Hyster MAST N50F Operating instructions

MAST
REPAIR
N50FA; N40-45FR [D138]; N30XMH,
N30XMH2[C210]; N25XMDR3, N30-
40XMR3 [C470]; N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138]; N30XMXDR3,
N45XMXR3 [B264]; W30-40ZA [B453];
W20-30ZR [B455]; W25-30-40ZC [B454];
W25-30ZA2[B495]; V30ZMD [D210/E210]
PART NO. 897447 4000 SRM 482

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.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•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 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 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.

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 2
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks .................................................. 3
Load Backrest Extension, Remove and Install............................................................................................ 3
Carriage Assembly, Remove and Install....................................................................................................... 3
Carriage Load Rollers, Remove and Install ................................................................................................. 6
Side Rollers, Disassemble and Assemble ..................................................................................................... 6
Fork, Replace ................................................................................................................................................. 7
Hook-Type Forks ....................................................................................................................................... 7
Remove .................................................................................................................................................. 8
Install..................................................................................................................................................... 8
Two-Stage Mast Assembly................................................................................................................................. 8
Remove ........................................................................................................................................................... 8
Clean and Inspect.......................................................................................................................................... 11
Lift Cylinders, Remove and Install Dual-Lift Cylinders............................................................................. 13
Lift Cylinder, Remove and Install Single Main-Lift Cylinders................................................................... 14
Remove....................................................................................................................................................... 15
Install......................................................................................................................................................... 15
Inner Mast Assembly, Remove and Install................................................................................................... 16
Hoses, Replace ............................................................................................................................................... 16
Hose and Cable Sheaves, Replace ................................................................................................................ 18
Two-Stage Lift Chains................................................................................................................................... 18
Remove and Install ................................................................................................................................... 19
Clean and Inspect...................................................................................................................................... 19
Two-Stage Chain Sheave, Remove and Install ............................................................................................ 19
Load Rollers and Wear Plugs, Remove and Install...................................................................................... 20
Two-Stage Mast Assembly, Install................................................................................................................ 21
Three-Stage Mast Assembly.............................................................................................................................. 22
Three-Stage Mast Assembly, Remove........................................................................................................... 22
N30XHM, N30XMH2(C210), and V30ZMD (D210/E210) Only ............................................................. 25
Clean and Inspect.......................................................................................................................................... 25
Free-Lift Cylinder, Remove and Install........................................................................................................ 26
Main Cylinders (Standard), Remove and Install......................................................................................... 28
Main Cylinders N30XMH, N30XMH2(C210) and V30ZMD (D210/E210), Remove and Install............... 28
Inner and Intermediate Mast Assemblies, Remove and Install ................................................................. 29
Hoses, Replace ............................................................................................................................................... 31
Hose and Cable Sheaves, Replace ................................................................................................................ 31
Free-Lift Hose Sheave............................................................................................................................... 31
Carriage Sheaves....................................................................................................................................... 32
Three-Stage Lift Chains, Remove and Install.............................................................................................. 32
General....................................................................................................................................................... 32
Free-Lift Chains ........................................................................................................................................ 32
Main-Lift Chains....................................................................................................................................... 33
Three-Stage Chain Sheaves, Disassemble and Assemble ........................................................................... 33
Free-Lift Chain Sheaves ........................................................................................................................... 33
Main-Lift Chain Sheaves .......................................................................................................................... 33
Load Rollers and Wear Plugs, Remove and Install...................................................................................... 34
Three-Stage Mast Assemble, Install ............................................................................................................ 35
Mast Operation Check....................................................................................................................................... 36
Hydraulic System Leaks Check ........................................................................................................................ 36
Lift Chains Check .............................................................................................................................................. 37
©2008 HYSTER COMPANY i

Table of Contents Mast
TABLE OF CONTENTS (Continued)
General........................................................................................................................................................... 37
Clean and Inspect .......................................................................................................................................... 37
Lubrication..................................................................................................................................................... 37
Mast Adjustments.............................................................................................................................................. 38
General........................................................................................................................................................... 38
Adjust Wear Plugs - Mast ............................................................................................................................. 39
Adjust Free-Lift Chain (Three-Stage Only) ................................................................................................. 40
Adjust Main-Lift Chains ............................................................................................................................... 41
Two-Stage................................................................................................................................................... 41
Three-Stage ............................................................................................................................................... 42
Adjust Wear Strips ........................................................................................................................................ 42
Carriage Adjustments........................................................................................................................................ 43
Adjust Wear Plug - Carriage......................................................................................................................... 43
Adjust Side Rollers - Carriage ...................................................................................................................... 43
Adjust Thrust Rollers - Carriage .................................................................................................................. 44
Troubleshooting.................................................................................................................................................. 45
This section is for the following models:
N50FA N40-45FR [D138];
N30XMH, N30XMH2[C210];
N25XMDR3, N30-40XMR3 [C470];
N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138];
N30XMXDR3, N45XMXR3 [B264];
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454];
W25-30ZA2[B495];
V30ZMD [D210/E210]
ii

4000 SRM 482 General
General
This manual has the removal, installation, and ad-
justment procedures for the two-stage (limited free-
lift) and three-stage (full free-lift) masts. The de-
scription and operation of the masts are outlined in
the section Mast,Description 4000 SRM 480. A
troubleshooting chart is listed at the end of this sec-
tion. Repair procedures for the reach carriages are
covered in the section Reach Carriages 4500 SRM
483 or Reach Carriages 4500 SRM 971. Repair pro-
cedures for the attachment carriage are covered in
Attachment 5000 SRM 580.
These mast assemblies and carriages have wear
plugs and can have wear strips to allow for wear and
adjustment. The wear plugs are in the stub shafts
of the load rollers and slide against the center of the
channel. A setscrew and jam nut keep each wear
plug in the correct position. The load rollers take
the forward and back stress loads during operation
of the mast. The load rollers have ball bearings with
grease seals. The wear strips are made of a friction
material and slide against the outside edge of the
channel flange.
WARNING
The mast and carriage assemblies, and their
components, are heavy. To help prevent dam-
age or an injury, a lifting device must be used
during all service procedures.
The mast assemblies must have the mast weldments
parallel with equal clearance on each side between
all weldments. Correct operation also depends on
periodic cleaning, lubrication, and adjustment. See
Mast Operation Check, Hydraulic System Leaks
Check, Lift Chains Check, Mast Adjustments, and
Carriage Adjustments at the rear of this section.
NOTE: For the correct maintenance and inspection
procedures for the masts, hydraulic cylinders, forks,
chains, and carriages for your lift truck, see the
section Periodic Maintenance 8000 SRM 1027,
Periodic Maintenance 8000 SRM 555, Periodic
Maintenance 8000 SRM 1379, or Periodic Main-
tenance 8000 SRM 970.
NOTE: The standard carriage, the reach carriage,
and the attachment carriage can be removed from
the mast assembly with the load backrest extension
and forks attached. Both the two-stage and three-
stage mast assembly can also be removed with the
carriage installed. It is recommended that the at-
tachment carriage be removed prior to removing the
three-stage mast assembly. Do only those procedures
necessary for your repair.
1

Safety Procedures When Working Near Mast 4000 SRM 482
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 of the
mast or carriage are completely lowered or
a safety chain is installed.
• Make sure that the power is off and the key
is removed. Put a DO NOT OPERATE tag in
the operator’s compartment. Disconnect the
battery 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.
• 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 this manual.
WHEN WORKING NEAR THE MAST, ALWAYS:
• Lower the mast and carriage completely.
Push the lift/lower control and make sure
there is no movement in the mast. Release
the lift/lower control. 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:
NOTE: Mast operator guard must be removed to in-
stall safety chain. Remove safety chain and install
the guard after repairs are complete.
1. 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 mast, the moving
part is the inner weldment. On the three-stage
mast, it is the intermediate weldment. See Fig-
ure 1.
2. Use a 3/8-inch minimum safety chain with a
hook to fasten the crossmembers together so the
movable member cannot lower. Put the hook on
the back side of the mast. Make sure the hook
is completely engaged with a link in the chain.
Make sure the safety chain does not touch lift
chains, chain sheaves, tubes, hoses, fittings, or
other parts on the mast.
3. Lower the mast until there is tension in
the safety chain and the free-lift cylinder
(three-stage mast only) is completely retracted.
Move the key to the OFF position and remove
the key from the key switch. Put a DO NOT
OPERATE tag in the operator’s compartment.
Disconnect the battery and put a tag or lock
on the battery connector. Install a DO NOT
REMOVE tag on the safety chain(s).
4. Install another safety chain (3/8-inch minimum)
between the top or bottom crossmember of the
carriage and a crossmember on the outer weld-
ment.
2

4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks
A. TWO-STAGE MAST B. THREE-STAGE MAST
1. OUTER WELDMENT
2. INNER WELDMENT 3. INTERMEDIATE WELDMENT 4. SAFETY CHAIN HOOK 5. FREE-LIFT CYLINDER 6. CROSSMEMBER
Figure 1. Safety Chain the Mast, Typical Mast
Load Backrest Extension, Carriage, Load Rollers,
Side Rollers, and Forks
LOAD BACKREST EXTENSION, REMOVE
AND INSTALL
1. Loosen the two upper capscrews that fasten the
load backrest extension to the carriage.
2. Remove these two capscrews and lay the load
backrest extension on the forks.
3. Remove the two lower capscrews that fasten the
load backrest extension to the carriage.
4. Lift the load backrest extension off the forks.
5. Reversetheproceduretoinstalltheloadbackrest
extension. Tighten the capscrews to 203 N•m
(150 lbf ft).
CARRIAGE ASSEMBLY, REMOVE AND
INSTALL
See the section Attachment 5000 SRM 580 or At-
tachment 5000 SRM 1254 to remove and install the
attachment carriage.
NOTE: The carriage can be removed with the forks
and load backrest extension attached or with the
forks and load backrest removed. Do only those
procedures necessary for your repair. See Fork,
Replacetoremovetheforks. SeeLoadBackrest
Extension, Remove and Install to remove the load
backrest extension.
NOTE: Most repairs of the reach carriage can be com-
pleted without removing it from the mast. See the
section Reach Carriages 4500 SRM 483 or Reach
Carriages 4500 SRM 971 for repair procedures.
3

Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 4000 SRM 482
Read and follow the Safety Procedures When Work-
ing Near Mast, as well as all WARNINGS and CAU-
TIONS.
Removethecarriageasfollows:
1. On reach units, operate the REACH/RETRACT
control button to retract the forks fully. Install
safety chains so that the forks cannot extend. In-
stall the safety chains around the center plates
of the scissor arm weldment and a crossmember
of the mast. Make sure a safety chain does not
touch the mount for the hose sheave, lift chains,
chain or hose sheaves, hoses, tubes, or fittings.
2. Operate the LIFT/LOWER control to raise the
carriage assembly until the thrust rollers of the
inner frame (reach) or the carriage frame are
above the top of the outer weldment.
3. Move the key to the OFF position and disconnect
the battery. Remove the operator guard from the
mast assembly.
4. Usesafetychainstofastenthemovablemember
of the mast to the outer weldment so that it can-
not move.
5. Remove the snap rings, washers, thrust rollers,
and spacers. For standard units, see Figure 2.
For reach units, see Figure 3.
1. CARRIAGE FRAME
2. SCREW
3. NUT
4. STUD
5. THRUST ROLLER
6. WASHER
7. SNAP RING
8. GREASE FITTING
9. LOAD ROLLER
10. SNAP RING
11. WEAR PLUG
12. SHIM
13. SIDE ROLLER
14. LOCKWASHER
15. SCREW
16. GREASE FITTING
17. SNAP RING
18. CHAIN ANCHOR
19. COTTER PIN
20. FORK REMOVAL NOTCH
Figure 2. Typical Standard Carriage
4

4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks
1. LOAD ROLLER (4
OR 6)
2. CHAIN ANCHORS
3. INNER FRAME
4. SHIMS
5. SNAP RING
6. SIDE ROLLER
7. THRUST ROLLER
8. SPACER
9. WASHER
10. GREASE FITTING
11. WEAR PLUG
Figure 3. Inner Frame Assembly (Reach
Carriage)
WARNING
Lift chains, hoses, and cables can roll over the
sheaves to fall and cause an injury if the ends
are not fastened. Keep control of the ends of
the lift chains, hoses, and cables as they are
removed. Use wire to connect the ends of the
lift chains, hoses, or cable temporarily to the
masts.
6. On three-stage masts, remove the safety chains
installed in Step 4. Lower the carriage assembly
for access to the chain anchors at the back of the
free-lift cylinder. Use safety chains to fasten the
movable member of the mast to the outer weld-
ment so that it cannot move. Move the key to the
OFF position and disconnect the battery.
7. On reach units, install lifting eyes in the carriage
assembly for chains or slings. Fasten chains or
slings to the carriage assembly so the carriage
cannot tip as it is removed from the mast weld-
ment. Fasten the chains to the lifting eyes on
reach units. Fasten the chains or slings to the
carriage frame on standard units. Use the crane
to raise the carriage assembly so the lift chains
become loose.
8. Disconnect the hydraulic lines (sideshift or reach
only) at the carriage. Put tags on the fittings
for correct connection during installation. Make
sure to put caps on the open fittings to keep dirt
out of the system. Disconnect the electrical con-
nections (reach only) at the selector valve.
NOTE: Removing the pins at the chain anchors
will disconnect the lift chains without changing the
chain adjustment. Always adjust the chains if new
lift chains or other components are installed.
9. Hold the lift chains to keep them from falling.
Remove the pins in the chain anchors at the back
of the outer weldment of two-stage masts. Re-
move the pins in the chain anchors at the back
of the free-lift cylinder of three-stage masts.
Disconnect the lift chains. Carefully move the
lift chains through the sheaves and lay the lift
chains over the carriage.
WARNING
The carriage assembly is heavy and can cause
an injury if it tips or falls. Make sure the car-
riage assembly has stability during and after
removal.
CAUTION
Do not damage lift chains, hoses, or electrical
cables as the carriage assembly is lifted out of
the mast weldment.
10. Carefully lift the carriage assembly out of the
channels of the inner weldment. Carefully lower
the carriage assembly to the floor.
WARNING
Make sure that the carriage has stability and
cannot fall to cause an injury. If the forks are
removed, put the carriage on the floor so that
the load rollers are up.
NOTE: The carriage side rollers must be adjusted
whilethecarriageisoutofthemast.Adjusttheside
rollers as described in Adjust Side Rollers - Carriage
before installing the carriage.
5

Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 4000 SRM 482
11. To install the carriage assembly, reverse the re-
moval procedures. Always use new cotter pins
when installing the lift chains. Apply Loctite™
to the studs of the thrust rollers during installa-
tion.
12. Adjustthecarriageassembly. SeeCarriageAd-
justments. Test the carriage assembly for correct
operation.
CARRIAGE LOAD ROLLERS, REMOVE
AND INSTALL
1. Remove the carriage assembly from the mast as-
sembly to remove and install the carriage load
rollers. See Carriage Assembly, Remove and In-
stall.
2. Remove the jam nuts and setscrews for the load
rollers. SeeFigure4.
1. LOAD ROLLER
2. WEAR PLUG
3. SNAP RING
4. SETSCREW
5. JAM NUT
6. MAST OR CARRIAGE
Figure 4. Load Roller and Wear Plug Assembly
3. If necessary, replace the wear plugs by pushing
at the back of the wear plug.
4. Remove the snap rings from the stub shaft for the
load roller.
5. Useaprybartoremovetheloadrollerfromthe
stub shaft for the load roller. See Figure 5.
6. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings that
do not turn freely. Replace any roller that shows
wear or is damaged.
7. Install the carriage. See Carriage Assembly, Re-
move and Install.
8. Adjust the carriage. See Carriage Adjustments.
1. LOAD ROLLER WITH SNAP RING REMOVED
2. PRY BAR
3. MAST OR CARRIAGE COMPONENT (CARRIAGE
SHOWN)
4. SIDE ROLLER
Figure 5. Removing Load Roller
SIDE ROLLERS, DISASSEMBLE AND
ASSEMBLE
1. Remove the carriage assembly from the mast to
replace the side rollers. See Carriage Assembly,
Remove and Install to remove the carriage. See
Figure 2 and Figure 3.
2. Remove the capscrews that fasten the side roller
bracket.
NOTE: Observe the position of the shims.
3. Inspect and replace all damaged or worn parts.
6

4000 SRM 482 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks
4. Reversetheproceduretoinstallthesiderollers.
Adjust the carriage side rollers during assembly.
See Carriage Adjustments.
NOTE: To remove and replace load rollers, wear
plugs, weldments, or lift cylinders, it is necessary to
remove the two-stage mast assembly from the truck.
FORK, REPLACE
Read and follow the Safety Procedures When Work-
ing Near Mast, as well as all WARNINGS and CAU-
TIONS.
Hook-Type Forks
WARNING
Forks are heavy and can cause an injury. Do
not try to remove forks without using a lifting
device.
Theseforksareconnectedtothecarriagebyhooks.
See Figure 6. Latch pins fit through the top fork
hooks and into slots on the top crossmember of the
carriage to keep the forks in position.
Figure 6. Forks
7

Two-Stage Mast Assembly 4000 SRM 482
Legend for Figure 6
A. OLD STYLE LATCH PIN ASSEMBLY B. NEW STYLE LATCH PIN ASSEMBLY
1. FORK
2. LATCH PIN
3. SPRING
4. WASHER
5. WASHER
6. WEDGE
7. KNOB
8. LEVER
9. ROLL PIN
10. LATCH PIN ASSEMBLY
Remove
Liftthelatchleverandslidetheforktotheforkre-
moval notch on the carriage. The removal notch is in
the bottom crossmember of the carriage as shown in
Figure 2. Lower the carriage with a block under the
fork or raise the fork tip. See Figure 7. The bottom
hook of the fork will move through the fork removal
notch. Lower the carriage further or raise the fork so
that the top hook of the fork is disengaged from the
top crossmember. Move the carriage away from the
fork, or use the lifting device to move the fork away
from the carriage. Follow the same procedure to re-
move the other fork.
Install
Movetheforkorcarriagesothatthetophookon
the fork engages the top crossmember of the carriage.
Raisethecarriageorlowertheforktomovethelower
hook through the removal notch. Slide the fork on
the carriage so that both upper and lower hooks are
engaged and the latch pin engages a notch.
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 7. Hook Fork Removal
Two-Stage Mast Assembly
REMOVE
Read and follow the Safety Procedures When Work-
ing Near Mast, as well as all WARNINGS and CAU-
TIONS.
NOTE: If the mast assembly will be disassembled af-
ter it is removed from the truck, first remove the
standard carriage or the reach carriage as a complete
assembly. See Carriage Assembly, Remove and In-
stall. If the reach carriage will be removed with the
mast assembly, operate the REACH/RETRACT con-
trol button to retract the forks fully. Install safety
chains so that the forks cannot extend. Install the
safety chains around the center plates of the scis-
sor arm weldment and a crossmember of the mast.
Make sure a safety chain does not touch the mount
for the hose sheave, lift chains, chain or hose sheaves,
hoses, tubes, or fittings. If installed, operate the
SIDESHIFT control to move the sideshift frame to
the center position.
1. Remove the capscrews and nuts that fasten the
operator guard and remove the guard. See Fig-
ure 8 or Figure 9.
8

4000 SRM 482 Two-Stage Mast Assembly
1. OVERHEAD
GUARD
2. LEG
3. MAST CAPSCREW
4. LEG CAPSCREW
5. MAST OPERATOR
GUARD
6. CAPSCREW
Figure 8. Overhead Guard and Operator
Guard Narrow Aisle Trucks
2. For the Narrow Aisle lift trucks, remove the cap-
screws that fasten the rear legs to the overhead
guard. See Figure 8. The overhead guard will be
removed with the mast assembly.
CAUTION
DO NOT move the control button for the reach,
retract, tilt, or sideshift functions. Oil will flow
from the hoses for these functions.
3. Operate the LIFT/LOWER control to raise the in-
ner weldment for access to the four capscrews,
the shims, and the nutplates that fasten the bot-
tom of the outer weldment to the truck frame.
SeeFigure10orFigure11.
1. OPERATOR
GUARD 2. CAPSCREW
Figure 9. Operator Guard Walkie High Lift
Trucks
4. Install safety chains to keep the mast compo-
nents from moving. Remove the capscrews,
washers, and clamps that fasten the lift cylinder
hoses to the mast weldments. DO NOT discon-
nect any hydraulic fittings.
5. Remove the safety chains installed in Step 4. Do
not damage hydraulic hoses as the mast lowers.
Carefully operate the LIFT/LOWER control to
lower the inner weldment fully. Make sure that
all hydraulic pressure is removed from the sys-
tem by holding the control in the LOWER posi-
tion for approximately 5 seconds.
9

Two-Stage Mast Assembly 4000 SRM 482
Figure 10. Two-Stage Mast Assembly (Dual-Lift Cylinders)
10

4000 SRM 482 Two-Stage Mast Assembly
Legend for Figure 10
A. BACK VIEW
1. INNER WELDMENT
2. CHAIN SHEAVE
3. RETAINER
4. LOAD ROLLER
5. LIFT CYLINDER
6. OUTER WELDMENT
7. LIFT TRUCK FRAME
8. HYDRAULIC HOSE (LIFT)
9. FLOW REGULATOR HOUSING
10. HYDRAULIC TUBE (LIFT)
11. LOCK PLATE
12. NUTPLATE
13. SHIM
14. MOUNT CAPSCREWS FOR MAST ASSEMBLY
15. REGULATOR MOUNT PLATE
16. LOCATING DOWEL PIN
17. TRUNNION STUB SHAFT
18. ELECTRIC CABLE FOR REACH CARRIAGE
19. HOSES FOR REACH OR SIDESHIFT CARRIAGE
20. WEAR STRIP
21. HYDRAULIC HOSE TO TRUCK
NOTE: On models with trunnion caps, mark the trun-
nion caps so they can be reassembled in the same po-
sition and on the same trunnion from which they are
removed.
6. Use chains to connect a crane or other lifting de-
vice to the top of the mast assembly. Make sure
the chains will not damage the sheaves or other
parts of the mast assembly. Make sure the chains
and crane have the capacity to lift approximately
2000 kg (4409 lb). Use safety chains to fasten
all the mast weldments together so they cannot
move. If the reach carriage is installed, install
achainorslingtothereachcarriagetokeep
the mast assembly from tipping during removal.
Remove the hardware securing the mast to the
frame.
7. Operate the crane until it gives support to the
weight of the mast assembly. Move the crane to
a position so that the mast assembly will be lifted
vertically. Raise the mast assembly high enough
to clear the trunnions. Move the mast assembly
approximately 30 cm (1 ft) away from the truck
for access to the hoses.
8. Installlabelsonallplugsandwiresfortheelec-
trical cable for correct connection during installa-
tion. Disconnect the plugs and wires so that the
cable is completely disconnected from the truck.
Theplugsarenearthecabletensiondeviceinside
the electrical compartment above the battery.
9. Move the mast assembly away from the truck.
NOTE: To disassemble models with an overhead
guard, position the mast with the overhead guard
on the bottom as a support. Install a secure support
under the other end. Make sure the mast is level.
Keep the safety chains installed.
10. If the mast will be disassembled, position the
mast with the carriage up across wooden beams
on a level floor Make sure the mast is level. Keep
the safety chains that were installed in Step 6 on
the mast assembly.
11. If the mast will NOT be disassembled, position
the mast across beams on a level floor with the
overhead guard on top.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
CAUTION
DO NOT use steam to clean the lift chains,
sheaves, or load rollers. The sheaves and
roller bearings are sealed and permanently
lubricated. Do not use compressed air on the
bearings. The air can force the lubricant out
of the bearings.
1. Clean the mast weldments with steam or solvent.
WARNING
Some parts may be damaged by welding. To
prevent an injury, always get authorization
from your dealer for Hyster lift trucks before
welding on the mast, forks, or carriage.
2. Inspect the sliding and rolling surfaces of the
channels for damage (dents) and wear (grooves).
Inspect all welds for cracks.
11

Two-Stage Mast Assembly 4000 SRM 482
Figure 11. Two-Stage Mast Assembly (Single-Lift Cylinder)
12

4000 SRM 482 Two-Stage Mast Assembly
Legend for Figure 11
1. INNER WELDMENT
2. OUTER WELDMENT
3. BUSHING
4. SCREW
5. NUT
6. LOAD ROLLER
7. SNAP RING
8. PLUG
9. PIN
LIFT CYLINDERS, REMOVE AND INSTALL
DUAL-LIFT CYLINDERS
NOTE: It is necessary to remove the mast assembly
from the truck to remove the lift cylinders.
1. Remove the mast assembly as described in Re-
move.
WARNING
The mast weldments can move and cause an
injury even if the mast assembly has been re-
moved from the lift truck. Make sure the mast
assembly is level to prevent the components
from moving without being moved. Use safety
chains to prevent movement after components
are in the correct position.
2. Remove the safety chains that fasten the mast
weldments together and use a pry bar to move
the inner weldment approximately 75 mm (3 in.)
out of the outer weldment carefully and slowly.
3. Remove the capscrews, washers, and lock plate
at the base of the lift cylinder.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during 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.
4. Remove the snap ring, backup washer, rubber
bushing, and shims (if applicable) that fasten one
cylinder rod to the inner weldment. See Fig-
ure 12. If shims are used, make a note of the
shim arrangement. Normally, the shim arrange-
ment for the replacement cylinder will be similar.
5. Removethehoseortubebetweentheliftcylinder
and the flow regulator. See Figure 10. Install a
cap on the regulator fitting to prevent leakage.
1. INNER WELDMENT
2. LIFT CYLINDER
3. OUTER
WELDMENT
4. SNAP RING
5. WASHER
6. RUBBER BUSHING
7. SHIMS (IF
REQUIRED)
8. RETAINER
9. LOCK PLATE
Figure 12. Lift Cylinder Removal
13

Two-Stage Mast Assembly 4000 SRM 482
6. Install a sling and crane to support the cylinder.
Remove the lift cylinder retainer, capscrews, and
washers.
7. Push the cylinder toward the top of the mast as-
sembly to move the lift cylinder off the locating
dowel pin. Continue to push the cylinder so that
therodmovesintothecylindertoallowremoval
from the inner weldment.
8. Repeat Step 2 through Step 7 to remove the other
lift cylinder.
NOTE: See the section Lift Cylinders 4000 SRM 481
to disassemble and repair the cylinder.
9. Reverse the procedure to install the lift cylinders.
LIFT CYLINDER, REMOVE AND INSTALL
SINGLE MAIN-LIFT CYLINDERS
For the following instructions, refer to Figure 13 and
Figure 14.
Figure 13. Lift Chains and Sheaves, Single-Lift
Cylinder
Legend for Figure 13
1. SNAP RING
2. CAPSCREW AND LOCKWASHER
3. SUPPORT BRACKET
4. SHAFT
5. SPACER
6. SHEAVE
7. BALL BEARING
8. RETAINING RING
9. WASHER
10. LIFT CHAIN
11. COTTER PIN
12. PIN
13. CHAIN ANCHOR
14. NUT
15. LOCKWASHER
16. PIN
17. CHAIN ANCHOR
18. SNAP RING
19. LUBE FITTING
20. COTTER PIN
Figure 14. Two-Stage Single-Lift Cylinder -
Hydraulic Connections
14

4000 SRM 482 Two-Stage Mast Assembly
LegendforFigure14
1. CAPSCREW
2. WASHER
3. LIFT CYLINDER
4. FITTING
5. TUBE
6. FITTING
7. FLOW REGULATOR
8. HOUSING
9. FITTING
10. CAPSCREW
Remove
NOTE: It is not necessary to remove the mast assem-
bly from the truck to remove the lift cylinder.
1. Move lift truck to a safe, level area.
2. Block wheels to prevent movement of lift truck.
3. Remove load backrest from carriage.
4. Raise the inner mast weldment high enough to
align the crossmember with the crossmember of
the outer mast weldment.
WARNING
To prevent possible personal injury or damage
to equipment, always install a safety chain to
restrain the moving parts of the mast.
5. Install a safety chain around the two crossmem-
bers. See Safety Procedures When Working Near
Mast.
6. Remove capscrew, washer, and lockwasher that
hold bottom of lift cylinder to mast.
7. Remove safety chain.
8. Lower carriage completely so that forks rest on
the floor. This will relieve the hydraulic pressure
on the lift cylinder and strain on the lift chains.
9. Place a drip pan under mast and carriage.
WARNING
Hydraulic oil in hoses may still be under high
pressure even though the mast is fully lowered.
To prevent possible injury, slowly loosen hose
connections.
10. Slowly loosen hydraulic tube and allow excess oil
to drain into drip pan.
CAUTION
To prevent dirt or contaminants from entering
the hydraulic system, always install caps on
thetubeandflowregulator.
11. Remove hydraulic tube from lift cylinder. Install
caps on the tube and flow regulator.
12. Clean up spilled oil.
13. Remove lift chains from cylinder and chain
sheaves.
14. Install a sling around the cylinder at the chain
weldment.
15. Attach the sling to a crane or other suitable lift-
ingdevicetosupportthecylinder.
16. Remove two capscrews and lockwashers that
hold support bracket to inner mast weldment.
17. Using the crane, tilt cylinder forward and lift
cylinder out of mast weldment.
Install
1. Using the crane, align base of cylinder with lower
crossmember of outer mast weldment.
2. Tilt lift cylinder backward and align support
bracket with two screw holes in inner mast
weldment.
3. Install two capscrews and lockwashers that hold
support bracket to inner mast weldment.
4. Align base of cylinder with screw hole in lower
crossmember of outer mast weldment.
5. Install capscrew, washer, and lockwasher that
hold bottom of lift cylinder to mast.
6. Removecapsonthetubeandflowregulator.
7. Install tube on flow regulator.
8. Clean up spilled oil.
9. Place lift chains over the top of the chain sheaves.
10. Install lift chains to chain anchors.
11. Exercise cylinder by raising and lowering mast
several times.
12. Check hydraulic oil level in tank and fill to proper
level if necessary.
15

Two-Stage Mast Assembly 4000 SRM 482
13. Install load backrest to carriage.
INNER MAST ASSEMBLY, REMOVE AND
INSTALL
Read and follow the Safety Procedures When Work-
ing Near Mast, as well as all WARNINGS and CAU-
TIONS.
To remove the inner weldment from the mast assem-
bly, the mast assembly must be removed from the lift
truck. The lift cylinders and chain sheaves must also
be removed.
1. Remove the mast assembly as described in
Remove. Remove the lift cylinders. See Lift
Cylinders, Remove and Install Dual-Lift Cylin-
ders. Remove the chain sheaves. See Two-Stage
Chain Sheave, Remove and Install.
2. If it is necessary to repair the inner mast assem-
bly, the load rollers and wear plugs must be re-
moved. See Load Rollers and Wear Plugs, Re-
move and Install.
3. Use a crane or lifting device to support the inner
weldment while sliding the inner weldment far
enough out to clear the outer weldment.
4. Reverse the removal procedure to install the in-
ner mast assembly into the outer weldment.
HOSES, REPLACE
Read and follow the Safety Procedures When Work-
ing Near Mast, as well as all WARNINGS and CAU-
TIONS.
1. To replace any hydraulic hoses, fully lower the
carriage. See Figure 10 and Figure 15. Make
sure that the system does not have hydraulic
pressure. Hold the control (for each function) in
the forward position for approximately 5 seconds
toreleasethepressure.Makesurethehydraulic
pump does NOT operate. Move the key to the
OFF position. Disconnect the battery and put a
tag or lock on the battery connector.
2. Disconnect hose and install caps to prevent dirt
from entering the hydraulic system.
3. Replacethehose.Operatethesystemtoremove
all the air from the oil and to check for leaks.
Legend for Figure 15
NOTE: COMPONENTS IN BOXES - STANDARD WITH SIDESHIFT OR REACH CARRIAGES.
1. TO SHEAVE AND CARRIAGE (1 OF 2)
2. OUTER MAST
3. TO TRUCK (1 OF 2)
4. ELECTRICAL CABLE AND TENSION DEVICE
(REACH ONLY)
5. CAPSCREW
6. SHEAVE SUPPORT
7. SHAFT
8. COTTER PIN
9. HOSE AND CABLE SHEAVE
10. SHIM (AS REQUIRED)
11. HOSE SHEAVE
12. LIFT TRUCK FRAME
13. HYDRAULIC HOSE - LIFT
14. HYDRAULIC TUBE - LIFT
15. FLOW REGULATOR HOUSING
16. REGULATOR MOUNT PLATE
17. INNER WELDMENT
18. HYDRAULIC HOSE TO TRUCK
16