOCK PIN ASSEMBLY B. NEW STYLE PIN ASSEMBLY
1. FORK
2. LOCK PIN
3. SPRING
4. WASHER
5. WASHER
6. WEDGE
7. KNOB
8. LEVER
9. COTTER PIN
10. LOCK PIN ASSEMBLY
Figure 6. Fork Lock Pin Assembly
7

Fork Replacement 4000 SRM 736
Theforkscanbeconnectedtothecarriagebyoneof
two types of hooks and lock pins. See Figure 6. These
lock pins are installed through the top fork hooks and
fit into slots in the top carriage bar. Separate the
forks as much as possible for maximum support of
theload.Hookforkswillslidealongthecarriagebars
to adjust for the load to be lifted. Raise the lock pin in
each fork to slide the fork on the carriage bar. Make
sure the lock pin is engaged in the carriage bar to
lock the fork in position after the width adjustment
is made.
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance.
REMOVE
WARNING
Do not try to move a fork without a lifting de-
vice. Each fork for these lift trucks can weigh
66 to 183 kg (145 to 403 lb).
1. Slide fork to fork removal notch on carriage. See
Figure 7.
Figure 7. Forks Check
Legend for Figure 7
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF DIMENSION
"X")
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93
8. FORK REMOVAL NOTCH
2. Lower fork onto blocks so that bottom hook of
fork moves through fork removal notch. See Fig-
ure 8.
1. CARRIAGE FORKS
2. HOOK FORK 3. BLOCKS
Figure 8. Hook Fork Removal
3. Lower carriage further so that top hook of fork is
disengaged from the top carriage bar.
4. Move carriage away from fork, or use a lifting
device to move fork away from carriage.
INSTALL
1. Move fork and carriage so that top hook on fork
can engage the upper carriage bar.
2. Raise carriage to move lower hook through the
fork removal notch.
3. Slide fork on the carriage so that both upper and
lower hooks engage the carriage.
4. Engage lock pin with a notch in the upper car-
riage bar.
8

4000 SRM 736 Carriage Repair
Carriage Repair
REMOVE
WARNING
Do not work under a raised carriage. Lower
the carriage or use a chain or blocks to prevent
the carriage and inner weldment from lower-
ing.
NOTE: If the mast is equipped with a sideshift car-
riage, see the paragraphs under Sideshift Carriage
Repair.
1. Put weight on the forks so carriage has stability
and will not fall when it is disconnected from the
mast.
2. Lower carriage and forks on blocks so lift chains
become loose.
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 and causing an injury or damage.
3. Remove pin from each chain anchor at the car-
riage. Disconnect lift chains from carriage. See
Figure 9.
1. CARRIAGE
2. LOAD ROLLER
3. SHIMS
4. SNAP RING
5. SIDE ROLLER
6. CHAIN ANCHOR (TWO-STAGE MAST)
7. CHAIN ANCHOR (FREE-LIFT AND
THREE-STAGE MAST)
Figure 9. Carriage
9

Sideshift Carriage Repair 4000 SRM 736
WARNING
Make sure the carriage has stability and will
not fall over when the inner weldment is raised
above the load rollers of the carriage.
4. Use lift cylinders to raise inner weldment until it
is above the load rollers 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 inner weldment until it is above the
load rollers of the carriage.
5. Move lift truck from carriage. Connect a lifting
device to the carriage. Make sure carriage is sta-
ble. Remove load backrest and forks. Put car-
riage on floor so that load rollers are up.
6. If any of the load rollers must be replaced, make
a note of the arrangement of the shims.
7. Reverse this procedure for carriage installation.
Sideshift Carriage Repair
REMOVE
1. Relieve hydraulic pressure to the sideshift cylin-
der by moving sideshift lever in both directions
several times.SeeFigure10.
2. Disconnect hydraulic lines from sideshift cylin-
der. Put caps and plugs on open lines and cylin-
der ports.
3. Remove sideshift carriage as described below:
a. Put weight on the forks so carriage is stable
and will not fall when it is disconnected from
the mast.
b. Lower carriage and forks on blocks so lift
chains become loose.
WARNING
When disconnecting the lift chains, keep con-
troloftheends. Usewiretotemporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling and causing an injury or damage.
c. Remove pin from each chain anchor at the
carriage. Disconnect lift chains from car-
riage. SeeFigure9.
DISASSEMBLE
1. Remove capscrews from lower hooks and remove
thelowerhooks.SeeFigure10.
2. Lift the mobileframefromthebottomandrotate
it forward to free it from the fixed frame.
3. Remove upper and lower pads from the fixed
frame.
4. If damaged, remove grease fittings from the fixed
frame.
5. Remove sideshift cylinder rods from each end of
the cylinder body.
6. Remove snap rings from each end of the cylinder
body and remove rod scrapers, rod bushings, and
seals fromcylinderbody.
ASSEMBLE
1. Lubricate with clean hydraulic oil and install
seals, rod bushings, and rod scrapers into the
cylinder body and secure with snap rings. See
Figure 10.
2. Install cylinder rods into each end of the cylinder
body.
3. Install grease fittings into the fixed frame if re-
moved.
4. Install upper and lower pads onto the fixed
frame.
10

4000 SRM 736 Sideshift Carriage Repair
1. CAPSCREWS
2. LOWER HOOK
3. MOBILE FRAME
4. LOWER PADS
5. UPPER PADS
6. GREASE FITTINGS
7. CYLINDER ROD
8. SNAP RING
9. ROD SCRAPER
10. ROD BUSHING
11. SEAL
12. FIXED FRAME
Figure 10. Sideshift Carriage
5. Install the mobile frame onto the fixed frame by
hooking it at the top of the fixed frame first and
lowering it to the bottom.
6. Install lower hooks and capscrews. Tighten the
capscrews to 78 N•m (58 lbf ft).
INSTALL
1. To install the sideshift carriage onto the truck,
reverse the procedure for removal as described
in section Carriage Repair.
2. Remove protective caps and plugs from hydraulic
lines and cylinder ports. Connect lines to the
sideshift cylinder.
11

Two-Stage Mast with Limited Free-Lift Repair 4000 SRM 736
Two-Stage Mast with Limited Free-Lift Repair
REMOVE - H3.50-5.50XM (H70-120XM)
MODEL LIFT TRUCKS
1. Fully lower the inner weldment. If mast must be
disassembled, remove forks and carriage as de-
scribed in sections Fork Replacement and Car-
riage Repair.
2. Connect a lifting device to all top crossmembers
of the mast weldments (see Figure 5.) Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.
3. Remove anchor pins for tilt cylinders at the mast
(see Figure 26.) Use the hydraulic system to re-
tracttiltcylinders.
4. Disconnect hydraulic line for the mast at the low-
eringcontrolvalve(seeFigure11). Disconnect
breather lines for the cylinders. Put plugs in the
open lines.
5. Remove capscrews for the pivot pins at the frame
of the lift truck (see Figure 26.) Use a lifting
device to move mast from the lift truck. Put mast
in a position so crossmembers are on the floor.
REMOVE - S3.50-5.50XM (S70-120XM) AND
E3.50-5.50XL3(E70-120XL3) MODEL LIFT
TRUCKS
1. Fully lower inner weldment. If mast must be
disassembled, remove forks and carriage as de-
scribed in sections Fork Replacement and Car-
riage Repair.
2. Connect a lifting device to all top crossmembers
of the mast weldments (see Figure 5.) Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.
3. Remove tilt pins, tilt pin retainers, anchor pin
capscrews, and washers for tilt cylinders at the
mast. Use hydraulic system to retract tilt cylin-
ders. See Figure 12.
4. Disconnect hydraulic line for the mast at the low-
ering control valve. Disconnect breather lines for
lift cylinders. Put plugs in open lines. See Fig-
ure 13.
5. Remove the four capscrews holding the left and
right mast mounting hangers to the drive axle.
Usealiftingdevicetomovemastfromlifttruck.
Put mast in a position so the crossmembers are
on the floor.
DISASSEMBLE
1. Clean area around hydraulic fittings for the lift
cylinders. Disconnect fittings at the lift cylinders
and put caps on open lines. See Figure 11 and
Figure 13.
2. Remove capscrews, washers, and brackets that
mount the bottom of each lift cylinder.
3. Slide inner weldment from outer weldment ap-
proximately 30 cm (12 in.) to disengage lift cylin-
ders from inner weldment. Remove lift cylinders
from the mounts at the bottom of outer weld-
ment.
4. Slide inner weldment from the bottom of outer
weldment approximately 30 cm (12 in.). Remove
strip bearings. Remove load rollers from both
weldments. Make a note of the shim arrange-
ment. The shim arrangement will be approxi-
mately the same during assembly procedures.
5. Slide inner weldment halfway out of the top of
outer weldment. Connect a crane to the center
of inner weldment. See Figure 14. Slide inner
weldment out of the outer weldment until stub
shafts are in the notches of the outer weldment.
Remove inner weldment from outer weldment.
6. For H3.50-5.50XM (H70-120XM) model lift
trucks, remove snap rings and bushings at the
mast mounts. See Figure 26.
7. For S3.50-5.50XM (S70-120XM) and E3.50-
5.50XL3(E70-120XL3) model lift trucks, remove
bushings and plugs at the mast mounting hang-
ers. See Figure 12.
8. Remove and disassemble chain sheaves as neces-
sary for cleaning and repair.
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4000 SRM 736 Two-Stage Mast with Limited Free-Lift Repair
Figure 11. Two-Stage Mast With Limited Free-Lift - H3.50-5.50XM (H70-120XM) Model Lift Trucks
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Two-Stage Mast with Limited Free-Lift Repair 4000 SRM 736
Legend for Figure 11
1. OUTER WELDMENT
2. INNER WELDMENT
3. LIFT CYLINDER
4. LIFT CHAIN
5. CHAIN SHEAVE
6. CHAIN ANCHOR
7. LOAD ROLLER
8. SHIMS
9. SNAP RING
10. STRIP BEARING
11. SHIMS
12. FITTING
13. CLAMP
14. CLAMP
15. CLAMP
16. HOSE
17. VELOCITY FUSE
18. BRACKET
19. HOUSING
20. FITTING
21. LOWERING CONTROL VALVE
22. FITTING
23. FITTING
1. TILT PIN
2. ANCHOR PIN CAPSCREWS
3. CAPSCREW AND WASHER
4. LUBE FITTINGS
5. MAST MOUNTING HANGER
6. MAST MOUNTING CAP
7. MAST BUSHING
8. MAST MOUNTING
CAPSCREWS
9. TILT PIN RETAINER
10. ROD END
11. TILT CYLINDER ASSEMBLY
12. CAPSCREW AND WASHER
FOR MAIN LIFT CYLINDER
RESTRAINT BRACKET
Figure 12. Mast Mounting and Tilt Cylinder Removal - S3.50-5.50XM (S70-120XM) and
E3.50-5.50XL3(E70-120XL3)ModelLiftTrucks
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