Hyster S30FT User manual

Hyster F001 (H1.6FT H1.8FT H2.0FTS Europe) Forklift

MAST REPAIRS
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
•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 Repairs Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Fork Repair ........................................................................................................................................................ 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 3
Checks ............................................................................................................................................................ 4
Carriages Repair ................................................................................................................................................ 5
Standard Carriage......................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Repair......................................................................................................................................................... 6
Install......................................................................................................................................................... 6
Integral Sideshift Carriage ........................................................................................................................... 6
Remove....................................................................................................................................................... 6
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 10
Install......................................................................................................................................................... 11
Mast Repair........................................................................................................................................................ 11
Mast, Remove................................................................................................................................................. 11
Two-Stage LFL and Two-Stage FFL Masts, Disassemble........................................................................... 15
Clean and Inspect.......................................................................................................................................... 21
Three-Stage FFL Mast .................................................................................................................................. 22
Disassemble............................................................................................................................................... 22
Clean and Inspect...................................................................................................................................... 26
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 27
Three-Stage FFL Mast, Assemble ................................................................................................................ 28
Four-Stage FFL, Disassemble....................................................................................................................... 30
Clean and Inspect.......................................................................................................................................... 34
Four-Stage FFL, Assemble............................................................................................................................ 36
Mast, Install................................................................................................................................................... 38
Header Hose Arrangement................................................................................................................................ 41
Two-Stage LFL............................................................................................................................................... 41
Two-Stage FFL............................................................................................................................................... 48
Three-Stage FFL............................................................................................................................................ 60
Four-Stage FFL ............................................................................................................................................. 75
Adjustment..................................................................................................................................................... 83
Lift Chains Adjustment ..................................................................................................................................... 84
Carriage Adjustments........................................................................................................................................ 86
Tilt Cylinders Adjustment................................................................................................................................. 86
Mast Adjustments.............................................................................................................................................. 90
Load Roller Adjustment............................................................................................................................ 90
Mast Side Kicking Adjustment................................................................................................................. 92
©2008 HYSTER COMPANY i

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Table of Contents Mast Repairs
TABLE OF CONTENTS (Continued)
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]
ii

4000 SRM 1148 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);
and Four-Stage, Full Free-Lift (FFL) masts and
carriages. Procedures for Carriage Adjustments are
locatedattheendofthissection.
NOTE: For models J1.60-2.00XMT (J30-40ZT)
[J160], this section applies to only to Four-Stage
masts. Refer toMast Repairs,2 and 3-Stage
Masts 4000 SRM 522 for Two-Stage and Three-Stage
masts for theseparticularmodels.
NOTE: Hoses haveaservicelifethatisdetermined
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.
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
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery and put a tag or lock on the bat-
tery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Usealadderorpersonnellifttowork
on the mast.
• 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
•Ifpartso
f 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. Putmasti
n vertical position.
2. Raise mast to align bottom crossmember of mast
upright that moves in outer mast with crossmem-
ber 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-stagemast,itisthefirstintermediatemast.
See Figure 1.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side
of 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 com-
pletely retracted.
1

Safety Procedures When Working Near Mast 4000 SRM 1148
Figure 1. Safety Chaining the Mast
2

4000 SRM 1148 Fork Repair
Legend for Figure 1
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
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and remove
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 (6) and a crossmember on the outer
mast as a secondary safety device. Install a DO
NOT REMOVE tag on the safety chain(s).
Fork Repair
The forks are held on the carriage by hooks. The
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that the pins for
the forks keep the forks in position on the carriage.
Replace damaged fork pin 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).
A fork can be 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.
INSTALL
Movetheforkandcarriagesothetophookonthe
fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork re-
moval notch. Slide the fork on the carriage so both
upperandlowerhooksengagethecarriagebars.En-
gagethelatchpinwithanotchintheuppercarriage
bar.
1. CARRIAGE BARS
2. HOOK FORK 3. BLOCKS
Figure 2. Hook Fork Removal
3

Fork Repair 4000 SRM 1148
1. LOAD BACKREST
2. CARRIAGE
3. FORKS
4. FORK
5. KNOB
6. WEDGE
7. WASHER
8. SPRING
9. PIN
10. FORK REMOVAL NOTCH
Figure 3. Carriage and Forks
CHECKS
WARNING
Never repair damaged forks by heating or
welding. Forks are made of tempered steel
using special procedures. Always replace dam-
aged forks as a pair.
Inspect the forks for cracks and wear. Check the
alignment of the fork tips. The difference in height
of the fork tips must be less than three percent of the
length of the forks. See Table 1 and Figure 4.
Some applications may require closer alignment. If
the forks do not meet specification, they both must
be replaced. Check that the bottom of each fork is
not excessively worn. Check for smooth and proper
operation of the fork lock pins. Repair or replace any
damaged or broken fork lock pins or components and
lubricate, as necessary. See Figure 3.
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.
4

4000 SRM 1148 Carriages Repair
Figure 4. Fork Check
Legend for Figure 4
A. HEEL OF FORK (MUST BE 90% OF
DIMENSION 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
Carriages Repair
STANDARD CARRIAGE
Remove
1. Remove the forks. See Fork Repair.
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 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 pin from each chain anchor at the
carriage. See Figure 5. Disconnect the lift chains
fromthecarriage. Usewiretoconnecttheends
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. CHAINPIN
7. COTTER PIN
8. ANCHOR PIN
9. SPACER
Figure 5. Standard Carriage
5

Carriages Repair 4000 SRM 1148
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 in-
nerorinterm
ediate mast. See the section Cylin-
der Repair 2100 SRM 1139. 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 position and dis-
connect the crane. See Safety Procedures When
Working NearMast.
6. Move the lift truck away from the carriage. Com-
pletely lower the inner mast so it cannot move.
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
anoteoft
he location and number of the shims.
Install the shims, load rollers, and snap rings.
See Carriage Adjustments for correct adjustment
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. Ifthecarriagebarshaveanyprotrudingwelds
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. If the hydraulic
system cannot be used, disconnect the lift cylin-
ders from the inner or intermediate mast. See
the section Cylinder Repair 2100 SRM 1139.
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. In-
stall safety chains to secure the mast in its ex-
tended position and disconnect the crane. See
Safety Procedures When Working Near Mast.
2. Move the lift truck toward the carriage until the
inner mast is aligned with the carriage rollers.
If the inner mast has been raised and secured
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
2100 SRM 1139.
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 Repair.
INTEGRAL SIDESHIFT CARRIAGE
Remove
1. Lower the carriage completely. Remove the forks
and the load backrest extension. See Fork Repair
and Figure 6 or Figure 7.
6

4000 SRM 1148 Carriages Repair
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
23. FORK REMOVAL NOTCH
Figure 6. Integral Sideshift Carriage for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)
7

Carriages Repair 4000 SRM 1148
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
23. FORK REMOVAL NOTCH
Figure 7. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001)
8

4000 SRM 1148 Carriages Repair
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
NOTE: Tag hydraulic lines prior to disconnecting to
insure correct connection during installation.
2. Disconnect the hydraulic lines at the sideshift
cylinder. Put caps on the open hydraulic lines.
3. Remove the lower mounting hooks by removing
the four capscrews securing the hooks.
4. Remove two hairpins, two pins, and sideshift
cylinder from the carriage. See Figure 6 or Fig-
ure 7.
5. 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.
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 0.76 mm
(0.03 in.) minimum and 1.52 mm (0.06 in.) max-
imum. See Ain Figure 8.
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 (0.1 in.) thickness, replace both
upper bearings by driving the upper 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 (0.1 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 9.
A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
Figure 8. Lower Mounting Hooks Wear Limit
and Clearance Adjustment
9

Carriages Repair 4000 SRM 1148
1. CYLINDER SHELL
AND ROD
2. SEAL
3. O-RING
4. RETAINER
5. WIPER
Figure 9. Integral Sideshift Cylinder
Repair
NOTE: Drain the oil from the cylinder before under-
taking any repairs.
1. If any of the load rollers must be replaced, make a
note of the location and number of the shims. In-
stall the shims, load rollers, and snap rings. See
Carriage Adjustments for correct adjustment.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect func-
tion of the mast. Consult your Hyster lift truck
dealer for more information before welding on
the mast.
2. Ifthecarriagebarshaveanyprotrudingwelds
or damaged notches, repair by grinding, filing,
or welding.
3. Replace the cylinder rod seals as follows:
a. Clamponeendofthecylinderinavisebe-
tween the hydraulic fitting and the retainer
on the same end.
b. Unscrew the retainer from the cylinder.
Slide the retainer off the cylinder rod.
c. Clamp the other end of the cylinder in a
vise between the hydraulic fitting and the
retainer on the same end.
d. Unscrew the retainer from the cylinder.
NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step h.
e. Remove and discard the seals and O-ring
from each retainer 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.
f. Clean the retainers and the cylinder rod with
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
g. 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.
h. Apply a film of hydraulic oil to the inside of
the retainers.
i. Clamp one end of the cylinder in a vise be-
tween the hydraulic fitting and the end.
j. Screw the retainer into the cylinder. Tighten
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
k. Clamp the other end of the cylinder in a vise
between the hydraulic fitting and the end.
l. Slide the retainer onto the cylinder rod.
Screw the retainer into the cylinder. Tighten
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
10

4000 SRM 1148 Mast Repair
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 6.
NOTE: The pin, located on the left top of the cylinder
looking from the front of the carriage, is for align-
ment purposes and to prevent the cylinder from
rolling to the front or to the back.
2. Install sideshift cylinder onto the carriage with
the pin in the up position. Install two pins and
twohairpins.SeeFigure6orFigure7.
3. Use a crane with a capacity of at least 450 kg
(992lb)toinstalltheouterframeontheinner
frame.
4. Install the lower mounting hooks using four cap-
screws. Tighten to 165 ±15 N•m (120 ±12 lbf ft).
Forpropersideshiftoperation,makesurethere
is 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
between the bottom of the hooks and the outer
frame. See Bin Figure 8.
5. Connect the hydraulic lines, as noted during re-
moval, to the sideshift cylinder.
6. Install the backrest on the sideshift carriage.
Tighten the capscrews to 195 N•m (144 lbf ft).
7. Install the forks.
Mast Repair
MAST, REMOVE
WARNING
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
CAUTION
Make sure all the mast weldments are fastened
together. Make sure the safety chains will not
damage the sheaves, tubing, or other parts of
the mast.
NOTE: If themastneedstobedisassembled,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 section Cylin-
der Repair 2100 SRM 1139.
NOTE: The length of the lift chains must be checked
before the mast is removed. See Lift Chains Adjust-
ment.
1. Fully lower all of the mast weldments. Tilt the
mast fully forward. Connect a crane with a ca-
pacityofatleast907kg(2000lb)tothetopof
the mast using chains to support the mast in an
upright position when the tilt cylinders are dis-
connected.
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of the
lift pump or disconnecting any hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
2. Position a drip pan with a capacity of 19 liter
(5 gal) under the area of the hydraulic fittings.
Disconnect the hydraulic line at the external low-
ering control valve on the outer mast.
11

Mast Repair 4000 SRM 1148
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 capscrews, washers, and anchor pins
at the tilt cylinder mounts on the outer mast. See
Figure 10, Figure 11, and Figure 12.
1. O-RING
2. SPACER
3. SHIMS
4. WASHER
5. NUT
6. CAPSCREW
7. PIVOT PIN
8. GREASE FITTING
9. RETAINER PIN
10. CAPSCREW
11. ROD END
12. TILT CYLINDER
Figure 10. Mast Mounting for Lift Truck
Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z)
(G108)
1. WASHER
2. NUT
3. ROD END
4. PIVOT PIN
5. GREASE FITTING
6. CAPSCREW
7. RETAINER PIN
8. CAPSCREW
9. TILT CYLINDER
Figure 11. Mast Mounting for Lift Truck Models
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001)
12

4000 SRM 1148 Mast Repair
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 for Lift Truck
Models J1.60-2.00XMT (J30-40ZT) [J160] and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
NOTE: Allow the mast to tilt forward enough to gain
access to the mast mount capscrews.
4. Disconnect the lower mast mounts from the lift
truck:
a. Pivot Pin Connections - Remove the cap-
screws that hold the mast pivot pins to the
mounts on the drive axle. See Figure 13 and
Figure 14.
b. Stub Shaft Connections - Remove the four
capscrews securing the retainer cap over the
stub shafts on each side of the mast. See
Figure 12.
WARNING
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
5. Use the crane to lift the mast assembly from
the lift truck. Position the mast across wooden
beams on the floor with the carriage side up.
6. Check the mast and mounting flanges for wear
or damage:
a. Pivot Pin Connections - Remove the mast
pivot pins from the outer mast. Check that
the pins fit snug in the outer mast. If pins
can be moved up and down a minimum of
4 mm (0.20 in.), replace bushings in outer
mast and/or mast pivot pins as required. See
Figure 16.
b. Stub Shaft Connections - Remove the bush-
ing from the stub shaft. Check that the bush-
ing fits snug over the stub shaft. Place the
bushing into the drive unit mounts and place
the retainer cap into position. Check that the
bushing is snug under the retainer cap. If
pins can be moved up and down a minimum
of 4.0 mm (0.2 in.), replace bushings as re-
quired.
13

Mast Repair 4000 SRM 1148
1. OUTER MAST 2. BUSHING 3. GREASE FITTING
Figure 13. Mast Mounts, Outer Mast
1. DRIVE AXLE
2. HANGER MOUNTS
Figure 14. Mast Mounts, Drive Axle
1. HANGER MOUNTS
2. TRACTION MOTOR
Figure 15. Mast Mounting For Lift Truck Model
J2.00-3.20XM (J40-65Z) (B416)
14