MAST REPAIR

(S/N D515, E509, E564)

TWO-STAGE FFL AND FOUR-STAGE
FFL MASTS
S2.0-3.5FT (S40-70FT, S55FTS) [G187, H187];
H2.0-3.5FT (H40-70FT) [N177, P177]

PART NO. 4109218 4000 SRM 1693

 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.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Safety Procedures When Working Near Mast ....................................................................................................... 3
Fork Replacement ................................................................................................................................................... 5
Standard Carriage and Integral Sideshift Carriage ......................................................................................... 5
Remove ............................................................................................................................................................ 5
Install .............................................................................................................................................................. 7
Checks ............................................................................................................................................................. 7
Fork Positioner Carriage .................................................................................................................................... 8
Remove ............................................................................................................................................................ 9
Install .............................................................................................................................................................. 9
Checks ........................................................................................................................................................... 11
Carriages Repair, Two-Stage FFL Mast .............................................................................................................. 12
Standard Carriage ............................................................................................................................................ 12
Remove .......................................................................................................................................................... 12
Clean and Inspect ......................................................................................................................................... 13
Install ............................................................................................................................................................ 14
Integral Sideshift Carriage ...............................................................................................................................14
Remove .......................................................................................................................................................... 14
Disassemble .................................................................................................................................................. 16
Clean and Inspect ......................................................................................................................................... 16
Assemble ....................................................................................................................................................... 18
Install ............................................................................................................................................................ 18
Fork Positioner Carriage .................................................................................................................................. 18
Remove .......................................................................................................................................................... 18
Install ............................................................................................................................................................ 20
Fork Positioner Hydraulic Hose Adjustment ..............................................................................................22
Two-Stage Mast With Full Free-Lift Repair ........................................................................................................24
Mast With Serial Number E509 .......................................................................................................................24
Remove .............................................................................................................................................................. 24
Disassemble .......................................................................................................................................................27
Clean and Inspect ............................................................................................................................................. 31
Assemble ............................................................................................................................................................33
Install .................................................................................................................................................................34
Header Hose Procedures ...................................................................................................................................35
Remove .......................................................................................................................................................... 35
Installation ....................................................................................................................................................36
Adjustment ....................................................................................................................................................43
Mast With Serial Number E564 .......................................................................................................................43
Remove .............................................................................................................................................................. 43
Disassemble .......................................................................................................................................................47
Clean and Inspect ............................................................................................................................................. 51
Assemble ............................................................................................................................................................53
Install .................................................................................................................................................................54
Header Hose Procedures ...................................................................................................................................56
Remove .......................................................................................................................................................... 56
Installation ....................................................................................................................................................56
Adjustment ....................................................................................................................................................63
Carriages Repair, Four-Stage FFL Mast ............................................................................................................. 64
Standard Carriage ............................................................................................................................................ 64
Remove .......................................................................................................................................................... 64

©2014 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Clean and Inspect ......................................................................................................................................... 66

Install ............................................................................................................................................................ 66
Integral Sideshift Carriage ...............................................................................................................................67
Remove .......................................................................................................................................................... 67
Disassemble .................................................................................................................................................. 69
Clean and Inspect ......................................................................................................................................... 69
Assemble ....................................................................................................................................................... 72
Install ............................................................................................................................................................ 72
Fork Positioner Carriage .................................................................................................................................. 72
Four-Stage Mast With Full Free-Lift Repair .......................................................................................................73
Mast With Serial Number D515 ...................................................................................................................... 73
Remove .............................................................................................................................................................. 73
Disassemble .......................................................................................................................................................77
Clean and Inspect ............................................................................................................................................. 85
Assemble ............................................................................................................................................................87
Install .................................................................................................................................................................92
Header Hose Procedures ...................................................................................................................................93
Remove .......................................................................................................................................................... 93
Installation ....................................................................................................................................................93
Adjustment ..................................................................................................................................................102
Carriage Adjustments ......................................................................................................................................... 103
Lift Chains Adjustment ...................................................................................................................................... 105
Lift Trucks Equipped with Forks .............................................................................................................. 105
Lift Trucks Equipped with Hook-Type Carriage and Attachment Without Forks ................................. 105
Lift Trucks Equipped With Pin-Type Carriage and Attachment Without Forks ................................... 106
Mast Adjustments ............................................................................................................................................... 107
Load Roller, Adjust ......................................................................................................................................... 107
Mast Side Kicking, Adjust ..............................................................................................................................109
Hydraulic Quick Disconnect Hoses .................................................................................................................... 110
Disconnecting Attachment Hydraulic Quick Disconnect Hoses ...................................................................110
Lift Trucks Equipped With E-Hydraulic Controls ....................................................................................110
Lift Trucks Equipped With Manual Hydraulic Controls ..........................................................................111
Connecting Attachment Hydraulic Quick Disconnect Hoses ....................................................................... 112
Lift Trucks Equipped With E-Hydraulic Controls ....................................................................................112
Lift Trucks Equipped With Manual Hydraulic Controls ..........................................................................112

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS) [G187, H187];

H2.0-3.5FT (H40-70FT) [N177, P177]

ii
4000 SRM 1693 General

General
This section has the repair procedures for the Two-
WARNING Stage, Full Free-Lift (FFL) mast, with serial
Before working on or near the mast, see section numbers E509 and E564, and Four-Stage, Full
Safety Procedures When Working Near Mast in Free-Lift (FFL) mast with serial number D515. The
this SRM. mast serial number is located on the right side of
the outer mast. Other information about the mast
NOTE: Hoses have a service life that is determined can also be found in this area. See Figure 1.
by application and time. Install a new hose if the
hose is leaking, worn through, or damaged. A hose Procedures to repair the carriage, replace the forks,
has been damaged if the hose cover is cracked, and adjust the lift chains, carriage, and mast are
exposing the braiding, or if the hose has been also covered in this manual.
kinked or crushed, or if the hose is no longer
flexible. Install a new hose if the hose has been
tensioned beyond the adjustment range. If
necessary, make a comparison to a new hose that is
the correct replacement for the hose you are
inspecting.

1
General 4000 SRM 1693

1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILLIMETERS)

2. MANUFACTURING PLANT 5. MAST ASSEMBLY PART NUMBER
3. PRODUCTION SEQUENCE

Figure 1. Mast Serial Number Location

2
4000 SRM 1693
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
Safety Procedures When Working Near Mast
• 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
four-stage mast, it is the first intermediate
mast. See Figure 2.
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 (5, Figure 2) and a crossmember on the
outer mast as a secondary safety device. Install
a DO NOT REMOVE tag on the safety
chain(s).
3
Safety Procedures When Working Near Mast 4000 SRM 1693

A. TWO-STAGE FFL MAST B. FOUR-STAGE FFL MAST

1. OUTER MAST 5. CARRIAGE BAR
2. INNER MAST 6. CROSSMEMBER
3. HOOK 7. FIRST INTERMEDIATE MAST
4. FREE-LIFT CYLINDER

Figure 2. Safety Chaining the Mast

4
4000 SRM 1693 Fork Replacement

Fork Replacement
STANDARD CARRIAGE AND INTEGRAL NOTE: Forks are to be replace in sets by trained
SIDESHIFT CARRIAGE personnel only. DO NOT replace forks individually.

On lift trucks equipped with a standard carriage or
an integral sideshift carriage, the forks are held on
carriage by hooks. Forks are held in position by
pins that fit through the top fork hooks and into
slots in top carriage bar.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that pins for
forks keep forks in position on carriage. Replace
damaged fork pin parts.
1. Slide fork to fork removal notch on bottom bar
of carriage. See Figure 3.
2. Lower fork onto blocks (see Figure 4), so bottom
hook of fork moves through fork removal notch.
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.

Remove

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).

5
Fork Replacement 4000 SRM 1693

1. LOAD BACKREST 6. WASHER

2. CARRIAGE 7. SPRING
3. FORKS 8. PIN
4. KNOB 9. FORK REMOVAL NOTCH
5. WEDGE 10. PIN ASSEMBLY

Figure 3. Carriage and Forks

6
4000 SRM 1693 Fork Replacement

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 4.

4. Install latch pin in top hook and notch in upper

carriage bar. See Figure 3.

Checks

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
1. CARRIAGE BARS 3. BLOCKS a pair.
2. HOOK FORK
Inspect forks for cracks and wear. Check alignment
Figure 4. Hook Fork, Remove
of fork tips. The difference in height of fork tips
must be less than three percent of the length of the
Install forks. See Table 1 and Figure 5.

Some applications may require closer alignment. If

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).
NOTE: Forks are to be replace in sets by trained
personnel only. DO NOT replace forks individually.
forks do not meet specification, they both must be
replaced. Check for smooth and proper operation of
the fork lock pins. Repair or replace any damaged
or broken fork lock pins or components and lubri-
cate, as necessary. See Figure 5.

7
Fork Replacement 4000 SRM 1693

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications

Standard Fork Lengths Maximum Fork Tip Difference*
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)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.

FORK POSITIONER CARRIAGE

NOTE: Only lift trucks equipped with a two-stage
FFL mast with serial numbers E509 or E564 (see
Figure 1) can be equipped with an optional fork po-
sitioner.

NOTE: The fork positioner can be removed from

the integral sideshift carriage with integral side-
shift carriage on or off the mast. In the steps below,
the fork positioner is removed with integral side-
shift carriage on the mast. If integral sideshift car-
riage must be removed from mast first, go to sec-
tion Standard Carriage and Integral Sideshift Car-
riage, Remove for removal procedures.

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
A. HEEL OF FORK (MUST BE 90% OF DIMEN-
SION B) slide along the fork positioner cylinder. Depending
B. ORIGINAL FORK THICKNESS (DIMENSION B) on the size and configuration of forks installed on
lift truck, there may be a spacer bar between inner
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF and outer fork carriers. See Figure 6. Forks are re-
FORK LENGTH)
2. CRACKS moved from carriage by aligning forks with fork re-
3. MAXIMUM ANGLE 93° moval notch. Fork removal notch is in the bottom
4. FORK REMOVAL NOTCH bar of carriage. See Figure 7.
5. CARRIAGE

Figure 5. Fork Checks

8
4000 SRM 1693 Fork Replacement

2. Slide fork to fork removal notch in bottom bar

of carriage. See Figure 7.

3. Lower forks onto blocks (see Figure 4) so bot-

tom hook of fork moves through fork removal
notch. 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.

Install

1. OUTER FORK CARRIER WARNING

2. CAPSCREW
3. SPACER BAR* DO NOT try to install a fork without a lifting de-
4. INNER FORK CARRIER vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
*SPACER BAR USED ON 977 mm (38.5 in.) AND
1067 mm (42 in.) CLASS II CARRIAGES.
Figure 6. Fork Carrier Components
CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
Remove components can occur if fork latch pins are not
removed prior to using attachment.
WARNING NOTE: Forks are to be replace in sets by trained
DO NOT try to remove a fork without a lifting de- personnel only. DO NOT replace forks individually.
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.

CAUTION 2. Raise carriage to move bottom hook of fork

Remove fork latch pins if adding a fork positioner through fork removal notch. See Figure 7.
attachment. Damage to forks and other carriage
3. Slide fork on carriage so both upper and lower
components can occur if fork latch pins are not
hooks engage carriage bars. See Figure 4.
removed prior to using attachment.
4. Move fork into place on outer fork carrier. Se-
NOTE: Forks are to be replace in sets by trained
cure inner fork carrier to outer fork carrier us-
personnel only. DO NOT replace forks individually.
ing four capscrews. Tighten capscrew to
1. Lower carriage and remove four capscrews from 35 N•m (25 lbf ft). See Figure 7.
inner fork carriers. Slide inner fork carriers
down cylinder shell to remove forks. See Fig-
ure 7.

9
Fork Replacement 4000 SRM 1693

1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME

Figure 7. Fork Positioner Fork Removal

10
4000 SRM 1693 Fork Replacement

Checks Some applications may require closer alignment. If

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.
forks do not meet specification, they both must be
replaced. Check for smooth and proper operation of
the fork lock pins. Repair or replace any damaged
or broken fork lock pins or components and lubri-
cate, as necessary. See Figure 8.

Inspect forks for cracks and wear. Check the align-

ment of fork tips. The difference in height of fork
tips must be less than three percent of the length of
the forks. See Table 2 and Figure 8.

Table 2. Fork Tip Alignment

Fork Tip Alignment Specifications

Standard Fork Lengths Maximum Fork Tip Difference*
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)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.

11
Fork Replacement 4000 SRM 1693

Legend for Figure 8

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 Checks

Carriages Repair, Two-Stage FFL Mast

STANDARD CARRIAGE
Remove
1. Remove forks. See Fork Replacement for proce-
dures.

2. Remove four capscrews and load backrest from

carriage. See Figure 9.

3. Connect a lifting device to carriage. Lift car-

riage so that 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 and caus-
ing an injury or damage.

4. Remove chain pin from each chain anchor at

the carriage. Disconnect lift chains from car-
riage. Use wire to connect the ends of lift chains
to a part of the mast. Make sure chains can
move freely when inner mast is raised. See Fig-
ure 10. 1. CAPSCREW 4. CARRIAGE
2. WASHER 5. LOAD BACKREST
3. NUT
Figure 9. Load Backrest, Remove

12
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

Clean and Inspect

NOTE: Shims are installed on the bottom and mid-
dle load rollers only.

1. If load rollers must be replaced, make a note of

the location and number of shims. Install
shims, load rollers, and snap rings. See Car-
riage Adjustments section for correct adjust-
ment of the load rollers.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using clean-
1. CARRIAGE 6. CHAIN ANCHOR ing solvents, always follow the recommendations
2. LOAD ROLLER 7. PIN of the manufacturer.
3. SNAP RING 8. ANCHOR PIN
4. SHIM 9. COTTER PIN
5. SPACER CAUTION
Figure 10. Standard Carriage Components DO NOT use cleaning solvent, compressed air, or
steam to clean lift chain sheaves or load rollers.
The bearings in the lift chain sheaves and load
rollers are sealed and lubricated. Cleaning sol-
WARNING vent, compressed air, and steam can damage the
To help prevent possible injury, make sure the load roller bearings.
carriage is stable and will not fall over when the
2. Clean any oil, grease, dirt, and other debris
inner mast is raised above the load rollers of the
from carriage frame. Use a cleaning solvent and
carriage.
compressed air to dry.
5. Use lift cylinders to raise inner mast. If hy-
draulic system cannot be used, disconnect lift WARNING
cylinders from inner mast. See Cylinder Re-
pair (Mast S/N D515, E509, E564) Improper welding procedures can damage the
2100SRM1692 for procedures. structure of the mast or cause incorrect function
of the mast. Consult a Resident Service Engineer-
6. Connect a crane with a capacity of at least ing through the Contact Management System be-
681 kg (1501 lb), to top of inner mast. Carefully fore welding on the mast.
raise inner mast until it is above the load roll-
ers of the carriage. Install safety chains to se- 3. If carriage bars have any protruding welds or
damaged notches, repair by grinding, filing, or
cure mast in its extended position and discon-
welding.
nect the crane. See Safety Procedures When
Working Near Mast.

7. Move lift truck away from carriage. Completely

lower inner mast so it cannot move.

13
Carriages Repair, Two-Stage FFL Mast 4000 SRM 1693

4. Clean and inspect the chain anchors and chain
anchor pins. See Figure 10. Check chain an-
chors and anchor pins for wear and serviceabil-
ity. Discard worn or unserviceable chain an-
chors and chain anchor pins. Discard used cot-
ter pins.
Install
1. Move the lift truck towards the carriage until
inner mast is aligned with carriage rollers. If
inner mast has been raised and secured using a
crane and safety chains, connect the crane,
raise inner mast, and remove safety chains.
Carefully lower inner mast until it engages all
of the load rollers. Disconnect the crane, if at-
tached, and reconnect lift cylinders. See Cylin-
der Repair (Mast S/N D515, E509, E564)
2100SRM1692.
2. Check clearance of load rollers. See Carriage
Adjustments section for procedures.
NOTE: Use new cotter pins each time chain pins
are removed.
3. Relieve hydraulic pressure to sideshift cylinder
by moving sideshift lever in both directions sev-
eral times.
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.
WARNING
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.
NOTE: Tag hydraulic lines and fittings prior to dis-
connecting to aid in connecting during installation.
See Figure 11.

3. Connect lift chains to chain anchors at the car- 4. Disconnect hydraulic lines from sideshift cylin-
riage. Install cotter pins in chain pins. Adjust der. Put caps and plugs on open lines and cylin-
lift chains as described in Lift Chains Adjust- der ports. See Figure 11.
ment.

4. Install load backrest on carriage. Tighten cap-

screws to 195 N•m (144 lbf ft).

5. Install forks. See section Fork Replacement for

procedures.

INTEGRAL SIDESHIFT CARRIAGE

Remove
1. Lower carriage completely. Remove forks. See
Fork Replacement for removal procedures.

2. Remove four capscrews and load backrest from

carriage. See Figure 9.

1. HOSE FITTINGS
WARNING 2. HOSES
Before disconnecting the hydraulic hoses, relieve 3. INTEGRAL SIDESHIFT CYLINDER
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy- Figure 11. Integral Sideshift Carriage Hydraulic
draulic system prior to disconnecting hydraulic Connections
hoses.

14
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

5. Remove lower mounting hooks by removing 7. Use a crane with a capacity of at least
four capscrews securing the hooks. See Fig- 450 kg (992 lb) to lift outer frame away from in-
ure 12. ner frame. Lay outer frame flat on a pallet or
work bench. See Figure 13.
6. Remove sideshift cylinder from carriage. See
Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692.

NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY.

1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 13. COTTER PIN
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. LOAD ROLLER
6. LOWER HOOK 16. SHIMS
7. CAPSCREW 17. SPACER
8. WASHER 18. FORK REMOVAL NOTCH
9. CLEVIS PIN 19. CHAIN ANCHOR PIN
10. PIN

Figure 12. Integral Sideshift Carriage Component Parts

15
Carriages Repair, Two-Stage FFL Mast 4000 SRM 1693

Disassemble 0.76 mm (0.03 in.) minimum and

1. Remove upper and lower bearings from inner
frame. See Clean and Inspect section for proce-
dures. See Figure 12.
2. If damaged, remove lube fittings from outer
frame. See Figure 12.
3. Disassemble intergral sideshift cylinder. See
Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692 for procedures.
1.52 mm (0.06 in.) maximum. See A in Fig-
ure 14.
CAUTION
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. Clean and inspect carriage bars for damage and
smoothness. Ensure carriage bars are parallel
and ends are flush. If carriage bars have any
protruding welds or damaged notches, repair by
grinding, filing, or welding.

3. Clean bearing areas. Inspect sideshift bearings

for wear as follows:

a. If either upper bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace both up-
per bearings by driving the upper bearings
from the inner frame.

b. If either lower bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace lower
bearings by prying the lower bearings from
the inner frame.

1. OUTER FRAME 3. LIFTING DEVICE 4. Inspect the sideshift cylinder. See Cylinder
2. LIFTING HOOK Repair (Mast S/N D515, E509, E564)
Figure 13. Remove Outer Frame 2100SRM1692 for procedures.

5. Inspect load rollers for wear or damage. If load

Clean and Inspect rollers must be replaced, make a note of the lo-
cation and number of shims. Install shims, load
1. Inspect lower mounting hooks for wear. Replace rollers and snap rings. See Carriage Adjust-
hooks if they are worn beyond the wear limit. ments for correct adjustment.
The wear limit clearance range is

16
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

Legend for Figure 14

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 14. Lower Mounting Hooks Wear Limit and

Clearance Adjustment

A. MINIMUM THICKNESS 2.5 mm (0.1 in.).

1. LOWER BEARINGS 3. UPPER BEARINGS
2. CARRIAGE BARS
*BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE.

Figure 15. Checking Upper and Lower Bearings

17
Carriages Repair, Two-Stage FFL Mast
Assemble
1. Assemble integral sideshift cylinder. See Cyl-
inder Repair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 12.
NOTE: Use a wood block or a plastic hammer to
fully seat upper bearings onto inner frame. Proper
lower hook clearance requires the upper bearings
be fully seated.
3. Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces. In-
stall upper and lower bearings into the inner
frame. Bearings snap into place. See Figure 15.
Install
1. Install integral sideshift cylinder onto carriage.
See Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692 for procedures.
2. Use a crane with a capacity of at least
450 kg (992 lb) and install outer frame onto in-
ner frame. See Figure 12.
3. Install lower mounting hooks using four cap-
screws. Tighten to 150 to 180 N•m (108 to
132 lbf ft). For proper sideshift operation, make
sure there 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 B in Figure 14.
4. Connect hydraulic lines, as noted during re-
moval, to sideshift cylinder. See Figure 11.
5. Install load backrest to sideshift carriage.
Tighten capscrews to 195 N•m (144 lbf ft). See
Figure 9.
6. Install forks. See Fork Replacement, in this
manual, for procedures.
18
4000 SRM 1693
FORK POSITIONER CARRIAGE
Remove
NOTE: The fork positioner can be removed from
the integral sideshift carriage with integral side-
shift carriage on or off the mast. In the steps below,
the fork positioner is removed with integral side-
shift carriage on the mast. If integral sideshift car-
riage must be removed from mast first, go to Inte-
gral Sideshift Carriage, Remove in this section.
1. Remove forks. See Fork Replacement section
for procedures.
2. Remove four capscrews and load backrest from
carriage. See Figure 9.
WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy-
draulic system prior to disconnecting hydraulic
hoses.
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.
WARNING
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.
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

5. Install lifting eye in hole (see Figure 17) on in-

CAUTION tegral sideshift carriage and use lifting device
Protect the hydraulic system from dirt and con- to lift outer frame up.
taminants when servicing the hydraulic system.
6. Disconnect relief tube assembly and hydraulic
hoses (open and close) from fork positioner. See
CAUTION Figure 16.
DO NOT bend tube assemblies during removal.
NOTE: Make note of shims used to aid in reassem-
NOTE: Tag all hydraulic hoses, lines, and fittings bly.
prior to removal to aid in installation.
7. Remove capscrews, lockwashers, and shims
3. Disconnect and cap tube assemblies (8, Fig- from integral sideshift carriage. See Figure 17.
ure 16) from header hoses.
8. Remove fork positioner from outer frame.
4. Remove capscrews and washers and remove
lower hooks and bracket weldments from car-
riage. See Figure 17 and Figure 19.

NOTE: BACK (DRIVER'S) VIEW SHOWN. PARTS OF FORK POSITIONER OMITTED FOR CLARITY.

1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. OUTER FRAME

2. FORK POSITIONER HYDRAULIC HOSE 6. FORK CARRIER
(CLOSED) 7. RELIEF TUBE ASSEMBLY
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 8. TUBE ASSEMBLY
HOSES 9. HOSE GUIDE
4. FORK POSITIONER

Figure 16. Hydraulic Connections, Fork Positioner Cylinder

19
Carriages Repair, Two-Stage FFL Mast 4000 SRM 1693

NOTE: RIGHT OUTER FRAME BAR REMOVED FOR CLARITY.

NOTE: FRONT VIEW SHOWN.

1. CAPSCREW AND LOCKWASHER 5. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY

2. SHIM 6. LOWER HOOK
3. FORK POSITIONER CYLINDER 7. TAPPED HOLE FOR LIFT EYE
4. FORK CARRIER

Figure 17. Fork Positioner Cylinder Removal

For procedures to repair the fork positioner cylin-
der, see Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692.
Install
1. Place fork positioner cylinders onto outer
frame. Install lockwasher and capscrew on one
side and hand tighten capscrew. See Figure 17.
Add shims as follows:
NOTE: The maximum number of shims per side is
five. The maximum difference in number of shims
per side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.).
a. Measure gap at opposite side and determine
the number of shims required.
b. Install shims on both sides of the fork posi-
tioner assembly.

20
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

2. Install second lockwasher and capscrew.

Tighten both capscrews to 65 N•m (50 lbf ft).
See Figure 17.
3. Connect fork positioner hydraulic hoses to fork
positioner manifold. Tighten hoses to
21 N•m (186 lbf in). See Figure 16.
4. Thread fork positioner hydraulic hoses through
hose guides. See Figure 16.
5. Install outer frame, with fork positioner, on in-
ner frame.
6. Using a lifting device, position outer frame at
the same height of inner frame and
150 mm (6 in.) away.
CAUTION
Remove fork latch pins (see Figure 3) 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 a fork posi-
tioner attachment.
NOTE: Before proceeding to Step 12 and Step 13,
adjust fork positioner hydraulic hoses. See Fork Po-
sitioner Hydraulic Hose Adjustment for procedures.
12. Install forks to outer fork carriers. Secure inner
fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
35 N•m (25 lbf ft). See Figure 7.

7. From rear of outer frame, connect fork posi- 13. To adjust the fork positioner cylinders, see Cyl-
tioner hydraulic tubes to header hoses and inder Repair (Mast S/N D515, E509, E564)
hand tighten. See Figure 16. 2100SRM1692 for procedures.

8. Position fork positioner hydraulic tubes so they

are in line with inner frame retainer plates. See
Figure 18.

9. Using washer and capscrew, install bracket

weldment to lower hook and hand tighten cap-
screw. Install lower hook on retainer plate with
washer and capscrew and tighten capscrews to
165 N•m (122 lbf ft). See Figure 19.

10. Position bracket weldment over fork positioner

hydraulic hoses (see Figure 16) and adjust so
that bracket weldment makes contact with fork
positioner hoses. Tighten capscrew to
8 N•m (71 lbf in). See Figure 19.

11. Tighten fork positioner hydraulic tubes to

header hoses to 42 N•m (31 lbf ft).

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. RETAINER PLATE 2. INNER FRAME

Figure 18. Inner Frame Retainer Plates

21
Carriages Repair, Two-Stage FFL Mast 4000 SRM 1693

Fork Positioner Hydraulic Hose Adjustment

1. To adjust the fork positioner hydraulic hoses,
hold the large hex nut and rotate the small hex
nut towards the load face of the carriage (to-
wards the forks). See Figure 20.

2. Fork positioner hoses are correctly adjusted

when fork positioner hydraulic hoses stay en-
tirely within the integral sideshift carriage and
do not contact mast channels under all condi-
tions.

3. Move fork positioner and check to ensure fork

carriers clear fork positioner relief tubes
through complete fork carrier cycle. See Fig-
ure 20.

4. Install load backrest to sideshift carriage.

Tighten capscrews to 195 N•m (144 lbf ft). See
Figure 9.

1. BRACKET WELDMENT
2. RETAINER PLATE
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK)
6. CAPSCREW (BRACKET WELDMENT)

Figure 19. Bracket Weldment and Lower Hook

Assembly

22
4000 SRM 1693 Carriages Repair, Two-Stage FFL Mast

NOTE: BACK (DRIVER'S) VIEW SHOWN. PARTS OF FORK POSITIONER OMITTED FOR CLARITY.

1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 4. LARGE HEX NUT

2. FORK POSITIONER HYDRAULIC HOSE 5. TUBE ASSEMBLY
(CLOSE) 6. RELIEF TUBE ASSEMBLY
3. SMALL HEX NUT 7. INTEGRAL SIDESHIFT HYDRAULIC HOSES

Figure 20. Fork Positioner Hydraulic Hose Adjustment

23
Two-Stage Mast With Full Free-Lift Repair
Two-Stage Mast With Full Free-Lift Repair
MAST WITH SERIAL NUMBER E509
Lift truck models S2.0-2.5FT (S40-50FT, S55FTS)
(G187, H187) and H2.0-2.5FT (H40-50FT) (N177,
P177) are equipped with a two-stage FFL mast
with serial number E509.
REMOVE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
Mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
CAUTION
Make sure all the mast weldments are fastened to-
gether. Make sure the safety chains will not dam-
age the sheaves, tubing, or other parts of the
mast.
NOTE: If mast needs to be disassembled, remove
forks and carriage. See Fork Replacement and Car-
riages Repair, Two-Stage FFL Mast in this service
manual for procedures. If only the main lift cylin-
ders need to be removed for repair, the mast does
not need to be removed from the lift truck. See Cyl-
inder Repair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures to remove main lift
cylinders.
24
4000 SRM 1693
NOTE: The length of the lift chains must be
checked before the mast is removed. See Lift
Chains Adjustment section in this manual for pro-
cedures.
1. Fully lower all of the mast weldments. Tilt the
mast fully forward. Connect a crane with a ca-
pacity of at least 907 kg (2000 lb) to top of mast
using chains to support mast in an upright po-
sition when tilt cylinders are disconnected. See
section Safety Procedures When Working Near
Mast in this manual.
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.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hoses.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
2. Position a drip pan under the area of the hy-
draulic fittings. Disconnect hydraulic line at
the external lowering control valve on outer
mast.
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

outer mast and/or mast pivot pins as required.

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 serious
injury.
Use a brass drift pin to remove mast mounting
bushings from outer mast. Discard mast
mounting bushings. See Figure 22 and Fig-
ure 24.

3. Remove capscrews, washers, anchor pins, and

pivot pins at tilt cylinder mounts on outer mast.
See Figure 21.

4. Using a brass drift pin, remove tilt rod bush-

ings from outer mast. Discard tilt rod bushings.
See Figure 22.

NOTE: Allow the mast to tilt forward enough to

gain access to the mast mount capscrews.

5. Disconnect lower mast mounts from lift truck

by removing capscrews and mast pivot pins
from mast mounts on drive axle. See Figure 23
and Figure 24.

WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.

6. Use crane to lift mast assembly from lift truck.

Position mast across wooden beams on floor 1. O-RING 7. PIVOT PIN
2. SPACER 8. GREASE FITTING
with carriage side up. 3. SHIMS 9. ANCHOR PIN
4. NUT 10. ROD END
7. Check mast and mounting flanges for wear or 5. WASHER 11. TILT CYLINDER
damage by removing mast pivot pins from the 6. CAPSCREW
outer mast. Check that pins fit snug in outer
mast. If pins can be moved up and down a mini- Figure 21. Mast Mounting, Tilt Cylinder
mum of 4 mm (0.20 in.), replace bushings in

25
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. TILT ROD BUSHING 5. LUBE FITTING

2. MAST MOUNTING BUSHING (BRONZE) 6. WASHER
3. OUTER MAST 7. BUSHING HOLE
4. BUSHING SPLIT 8. LUBE CAPSCREW

Figure 22. Tilt Rod and Mast Mounting Bushings

1. DRIVE AXLE
2. HANGER MOUNTS
1. MAST PIVOT PINS 2. BUSHING
Figure 23. Mast Mounts, Drive Axle
Figure 24. Mast Pivot Pin

26
4000 SRM 1693
DISASSEMBLE
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.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
NOTE: If main lift cylinders alone need to be re-
moved and repaired, the mast does not need to be
disassembled. See service manual Cylinder Re-
pair (Mast S/N D515, E509, E564) 2100SRM1692
for procedures to remove and repair main lift cylin-
ders.
1. Clean area around hydraulic fittings for main
lift cylinders. Disconnect fittings at main lift
cylinders and put caps on open lines. See Fig-
ure 25.
2. Remove lift chains and header hoses. Remove
brackets and disconnect FFL supply tube from
free-lift cylinder. Remove free-lift cylinder. Dis-
connect free-lift chains at the crossmember. See
Figure 25 and Figure 26.
Two-Stage Mast With Full Free-Lift Repair
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause
an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal
or installation.
3. Remove nut, capscrew, washers, and spacer at
cylinder mount near top of each main lift cylin-
der. Remove snap rings and washers from top
of right main lift cylinder Disconnect main lift
chains at the mounts. See Figure 25.
4. Disconnect the FFL supply tube from left main
lift cylinder and remove hydraulic fitting and
snap ring from top of left main lift cylinder
(from driver's view). Remove clamp, at top of in-
ner mast, and FFL supply tube from inner
mast. See Figure 25 and Figure 26.
WARNING
The mast weldments can slide when the mast is
moved. A weldment that slides can cause injury.
5. Slide the inner mast from outer mast approxi-
mately 30 cm (12 in.) to disengage main lift cyl-
inders from inner mast. Remove main lift cylin-
ders from outer mast. See Figure 25.
6. Slide inner mast from bottom of outer mast ap-
proximately 30 cm (12 in.). Remove strip bear-
ings and load rollers from top of the outer mast.
Remove load rollers from bottom of the inner
mast. Make a note of each shim arrangement
and load roller location. The shim arrange-
ments will be the same during assembly. See
Figure 25 and Figure 26.
27
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 25. Outer Mast, Main Lift Cylinders, And Hydraulic Fittings

28
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 25

1. OUTER MAST 11. CYLINDER MOUNT

2. SHIM 12. FITTING
3. SNAP RING 13. ROD END O-RING
4. O-RING 14. RIGHT MAIN LIFT CYLINDER
5. STRIP BEARING 15. LEFT MAIN LIFT CYLINDER
6. CAPSCREW 16. FFL SUPPLY TUBE
7. BUSHING (BRONZE) 17. VELOCITY FUSE
8. WASHER 18. HOSE ASSEMBLY
9. SPACER 19. LOWERING CONTROL VALVE HOUSING
10. NUT 20. LOAD ROLLER

29
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. CAPSCREW 11. WASHER

2. CLAMP 12. CHAIN GUARD
3. PIN 13. ROLL PIN
4. CHAIN ANCHOR PIN 14. BALL BEARING
5. CHAIN ANCHOR 15. CHAIN SHEAVE
6. INNER MAST 16. FREE-LIFT CHAIN
7. LOCKNUT 17. CROSSHEAD ASSEMBLY
8. SHIM 18. NUT
9. SNAP RING 19. BRACKET
10. LOAD ROLLER 20. FITTING

Figure 26. Inner Mast And Free-Lift Cylinder Assembly

30
4000 SRM 1693
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
NOTE: When replacing outer mast, copy the part
number and date code information from the old
channel and stamp that information on new chan-
nel with a letter R at the end to indicate that it has
been replaced.
7. Slide inner mast halfway out of the top of outer
mast. Connect a crane with a capacity of at
least 907 kg (2000 lb) to the center of inner
mast. See Figure 27. Slide inner mast out of
outer mast until mast stub shafts of inner mast
are in the notches of outer channels. Remove
inner mast from outer mast.
8. Remove the chain sheaves and disassemble
them as necessary for repair and cleaning.
Figure 27. Mast Disassembly
Two-Stage Mast With Full Free-Lift Repair
CLEAN AND INSPECT
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam and
high-pressure water can remove the lubrication
from the bearings in the load rollers. Water in the
bearings of the sheaves and the link pins of
chains can also shorten the service life of these
parts.
1. Inspect chain sheaves and load rollers for wear
or damage. DO NOT use steam to clean lift
chain sheaves or load rollers. The bearings in
the sheaves and load rollers are sealed and lu-
bricated. See Figure 25 and Figure 26.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
commercial cleaning solvents, always comply
with solvent manufacturer's recommended safety
precautions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
2. Clean the lift chains by soaking in solvent for
30 minutes to remove all dirt and grease. Hang
lift chains up and remove solvent using com-
pressed air.
31
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

3. Inspect lift chains for wear and damage. A lift

WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
Damage to the lift truck and serious injury can oc-
cur if lift chains are not replaced correctly.
NOTE: Lift chains must be inspected in the area of
chain that passes over chain sheave during first
portion of a lift. These links will show maximum
wear.
chain becomes longer when it is worn. If a
chain is 3 percent longer than a new lift chain,
the lift chain must be replaced.
4. If a chain scale is available (Hyster Part No.
599737), check lift chains as shown in Fig-
ure 28. If a chain scale is not available measure
20 links of chain. Measure from the center of a
pin to the center of another pin 20 pitches
away. Compare the length with the chart in
Figure 28. Replace chain if the length of 20
links of the worn section is more than the maxi-
mum wear limit.

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 4. HOLE WEAR 7. RUST

2. CRACKS 5. LOOSE LEAVES 8. CHAIN WEAR SCALE
3. EDGE WEAR 6. DAMAGED PIN

Figure 28. Lift Chains Check

32
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

5. Lubricate lift chains by soaking them in SAE
30 engine oil for 30 minutes. Hang chains over
a drip pan for one hour to remove excess oil.
NOTE: Chain anchor pins MUST be replaced any-
time chains are replaced.
6. Inspect chain anchors, chain anchor pins, and
pins. Replace any parts that are worn or dam-
aged. See Figure 26.
NOTE: The shims for the load rollers keep mast
weldments parallel and provide correct clearance.
During assembly, shims should be reinstalled in
the same location they were in before disassembly.
Check clearance and adjust shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. Shims for strip bears
should also be reinstalled in the same location they
were in before disassembly. See Mast Adjustments
in this manual for adjustment procedures.

WARNING 1. Connect a crane with a capacity of at least

907 kg (2000 lb) to center of inner mast. Fit
Cleaning solvents may be flammable and toxic
stub shafts through notches in outer mast.
and can cause severe skin irritation. When using
Slide inner mast into outer mast so stub shafts
commercial cleaning solvents, always comply
are seen at top and bottom of weldments. See
with solvent manufacturer's recommended safety
Figure 25 and Figure 26.
precautions.
2. Install strip bearings and shims on outer mast.
WARNING See Figure 29. Apply chassis lube to bearing
surface. Check clearance of strip bearings as
Steam can cause serious burns. Wear protective
described in Mast Adjustments in this manual.
clothing, gloves, and eye protection. Never ex-
pose your skin to steam.

7. Clean mast weldments with steam or solvent.

WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast which can result in serious injury to
personnel. Consult your Hyster lift truck dealers
for more information before welding on the mast.

8. Inspect sliding surfaces for wear or damage. In-

spect load roller contact surfaces for wear or
damage. Inspect all welds for cracks.

ASSEMBLE
Figure 29. Strip Bearings

WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
3. Install the load rollers and shims on both weld-
ments. Check the clearance of the load rollers
as described in Carriage Adjustments.

NOTE: To remove, adjust, and install header ho-

ses, see Header Hose Procedures in this section.

33
Two-Stage Mast With Full Free-Lift Repair
NOTE: The clearance check and adjustment in
Step 4 is only an initial setup. The final check and
adjustment is done after mast is installed on lift
truck.
4. To install main lift cylinders, perform the fol-
lowing procedures (see Figure 25):
a. Install main lift cylinders in the mounts at
bottom of outer mast.
b. Install washers at top of right main lift cylin-
der. Push inner mast to engage rods of lift
cylinders.
c. Check clearance at top of main lift cylinder
mounts. Add or remove washers at right
main lift cylinder until it is even with left
main lift cylinder.
d. Install snap ring at top of right main lift cyl-
inder. Install snap ring, rod end O-ring, and
hydraulic fitting on left main lift cylinder.
5. Install spacers, washers, capscrews and nuts at
mounts for main lift cylinders. Tighten nuts to
40 N•m (30 lbf ft). See Figure 25.
6. Install housing for lowering control valve on
outer mast. Tighten nuts for lowering control
valve housing to 18 N•m (13 lbf ft). Install low-
ering control valve in the housing. Connect hy-
draulic lines and fittings between housing and
main lift cylinders. See Figure 25.
7. Install free-lift cylinder in mount on inner
mast. Install brackets for free-lift cylinder and
tighten nuts to 53 N•m (39 lbf ft). See Fig-
ure 26.
8. Install FFL supply tube to connect free-lift cyl-
inder to main lift cylinders. Tighten capscrew
for FFL supply tube clamp (at top of inner
mast) to 33 N•m (24 lbf ft). See Figure 25 and
Figure 26.
9. Connect free-lift chains to chain anchors at
crossmember. Attach a wire between the end of
the lift chain and the bottom of the mast to con-
trol the lift chain during installation.
34
4000 SRM 1693
INSTALL
1. Install new bushings into mast mounts at bot-
tom of outer mast. Be sure to align the hole in
the bushing with the lube fitting hole in the
bottom of the outer mast. See Figure 22. Bush-
ing must be flush with outer mast surface.
2. Lubricate the lower mast mounting surface to
prepare for installation. Apply an even coat of
grease to the pivot pins and install them into
mounts at bottom of outer mast. See Figure 24.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
3. Connect crane to top of mast using chains.
Make sure all mast uprights are fastened to-
gether. Make sure chains will not damage
sheaves, tubing, or other parts of mast. Make
sure crane has a capacity of at least
907 kg (2000 lb).
4. Use crane to position mast assembly onto its
lower mounts. Position mast so pivot pins seat
into hanger mounts on drive axle. Install cap-
screws that hold mast pivot pins to drive axle
hangers. Tighten capscrews to
270 N•m (199 lbf ft). Refer to Figure 23 and
Figure 24.
5. Install new tilt rod bushings into outer mast.
Be sure to install bushings with split at correct
angle as shown in Figure 22.
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The tilt cyl-
inder or mast can shift and cause serious injury.
NOTE: Use multipurpose grease #2 with 2 to 4%
molybdenum disulfide for normal operations.
6. Apply grease to pivot pins and connect tilt cyl-
inders to mast using pivot pins. Install anchor
pins and capscrews to rod ends. Apply antiseize
compound to capscrew threads and tighten to
38 N•m (28 lbf ft). See Figure 30.
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

10. Raise the mast, without a load to its full height

and check for side kicking. Mast side kicking is
when mast moves either to the right or left as it
is being raised to its full height. If mast is side
kicking, see Mast Adjustments section for pro-
cedures to correct mast side kicking.

NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.

11. Lubricate sliding surfaces and load roller surfa-

ces along full length of channels as shown in
Figure 31. Apply lubricant only to surfaces indi-
cated in Figure 31.

1. O-RING 7. PIVOT PIN

2. SPACER 8. GREASE FITTING
3. SHIMS 9. ANCHOR PIN
4. NUT 10. ROD END
5. WASHER 11. TILT CYLINDER
6. CAPSCREW A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
Figure 30. Mast Mounting, Tilt Cylinder
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
7. Connect hydraulic line to lowering control
valve. Figure 31. Lubricate Mast
8. Install carriage as described in Carriages Re-
pair, Two-Stage FFL Mast.
HEADER HOSE PROCEDURES

WARNING
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.
Remove
Read and follow the Safety Procedures When Work-
ing Near Mast as well as all WARNINGS and
CAUTIONS before removing any header hoses.

9. Check tilt cylinder adjustment as described in
Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692. Operate mast and check
for leaks and correct operation. Check lift
chains as described in Lift Chains Adjustment.
NOTE: Access to some of the fittings can be diffi-
cult. If necessary, operate hydraulic system to move
mast weldments or carriage. Make sure the hy-
draulic system does not have pressure as described
in Step 1.

NOTE: Before checking for mast side kicking, the

mast must be fully assembled to include carriage,
forks, load backrest and any attachments.

35
Two-Stage Mast With Full Free-Lift Repair
1. To replace any header hoses, fully lower car-
riage. Make sure hydraulic system does not
have hydraulic pressure. Hold the control for
each function in the forward position for ap-
proximately five seconds to release pressure.
Make sure hydraulic pump does not operate.
Move key or keyless switch, if equipped, to the
OFF position.
2. Disconnect battery and put a tag or lock on bat-
tery connector.
3. Disconnect header hoses and install caps on
ends to prevent dirt and debris from entering
the hydraulic system.
Installation
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.
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.
36
4000 SRM 1693
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this sec-
tion.
Before installing the header hoses, make sure you
know the lift height of the mast. The tension on the
header hoses is adjusted according to lift height.
The lift height is on the Nameplate of the lift truck
and on the right side of the outer mast. See Fig-
ure 1.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage.
Examples of attachments that use these auxiliary
functions are sideshift carriages, roll clamps, and
fork positioners. These auxiliary functions require
header hoses for their operation.
NOTE: This procedure is for the four-function op-
tion. The three-function option will have hoses A
and B only.
NOTE: The carriage height must be correct before
the header hoses can be adjusted. See Lift Chains
Adjustment for carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C,
and D. See Figure 32.
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

A. HEADER HOSE D. HEADER HOSE

B. HEADER HOSE E. REAR VIEW
C. HEADER HOSE F. TOP VIEW

Figure 32. Header Hose Alignment

2. Dimensions E and G are determined by the • S2.0-2.5FT (S40-50FT, S55FTS) (G187,

height of the outer mast channel from the H187)
ground and the length of the outer mast chan-
nel. See dimensions Y and Z in Figure 33. To Table 4 for lift truck models
find E and G see: • H2.0-2.5FT (H40-50FT) (N177, P177)

Table 3 for lift truck models

37
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 33. Header Hose Measurement for Two-Stage Full Free-Lift Mast

38
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 33

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE

Table 3. Standard Two-Stage FFL Hose Dimensions, Lift Truck Models S2.0-2.5FT (S40-50FT, S55FTS)
(G187, H187)

Channel Length Dimension "G" Dimension "G"

Lift Height Dimension "E"
(Reference) Third Function Fourth Function
mm in. mm in. mm in. mm in. mm in.
3262 128.4 2040 80.3 1412 55.6 3249 127.9 3121 122.8
Lift height is measured from bottom of forks. Lift heights shown are standard. If your lift height is not
shown, go to Hyster Hypass Online to find the correct header hose measurement for your lift height.

Table 4. Standard Two-Stage FFL Hose Dimensions, Lift Truck Models H2.0-2.5FT (H40-50FT) (N177,
P177)

Channel Length Dimension "G" Dimension "G"

Lift Height Dimension "E"
(Reference) Third Function Fourth Function
mm in. mm in. mm in. mm in. mm in.
3262 128.4 2040 80.3 1443 58.8 3263 128.5 3134 123.3
Lift height is measured from bottom of forks. Lift heights shown are standard. If your lift height is not
shown, go to Hyster Hypass Online to find the correct header hose measurement for your lift height.

3. Clamp the end of the hose (the smaller fitting) 5. Attach the hoses to the carriage bracket with
that attaches to the carriage in a vise (DO clamps. Tighten hardware to
NOT clamp on the threads), and pull on the 18 N•m (159 lbf in). See Figure 34.
other end until the hose is straight. DO NOT
apply enough force to stretch the hose. See Fig- 6. Put header hoses over the free-lift chains. See
ure 33. Figure 32 and Figure 34.

NOTE: These marks will be used to pretension

header hoses during installation.

4. Place a mark on all hoses at dimension E and

G. All measurements are made from carriage
end of the hose (the smaller fitting).

39
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 34. Header Hoses for Two-Stage Full Free-Lift Mast

40
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 34

NOTE: THREE-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CHANNEL 14. CARRIAGE BRACKET
2. COWL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
6. CLAMP 19. CAPSCREW
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUB SHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN

41
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

7. Put the clamps over the header hoses and at- over hoses and attach the clamps to the chan-
tach the clamps to the free-lift bracket. DO nels. Tighten the hardware to
NOT tighten the hardware. 8 N•m (71 lbf in).

NOTE: To make the alignment of dimension E eas-
ier, use a crane with a capacity at least
907.2 kg (2000 lb) to raise the carriage high enough
to install a safety chain. See Figure 35.
8. Align mark E at bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in). See Fig-
ure 34.
10. Connect header hoses C and D to cowl hoses.
Connect header hoses A and B to tubes. See
Figure 32 and Figure 34.
11. Use rubber clamps and strap clamps to attach
hoses to the main lift cylinders. DO NOT allow
cowl hoses to stretch or fold while tilting mast
fully forward and backward.

9. Apply a spray lubricant on the hoses in area

that will contact channels. Make sure hoses are
properly aligned in the channels. Put clamps

1. HOOK 2. SHACKLE

Figure 35. Chaining the Carriage (FFL)

42
4000 SRM 1693
Adjustment
When properly adjusted, the hoses will not be so
tight that they compress when they pass over the
sheaves, nor will they be so loose that they touch
the load backrest or any crossmember that is next
to a sheave.
1. Cap off hoses when attachments have been re-
moved.
2. Check that hoses and cables are routed prop-
erly.
3. Slowly raise free-lift and main cylinders to take
up slack in lift chains.
4. Tighten strap clamps at bracket weldment.
5. Cycle mast a few times to ensure proper track-
ing of hoses.
6. Secure hose assemblies to main lift cylinders
with hose clamp and screw clamp.
NOTE: If the hose tension between the carriage
and the clamp at the free-lift bracket is correct, go
to Step 7.
If the hose tension between carriage and clamp
at free-lift bracket is incorrect, loosen clamps
and pull (if the hoses are loose) or push (if the
hoses are tight) on the hoses so they move
15.0 mm (0.6 in.) side to side. Tighten hardware
to 8 N•m (71 lbf in).
NOTE: If the hose tension between the clamp at
the upper bracket and the clamp at the free-lift
bracket is correct, go to Step 8.
7. If the tension of hoses is incorrect, loosen
clamps and pull hoses down (if too loose) or
push the hoses up (if too tight) so they can
move 15.0 mm (0.6 in.) side to side. Tighten
hardware to 8 N•m (71 lbf in).
8. With no load on the forks, check header hose
adjustment by operating mast through full lift
cycle two times. When properly adjusted, the
hoses will not be so tight that they compress
when they pass over the sheaves nor will they
be so loose that they touch the load backrest or
any crossmember that is next to a sheave. If
necessary, repeat until the hoses are properly
adjusted.
Two-Stage Mast With Full Free-Lift Repair
MAST WITH SERIAL NUMBER E564
Lift truck models S3.0-3.5FT (S60-70FT) (G187,
H187) and H3.0-3.5FT (H60-70FT) (N177, P177)
are equipped with a two-stage FFL mast with se-
rial number E564.
REMOVE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
Mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
CAUTION
Make sure all the mast weldments are fastened to-
gether. Make sure the safety chains will not dam-
age the sheaves, tubing, or other parts of the
mast.
NOTE: If mast needs to be disassembled, remove
forks and carriage. See Fork Replacement and Car-
riages Repair, Two-Stage FFL Mast in this service
manual for procedures. If only the main lift cylin-
ders need to be removed for repair, the mast does
not need to be removed from the lift truck. See Cyl-
inder Repair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures to remove main lift
cylinders.
NOTE: The length of the lift chains must be
checked before the mast is removed. See Lift
Chains Adjustment section in this manual for pro-
cedures.
1. Fully lower all of the mast weldments. Tilt the
mast fully forward. Connect a crane with a ca-
pacity of at least 907 kg (2000 lb) to top of mast
using chains to support mast in an upright po-
sition when tilt cylinders are disconnected. See
section Safety Procedures When Working Near
Mast in this manual.
43
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

6. Use crane to lift mast assembly from lift truck.

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.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hoses.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
Position mast across wooden beams on floor
with carriage side up.
7. Check mast and mounting flanges for wear or
damage by removing mast pivot pins from the
outer mast. Check that pins fit snug in outer
mast. If pins can be moved up and down a mini-
mum of 4 mm (0.20 in.), replace bushings in
outer mast and/or mast pivot pins as required.
Use a brass drift pin to remove mast mounting
bushings from outer mast. Discard mast
mounting bushings. See Figure 37 and Fig-
ure 39.

CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.

2. Position a drip pan under the area of the hy-

draulic fittings. Disconnect hydraulic line at
the external lowering control valve on outer
mast.

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 serious
injury.

3. Remove capscrews, washers, anchor pins, and

pivot pins at tilt cylinder mounts on outer mast.
See Figure 36.

4. Using a brass drift pin, remove tilt rod bush-

ings from outer mast. Discard tilt rod bushings.
See Figure 37.

NOTE: Allow the mast to tilt forward enough to 1. O-RING 7. PIVOT PIN
gain access to the mast mount capscrews. 2. SPACER 8. GREASE FITTING
3. SHIMS 9. ANCHOR PIN
5. Disconnect lower mast mounts from lift truck 4. NUT 10. ROD END
5. WASHER 11. TILT CYLINDER
by removing capscrews and mast pivot pins 6. CAPSCREW
from mast mounts on drive axle. See Figure 38
and Figure 39. Figure 36. Mast Mounting, Tilt Cylinder

WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.

44
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

1. TILT ROD BUSHING 5. LUBE FITTING

2. MAST MOUNTING BUSHING (BRONZE) 6. WASHER
3. OUTER MAST 7. BUSHING HOLE
4. BUSHING SPLIT 8. LUBE CAPSCREW

Figure 37. Tilt Rod and Mast Mounting Bushings

45
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. DRIVE AXLE
2. HANGER MOUNTS

Figure 38. Mast Mounts, Drive Axle

1. MAST PIVOT PINS

2. BUSHING

Figure 39. Mast Pivot Pin

46
4000 SRM 1693
DISASSEMBLE
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.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
NOTE: If main lift cylinders alone need to be re-
moved and repaired, the mast does not need to be
disassembled. See Cylinder Repair (Mast S/N
D515, E509, E564) 2100SRM1692 for procedures
to remove and repair main lift cylinders.
1. Clean area around hydraulic fittings for main
lift cylinders. Disconnect fittings at main lift
cylinders and put caps on open lines. See Fig-
ure 40.
2. Remove lift chains and header hoses. Remove
brackets and disconnect FFL supply tube from
free-lift cylinder. Remove free-lift cylinder. Dis-
connect free-lift chains at the crossmember. See
Figure 40 and Figure 41.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause
Two-Stage Mast With Full Free-Lift Repair
an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal
or installation.
3. Remove nut, capscrew, washers, and spacer at
cylinder mount near top of each main lift cylin-
der. Remove snap rings and washers from top
of right main lift cylinder Disconnect main lift
chains at the mounts. See Figure 41.
4. Disconnect the FFL supply tube from left main
lift cylinder and remove hydraulic fitting and
snap ring from top of left main lift cylinder
(from driver's view). Remove clamp, at top of in-
ner mast, and FFL supply tube from inner
mast. See Figure 40 and Figure 41.
WARNING
The mast weldments can slide when the mast is
moved. A weldment that slides can cause injury.
5. Slide the inner mast from outer mast approxi-
mately 30 cm (12 in.) to disengage main lift cyl-
inders from inner mast. Remove main lift cylin-
ders from outer mast. See Figure 40.
6. Slide inner mast from bottom of outer mast ap-
proximately 30 cm (12 in.). Remove strip bear-
ings and load rollers from top of the outer mast.
Remove load rollers from bottom of the inner
mast. Make a note of each shim arrangement
and load roller location. The shim arrange-
ments will be the same during assembly. See
Figure 40 and Figure 41.
47
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 40. Outer Mast, Main Lift Cylinders, And Hydraulic Fittings

48
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 40

1. OUTER MAST 11. CYLINDER MOUNT

2. SHIM 12. FITTING
3. SNAP RING 13. ROD END O-RING
4. O-RING 14. RIGHT MAIN LIFT CYLINDER
5. STRIP BEARING 15. LEFT MAIN LIFT CYLINDER
6. CAPSCREW 16. FFL SUPPLY TUBE
7. BUSHING (BRONZE) 17. VELOCITY FUSE
8. WASHER 18. HOSE ASSEMBLY
9. SPACER 19. LOWERING CONTROL VALVE HOUSING
10. NUT 20. LOAD ROLLER

49
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. CAPSCREW 11. WASHER

2. CLAMP 12. CHAIN GUARD
3. PIN 13. ROLL PIN
4. CHAIN ANCHOR PIN 14. BALL BEARING
5. CHAIN ANCHOR 15. CHAIN SHEAVE
6. INNER MAST 16. FREE-LIFT CHAIN
7. LOCKNUT 17. CROSSHEAD ASSEMBLY
8. SHIM 18. NUT
9. SNAP RING 19. BRACKET
10. LOAD ROLLER 20. FITTING

Figure 41. Inner Mast And Free-Lift Cylinder Assembly

50
4000 SRM 1693
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
NOTE: When replacing outer mast, copy the part
number and date code information from the old
channel and stamp that information on new chan-
nel with a letter R at the end to indicate that it has
been replaced.
7. Slide inner mast halfway out of the top of outer
mast. Connect a crane with a capacity of at
least 907 kg (2000 lb) to the center of inner
mast. See Figure 42. Slide inner mast out of
outer mast until mast stub shafts of inner mast
are in the notches of outer channels. Remove
inner mast from outer mast.
8. Remove the chain sheaves and disassemble
them as necessary for repair and cleaning.
Figure 42. Mast Disassembly
CLEAN AND INSPECT
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam and
high-pressure water can remove the lubrication
from the bearings in the load rollers. Water in the
Two-Stage Mast With Full Free-Lift Repair
bearings of the sheaves and the link pins of
chains can also shorten the service life of these
parts.
1. Inspect chain sheaves and load rollers for wear
or damage. DO NOT use steam to clean lift
chain sheaves or load rollers. The bearings in
the sheaves and load rollers are sealed and lu-
bricated. See Figure 40 and Figure 41.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
commercial cleaning solvents, always comply
with solvent manufacturer's recommended safety
precautions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
2. Clean the lift chains by soaking in solvent for
30 minutes to remove all dirt and grease. Hang
lift chains up and remove solvent using com-
pressed air.
WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
Damage to the lift truck and serious injury can oc-
cur if lift chains are not replaced correctly.
NOTE: Lift chains must be inspected in the area of
chain that passes over chain sheave during first
portion of a lift. These links will show maximum
wear.
3. Inspect lift chains for wear and damage. A lift
chain becomes longer when it is worn. If a
chain is 3 percent longer than a new lift chain,
the lift chain must be replaced.
51
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

4. If a chain scale is available (Hyster Part No. NOTE: Chain anchor pins MUST be replaced any-
599737), check lift chains as shown in Fig- time chains are replaced.
ure 43. If a chain scale is not available measure
20 links of chain. Measure from the center of a 6. Inspect chain anchors, chain anchor pins, and
pin to the center of another pin 20 pitches pins. Replace any parts that are worn or dam-
away. Compare the length with the chart in aged. See Figure 41.
Figure 43. Replace chain if the length of 20
links of the worn section is more than the maxi-
mum wear limit.

5. Lubricate lift chains by soaking them in SAE

30 engine oil for 30 minutes. Hang chains over
a drip pan for one hour to remove excess oil.

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 43. Lift Chains Check

52
4000 SRM 1693
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
commercial cleaning solvents, always comply
with solvent manufacturer's recommended safety
precautions.
WARNING
Steam can cause serious burns. Wear protective
clothing, gloves, and eye protection. Never ex-
pose your skin to steam.
7. Clean mast weldments with steam or solvent.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast which can result in serious injury to
personnel. Consult your Hyster lift truck dealers
for more information before welding on the mast.
8. Inspect sliding surfaces for wear or damage. In-
spect load roller contact surfaces for wear or
damage. Inspect all welds for cracks.
ASSEMBLE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
NOTE: To remove, adjust, and install header ho-
ses, see Header Hose Procedures in this section.
NOTE: The shims for the load rollers keep mast
weldments parallel and provide correct clearance.
During assembly, shims should be reinstalled in
the same location they were in before disassembly.
Check clearance and adjust shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. Shims for strip bears
should also be reinstalled in the same location they
were in before disassembly. See Mast Adjustments
in this manual for adjustment procedures.
1. Connect a crane with a capacity of at least
907 kg (2000 lb) to center of inner mast. Fit
stub shafts through notches in outer mast.
Two-Stage Mast With Full Free-Lift Repair
Slide inner mast into outer mast so stub shafts
are seen at top and bottom of weldments. See
Figure 40 and Figure 41.
2. Install strip bearings and shims on outer mast.
See Figure 44. Apply chassis lube to bearing
surface. Check clearance of strip bearings as
described in Mast Adjustments in this manual.
Figure 44. Strip Bearings
3. Install the load rollers and shims on both weld-
ments. Check the clearance of the load rollers
as described in Carriage Adjustments.
NOTE: The clearance check and adjustment in
Step 4 is only an initial setup. The final check and
adjustment is done after mast is installed on lift
truck.
4. To install main lift cylinders, perform the fol-
lowing procedures (see Figure 40):
a. Install main lift cylinders in the mounts at
bottom of outer mast.
b. Install washers at top of right main lift cylin-
der. Push inner mast to engage rods of lift
cylinders.
c. Check clearance at top of main lift cylinder
mounts. Add or remove washers at right
main lift cylinder until it is even with left
main lift cylinder.
d. Install snap ring at top of right main lift cyl-
inder. Install snap ring, rod end O-ring, and
hydraulic fitting on left main lift cylinder.
53
Two-Stage Mast With Full Free-Lift Repair
5. Install spacers, washers, capscrews and nuts at
mounts for main lift cylinders. Tighten nuts to
40 N•m (30 lbf ft). See Figure 40.
6. Install housing for lowering control valve on
outer mast. Tighten nuts for lowering control
valve housing to 18 N•m (13 lbf ft). Install low-
ering control valve in the housing. Connect hy-
draulic lines and fittings between housing and
main lift cylinders. See Figure 40.
7. Install free-lift cylinder in mount on inner
mast. Install brackets for free-lift cylinder and
tighten nuts to 53 N•m (39 lbf ft). See Fig-
ure 41.
8. Install FFL supply tube to connect free-lift cyl-
inder to main lift cylinders. Tighten capscrew
for FFL supply tube clamp (at top of inner
mast) to 33 N•m (24 lbf ft). See Figure 40 and
Figure 41.
9. Connect free-lift chains to chain anchors at
crossmember. Attach a wire between the end of
the lift chain and the bottom of the mast to con-
trol the lift chain during installation.
INSTALL
1. Install new bushings into mast mounts at bot-
tom of outer mast. Be sure to align the hole in
the bushing with the lube fitting hole in the
bottom of the outer mast. See Figure 37. Bush-
ing must be flush with outer mast surface.
2. Lubricate the lower mast mounting surface to
prepare for installation. Apply an even coat of
grease to the pivot pins and install them into
mounts at bottom of outer mast. See Figure 39.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
54
4000 SRM 1693
3. Connect crane to top of mast using chains.
Make sure all mast uprights are fastened to-
gether. Make sure chains will not damage
sheaves, tubing, or other parts of mast. Make
sure crane has a capacity of at least
907 kg (2000 lb).
4. Use crane to position mast assembly onto its
lower mounts. Position mast so pivot pins seat
into hanger mounts on drive axle. Install cap-
screws that hold mast pivot pins to drive axle
hangers. Tighten capscrews to
270 N•m (199 lbf ft). Refer to Figure 38 and
Figure 39.
5. Install new tilt rod bushings into outer mast.
Be sure to install bushings with split at correct
angle as shown in Figure 37.
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The tilt cyl-
inder or mast can shift and cause serious injury.
NOTE: Use multipurpose grease #2 with 2 to 4%
molybdenum disulfide for normal operations.
6. Apply grease to pivot pins and connect tilt cyl-
inders to mast using pivot pins. Install anchor
pins and capscrews to rod ends. Apply antiseize
compound to capscrew threads and tighten to
38 N•m (28 lbf ft). See Figure 45.
7. Connect hydraulic line to lowering control
valve.
8. Install carriage as described in Carriages Re-
pair, Two-Stage FFL Mast.
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

NOTE: Before checking for mast side kicking, the

mast must be fully assembled to include carriage,
forks, load backrest and any attachments.

10. Raise the mast, without a load to its full height

and check for side kicking. Mast side kicking is
when mast moves either to the right or left as it
is being raised to its full height. If mast is side
kicking, see Mast Adjustments section for pro-
cedures to correct mast side kicking.

NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.

11. Lubricate sliding surfaces and load roller surfa-

ces along full length of channels as shown in
Figure 46. Apply lubricant only to surfaces indi-
cated in Figure 46.

1. O-RING 7. PIVOT PIN

2. SPACER 8. GREASE FITTING
3. SHIMS 9. ANCHOR PIN
4. NUT 10. ROD END
5. WASHER 11. TILT CYLINDER
6. CAPSCREW

Figure 45. Mast Mounting, Tilt Cylinder

A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
WARNING
Never check for leaks by putting hands on hy- 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
draulic lines or components under pressure. Hy- 3. LOAD ROLLER
draulic oil under pressure can be injected into the
skin. Figure 46. Lubricate Mast

9. Check tilt cylinder adjustment as described in

Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692. Operate mast and check
for leaks and correct operation. Check lift
chains as described in Lift Chains Adjustment.

55
Two-Stage Mast With Full Free-Lift Repair
HEADER HOSE PROCEDURES
Remove
Read and follow the Safety Procedures When Work-
ing Near Mast as well as all WARNINGS and
CAUTIONS before removing any header hoses.
NOTE: Access to some of the fittings can be diffi-
cult. If necessary, operate hydraulic system to move
mast weldments or carriage. Make sure the hy-
draulic system does not have pressure as described
in Step 1.
1. To replace any header hoses, fully lower car-
riage. Make sure hydraulic system does not
have hydraulic pressure. Hold the control for
each function in the forward position for ap-
proximately five seconds to release pressure.
Make sure hydraulic pump does not operate.
Move key or keyless switch, if equipped, to the
OFF position.
2. Disconnect battery and put a tag or lock on bat-
tery connector.
3. Disconnect header hoses and install caps on
ends to prevent dirt and debris from entering
the hydraulic system.
Installation
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.
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.
56
4000 SRM 1693
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this sec-
tion.
Before installing the header hoses, make sure you
know the lift height of the mast. The tension on the
header hoses is adjusted according to lift height.
The lift height is on the Nameplate of the lift truck
and on the right side of the outer mast. See Fig-
ure 1.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage.
Examples of attachments that use these auxiliary
functions are sideshift carriages, roll clamps, and
fork positioners. These auxiliary functions require
header hoses for their operation.
NOTE: This procedure is for the four-function op-
tion. The three-function option will have hoses A
and B only.
NOTE: The carriage height must be correct before
the header hoses can be adjusted. See Lift Chains
Adjustment for carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C,
and D. See Figure 47.
2. Dimensions E and G are determined by the
height of the outer mast channel from the
ground and the length of the outer mast chan-
nel. See dimensions Y and Z in Figure 48. To
find E and G see:
Table 5 for lift truck models
• S3.0-3.5FT (S60-70FT) (G187, H187)
Table 6 for lift truck models
• H3.0-3.5FT (H60-70FT) (N177, P177)
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

A. HEADER HOSE D. HEADER HOSE

B. HEADER HOSE E. REAR VIEW
C. HEADER HOSE F. TOP VIEW

Figure 47. Header Hose Alignment

57
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 48. Header Hose Measurement for Two-Stage Full Free-Lift Mast

58
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 48

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE

Table 5. Standard Two-Stage FFL Hose Dimensions, Lift Truck Models S3.0-3.5FT (S60-70FT)
(G187, H187)

Channel Length Dimension "G" Dimension "G"

Lift Height Dimension "E"
(Reference) Third Function Fourth Function
mm in. mm in. mm in. mm in. mm in.
3060 120.5 2040 80.3 1363 53.6 3183 125.3 3054 120.2
3262 128.4 2140 84.3 1412 55.6 3380 133.1 3251 127.9
Lift height is measured from bottom of forks. Lift heights shown are standard. If your lift height is not
shown, go to Hyster Hypass Online to find the correct header hose measurement for your lift height.

Table 6. Standard Two-Stage FFL Hose Dimensions, Lift Truck Models H3.0-3.5FT (H60-70FT)
(N177, P177)

Channel Length Dimension "G" Dimension "G"

Lift Height Dimension "E"
(Reference) Third Function Fourth Function
mm in. mm in. mm in. mm in. mm in.
3060 120.5 2040 80.3 1438 56.6 3276 128.9 3147 123.8
3262 128.4 2140 84.3 1487 58.5 3473 136.7 3344 131.6
Lift height is measured from bottom of forks. Lift heights shown are standard. If your lift height is not
shown, go to Hyster Hypass Online to find the correct header hose measurement for your lift height.

3. Clamp the end of the hose (the smaller fitting)
that attaches to the carriage in a vise (DO
NOT clamp on the threads), and pull on the
other end until the hose is straight. DO NOT
apply enough force to stretch the hose. See Fig-
ure 48.
NOTE: These marks will be used to pretension
header hoses during installation.
4. Place a mark on all hoses at dimension E and
G. All measurements are made from carriage
end of the hose (the smaller fitting).
5. Attach the hoses to the carriage bracket with
clamps. Tighten hardware to
18 N•m (159 lbf in). See Figure 49.
6. Put header hoses over the free-lift chains. See
Figure 47 and Figure 49.

59
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 49. Header Hoses for Two-Stage Full Free-Lift Mast

60
4000 SRM 1693 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 49

NOTE: THREE-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CHANNEL 14. CARRIAGE BRACKET
2. COWL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
6. CLAMP 19. CAPSCREW
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUB SHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN

61
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

7. Put the clamps over the header hoses and at- over hoses and attach the clamps to the chan-
tach the clamps to the free-lift bracket. DO nels. Tighten the hardware to
NOT tighten the hardware. 8 N•m (71 lbf in).

NOTE: To make the alignment of dimension E eas-
ier, use a crane with a capacity at least
907.2 kg (2000 lb) to raise the carriage high enough
to install a safety chain. See Figure 50.
8. Align mark E at bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in). See Fig-
ure 49.
10. Connect header hoses C and D to cowl hoses.
Connect header hoses A and B to tubes. See
Figure 47 and Figure 49.
11. Use rubber clamps and strap clamps to attach
hoses to the main lift cylinders. DO NOT allow
cowl hoses to stretch or fold while tilting mast
fully forward and backward.

9. Apply a spray lubricant on the hoses in area

that will contact channels. Make sure hoses are
properly aligned in the channels. Put clamps

1. HOOK 2. SHACKLE

Figure 50. Chaining the Carriage (FFL)

62
4000 SRM 1693
Adjustment
When properly adjusted, the hoses will not be so
tight that they compress when they pass over the
sheaves, nor will they be so loose that they touch
the load backrest or any crossmember that is next
to a sheave.
1. Cap off hoses when attachments have been re-
moved.
2. Check that hoses and cables are routed prop-
erly.
3. Slowly raise free-lift and main cylinders to take
up slack in lift chains.
4. Tighten strap clamps at bracket weldment.
5. Cycle mast a few times to ensure proper track-
ing of hoses.
6. Secure hose assemblies to main lift cylinders
with hose clamp and screw clamp.
NOTE: If the hose tension between the carriage
and the clamp at the free-lift bracket is correct, go
to Step 7.
Two-Stage Mast With Full Free-Lift Repair
If the hose tension between carriage and clamp
at free-lift bracket is incorrect, loosen clamps
and pull (if the hoses are loose) or push (if the
hoses are tight) on the hoses so they move
15.0 mm (0.6 in.) side to side. Tighten hardware
to 8 N•m (71 lbf in).
NOTE: If the hose tension between the clamp at
the upper bracket and the clamp at the free-lift
bracket is correct, go to Step 8.
7. If the tension of hoses is incorrect, loosen
clamps and pull hoses down (if too loose) or
push the hoses up (if too tight) so they can
move 15.0 mm (0.6 in.) side to side. Tighten
hardware to 8 N•m (71 lbf in).
8. With no load on the forks, check header hose
adjustment by operating mast through full lift
cycle two times. When properly adjusted, the
hoses will not be so tight that they compress
when they pass over the sheaves nor will they
be so loose that they touch the load backrest or
any crossmember that is next to a sheave. If
necessary, repeat until the hoses are properly
adjusted.
63
Carriages Repair, Four-Stage FFL Mast 4000 SRM 1693

Carriages Repair, Four-Stage FFL Mast

Only lift truck models S40-70FT, S55FTS (G187,
H187) can be equipped with a four-stage FFL mast.

STANDARD CARRIAGE
NOTE: Lift trucks equipped with a four-stage FFL
mast may also be equipped with a heavy duty,
standard carriage.

Remove
1. Remove forks. See Fork Replacement for proce-
dures.

2. Remove four capscrews and load backrest from

carriage. See Figure 51.

3. Connect a lifting device to carriage. Lift car-

riage so that 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 and caus-
ing an injury or damage. 1. CAPSCREW 4. CARRIAGE
2. WASHER 5. LOAD BACKREST
4. Remove chain pin from each chain anchor at 3. NUT
carriage. Disconnect lift chains from carriage.
Use wire to connect ends of lift chains to a part Figure 51. Load Backrest, Remove
of the mast. Make sure chains can move freely
when inner mast is raised. See Figure 52.

64
4000 SRM 1693 Carriages Repair, Four-Stage FFL Mast

A. STANDARD CARRIAGE B. HEAVY DUTY STANDARD CARRIAGE

1. SNAP RING 6. CHAIN PIN
2. SPACER 7. ANCHOR PIN
3. SHIM 8. COTTER PIN
4. LOAD ROLLER 9. CARRIAGE
5. CHAIN ANCHOR

Figure 52. Standard Carriage Components

65
Carriages Repair, Four-Stage FFL Mast
WARNING
To help prevent possible injury, make sure the
carriage is stable and will not fall over when the
inner mast is raised above the load rollers of the
carriage.
5. Use lift cylinders to raise inner mast. If hy-
draulic system cannot be used, disconnect lift
cylinders from inner mast. See Cylinder Re-
pair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures.
6. Connect a crane with a capacity of at least
681 kg (1501 lb), to top of inner mast. Carefully
raise inner mast until it is above the load roll-
ers of the carriage. Install safety chains to se-
cure mast in its extended position and discon-
nect the crane. See Safety Procedures When
Working Near Mast.
7. Move lift truck away from carriage. Completely
lower inner mast so it cannot move.
Clean and Inspect
NOTE: Shims are installed on the bottom and mid-
dle load rollers only.
1. If load rollers must be replaced, make a note of
the location and number of shims. Install
shims, load rollers, and snap rings. See Car-
riage Adjustments section for correct adjust-
ment of the load rollers.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using clean-
ing solvents, always follow the recommendations
of the manufacturer.
66
4000 SRM 1693
CAUTION
DO NOT use cleaning solvent, compressed air, or
steam to clean lift chain sheaves or load rollers.
The bearings in the lift chain sheaves and load
rollers are sealed and lubricated. Cleaning sol-
vent, compressed air, and steam can damage the
load roller bearings.
2. Clean any oil, grease, dirt, and other debris
from carriage frame. Use a cleaning solvent and
compressed air to dry.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast. Consult a Resident Service Engineer-
ing through the Contact Management System be-
fore welding on the mast.
3. If carriage bars have any protruding welds or
damaged notches, repair by grinding, filing, or
welding.
4. Clean and inspect the chain anchors and chain
anchor pins. See Figure 52. Check chain an-
chors and anchor pins for wear and serviceabil-
ity. Discard worn or unserviceable chain an-
chors and chain anchor pins. Discard used cot-
ter pins.
Install
1. Move lift truck towards carriage until inner
mast is aligned with carriage rollers. If inner
mast has been raised and secured using a crane
and safety chains, connect crane, raise inner
mast, and remove safety chains. Carefully
lower inner mast until it engages all of the load
rollers. Disconnect the crane, if attached, and
reconnect lift cylinders. See Cylinder Repair
(Mast S/N D515, E509, E564) 2100SRM1692
for procedures.
2. Check clearance of load rollers. See Carriage
Adjustments section for procedures.
4000 SRM 1693 Carriages Repair, Four-Stage FFL Mast

NOTE: Use new cotter pins each time chain pins
are removed.
3. Connect lift chains to chain anchors at the car-
riage. Install cotter pins in chain pins. Adjust
lift chains as described in Lift Chains Adjust-
ment.
NOTE: Tag hydraulic lines and fittings prior to dis-
connecting to aid in connecting during installation.
See Figure 53.
4. Disconnect hydraulic lines from sideshift cylin-
der. Put caps and plugs on open lines and cylin-
der ports. See Figure 53.

4. Install load backrest on carriage. Tighten cap-

screws to 195 N•m (144 lbf ft).

5. Install forks. See section Fork Replacement for

procedures.

INTEGRAL SIDESHIFT CARRIAGE

Remove
1. Lower carriage completely. Remove forks. See
Fork Replacement for removal procedures.

2. Remove four capscrews and load backrest from

carriage. See Figure 51.

1. HOSE FITTINGS
WARNING 2. HOSES
Before disconnecting the hydraulic hoses, relieve 3. INTEGRAL SIDESHIFT CYLINDER
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy- Figure 53. Integral Sideshift Carriage Hydraulic
draulic system prior to disconnecting hydraulic Connections
hoses.

3. Relieve hydraulic pressure to sideshift cylinder 5. Remove lower mounting hooks by removing
by moving sideshift lever in both directions sev- four capscrews securing the hooks. See Fig-
eral times. ure 54.

6. Remove sideshift cylinder from carriage. See

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.
Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692 for procedures..
7. Use a crane with a capacity of at least
450 kg (992 lb) to lift outer frame away from in-
ner frame. Lay outer frame flat on a pallet or
work bench. See Figure 55.

WARNING
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.

67
Carriages Repair, Four-Stage FFL Mast 4000 SRM 1693

NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY.

1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 13. COTTER PIN
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. LOAD ROLLER
6. LOWER HOOK 16. SHIMS
7. CAPSCREW 17. SPACER
8. WASHER 18. FORK REMOVAL NOTCH
9. CLEVIS PIN 19. CHAIN ANCHOR PIN
10. PIN

Figure 54. Integral Sideshift Carriage Component Parts

68
4000 SRM 1693 Carriages Repair, Four-Stage FFL Mast

Disassemble Clean and Inspect

1. Remove upper and lower bearings from inner 1. Inspect lower mounting hooks for wear. Replace
frame. See Clean and Inspect section for proce- hooks if they are worn beyond the wear limit.
dures. See Figure 54. The wear limit clearance range is
0.76 mm (0.03 in.) minimum and
2. If damaged, remove lube fittings from outer 1.52 mm (0.06 in.) maximum. See A in Fig-
frame. See Figure 54. ure 56.
3. Disassemble intergral sideshift cylinder. See
Cylinder Repair (Mast S/N D515, E509, CAUTION
E564) 2100SRM1692 for procedures. 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. Clean and inspect carriage bars for damage and

smoothness. Ensure carriage bars are parallel
and ends are flush. If carriage bars have any
protruding welds or damaged notches, repair by
grinding, filing, or welding.

3. Clean bearing areas. Inspect sideshift bearings

for wear as follows:

a. If either upper bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace both up-
per bearings by driving the upper bearings
from the inner frame.

1. OUTER FRAME 3. LIFTING DEVICE b. If either lower bearing is worn to less than
2. LIFTING HOOK 2.5 mm (0.1 in.) thickness, replace lower
bearings by prying the lower bearings from
Figure 55. Remove Outer Frame
the inner frame.

69
Carriages Repair, Four-Stage FFL Mast 4000 SRM 1693

4. Inspect the sideshift cylinder. See Cylinder

Repair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures.

5. Inspect load rollers for wear or damage. If load

rollers must be replaced, make a note of the lo-
cation and number of shims. Install shims, load
rollers and snap rings. See Carriage Adjust-
ments for correct adjustment.

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 56. Lower Mounting Hooks Wear Limit and

Clearance Adjustment

70
4000 SRM 1693 Carriages Repair, Four-Stage FFL Mast

A. MINIMUM THICKNESS 2.5 mm (0.1 in.).

1. LOWER BEARINGS 3. UPPER BEARINGS
2. CARRIAGE BARS
*BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE.

Figure 57. Checking Upper and Lower Bearings

71
Carriages Repair, Four-Stage FFL Mast
Assemble
1. Assemble integral sideshift cylinder. See Cyl-
inder Repair (Mast S/N D515, E509, E564)
2100SRM1692 for procedures.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 54.
NOTE: Use a wood block or a plastic hammer to
fully seat upper bearings onto inner frame. Proper
lower hook clearance requires the upper bearings
be fully seated.
3. Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces. In-
stall upper and lower bearings into the inner
frame. Bearings snap into place. See Figure 57.
Install
1. Install integral sideshift cylinder onto carriage.
See Cylinder Repair (Mast S/N D515, E509,
E564) 2100SRM1692 for procedures.
2. Use a crane with a capacity of at least
450 kg (992 lb) and install outer frame onto in-
ner frame. See Figure 54.
72
4000 SRM 1693
3. Install lower mounting hooks using four cap-
screws. Tighten to 150 to 180 N•m (108 to
132 lbf ft). For proper sideshift operation, make
sure there 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 B in Figure 56.
4. Connect hydraulic lines, as noted during re-
moval, to sideshift cylinder. See Figure 53.
5. Install load backrest to sideshift carriage.
Tighten capscrews to 195 N•m (144 lbf ft). See
Figure 51.
6. Install forks. See Fork Replacement, in this
manual, for procedures.
FORK POSITIONER CARRIAGE
The four-stage FFL mast covered in this manual is
not equipped with a fork positioner carriage.
4000 SRM 1693
Four-Stage Mast With Full Free-Lift Repair
MAST WITH SERIAL NUMBER D515
The information in this section applies only to lift
truck models S40-70FT, S55FTS (G187, H187).
REMOVE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast. Seri-
ous injury can occur if the mast falls.
WARNING
Mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
CAUTION
Make sure all mast weldments are fastened to-
gether. Make sure the safety chains will not dam-
age sheaves, tubing, or other parts of the mast.
NOTE: If the mast needs to be disassembled, re-
move the forks and carriage. See sections Fork Re-
placement and Carriages Repair, Four-Stage FFL
Mast for procedures. If only main lift cylinders need
to be repaired, the mast does not need to be re-
moved from lift truck. See Cylinder Repair (Mast
S/N D515, E509, E564) 2100SRM1692 for proce-
dures. For header hose installation and adjustment
procedures, see the section Header Hose Proce-
dures.
Four-Stage Mast With Full Free-Lift Repair
NOTE: The length of lift chains must be checked
before mast is removed. See section Lift Chains Ad-
justment in this manual.
1. Fully lower all mast weldments. Tilt the mast
fully forward. Connect a crane with a capacity
of at least 946 kg (2100 lb) to all top crossmem-
bers of mast weldments using chains to support
mast in an upright position when tilt cylinders
are disconnected.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic hoses until the oil in the system has
cooled.
Completely lower forks to relieve hydraulic pres-
sure before disconnecting any hoses.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes con-
taminated, damage to hydraulic system can oc-
cur.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2. Position a drip pan under area of hydraulic fit-
tings. Disconnect hydraulic line at lowering
control valve on outer mast. See Figure 58.
73
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. BALANCE LINE 9. LOWERING CONTROL VALVE

2. SNAP RING 10. RIGHT MAIN LIFT CYLINDER
3. SHIM 11. SPACER
4. FITTING AND O-RING 12. RETAINER
5. LEFT MAIN LIFT CYLINDER 13. WASHER
6. VELOCITY FUSE 14. NUT
7. LOWERING CONTROL VALVE HOUSING 15. CAPSCREW
8. HOSE

Figure 58. Main Lift Cylinders and Lowering Control Valve

74
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

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 serious
injury.

3. Remove the capscrews, washers, nuts, anchor

pins, and pivot pins at the tilt cylinder mounts
on the outer mast. See Figure 59.

4. Using a brass drift pin, remove tilt rod bush-

ings from outer mast. Discard tilt rod bushings.
See Figure 60.

NOTE: Tilt mast forward enough to allow for ac-

cess to mast mount capscrews.

5. Disconnect lower mast mounts from lift truck

by removing capscrews that hold mast pivot
pins to mounts on drive axle. See Figure 61 and
Figure 62 .

6. Use lifting device to lift mast assembly from lift

truck. Position outer mast across wooden
1. O-RING 7. PIVOT PIN
beams on floor with carriage side up. 2. SPACER 8. GREASE FITTING
3. SHIMS 9. ANCHOR PIN
7. Check mast and mounting flanges for wear or 4. NUT 10. ROD END
damage by removing mast pivot pins from outer 5. WASHER 11. TILT CYLINDER
mast. Check that pins fit snug in the outer 6. CAPSCREW
mast. If pins can be moved up and down a mini-
Figure 59. Mast Mounting, Tilt Cylinder
mum of 4 mm (0.20 in.), replace bushings in
outer mast and/or mast pivot pins as required. .
Use a brass drift pin to remove mast mounting
bushings from outer mast. See Figure 60 and
Figure 62.

75
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. TILT ROD BUSHING 5. LUBE FITTING

2. MAST MOUNTING BUSHING (BRONZE) 6. WASHER
3. OUTER MAST 7. BUSHING HOLE
4. BUSHING SPLIT 8. LUBE CAPSCREW

Figure 60. Tilt Rod and Mast Mounting Bushings

76
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

DISASSEMBLE

WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic hoses until the oil in the system has
cooled.

Completely lower forks to relieve hydraulic pres-

sure before disconnecting any hydraulic hoses.

CAUTION
Protect the hydraulic system from dirt and con-
taminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes con-
1. DRIVE AXLE taminated, damage to the hydraulic system can
2. HANGER MOUNTS
occur.
Figure 61. Mast Mounts, Drive Axle
NOTE: If only main lift cylinders need to be re-
moved for repair, the mast does not need to be re-
moved from lift truck. See Cylinder Repair (Mast
S/N D515, E509, E564) 2100SRM1692 for proce-
dures to remove main lift cylinders.

1. Disconnect and remove hydraulic lines for free-

lift cylinder. Remove brackets for free-lift cylin-
der. Remove free-lift cylinder. Disconnect free-
lift chains at crossmember See Figure 63.

1. MAST PIVOT PINS

2. BUSHING
Figure 62. Mast Pivot Pin

77
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 63. Second Intermediate and Inner Mast

78
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 63

1. SNAP RING 10. SHIMS

2. BEARING 11. COTTER PIN
3. CHAIN SHEAVE 12. NUT
4. SECOND INTERMEDIATE MAST 13. WASHER
5. O-RING 14. CHAIN ANCHOR
6. SHIM(S) 15. ANCHOR PIN
7. STRIP BEARING 16. LIFT CHAIN
8. INNER MAST 17. FREE-LIFT CHAIN
9. LOAD ROLLER

2. Disconnect lift chains at bottom of inner mast

and top of first intermediate mast. Remove lift
chains. Push inner mast toward bottom of mast
assembly until bottom load rollers are seen. See
Figure 63 and Figure 64.

79
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 64. Outer and First Intermediate Masts

80
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 64

1. OUTER MAST 10. WASHER

2. O-RING 11. NUT
3. SHIM(S) 12. FIRST INTERMEDIATE MAST
4. STRIP BEARING 13. SNAP RING
5. LIFT CHAIN 14. SHIMS
6. SPACER 15. LOAD ROLLER
7. ANCHOR PIN 16. BEARING
8. COTTER PIN 17. CHAIN SHEAVE
9. CHAIN ANCHOR 18. LOWERING CONTROL VALVE BRACKET

81
Four-Stage Mast With Full Free-Lift Repair
3. Remove strip bearings at top of second inter-
mediate mast. Remove load rollers at bottom of
inner mast. See Figure 63. Remove load rollers
at top of second intermediate mast. Make a
note of each shim arrangement and load roller
location. The shim arrangements will be ap-
proximately the same during assembly.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
4. Slide inner mast halfway out of top of second
intermediate mast. Connect crane to center of
inner mast. See Figure 65. Slide inner mast out
until stubshafts are in notches of second inter-
mediate mast. Remove inner mast from second
intermediate mast.
Figure 65. Mast Disassembly
82
4000 SRM 1693
5. Disconnect lift chains at bottom of second inter-
mediate mast and top of outer mast. Remove
lift chains. Push second intermediate mast to-
ward bottom of mast assembly until bottom
load rollers are seen. See Figure 63 and Fig-
ure 64.
6. Remove strip bearings and spacers at top of
first intermediate mast. Remove load rollers at
bottom of second intermediate mast. Remove
load rollers at top of first intermediate mast.
Make a note of each shim arrangement and
load roller location. The shim arrangements
will be approximately the same during assem-
bly. See Figure 63 and Figure 64.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
7. Slide second intermediate mast halfway out of
top of first intermediate mast. Connect crane to
center of second intermediate mast. See Fig-
ure 65. Slide second intermediate mast out un-
til stub shafts are in notches of first intermedi-
ate mast. Remove second intermediate mast.
8. Remove nut, washer, and capscrew from outer
mast crossmember and bracket weldment and
remove hose channels from outer mast. See Fig-
ure 66.
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

NOTE: FOUR FUNCTION MAST WITH FOUR HOSE CHANNELS SHOWN. THREE FUNCTION MAST WILL
HAVE TWO HOSE CHANNELS.

A. REAR VIEW B. FRONT VIEW

1. NUT 5. OUTER MAST CROSSMEMBER
2. WASHER 6. OUTER MAST
3. CAPSCREW 7. CLAMP
4. HOSE CHANNEL

Figure 66. Hose Channel Removal, Four-Stage FFL Mast

83
Four-Stage Mast With Full Free-Lift Repair
9. Disconnect hydraulic lines at top and bottom of
lift cylinders. Disconnect balance line at top of
right-hand lift cylinder. See Figure 58.
WARNING
Be careful when removing or installing snap rings
on the main lift cylinders. These snap rings 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 when removing and installing snap
rings onto main lift cylinders.
10. Remove snap rings, shims, and washers at top
of main lift cylinders. See Figure 58. Remove
nut, capscrew, washer, and spacer at mount
near top of each main lift cylinder.
11. Push first intermediate mast to disengage lift
cylinders. Remove main lift cylinders. Keep
shims from top of right lift cylinder with cylin-
der.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
12. Slide first intermediate mast from bottom of
outer mast approximately 30 cm (12 in.). Re-
move strip bearings at top of outer mast. Re-
84
4000 SRM 1693
move snap rings and load rollers from both
mast uprights. Make a note of each shim ar-
rangement and load roller location. The shim
arrangements will be approximately the same
during assembly.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
13. Slide intermediate mast halfway out of top of
outer mast. Connect crane to center of first in-
termediate mast. See Figure 65. Slide first in-
termediate mast out of outer mast until stub
shafts are in notches of outer mast. Remove
first intermediate mast from outer mast.
14. Disassemble chain sheaves as necessary for re-
pair and cleaning. Remove hydraulic lines and
fittings from mast uprights as necessary.
4000 SRM 1693
CLEAN AND INSPECT
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam and
high-pressure water can remove the lubrication
from the bearings in the load rollers. Water in the
bearings of the sheaves and the link pins of
chains can also shorten the service life of these
parts.
1. Inspect chain sheaves and load rollers for wear
or damage. DO NOT use steam to clean lift
chain sheaves or load rollers. The bearings in
the sheaves and load rollers are sealed and lu-
bricated.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
commercial cleaning solvents, always comply
with solvent manufacturer's recommended safety
precautions.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Four-Stage Mast With Full Free-Lift Repair
2. Clean lift chains by soaking in solvent for 30
minutes to remove all dirt and grease. Hang lift
chains up and remove solvent using compressed
air.
WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
Damage to the lift truck and serious injury can oc-
cur if lift chains are not replace correctly.
NOTE: The chains must be inspected in the area of
chain that passes over chain sheave during first
portion of a lift. These links will show maximum
wear.
3. Inspect lift chains for wear and damage. A lift
chain becomes longer when it is worn. If a
chain is 3% longer than a new lift chain, the lift
chain must be replaced.
4. If a chain scale is available (Hyster Part No.
599737), check lift chains as shown in Fig-
ure 67. If a chain scale is not available measure
20 links of chain. Measure from the center of a
pin to the center of another pin 20 pitches
away. Compare the length with the chart in
Figure 67. Replace chain if the length of 20
links of the worn section is more than the maxi-
mum wear limit.
85
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.

Pitch
Total length of 20 links Wear Limit The maximum length
(pitch) of new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 67. Lift Chains Check

86
4000 SRM 1693
5. Lubricate lift chains by soaking them in SAE
30 engine oil for 30 minutes. Hang chains over
a drip pan for one hour to remove excess oil.
NOTE: Chain anchor pins MUST be replaced any-
time chains are replaced.
6. Inspect chain anchors and pins. Replace any
parts that are worn or damaged.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
commercial cleaning solvents, always comply
with solvent manufacturer's recommended safety
precautions.
WARNING
Steam can cause serious burns. Wear protective
clothing, gloves, and eye protection. Never ex-
pose your skin to steam.
7. Clean mast weldments with steam or solvent.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast which can result in serious injury to
personnel. Consult your Hyster lift truck dealer for
more information before welding on the mast.
8. Inspect sliding surfaces for wear or damage. In-
spect load roller contact surfaces for wear or
damage. Inspect all welds for cracks.
Four-Stage Mast With Full Free-Lift Repair
ASSEMBLE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
NOTE: Shims for the load rollers keep the mast
weldments parallel and provide correct clearance.
During assembly, shims should be reinstalled in
the same location they were in before disassembly.
Check clearance and adjust shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims and should also be re-
installed in the same location they were in before
disassembly. See Mast Adjustments in this service
manual for adjustment procedures.
NOTE: When the mast has header hoses installed,
see the procedures in the section Header Hose Pro-
cedures.
1. Put outer mast on floor with mast pivots to-
ward floor. Connect crane to center of first in-
termediate mast. See Figure 65. Fit lower stub-
shafts of first intermediate mast into notches in
top of outer mast. Slide first intermediate mast
into outer mast so stubshafts are seen at top
and bottom of both mast uprights.
87
Four-Stage Mast With Full Free-Lift Repair
2. Install strip bearings and shims on channels of
outer mast. See Figure 68. Apply grease to
bearing surfaces.
Figure 68. Strip Bearings
3. Install load rollers and shims on outer mast
and at bottom of first intermediate mast. Before
doing Step 4, adjust first intermediate mast as
described in Mast Adjustments in this service
manual. Install chain sheaves, shims, and snap
rings on first intermediate weldment.
WARNING
Be careful when removing or installing snap rings
on the main lift cylinders. These snap rings can
come loose during removal or installation with
88
4000 SRM 1693
enough force to cause an injury. Always use the
correct snap ring pliers and wear eye and face
protection when removing and installing snap
rings onto main lift cylinders.
4. Install main lift cylinders in mounts at bottom
of outer mast. See Figure 64. Push intermedi-
ate mast to engage lift cylinders. Check clear-
ance at top of lift cylinder mounts. Add or re-
move shims at top of left cylinder rod until both
cylinders are even. Install retainer at top of
right cylinder. Install snap ring and washer at
top of lift cylinders. Install nuts, capscrews,
washers, and spacers at lift cylinder mounts on
outer mast. Tighten nuts to 40 N•m (30 lbf ft).
5. Install housing for lowering control valve on
outer mast. Tighten nuts for lowering control
valve to 18 N•m (13 lbf ft). Install lowering con-
trol valve in housing. Connect hydraulic lines
and fittings between lowering control valve and
main lift cylinders. See Figure 58.
6. Install chain sheaves and snap rings on second
intermediate mast. See Figure 63.
7. Install hose channels onto outer mast using
capscrews, nuts, and washers. Tighten cap-
screws to 8 N•m (71 lbf in). See Figure 66.
4000 SRM 1693
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
8. Connect crane to center of second intermediate
mast. See Figure 65. Slide mast into first inter-
mediate mast so stub shafts are seen at top and
bottom of both mast uprights.
9. Install strip bearings and shims on channels of
first intermediate mast. See Figure 68. Apply
grease to bearing surfaces. Install load rollers
and shims on first and second intermediate
mast. Before doing Step 10, adjust second inter-
mediate mast as described in Mast Adjust-
ments.
10. Connect lift chains to chain anchors at outer
mast. Put lift chains over chain sheaves on first
intermediate mast and connect them to anchors
at bottom of second intermediate mast.
Four-Stage Mast With Full Free-Lift Repair
11. Connect crane to center of inner mast. See Fig-
ure 65. Slide mast into second intermediate
mast so stub shafts are seen at top and bottom
of both uprights.
12. Install strip bearings and shims on channels of
second intermediate mast. Apply grease to
bearing surfaces. Install load rollers and shims
on second intermediate and inner mast. Before
doing Step 13, adjust inner mast as described
in Mast Adjustments.
13. Connect lift chains to chain anchors at top of
first intermediate mast. Put lift chains over
chain sheaves on second intermediate mast and
connect them to anchors at bottom of inner
weldment. See Figure 64.
14. Install free-lift cylinder in mounts on inner
mast. Install brackets for cylinder and tighten
nuts and capscrew to 40 N•m (30 lbf ft). See
Figure 63 and Figure 69.
89
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 69. Free-Lift Cylinder Assembly

90
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 69

1. HOSE 11. BRACKET

2. SHEAVE 12. PIN
3. STUB SHAFT 13. FREE-LIFT CYLINDER
4. LOCKWASHER 14. CLAMP
5. CAPSCREW 15. STANDOFF
6. CHAIN GUARD 16. CLAMP
7. SPACER 17. FITTING
8. CHAIN SHEAVE 18. BEARING
9. RETAINING RING 19. FLOW CONTROL ASSEMBLY
10. PIN

91
Four-Stage Mast With Full Free-Lift Repair
15. Install hose sheave for free-lift cylinder. See
Figure 69. Install hydraulic hose and tubing
that connect free-lift cylinder to right main lift
cylinder. Install balance line between two main
lift cylinders. See Figure 58.
16. Connect free-lift chains to chain anchors at in-
ner crossmember. Attach wire between other
end of lift chain and bottom of mast to control
free-lift chain during installation of mast.
INSTALL
1. Install new bushings into mast mounts at bot-
tom of outer mast. Be sure to align hole in
bushing with lube fitting hole in the bottom of
outer mast and that bushing split is installed at
correct angle as shown in Figure 60. Bushing
must be flush with outer mast surface.
2. Apply an even coat of grease to mast pivot pins
and install them into mounts at the bottom of
the outer mast. See Figure 62.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 946 kg (2100 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast. Seri-
ous injury can occur if the mast falls.
3. Connect a lifting device to top of mast using
chains. Make sure all mast uprights are fas-
tened together. Make sure chains will not dam-
aged chain sheaves, tubing, or other parts of
the mast.
4. Use lifting device and position mast so that
pivot pins seat into hanger mounts on drive
axle. See Figure 61. Install capscrews that hold
mast pivot pins to drive axle hangers and
tighten capscrews to 270 N•m (199 lbf ft). See
Figure 62.
5. Install new tilt rod bushings into outer mast.
Be sure to install bushings with split at correct
angle as shown in Figure 60.
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The cylinder
or mast can shift and cause serious injury.
92
4000 SRM 1693
NOTE: Use multipurpose grease #2 with 2 to 4%
molybdenum disulfide for normal operations.
6. Apply grease to pivot pins and connect tilt cyl-
inders to mast using pivot pins. Install anchor
pins and capscrews to rod ends. Apply anti-
seize compound to capscrew threads and
tighten 38 N•m (28 lbf ft). See Figure 59.
7. Connect hydraulic hose to lowering control
valve. See Figure 58.
8. Install carriage as described in Carriages Re-
pair, Four-Stage FFL Mast and install forks as
shown in section Fork Replacement in this
service manual.
9. Check tilt cylinder adjustment. See Cylinder
Repair (Mast S/N D515, E509, E564)
2100SRM1692 for adjustment procedures.
10. Operate mast and check for leaks and to ensure
mast is operating correctly. Check lift chains as
described in section Lift Chains Adjustment.
11. Adjust chain anchors on outer mast until tops
of the second intermediate and outer mast are
at the same level within ±1.5 mm (0.06 in.). See
Figure 64. Adjust chain anchors on first inter-
mediate mast until the tops of inner and outer
mast are at the same level within
±1.5 mm (0.06 in.).
NOTE: Before checking for mast side kicking and
adjusting chain anchors on main lift cylinders, the
mast must be fully assembled to include carriage,
forks, load backrest and any attachments if lift
truck is equipped with one.
12. Raise mast, without a load to its full height and
check for side kicking. Mast side kicking is
where the mast, without a load, moves either to
the right or left as it is being raised to its full
height. If mast is side kicking, see Mast Adjust-
ments section for procedures to correct mast
side kicking.
13. Lubricate sliding surfaces and load roller surfa-
ces along full length of channels as shown in
Figure 70. Apply lubricant only to surfaces indi-
cated in Figure 70.
4000 SRM 1693
A. LOWER LOAD ROLLERS
B. UPPER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 70. Mast Lubrication
HEADER HOSE PROCEDURES
Remove
Read and follow Safety Procedures When Working
Near Mast as well as all WARNINGS and CAU-
TIONS before removing any header hoses.
1. To replace any header hoses, fully lower car-
riage. Make sure hydraulic system does not
have hydraulic pressure. Hold the control for
each function in the forward position for ap-
proximately five seconds to release pressure.
Make sure hydraulic pump does not operate.
Move key or keyless switch, if equipped, to the
OFF position.
2. Disconnect battery and put a tag or lock on bat-
tery connector.
3. Disconnect header hoses and install caps on
ends to prevent dirt and debris from entering
the hydraulic system.
Four-Stage Mast With Full Free-Lift Repair
Installation
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.
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.
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this serv-
ice manual.
Before installing header hoses, make sure you
know the lift height of the mast. The tension on
header hoses is adjusted according to lift height.
The lift height is on the Nameplate of the lift truck
and on the right side of the outer mast. See Fig-
ure 1.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage.
Examples of attachments that use these auxiliary
functions are sideshift carriages, roll clamps, and
fork positioners. These auxiliary functions require
header hoses for their operation.
NOTE: This procedure is for mast equipped with a
four-function option. The three-function option will
have hoses A and B only.
NOTE: The carriage height must be correct before
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedures.
NOTE: If header hoses were removed, use these
procedures to install the header hoses. See Table 7.
If mast components have not been assembled, as-
semble mast as described in Assemble section
above.
1. Raise carriage so free-lift chains are not tight.
See Figure 72. Raise inner channel so main lift
chains are not tight. Install chains to prevent
inner channel and carriage from moving. The
chains must not be in the path of the header
hose. See Figure 71.
93
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

1. HOOK 2. SHACKLE

Figure 71. Chaining The Carriage (FFL)

94
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

2. Install all hose sheaves loosely. DO NOT
tighten capscrews and nuts until header hoses
are installed.
3. Make sure replacement header hose is correct
part number for your mast assembly. Make
sure header hoses are straight on a flat surface.
Mark header hose at points E, G, and H (mm)
as shown in Table 7. Measure from end of hose
with small fitting.
5. Install plate at middle hose clamp and tighten
4. Loosely assemble hose sheaves as shown in Fig-
ure 72:
a. Put coating of multipurpose grease on stub
shafts before assembly.
b. The nuts for the sheave capscrew (axle) must
be on the inside of each assembly.
c. DO NOT tighten any nuts or capscrews.
They must be loose to allow installation of
hoses on hose sheave.
capscrews to 8 N•m (71 lbf in).

Table 7. Standard Four-Stage FFL Hose Dimensions

Channel Length Dimension "G" Dimension "H"

Lift Height Dimension "E"
(Reference) All Functions All Functions
mm in. mm in. mm in. mm in. mm in.
6058 238.5 2040 80.3 1773 69.8 5998 236.1 4125 162.4
6977 274.7 2345 92.3 2073 81.6 7188 283.0 5315 209.3
Lift height is measured from top of forks. Lift heights shown are standard. If your lift height is not shown,
go to Hyster Hypass Online to find the correct header hose measurement for your lift height.

95
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 72. Header Hoses, Hose Sheaves, and Routing - Four-Stage FFL Mast

96
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 72

NOTE: THREE FUNCTION MAST SHOWN. FOUR FUNCTION MAST HAS TWO DRIVER SIDE CHANNELS
(15).

1. HOSE CHANNEL (LOAD SIDE) 11. HOSE SHEAVE

2. CAPSCREW 12. HEADER HOSES
3. WASHER 13. RIGHT HOSE GUARD
4. NUT 14. LEFT HOSE GUARD
5. HOSE CHANNEL BRACKET WELDMENT 15. HOSE CHANNEL (DRIVER SIDE)
6. HOSE CLAMP 16. PLATE
7. STRAP CLAMP 17. CAP
8. HOSE CHANNEL BRACKET 18. BOTTOM HOSE GUIDE
9. STUBSHAFT 19. SNAP RING
10. SPACER

6. Install bottom hose guides as shown in Fig-
ure 72. Put some grease on bottom of guides so
hoses can slip to equalize the pressure. Ensure
that inside hose goes through the rear of bot-
tom hose guide and tracks to the inside. The
outside hose goes through front of the bottom
hose guide and becomes the outside. Tighten
capscrews and nuts of bottom hose guide to
18 N•m (13 lbf ft). DO NOT tighten capscrews
and nuts for strap clamps at this time.
7. Install hose guides (flare toward outside) and
snap rings to chain sheaves. Install free-lift
sheaves, chains, and hose guards as shown in
Figure 72 and Figure 73.
8. Route hoses over hose sheave 2 (on free-lift cyl-
inder) with marks E aligned with either the top
edge of clamp or bottom edge of clamp (1 or 2 in
Figure 73). Tighten capscrews and nuts of
clamps to 8 N•m (71 lbf in).
9. Route hose assembly down and under hose
guide and install strap clamps over hoses.
Tighten capscrews and nuts of strap clamps to
18 N•m (159 lbf in).
11. Route hoses through hose channels (load side)
and over hose channel brackets. Install clamps
over hoses. See Figure 72.
12. Align mark G with bottom edge of clamp at top
of outer mast. Torque clamp hardware
to8 N•m (71 lbf in). See Figure 73.
13. Slowly operate hydraulic system so lift chains
are tight. Remove chains that fasten carriage
and channel weldment. Slowly raise carriage
using hydraulic system. Make sure hoses move
through all sheaves correctly.
14. Slowly operate mast through a few cycles to
make sure hoses track correctly. Tighten strap
clamps at bottom hose clamps to
18 N•m (159 lbf in). Tighten capscrews and
nuts for hose sheaves to 53 N•m (39 lbf ft). Fas-
ten hose assemblies to main cylinders using
hose clamps as shown in Figure 72 and Fig-
ure 73.

10. Route hoses over hose sheave 1 (10, Figure 73).

Install clamps over hoses. Align mark H with
bottom edge of clamp. Tighten clamp capscrews
to8 N•m (71 lbf in).

97
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 73. Four-Stage FFL Mast Header Hose Arrangement (Sheet 1 of 3)

98
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Figure 73. Four-Stage FFL Mast Header Hose Arrangement (Sheet 2 of 3)

99
Four-Stage Mast With Full Free-Lift Repair 4000 SRM 1693

Figure 73. Four-Stage FFL Mast Header Hose Arrangement (Sheet 3 of 3)

100
4000 SRM 1693 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 73

NOTE: SOME MAST COMPONENT PARTS OMITTED FOR CLARITY.

A. HEADER HOSE A F. CHAIN, HOSE SHEAVES AND HEADER HOSES

B. HEADER HOSE B AT FREE-LIFT CYLINDER
C. HEADER HOSE C G. SIDE VIEW
D. HEADER HOSE D H. FRONT VIEW
E. HEADER HOSE ARRANGEMENT THROUGH
HOSE CHANNELS
1. ALIGN MARK E AT BOTTOM EDGE OF CLAMP 9. ALIGN HOSE MARK G AT BOTTOM OF CLAMP
2. ALIGN MARK E AT TOP EDGE OF CLAMP 10. HOSE SHEAVE 1
3. HOSE GUIDE 11. ALIGN HOSE MARK H AT BOTTOM OF CLAMP
4. HOSE CHANNEL BRACKET WELDMENT 12. CHAIN SHEAVE
5. HOSE CLAMP 13. FREE-LIFT CYLINDER
6. HOSE CLAMP 14. HOSE CHANNEL (LOAD SIDE)
7. HOSE CHANNEL (DRIVE SIDE) 15. MAIN LIFT CYLINDER
8. LOWERING CONTROL VALVE 16. HOSE SHEAVE 2

101
Four-Stage Mast With Full Free-Lift Repair
Adjustment
When properly adjusted, the hoses will not be so
tight that they compress when they pass over hose
sheaves, nor will they be so loose that they touch
the load backrest or any crossmember that is next
to a sheave.
1. Cap off hoses when attachments have been re-
moved.
2. Check that hoses and cables are routed prop-
erly.
3. Slowly raise the free-lift and main cylinders to
take up slack in lift chains.
4. Tighten strap clamps at the bracket weldment.
5. Cycle mast a few times to ensure proper track-
ing of hoses.
6. Secure hose assemblies to main lift cylinders
with hose clamp and screw clamp.
NOTE: If the hose tension between the carriage
and the clamp at the free-lift bracket is correct, go
to Step 7.
102
4000 SRM 1693
If the hose tension between carriage and clamp
at free-lift bracket is incorrect, loosen the clamps
and pull (if the hoses are loose) or push (if the
hoses are tight) on the hoses so they move
15.0 mm (0.6 in.) side to side. Tighten hardware
to 8 N•m (71 lbf in).
NOTE: If the hose tension between the clamp at
upper bracket and clamp at free-lift bracket is cor-
rect, go to Step 8.
7. If the tension of hoses is incorrect, loosen
clamps and pull hoses down (if too loose) or
push hoses up (if too tight) so they can move
15.0 mm (0.6 in.) side to side. Tighten hardware
to 8 N•m (71 lbf in).
8. With no load on the forks, check the header
hose adjustment by operating the mast through
the full lift cycle two times. If necessary, repeat
until the hoses are properly adjusted.
9. Loosen clamp at top of mast near sheave 1 (10,
Figure 73). Pull on hoses so that they move by
clamp width of 30 mm (12 in.). Tighten clamp
hardware to 8 N•m (71 lbf in).
4000 SRM 1693 Carriage Adjustments

Carriage Adjustments
1. Install the load rollers on the carriage. Install
the shims for the load rollers onto the stubshaft
in the same sequence as when disassembled.
There are no shims under the top load rollers.

See Figure 74 for lift trucks equipped with a two-

stage FFL mast

See Figure 75 for lift trucks equipped with a

four-stage FFL mast

2. Use a lifting device to raise carriage. Find the

point of tightest fit between carriage load roll-
ers and inner mast channels.

3. Remove carriage from mast. Adjust shim ar-

rangement for each load roller for clearance be-
tween load roller and inner channel. Repeat
Step 1 and Step 2 until there is zero clearance
at the point of tightest fit.

4. Keep shim arrangement on each side of car-

riage approximately equal. The carriage must
be centered within the inner mast within 1. CARRIAGE 6. CHAIN ANCHOR
+1.50 mm (0.06 in.). 2. LOAD ROLLER 7. PIN
3. SNAP RING 8. ANCHOR PIN
4. SHIM 9. COTTER PIN
5. SPACER
Figure 74. Carriage Adjustments, Two-Stage FFL
Mast

103
Carriage Adjustments 4000 SRM 1693

A. STANDARD CARRIAGE B. HEAVY DUTY STANDARD CARRIAGE

1. SNAP RING 6. CHAIN PIN
2. SPACER 7. ANCHOR PIN
3. SHIM 8. COTTER PIN
4. LOAD ROLLER 9. CARRIAGE
5. CHAIN ANCHOR

Figure 75. Carriage Adjustments, Four-Stage FFL Mast

5. Check lateral movement of carriage:

a. Fully lower carriage to ground.
b. Place hand or small pry bar between top of
carriage side plate and the inner channel
flange. See Mast Adjustments.
c. Move carriage back and forth and check
movement.
d. Carriage lateral movement must not be
greater than 2.5 mm (0.10 in.).
CAUTION
Too much grease will cause the rollers to slide
and wear flat areas on the rollers and introduce
contamination into and on mast channels.
6. After adjustment, lubricate channels with a
thin layer of grease. Adjust hydraulic hoses and
make sure connections are correct, if the car-
riage is equipped with hydraulic attachments.

e. If carriage lateral movement is greater than

2.5 mm (0.10 in.), add or remove shims and
repeat Step a through Step d until correct
movement is achieved.

104
4000 SRM 1693 Lift Chains Adjustment

Lift Chains Adjustment

Lift Trucks Equipped with Forks
WARNING
When working on or near the mast, see Safety 1. Adjust the chain anchors that support the car-
Procedures When Working Near Mast at the be- riage, until the bottom of the fork heel is 12
ginning of this manual. +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above the
floor level. See Figure 76.
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to pre-
vent it from falling. Keep all personnel away from
the lift truck during the tests.

Never allow anyone under a raised carriage. DO

NOT put any part of your body in or through the
lift mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.

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.

When the lift chains are correctly adjusted:

• The tension will be the same on each chain of
the chain set. Check tension by pushing on
both chains at the same time. 1. MAST
2. CARRIAGE
• The chain length will be correct. 3. FORK
• The chains must travel freely through the 4. HEEL OF FORK IS 12 +3.0/−6.0 mm (0.47
complete cycle. +0.12/−0.24 in.) ABOVE FLOOR LEVEL

Figure 76. Lift Chain Adjustment, With Forks

NOTE: When the lift chain adjustments are com-
plete, make sure the threads on the nuts of the
chain anchors are completely engaged. Inspect the
torque of the prevailing torque nut (locknut) used
Lift Trucks Equipped with Hook-Type
to adjust the chain anchor with every lift chain ad-
Carriage and Attachment Without Forks
justment. After carriage and or mast section(s) are 1. Adjust the chain anchors that support the car-
adjusted for proper ground clearance, prevent the riage, until the bottom of the lower carriage bar
carriage and or mast section(s) from fully lowering is above the floor level as shown in Table 8 and
(see Safety Procedures When Working Near Mast). Figure 77.
With slack chain(s), check locknut torque. If
2.5 N•m (22.1 lbf in) for ½-20, 4.5 N•m (39.8 lbf in)
for 5/8-18 nuts, 6.0 N•m (53.1 lbf in) for 3/4-16 of Table 8. Hook-Type Carriage Chain Adjustment
torque cannot be reached; replace locknut. The
chain anchors, after adjustment, must be able to Class II and III 82.5 ±3.0 mm (3.25 ±0.12 in.)
move on their mountings. Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)
NOTE: Prior to performing adjustment procedures,
make sure the forklift truck is parked on a level
surface and the mast is in the vertical position.

105
Lift Chains Adjustment 4000 SRM 1693

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER CAR-
RIAGE BAR
Figure 77. Lift Chain Adjustment, Hook-Type
Carriage

Lift Trucks Equipped With Pin-Type Carriage

and Attachment Without Forks
1. Adjust the chain anchors, which support the
carriage, until the center line of the fork pin is
above the floor level as shown in Table 9 and
Figure 78.
1. LOAD BACK REST
2. FORK PIN
Table 9. Pin-Type Carriage Chain Adjustment 3. DISTANCE FROM FORK PIN TO FLOOR
4-5.5T Class III 545.0 ±3.0 mm Figure 78. Lift Chain Adjustment, Pin-Type
(21.5 ±0.12 in.) Carriage
4-5.5T Class IV 708.0 ±3.0 mm
(27.87 ±0.12 in.)
6-7T Class IV 907.0 ±3.0 mm
(35.71 ±0.12 in.)

106
4000 SRM 1693 Mast Adjustments

Mast Adjustments
LOAD ROLLER, ADJUST 1. Load rollers control the alignment of the mast
uprights. See Figure 79. The alignment condi-
NOTE: Shims are installed on both sides of the tions are provided on a list below with the most
load rollers. DO NOT add to or remove shims from important condition first.
the stub shafts. To change the position of load
roller on stub shaft, move shims from one side of
load roller to the other.

During assembly, shims should be reinstalled in

the same location they were in before disassembly.
Check clearance and adjust shims after repairs
have been completed.

107
Mast Adjustments 4000 SRM 1693

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE
AT POINT OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW
B. MAST FRONT VIEW
1. CHANNEL 8. EQUAL SPACE ±1.5 mm (0.060 in.)
2. LOAD ROLLER 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
3. STUB SHAFT 10. PUT SPACER ON OUTSIDE OF TOP LOAD
4. SNAP RING ROLLER, UNDER SNAP RING
5. SHIMS 11. SHIM FOR ZERO CLEARANCE AT POINT OF
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) TIGHTEST FIT
7. ZERO CLEARANCE AT POINT OF TIGHTEST
FIT
Figure 79. Mast Adjustments

108
4000 SRM 1693
a. Mast uprights must be parallel to each other.
b. Use shims to adjust load rollers so there is
zero clearance between load roller and chan-
nel at point of tightest fit.
c. The number of shims under a load roller
must be approximately the same as the stub
shaft in the opposite side of the upright. This
ensures uprights will be approximately in
the center.
2. Perform following steps to adjust mast load
rollers:
a. Use a crowbar to move mast uprights from
side to side to measure movement. Measure
movement in a minimum of three different
positions of each mast upright.
b. Separate mast uprights and change shim ar-
rangements as required. Assemble uprights.
Slide upright all the way to the top and bot-
tom to find the tightest fit.
c. Repeat Step a and Step b until there is zero
clearance at point of tightest fit.
d. Measure distance between channels of mast
uprights on top and bottom. Change shims to
keep distance equal between top and bottom
so mast uprights are parallel. Also make
sure the mast uprights are parallel within
1.5 mm (0.060 in.).
MAST SIDE KICKING, ADJUST
Mast side kicking is where the mast, without a
load, moves either to the right or left as it is being
fully raised. When this happens, it is an indication
Mast Adjustments
that one of the main lift cylinders is raising at a
faster rate then the other. Before checking for mast
side kicking, mast must be completely assembled to
include the carriage, forks, load backrest, and any
attachments, if lift truck is equipped with one.
To adjust the mast for side kicking, do the follow-
ing:
1. Place lift truck on a level surface and apply
parking brake.
2. Raise mast and visually inspect it as it reaches
its full height.
3. If t mast is moving to the left, shims will need
to either be added or removed from top of right
main lift cylinder. If mast moves to the right,
shims will need to either be added or removed
from top of left main lift cylinder. See Two-
Stage Mast With Full Free-Lift Repair or Four-
Stage Mast With Full Free-Lift Repair.
4. If shims will be added, use smallest shim size
that can be used on mast that is being adjusted.
See the Parts Manual for shim sizes and part
numbers.
5. Raise mast again and visually inspect it to en-
sure that it is no longer side kicking. If side
kicking is still present, repeat Step 3 and
Step 4.
109
Hydraulic Quick Disconnect Hoses 4000 SRM 1693

Hydraulic Quick Disconnect Hoses

Some lift trucks are equipped with auxiliary tube
extensions to be used with optional equipment. The
auxiliary tube extensions use quick disconnect fit-
tings to attach together optional equipment.

DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
HOSES
Lift Trucks Equipped With E-Hydraulic
Controls

WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy-
draulic system prior to disconnecting hydraulic
hoses.

1. Turn key switch or keyless switch to OFF posi-

tion.

2. Disconnect the battery.

NOTE: If the Quick Disconnect hose connectors

cannot be disconnected, repeat Step 3 and Step 4. 1. PRESSURE RELIEF VALVE
2. PLUNGER BUTTON
3. Press the plunger button, located on the top of
the pressure relief valve, and listen for the flow Figure 80. Pressure Relief Valve Plunger Button
of hydraulic fluid through the valve when the
button is pressed. See Figure 80.

4. Disconnect the Quick Disconnect hose connec-

tions. See Figure 81.

110
4000 SRM 1693 Hydraulic Quick Disconnect Hoses

Lift Trucks Equipped With Manual Hydraulic

Controls

WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy-
draulic system prior to disconnecting hydraulic
hoses.

1. Turn key switch or keyless switch to OFF posi-

tion.

2. Disconnect the battery.

3. Disconnect the Quick Disconnect hose connec-

tions. See Figure 81.

1. QUICK DISCONNECT FITTINGS

2. HYDRAULIC TUBES

Figure 81. Quick Disconnect Hydraulic Hoses

111
Hydraulic Quick Disconnect Hoses
CONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
HOSES
Lift Trucks Equipped With E-Hydraulic
Controls
1. Connect the Quick Disconnect hose connectors.
See Figure 81.
2. Connect the battery.
3. Turn key switch or keyless switch to the ON
position and start lift truck.
4. Move the mini lever forward and backward.
WARNING
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.
5. Check the hydraulic system for leaks.
112
4000 SRM 1693
Lift Trucks Equipped With Manual Hydraulic
Controls
1. Connect the Quick Disconnect hose connectors.
See Figure 81.
2. Connect the battery.
3. Turn key switch or keyless switch to the ON
position.
4. Move the manual hydraulic lever forward and
backward.
WARNING
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.
5. Check the hydraulic system for leaks.
 TECHNICAL PUBLICATIONS

4000 SRM 1693 12/14 (4/14)