Hyster G160 Operating instructions

Hyster G160 (J1.60XMT, J1.80XMT, J2.00XMT) Forklift

MAST
REPAIRS
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT2[H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897507 4000 SRM 522

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Forks Repair....................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 4
Carriages Repair ................................................................................................................................................ 4
Standard Carriage, Remove.......................................................................................................................... 4
Hang-On Sideshift Carriage, Remove .......................................................................................................... 5
Standard Carriage and Hang-On Sideshift Carriage, Repair..................................................................... 6
Standard Carriage, Install............................................................................................................................ 6
Hang-On Sideshift Carriage, Install ............................................................................................................ 7
Integral Sideshift Carriage ........................................................................................................................... 7
Remove....................................................................................................................................................... 7
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 9
Install......................................................................................................................................................... 10
Mast Repair........................................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Two-Stage LFL and Two-Stage FFL Masts, Disassemble........................................................................... 12
Three-Stage FFL Mast .................................................................................................................................. 19
Disassemble............................................................................................................................................... 19
Mast and Chains, Clean and Inspect ....................................................................................................... 22
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 23
Three-Stage FFL Mast, Assemble ................................................................................................................ 24
Install ............................................................................................................................................................. 26
Lift Cylinders Repair ......................................................................................................................................... 27
Main Lift Cylinders, Remove ........................................................................................................................ 27
Free-Lift Cylinder, Remove........................................................................................................................... 27
Lift Cylinders, Disassemble .......................................................................................................................... 28
Lift Cylinders, Assemble ............................................................................................................................... 28
Main Lift Cylinders, Install .......................................................................................................................... 31
Free-Lift Cylinder, Install ............................................................................................................................. 32
Header Hose Arrangements .............................................................................................................................. 32
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 32
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 38
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 38
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 43
Three-Stage FFL Mast, New Hose Install ................................................................................................... 45
Three-Stage FFL Mast, Adjust Hoses After Installation ............................................................................ 55
Header Hose Arrangement................................................................................................................................ 56
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 56
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 56
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 60
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 65
Three-Stage FFL Mast, New Hose Install ................................................................................................... 67
Three-Stage FFL Mast, Adjust Hoses After Install..................................................................................... 72
Lift and Tilt System Leak Check ...................................................................................................................... 76
Lift Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Adjustment................................................................................................................................. 77
Lift Chains Adjustment..................................................................................................................................... 78
©2004 HYSTER COMPANY i

Table of Contents Mast
TABLE OF CONTENTS (Continued)
Mast Adjustment ............................................................................................................................................... 80
Carriage Adjustment ......................................................................................................................................... 82
Troubleshooting.................................................................................................................................................. 82
This section is for the following models:
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM2)[D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT2[H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]
ii

4000 SRM 522 Safety Procedures When Working Near Mast
General
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
This section has the repair procedures for the
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL)
masts; and for the sideshift carriages. Carriage
Adjustment and Troubleshooting are at the end of
this section. See the section Mast,Description
4000 SRM 521 for the description and operation of
the masts.
NOTE: Hoses have a service life that is determined
by application and time. All hoses must be inspected
at the intervals specified in the Maintenance Sched-
uleforthehy
draulic system. Install a new hose if the
hose is worn, damaged, soft or hard, and no longer
flexible. If necessary, make a comparison to a new
hose that is the correct replacement for the hose you
are inspecting.
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 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. 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 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:
1. Put the mast in a vertical position.
2. Raise the mast to align the bottom crossmem-
ber 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, it is the intermediate weld-
ment. See Figure 1.
3. Usea9.5mm(3/8in.) minimumsafetychain
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 the mast until there is tension in the
safety chain and the free-lift cylinder (two-stage
full free-lift and three-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).
NOTE: After lowering or restraining the mast, shut
off the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment.
1

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Safety Procedures When Working Near Mast 4000 SRM 522
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
2

4000 SRM 522 Forks Repair
Forks Repair
The forks are held on the carriage by hooks. The
forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the top
bar carriage. Always check that the latch pins for
the forks keep the forks in position on the carriage.
Replace damaged latch pins parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage.
REMOVE
WARNING
Do NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
Aforkcanb
e removed from the carriage for replace-
ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car-
riage further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
from the fork, or use a lifting device to move the fork
away from the carriage.
1. CARRIAGE BARS
2. HOOK FORK 3. BLOCKS
Figure 2. Hook Fork Removal
A. EARLIER MODELS B. LATER MODELS
1. FORKS
2. CARRIAGE
3. LOAD BACKREST EXTENSION
4. FORK REMOVAL NOTCH
5. LATCH PIN ASSEMBLY
6. LEVER
7. WASHER
8. SPRING
9. PIN
10. KNOB
Figure 3. Carriage and Forks
3

Carriages Repair 4000 SRM 522
INSTALL
Movetheforkandcarriagesothetophookonthe
fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork
removal notch. Slide the fork on the carriage so both
upperandlowerhooksengagethecarriagebars.En-
gagethelatchpinwithanotchintheuppercarriage
bar.
Carriages Repair
STANDARD CARRIAGE, REMOVE
1. Put a one-quarter capacity load on the forks. The
load must give the carriage stability so the car-
riage cannot fall when it is disconnected from the
mast.
2. Lower the carriage and forks on blocks so the lift
chains become loose.
3. Remove the load backrest extension.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pinfromeachchainanchoratthe
carriage. See Figure 4. Disconnect the lift chains
from the carriage. Usewiretoconnecttheends
of the liftchainstoapartofthemast.Makesure
the chains can move freely when the inner mast
weldmentisraised.
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast weld-
ment is above the load rollers of the carriage.
5. Use the lift cylinders to raise the inner mast
weldment. If the hydraulic system cannot be
used, disconnect the lift cylinders from the inner
or intermediate mast weldment. Connect a crane
[the capacity of the crane must be at least 681 kg
(1501 lb)] to the top of the inner mast weldment.
Carefully raise the inner mast weldment until it
is above the load rollers of the carriage.
NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
1. CARRIAGE
2. SNAP RING
3. SHIM
4. LOAD ROLLER
5. CHAIN ANCHOR
6. CHAIN PIN
7. COTTER PIN
8. ANCHOR PIN
9. SPACER
Figure 4. Standard Carriage
6. Move the lift truck away from the carriage. Com-
pletely lower the inner mast weldment so it can-
not move.
7. Connect a lifting device to the carriage. Remove
the load from the forks with another lift truck.
Lower the carriage to the floor so the load rollers
are facing up.
8. Iftheforksareremoved,usealiftingdeviceto
put the carriage on the floor so the load rollers
are up.
4

4000 SRM 522 Carriages Repair
HANG-ON SIDESHIFT CARRIAGE,
REMOVE
1. Lower the carriage completely. Remove the forks
and the load backrest extension.
2. Connect a crane [the capacity of the crane must
be at least 681 kg (1501 lb)] to the lifting eye on
thesideshiftcarriage.SeeFigure5.
3. Remove the two upper capscrews from the lower
apron. Slowly loosen the two bottom capscrews,
but do not remove them. The slotted holes will al-
low the lower apron to move down so the sideshift
carriage can be removed.
4. Carefully lift the sideshift carriage from the stan-
dard carriage. The sideshift cylinder support
bracket and cylinder will stay on the standard
carriage. Remove the bearings.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic lines of the system until the oil for the
system is cool and the pressure is relieved.
5. Disconnect the hydraulic lines at the sideshift
cylinder. Put caps on the open hydraulic lines.
Remove the cylinder support bracket from the
standard carriage. If necessary, remove the
threaded rods and shims in order to remove the
sideshift cylinder.
A. HYDRAULIC CONNECTIONS - TWO-STAGE,
FULL FREE-LIFT AND THREE-STAGE, FULL
FREE-LIFT
B. HYDRAULIC CONNECTIONS - TWO-STAGE,
LIMITED FREE-LIFT
1. TOP BEARING
2. CYLINDER SUPPORT BRACKET
3. THREADED ROD
4. SHIM
5. SIDESHIFT CYLINDER
6. GREASE FITTING
7. UPPER APRON
8. BOTTOM BEARING
9. LOWER APRON
10. LIFTING EYE
11. SHIM STRIP
Figure 5. Hang-On Sideshift Carriage
5

Carriages Repair 4000 SRM 522
STANDARD CARRIAGE AND HANG-ON
SIDESHIFT CARRIAGE, REPAIR
NOTE: The carriage can have four or six load rollers.
When the carriage has four load rollers, shims are
used behind all of the load rollers. When the carriage
has six load rollers, shims are installed on the bottom
and middle rollers only.
1. If any of the load rollers must be replaced, make
a note of the location and number of the shims.
Install the shims, load rollers, and snap rings.
See Carriage Adjustment for correct adjustment
of the load rollers.
2. If the carriage aprons have any protruding welds
or damaged notches, repair by grinding, filing, or
welding.
3. The repair procedure for the sideshift cylinder is
as follows (see Figure 5 and Figure 6):
a. Remove the retainers from the shell. Pull the
rod from the shell.
1. SHELL
2. O-RING
3. BACKUP RING
4. ROD SEAL
5. RETAINER
6. WIPER
7. PISTON AND ROD
8. PISTON SEAL
Figure 6. Sideshift Cylinder
b. Replace seals, O-rings, or backup rings as
necessary. Use the installation guides to pre-
vent damage to the seals.
c. Lubricate all internal parts with clean hy-
draulic oil.
d. Install the piston and rod in the shell. Ap-
ply Loctite®242 to the threads of the retain-
ers. Install the retainers and tighten them to
27 N•m (20 lbf ft).
4. Replace the cylinder rod seals as follows:
a. Clamp the cylinder in a soft-jawed vise. DO
NOT clamp on the cylinder shell.
b. With the cylinder rod centered, unscrew the
retainer from each end of the cylinder. Slide
the retainers off the cylinder rod.
NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step f.
c. Remove the seals and O-ring from each re-
tainer with a brass O-ring tool. DO NOT
scratch the grooves.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
d. Clean the retainers and the cylinder rod with
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
e. Install the seals into the retainer grooves.
Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc-
tion of the rod seals. Pressure seals are in-
stalled with the lip toward the pressure
side of the cylinder.
f. Apply a film of hydraulic oil to the inside
of the retainers. Carefully slide them onto
the cylinder rod. Tighten the retainers to
165 N•m (122 lbf ft).
STANDARD CARRIAGE, INSTALL
1. Use the hydraulic system of the lift truck or a
crane to raise the inner mast weldment. If the
hydraulic system cannot be used, disconnect the
lift cylinders from the inner or intermediate mast
weldment. Connect a crane [the capacity of the
crane must be at least 681 kg (1501 lb)] to the top
of the inner mast weldment. Carefully raise the
inner mast weldment until it is above the load
rollers of the carriage.
6

4000 SRM 522 Carriages Repair
2. Move the lift truck toward the carriage until the
inner mast weldment is aligned with the carriage
rollers. Carefully lower the inner mast weldment
until it engages all of the load rollers.
3. Check the clearance of the load rollers. See Car-
riage Adjustment in this section.
4. Connect the lift chains to the chain anchors at the
carriage. Use new cotter pins in the anchor pins.
Adjust the lift chains as described in Carriage
Adjustment in this section.
5. Install the backrest on the sideshift carriage.
Tighten the capscrews to 195 N•m (144 lbf ft).
HANG-ON SIDESHIFT CARRIAGE,
INSTALL
1. Install the sideshift cylinder in the cylinder sup-
port bracket. See Figure 5. Use an equal num-
ber of shims on both sides of the cylinder to limit
side-to-side movement within the bracket. Maxi-
mum movement is 0.6 mm (0.024 in.). Install the
threaded rods to hold the cylinder in position and
tighten to 18 N•m (159 lbf in).
2. Install the cylinder support bracket on the stan-
dard carriage. Make sure the bracket is engaged
in the center notch in the top carriage bar.
3. Connect the hydraulic lines to the sideshift cylin-
der. See Figure 5. Lubricate the ends of the cylin-
der rod with multipurpose grease.
4. Install the top bearing on the cylinder support
bracket. Lubricate only the outer surface of the
bearing with multipurpose grease.
5. Connect the top and bottom aprons by installing
the two bottom capscrews. Do NOT tighten the
capscrews. Lubricate only the outer surface of
the bottom bearing with multipurpose grease.
Install the bottom bearing in the lower apron.
6. Install the shim strips under the bottom bearing
strip (be sure the shims are seated between the
shim stops) so the bottom bearing strip will just
clear the lower lip of the standard carriage bar
when the lower apron is brought into position.
7. Make sure the standard carriage is completely
lowered. Connect a crane [the capacity of the
crane must be at least 908 kg (2002 lb)] to the
lifting eye. Install the sideshift carriage on the
standard carriage. Put blocks under the bottom
apron of the sideshift carriage so the bottom
bearing moves tight against the standard car-
riage when the lifting device is lowered.
Install the two top capscrews into the sideshift
carriage. Tighten the capscrews to the following
torque:
•On H/S1.50-1.75XM, H/S2.00XMS (H/S25-
35XM, H/S40XMS), E1.50-1.75XM (E25-
35XM, E25-35XM2) [D114], E2.00XMS
(E40XMS, E40XM2S [D114], E1.50-2.00XM
(E25-35Z, E40ZS) [E114], H/S2.00-2.75XM
(H/S40-55XM), S/E/J2.00-2.50XL (S/E/
J40-50XL), J1.60-2.00XMT (J30-40XMT),
J2.00-2.50XM (J40-50XM) [A216], and
J2.00-2.50XM (J40-50Z) [A416] units, tighten
all of the capscrews to 435 N•m (321 lbf ft).
•On H/S3.00-3.20XM (H/S60-65XM), J3.00-
3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z)
[A416], E2.00-3.20XM (E45-65Z) [G108], and
S/E/J3.00XL (S/E/J60XL) units, tighten all of
the capscrews to 755 N•m (557 lbf ft).
8. Install the load backrest extension on the
sideshift carriage. Tighten the capscrews to
195 N•m (144 lbf ft).
9. Remove the lifting device. Lubricate the top
bearings at the grease fittings.
INTEGRAL SIDESHIFT CARRIAGE
Remove
1. Lower the carriage completely. Remove the forks
and the load backrest extension. See Figure 3
and Figure 7.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic lines of the system until the oil for the
system is cool and the pressure is relieved.
2. Disconnect the hydraulic lines at the sideshift
cylinder. Put caps on the open hydraulic lines.
3. Remove the lower mounting hooks.
7

Carriages Repair 4000 SRM 522
NOTE: TWO AND THREE-STAGE FFL IS SHOWN.
1. INNER CARRIAGE
2. OUTER FRAME
3. SIDESHIFT CYLINDER
4. UPPER BEARING
5. LOWER BEARING
6. LOWER HOOK
7. CAPSCREW
8. WASHER
9. CLEVIS PIN
10. HAIRPIN
11. PIN
12. LUBE FITTING
13. PIN
14. CHAIN ANCHOR
15. SNAP RING
16. PIN
17. COTTER PIN
18. LOAD ROLLER
19. SHIMS
20. SPACER
21. SNAP RING
22. SPACER
Figure 7. Integral Sideshift Carriage
8

4000 SRM 522 Carriages Repair
4. Use a crane with a capacity of at least 450 kg
(992 lb) to lift the outer frame away from the in-
ner frame. Lay the outer frame flat on a pallet or
workbench.
5. If the sideshift cylinder or the bearings are to be
serviced, remove the capscrews and the cylinder
assembly from the inner frame.
Clean and Inspect
1. Inspect the lower mounting hooks for wear. Re-
place the hooks if they are worn beyond the wear
limit. The wear limit clearance range is 0.8 mm
(1/32 in.) minimum and 1.6 mm (1/16 in.) maxi-
mum. See Figure 7.
2. Clean and inspect the carriage bars for damage
and smoothness. Ensure the bars are parallel
and the ends are flush.
3. Clean the bearing areas. Inspect the sideshift
bearings for wear as follows:
a. Remove the upper bearings from the upper
apron. If either upper bearing is worn to
less than 2.5 mm (3/32 in.) thickness, re-
place both upper bearings by driving the up-
per bearings from the upper apron.
b. Remove the lower bearings from the lower
carriage bar. If either lower bearing is worn
to less than 2.5 mm (3/32 in.) thickness, re-
place both lower bearings by prying the lower
bearings from the lower carriage bar.
4. Inspect the sideshift cylinder. Replace the en-
tire cylinder assembly if a cylinder rod is bent or
scored or if there is damage on the outside of the
cylinder shell that could impair performance or
cause leaks under pressure. See Figure 8.
Repair
1. If any of the load rollers must be replaced, make
a note of the location and number of the shims.
Install the shims, load rollers, and snap rings.
See Carriage Adjustment for correct adjustment.
2. If the carriage bars have any protruding welds
or damaged notches, repair by grinding, filing,
or welding.
1. CYLINDER SHELL
AND ROD
2. SEAL
3. O-RING
4. RETAINER
5. WIPER
Figure 8. Integral Sideshift Cylinder
3. Replace the cylinder rod seals as follows:
a. Clamp the cylinder in a soft-jawed vise. DO
NOT clamp on the cylinder shell.
b. With the cylinder rod centered, unscrew the
retainer from each end of the cylinder. Slide
the retainers off the cylinder rod.
NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step f.
c. Remove the seals and O-ring from each re-
tainer with a brass O-ring tool. DO NOT
scratch the grooves.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
d. Clean the retainers and the cylinder rod with
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
9

Mast Repair 4000 SRM 522
e. Install the seals into the retainer grooves.
Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc-
tion of the rod seals. Pressure seals are in-
stalled with the lip toward the pressure
side of the cylinder.
f. Apply a film of hydraulic oil to the inside
of the retainers. Carefully slide them onto
the cylinder rod. Tighten the retainers to
165 N•m (122 lbf ft).
Install
NOTE: Useawoodblockoraplastichammertofully
seat the upper bearings onto the upper carriage bar.
Proper lower hook clearance requires the upper bear-
ings be fully seated.
1. If necessary, install the lower sideshift bearings.
Then install the upper sideshift bearings. Lubri-
cate the upper and lower sideshift bearings with
chassis grease. See Figure 7.
2. If necessary, install the sideshift cylinder.
3. Use a crane with a capacity of at least 450 kg
(992 lb) to install the outer frame on the inner
frame.
4. Install the lower mounting hooks. For proper
sideshift operation, make sure there is 0.8 to
1.6 mm (1/32 to 1/16 in.) clearance between the
bottom of the hooks and the outer frame.
5. Connect the hydraulic lines to the sideshift cylin-
der.
6. Install the backrest on the sideshift carriage.
Tighten the capscrews to 195 N•m (144 lbf ft).
7. Install the forks.
Mast Repair
REMOVE
WARNING
The mast is heavy. The mast can weigh approx-
imately 907.2 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
NOTE: If the mast needs to be disassembled, remove
the forks and carriage. If only the lift cylinders need
to be removed for repair, the mast does not need to be
removed from the lift truck. See the procedures for
Lift Cylinders Repair.
NOTE: The length of the lift chains must be checked
before the mast is removed. See Step 2 in Mast and
Chains, Clean and Inspect.
1. Fully lower all of the mast weldments and the
carriage. Tilt the mast fully forward. Connect a
crane with a capacity of at least 1600 kg (3527 lb)
tothetopofthemastusingchains. Makesureall
the mast weldments are fastened together. Make
sure the chains will not damage the sheaves, tub-
ing, or other parts of the mast.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic hoses until the oil in the system is cool.
2. Put a drain pan under the area of the hydraulic
fittings. Disconnect the hydraulic line at the ex-
ternal lowering control valve on the outer mast
weldment.
WARNING
Use a driver, NOT your fingers, to push the an-
chor pins from the clevises on the tilt cylinders.
The cylinder or mast can move and cause seri-
ous injury.
3. Remove the cotter pins and anchor pins or the
capscrews, washers, and anchor pins at the tilt
cylinder mounts on the outer mast weldment.
NOTE: To perform the next two steps, the lift truck
must be raised. See the Operator Manual or Pe-
riodic Maintenance Manual foryourlifttruckfor
instructions on how to put a lift truck on blocks.
4. On the H/S2.00-3.20XM (H/S40-65XM),
E2.00-3.20XM (E40-65XM, E40-65XM2)
(F108), E2.00-3.20XM (E45-65Z) (G108)
10

4000 SRM 522 Mast Repair
J2.00-3.20XM (J40-60XM, J40-60XM2) (A216),
and J2.00-3.20XM (J40-65Z) (A416), see Fig-
ure 9, remove the capscrews that hold the outer
mast weldment to the pivot pins at the mounts.
5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-
35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM2) (D114), E2.00XMS (E40XMS,
E40XMSS (D114), E1.50-2.00XM (E25-35Z,
E40ZS) (E114), and J1.60-2.00XMT (J30-
40XMT), see Figure 10; on S/E/J2.00-3.00XL
(S/E/J40-60XL), see Figure 11; and on J1.60-
2.00XMT (J30-40ZT), see Figure 12, and remove
thecapscrewsthatholdtheretainercapstothe
mast mounts.
1. SPACER
2. TILT CYLINDER
3. OUTER MAST
WELDMENT
4. SHIMS
5. PIN
6. ROD END
7. O-RING
8. PIVOT PIN
9. DRIVE AXLE
HANGER(MAST
MOUNT)
10. COTTER PIN
Figure 9. Mast Mounting H/S2.00-3.20XM
(H/S40-65XM), E2.00-3.20XM (E40-65XM,
E40-65XM2) (F108), E2.00-3.20XM (E45-65Z)
(G108), J2.00-3.20XM (J40-60XM, J40-60XM2)
(A216), and J2.00-3.20XM (J40-65Z) (A416),
1. RETAINERCAP
2. SPACER
3. TILT CYLINDER
4. OUTER MAST
WELDMENT
5. BUSHING
6. SHIMS
7. PIN
8. ROD END
9. O-RING
10. CAPSCREW
11. FLAT WASHER
Figure 10. Mast Mounting H/S1.50-1.75XM,
H/S2.00XMS (H/S25-35XM, H/S40XMS),
E1.50-1.75XM (E25-35XM, E25-35XM2) (D114),
E2.00XMS (E40XMS, E40XM2S (D114),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
J1.60-2.00XMT (J30-40XMT)
WARNING
The mast is heavy. The mast can weigh approx-
imately 907.2 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
6. Use the crane to lift the mast assembly from the
lift truck. Put the mast on the floor so the back
of the mast is toward the floor.
11

Mast Repair 4000 SRM 522
1. RETAINER CAP
2. SPACER
3. TILT CYLINDER
4. OUTER MAST
WELDMENT
5. BUSHING
6. SHIMS
7. PIN
8. ROD END
Figure 11. Mast Mounting S/E/J2.00-3.00XL
(S/E/J40-60XL)
TWO-STAGE LFL AND TWO-STAGE FFL
MASTS, DISASSEMBLE
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic lines of the system until the oil for the
system is cool and the pressure is relieved.
NOTE: If only the lift cylinders need to be removed
and repaired, see the procedures for Lift Cylinders
Repair. When the mast has header hoses, see the
procedures for the Header Hose Arrangements.
1. Clean the area around the hydraulic fittings for
the lift cylinders. Disconnect the fittings at the
lift cylinders and put caps on the open lines.
2. Remove the chains and header hoses. On the
two-stage FFL mast, remove the brackets and
disconnect the hydraulic line for the free-lift
cylinder. Remove the free-lift cylinder. Discon-
nect the free-lift chains at the crossmember.
1. RETAINER CAP
2. LOCKWASHER
3. TILT CYLINDER
4. OUTER MAST
WELDMENT
5. BUSHING
6. NUT
7. PIN
8. ROD END
9. WASHER
10. CAPSCREW
Figure 12. Mast Mounting J1.60-2.00XMT
(J30-40ZT)
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection
during removal or installation.
3. Remove the nut, bolt, and spacer at the mount
near the top of each main lift cylinder. Remove
the snap rings and washers from the top of
each main lift cylinder. Disconnect the main lift
chains at the mounts.
12

4000 SRM 522 Mast Repair
4. On the H/S2.00-3.20XM (H/S40-65XM),
E2.00-3.20XM (E40-65XM, E40-65XM2) (F108),
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
(J40-65Z) (A416), and S/E/J2.00-3.00XL
(S/E/J40-60XL), two-stage FFL mast, disconnect
the FFL supply tube and remove the hydraulic
fitting from the top of the left-hand main lift
cylinder.
On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-
35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM2) (D114), E2.00XMS (E40XMS,
E40XM2S) (D114), E1.50-2.00XM (E25-35Z,
E40ZS) (E114), and J1.60-2.00XMT (J30-
40XMT) two-stage FFL masts, disconnect the
FFL supply tube and remove the hydraulic fit-
ting from the top of the right-hand main lift
cylinder.
WARNING
The mast weldment can slide when the mast is
moved. A weldment that slides can cause in-
jury.
5. Slide the inner mast weldment from the outer
mast weldment approximately 30 cm (12 in.) to
disengage the main lift cylinders from the inner
mast weldment. Remove the main lift cylinders
from the outer mast weldment. See Figure 13
and Figure 14.
6. Slide the inner mast weldment from the bot-
tom of the outer mast weldment approximately
30 cm (12 in.). Remove the strip bearings and
load rollers from the top of the outer mast weld-
ment. Remove the load rollers from the bottom
of the inner mast weldment. Make a note of each
shim arrangement and load roller location. The
shim arrangements will be approximately the
same during assembly.
WARNING
The mast is heavy. The mast can weigh ap-
proximately 681 kg (1501 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
NOTE: When replacing the outer channel weldment,
copy the part number and date code information from
the old channel and stamp that information on the
new channel with a letter R at the end to indicate
that it has been replaced.
7. Slide the inner mast weldment halfway out of
the top of the outer mast weldment. Connect a
crane [the capacity of the crane must be at least
681 kg (1501 lb)] to the center of the inner mast
weldment. See Figure 15. Slide the inner mast
weldment out of the outer mast weldment until
the mast stub shafts of the inner mast weldment
are in the notches of the outer channels. Remove
the inner mast weldment from the outer mast
weldment.
8. Remove the chain sheaves and disassemble them
as necessary for repair and cleaning.
13

Mast Repair 4000 SRM 522
Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)
14