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