Hyster J160 User manual

Hyster J160 (J30ZT J35ZT J40ZT) Forklift

MAST REPAIRS (S/N A551, A555,
A559, A661, A662, A663, A664, B507,
B508, B509, B551, B555, B559, B562,
B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509,
D515, D562, D563, D564, E509, AND
E564)
2-, 3-, AND 4-STAGE MASTS
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
PART NO. 1580524 4000 SRM 1148

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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Safety Procedures When Working Near Mast .......................................................................................................2
Fork Replacement ................................................................................................................................................... 4
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork
Positioner Before August, 2012 ..........................................................................................................................4
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner ......................6
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner
Before August, 2012 ............................................................................................................................................7
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner ........................7
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork
Positioner Before August, 2012 ..........................................................................................................................8
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner .......................9
Carriages Repair ................................................................................................................................................... 10
Standard Carriage ............................................................................................................................................ 10
Remove .......................................................................................................................................................... 10
Repair ............................................................................................................................................................ 11
Install ............................................................................................................................................................ 11
Standard Carriage, Remove ............................................................................................................................. 12
Hang-On Sideshift Carriage, Remove ..............................................................................................................13
Standard Carriage and Hang-On Sideshift Carriage, Repair ........................................................................ 14
Standard Carriage, Install ............................................................................................................................... 15
Hang-On Sideshift Carriage, Install ................................................................................................................15
Integral Sideshift Carriage ...............................................................................................................................16
Remove .......................................................................................................................................................... 16
Clean and Inspect ......................................................................................................................................... 19
Repair ............................................................................................................................................................ 20
Install ............................................................................................................................................................ 20
Fork Positioner ..................................................................................................................................................21
Remove .......................................................................................................................................................... 21
Clean and Inspect ......................................................................................................................................... 26
Disassemble and Assemble .......................................................................................................................... 26
Install ............................................................................................................................................................ 26
Fork Positioner Hydraulic Hose Adjustment ..........................................................................................27
Disconnecting Attachment Hydraulic Quick Disconnect Hoses .....................................................................29
Connecting Attachment Hydraulic Quick Disconnect Hoses ......................................................................... 29
Mast Repair ........................................................................................................................................................... 30
Mast, Remove ....................................................................................................................................................30
Two-Stage LFL and Two-Stage FFL Masts .....................................................................................................33
Disassemble .................................................................................................................................................. 33
Clean and Inspect ......................................................................................................................................... 42
Three-Stage FFL Mast ......................................................................................................................................44
Disassemble .................................................................................................................................................. 44
Clean and Inspect ......................................................................................................................................... 48
Two-Stage LFL and Two-Stage FFL Mast ...................................................................................................... 50
Assemble ....................................................................................................................................................... 50
Three-Stage FFL Mast ......................................................................................................................................51
Assemble ....................................................................................................................................................... 51
Four-Stage FFL Mast - Manufactured Before July, 2009 .............................................................................. 53
Disassemble .................................................................................................................................................. 53
Clean and Inspect ......................................................................................................................................... 58
Table of Contents
i

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TABLE OF CONTENTS (Continued)
Assemble ....................................................................................................................................................... 60
Four-Stage FFL Mast - Manufactured After July, 2009 .................................................................................61
Disassemble .................................................................................................................................................. 61
Clean and Inspect ......................................................................................................................................... 69
Assemble ....................................................................................................................................................... 70
Mast, Install ...................................................................................................................................................... 71
Header Hose Arrangement ................................................................................................................................... 75
Two-Stage LFL ..................................................................................................................................................75
Two-Stage FFL ..................................................................................................................................................83
Three-Stage FFL ...............................................................................................................................................98
Standard ........................................................................................................................................................98
Four-Stage FFL Mast - Manufactured Before July, 2009 ............................................................................ 116
Four-Stage FFL Mast - Manufactured After July, 2009 ...............................................................................126
Adjustment ......................................................................................................................................................133
Lift Chains Adjustment ...................................................................................................................................... 133
Carriage Adjustments .........................................................................................................................................136
Mast Adjustments ............................................................................................................................................... 136
Load Roller Adjustment ..................................................................................................................................136
Mast Side Kicking Adjustment ...................................................................................................................... 139
This section is for the following models:
(S30FT, S35FT, S40FTS) [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
Table of Contents
ii

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);
and Four-Stage, Full Free-Lift (FFL) masts and
carriages. Procedures for Carriage Adjustments are
located at the end of this section.
NOTE: For models J1.60-2.00XMT (J30-40ZT)
[J160], this section applies to only to Four-Stage
masts. Refer to Mast Repairs 4000SRM0522 for
Two-Stage and Three-Stage masts for these
particular models.
NOTE: Hoses have a service life that is determined
by application and time. 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.
4000 SRM 1148 General
1

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 shift. Distances be-
tween 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
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
OPERATE tag in the operator's compart-
ment. Disconnect the battery 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. Use a ladder or personnel lift to
work on the mast.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely:
Turn the key switch to the ON position and
push the lift/lower control lever forward un-
til 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
mast upright that moves in outer mast with
crossmember on outer mast. On the two-stage
mast, the moving part is the inner mast. On the
three-stage mast, it is the intermediate mast.
On the four-stage mast, it is the first intermedi-
ate mast. See Figure 1.
3. Use a 3/8-inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put hook on
back side of mast. Make sure hook is completely
engaged 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 mast until there is tension in safety
chain and free-lift cylinder (full free-lift models)
is completely retracted.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and re-
move key. Put a DO NOT OPERATE tag in the
operator's compartment. Disconnect battery and
put a tag or lock on battery connector.
5. Install another safety chain (9.5 mm (3/8 in.)
minimum) between the top or bottom bar of the
carriage (item 6, Figure 1) and a crossmember
on the outer mast as a secondary safety device.
Install a DO NOT REMOVE tag on the safety
chain(s).
Safety Procedures When Working Near Mast 4000 SRM 1148
2

A. TWO-STAGE LFL MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST
D. FOUR-STAGE FFL MAST
1. OUTER MAST
2. INNER MAST
3. INTERMEDIATE MAST
4. HOOK
5. FREE-LIFT CYLINDER
6. CARRIAGE BAR
7. CROSSMEMBER
8. FIRST INTERMEDIATE MAST
Figure 1. Safety Chaining the Mast
4000 SRM 1148 Safety Procedures When Working Near Mast
3

Fork Replacement
Forks are held on the carriage by hooks and kept in
position by pins inserted through top fork hooks
into slots in top carriage bar. If pin does not remain
engaged in carriage slot, replace with new pin.
On lift truck models not equipped with a fork posi-
tioner attachment, or equipped with a fork posi-
tioner manufactured before August, 2012, forks are
held on the carriage by hooks and kept in position
by pins inserted through the top fork hooks into
slots in top carriage bar. See Figure 4.
CAUTION
Remove fork latch pins 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.
The forks are held on the carriage by hooks. Forks
on a standard carriage or an integral sideshift car-
riage not equipped with a fork positioner attach-
ment, are held in position by pins that fit through
the top fork hooks and into slots in the top carriage
bar. If pin does not remain engaged in carriage slot,
replace with new pin. Always check that pins for
forks keep forks in position on carriage. Replace
damaged fork pin parts. Forks are removed from
carriage by aligning forks with fork removal notch.
Fork removal notch is in bottom bar of carriage.
See Figure 4.
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. Depending
on the size and configuration of forks installed on
lift truck, there may be a spacer bar between the
inner and outer fork carriers. See Figure 2. The
forks are removed from the carriage by aligning the
forks with fork removal notch. Fork removal notch
is in the bottom bar of carriage. See Figure 4.
1. OUTER FORK CARRIER
2. CAPSCREW
3. SPACER BAR*
4. INNER FORK CARRIER
*SPACER BAR USED ON 977 mm (38.5 in.) AND
1067 mm (42 in.) CLASS II CARRIAGES.
Figure 2. Fork Carrier Components
REMOVE, LIFT TRUCKS NOT EQUIPPED
WITH FORK POSITIONER OR EQUIPPED
WITH FORK POSITIONER BEFORE
AUGUST, 2012
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
CAUTION
There are NO pins in forks on lift trucks equipped
with a fork positioner.
NOTE: Forks are to be replaced in sets, not indi-
vidually, by trained personnel only.
Safety Procedures When Working Near Mast 4000 SRM 1148
4

NOTE: If lift truck is equipped with a fork posi-
tioner, see the section Carriages Repair for proce-
dures to remove the forks.
1. Slide fork to fork removal notch in bottom bar
of carriage. See Figure 3 and Figure 4Figure 5.
2. Lower fork onto blocks so bottom hook of fork
moves through fork removal notch. See Fig-
ure 4Figure 5.
3. Lower carriage further so top hook of fork is
disengaged from top carriage bar.
4. Move carriage away from fork or use a lifting
device to move fork away from carriage.
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 3. Hook Fork Removal
1. LOAD BACKREST
2. CARRIAGE
3. FORKS
4. FORK
5. KNOB
6. WEDGE
7. WASHER
8. SPRING
9. PIN
10. FORK REMOVAL NOTCH
Figure 4. Carriage and Forks, Hook Forks
4000 SRM 1148 Fork Replacement
5

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 5. Carriage and Forks
REMOVE, LIFT TRUCKS
MANUFACTURED AFTER AUGUST, 2012
AND EQUIPPED WITH FORK
POSITIONER
WARNING
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
CAUTION
Remove fork latch pins 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 replaced in sets, not indi-
vidually, by trained personnel only.
NOTE: Before removing forks, make a notation of
the hole position of the fork carrier blocks and re-
tainer capscrews on the fork carrier. See Figure 6.
1. Lower forks onto blocks for support. See Fig-
ure 3.
2. Remove retainer capscrews and fork carrier
blocks from fork carriers. See Figure 6.
3. Attach a lifting device to forks. Slide forks off
carriers.
4. Move carriage away from fork or use a lifting
device to move fork away from carriage.
Fork Replacement 4000 SRM 1148
6

1. RETAINER CAPSCREWS
2. FORK CARRIER BLOCKS
3. FORKS
4. FORK CARRIER
Figure 6. Forks Removal, Lift Trucks Equipped with Fork Positioner Manufactured After August, 2012
INSTALL, LIFT TRUCKS NOT EQUIPPED
WITH FORK POSITIONER OR EQUIPPED
WITH FORK POSITIONER BEFORE
AUGUST, 2012
NOTE: If lift truck is equipped with a fork posi-
tioner, see Carriages Repair for procedures to re-
move the forks.
WARNING
DO NOT try to install a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
1. Move fork and carriage so top hook of fork can
engage upper carriage bar.
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 4Figure 5.
INSTALL, LIFT TRUCKS
MANUFACTURED AFTER AUGUST, 2012
AND EQUIPPED WITH FORK
POSITIONER
WARNING
DO NOT try to install a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
4000 SRM 1148 Fork Replacement
7

CAUTION
Remove fork latch pins 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 replaced in sets, not indi-
vidually, by trained personnel only.
1. Move carriage into position to install forks.
2. Use lifting device and slide forks onto fork car-
riers. See Figure 7.
NOTE: Install fork carrier blocks and retainer cap-
screws in hole positions on fork carriers as noted
during removal.
3. Install fork carrier blocks and retainer cap-
screws in hole positions on fork carriers as no-
ted during removal.
4. Tighten retainer capscrews to
100 N•m (75 lbf ft).
NOTE: DIMENSIONS SHOWN ON BOTTOM OF FORK CARRIERS ARE THE WIDTH OF THE FORK BEING
INSTALLED. THE TWO STAGE LFL CARRIAGE AND THE THREE STAGE FFL CARRIAGE ARE THE SAME.
1. RETAINER CAPSCREW
2. FORK CARRIER
3. FORK CARRIER BLOCK
Figure 7. Hole Location, Fork Mounting on Fork Carriers
CHECKS, LIFT TRUCKS NOT EQUIPPED
WITH FORK POSITIONER OR EQUIPPED
WITH FORK POSITIONER BEFORE
AUGUST, 2012
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.
1. Inspect forks for cracks and wear.
2. Check alignment of fork tips. Difference in
height of fork tips must be less than three per-
cent of fork length. See Table 1 and Figure 8.
Some applications may require closer align-
ment. If forks DO NOT meet specification they
both must be replaced.
Fork Replacement 4000 SRM 1148
8

Table 1. Fork Tip Alignment
Fork Tip Alignment Specifications
Standard Fork
Lengths
Maximum Fork Tip
Difference1
mm (in.) mm (in.)
914 (36) 27 (1.08)
1067 (42) 32 (1.26)
1219 (48) 37 (1.44)
1372 (54) 41 (1.62)
1524 (60) 46 (1.80)
1829 (72) 55 (2.16)
1Difference of alignment between fork tips must be
no more than 3% of the total fork length.
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 8. Fork Check
3. Check that the bottom of each fork is not exces-
sively worn.
4. Check for smooth and proper operation of the
fork lock pins. Repair or replace any damaged
or broken fork lock pins or components and lu-
bricate, as necessary. See Figure 4.
CHECKS, LIFT TRUCKS
MANUFACTURED AFTER AUGUST, 2012
AND EQUIPPED WITH FORK
POSITIONER
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.
1. Inspect forks for cracks and wear.
2. Check alignment of fork tips. Difference in
height of fork tips must be less than three per-
cent of fork length. See Table 2 and Figure 9.
Some applications may require closer align-
ment. If forks DO NOT meet specification they
both must be replaced.
3. Check that the bottom of each fork is not exces-
sively worn.
Table 2. Fork Tip Alignment
Fork Tip Alignment Specifications
Standard Fork
Lengths
Maximum Fork Tip
Difference1
mm (in.) mm (in.)
1219 (48) 37 (1.44)
1981 (78) 59 (2.32)
1Difference of alignment between fork tips must be
no more than 3% of the total fork length.
4000 SRM 1148 Fork Replacement
9

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 89°
4. CARRIAGE
5. WASHER
6. CAPSCREW
7. PIN
8. ROD
Figure 9. Pin Type Fork Check
Carriages Repair
STANDARD CARRIAGE
Remove
1. Remove the forks. See Fork Replacement.
2. Remove the four capscrews securing the load
backrest to the carriage. Remove the load back-
rest.
3. Connect a lifting device to the carriage. Lift the
carriage so that the lift chains become loose.
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 from the
sheaves and causing an injury or damage.
4. Remove the pin from each chain anchor at the
carriage. See Figure 10. Disconnect the lift
chains from the carriage. Use wire to connect
the ends of the lift chains to a part of the mast.
Make sure the chains can move freely when the
inner mast is raised.
Fork Replacement 4000 SRM 1148
10

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 10. Standard Carriage
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast is above
the load rollers of the carriage.
5. Use the lift cylinders to raise the inner or inter-
mediate mast. If the hydraulic system cannot
be used, disconnect the lift cylinders from the
inner or intermediate mast. See the section
Cylinder Repair (Mast S/N A551, A555,
A559, A661, A662, A663, A66, B507, B508,
B509, B551, B555, B559, B562, B563, B564,
B661, B662, B663, C515, C551, C555, C559,
D507, D508, D509, D515, D562, D563, D564,
E509, and E564) 2100SRM1139.
6. Connect a crane [the capacity of the crane must
be at least 681 kg (1501 lb)] to the top of the in-
ner mast. Carefully raise the inner mast until it
is above the load rollers of the carriage. Install
safety chains to secure the mast in its extended
position and disconnect the crane. See Safety
Procedures When Working Near Mast.
7. Move the lift truck away from the carriage.
Completely lower the inner mast so it cannot
move.
Repair
NOTE: The carriage can have four or six load roll-
ers. 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 Adjustments for correct ad-
justment of the load rollers.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast. Consult your Hyster® lift truck dealer
for more information before welding on the mast.
2. If the carriage bars have any protruding welds
or damaged notches, repair by grinding, filing,
or welding.
Install
1. Use the hydraulic system of the lift truck or a
crane to raise the inner mast. Connect a crane
[the capacity of the crane must be at least
681 kg (1501 lb)] to the top of the inner mast.
Carefully raise the inner mast until it is above
the load rollers of the carriage. Install safety
chains to secure the mast in its extended posi-
tion and disconnect the crane. See Safety Proce-
dures When Working Near Mast.
4000 SRM 1148 Carriages Repair
11

2. Move the lift truck toward the carriage until
the inner mast is aligned with the carriage roll-
ers. If the inner mast has been raised and se-
cured using a crane and safety chains, connect
the crane, raise the inner mast, and remove the
safety chains. Carefully lower the inner mast
until it engages all of the load rollers. Discon-
nect the crane, if attached, and reconnect the
lift cylinders. See the section Cylinder Repair
(Mast S/N A551, A555, A559, A661, A662,
A663, A66, B507, B508, B509, B551, B555,
B559, B562, B563, B564, B661, B662, B663,
C515, C551, C555, C559, D507, D508, D509,
D515, D562, D563, D564, E509, and E564)
2100SRM1139.
3. Check the clearance of the load rollers. See Car-
riage Adjustments in this section.
NOTE: Use new cotter pins each time the anchor
pins are removed.
4. Connect the lift chains to the chain anchors at
the carriage. Install the cotter pins in the an-
chor pins. Adjust the lift chains as described in
Carriage Adjustments in this section.
5. Install the backrest on the carriage. Tighten
the capscrews to 195 N•m (144 lbf ft).
6. Install the forks. See Fork Replacement.
STANDARD CARRIAGE, REMOVE
1. Put a one-quarter capacity load on the forks.
The load must give the carriage stability so the
carriage 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.
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 from the
sheaves and causing an injury or damage.
4. Remove the pin from each chain anchor at the
carriage. See Figure 11. Disconnect the lift
chains from the carriage. Use wire to connect
the ends of the lift chains to a part of the mast.
Make sure the chains can move freely when the
inner mast is raised.
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 11. Standard Carriage
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast is above
the load rollers of the carriage.
5. Use the lift cylinders to raise the inner or inter-
mediate mast. If the hydraulic system cannot
be used, disconnect the lift cylinders from the
inner or intermediate mast. Connect a crane
[the capacity of the crane must be at least
681 kg (1501 lb)] to the top of the inner mast.
Carefully raise the inner mast until it is above
the load rollers of the carriage.
Carriages Repair 4000 SRM 1148
12

6. Move the lift truck away from the carriage.
Completely lower the inner mast so it cannot
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 roll-
ers are facing up.
8. If the forks are removed, use a lifting device to
put the carriage on the floor so the load rollers
are up.
HANG-ON SIDESHIFT CARRIAGE,
REMOVE
1. Lower the carriage completely. Remove the
forks and the load backrest extension.
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 12. Hang-On Sideshift Carriage
4000 SRM 1148 Carriages Repair
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2. Connect a crane [the capacity of the crane must
be at least 681 kg (1501 lb)] to the lifting eye on
the sideshift carriage. See Figure 12.
3. Remove the two upper capscrews from the
lower apron. Slowly loosen the two bottom cap-
screws, but do not remove them. The slotted
holes will allow the lower apron to move down
so the sideshift carriage can be removed.
4. Carefully lift the sideshift carriage from the
standard carriage. The sideshift cylinder sup-
port bracket and cylinder will stay on the
standard carriage. Remove the bearings.
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.
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.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
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.
STANDARD CARRIAGE AND HANG-ON
SIDESHIFT CARRIAGE, REPAIR
NOTE: The carriage can have four or six load roll-
ers. 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 Adjustments for correct ad-
justment 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 12 and Figure 13):
a. Remove the retainers from the shell. Pull the
rod from the shell.
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. Apply
Loctite® 242 to the threads of the retainers.
Install the retainers and tighten them to
27 N•m (20 lbf ft).
1. SHELL
2. O-RING
3. BACKUP RING
4. ROD SEAL
5. RETAINER
6. WIPER
7. PISTON AND ROD
8. PISTON SEAL
Figure 13. Sideshift Cylinder
Carriages Repair 4000 SRM 1148
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