Hyster F001 (H1.6FT H1.8FT H2.

0FTS Europe) Forklift

 MAST REPAIRS
2, 3, AND 4-STAGE MASTS
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z,
E40ZS) [E114/F114]; J1.60-2.00XMT (J30-
40ZT) [J160]; J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]

PART NO. 1580524 4000 SRM 1148

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

• 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 exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mast Repairs Table of Contents

TABLE OF CONTENTS

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

©2008 HYSTER COMPANY i

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Table of Contents Mast Repairs

TABLE OF CONTENTS (Continued)

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]

ii
4000 SRM 1148 Safety Procedures When Working Near Mast

General
NOTE: For models J1.60-2.00XMT (J30-40ZT)
WARNING [J160], this section applies to only to Four-Stage
Before working on or near the mast, see Safety masts. Refer to Mast Repairs, 2 and 3-Stage
Procedures When Working Near Mast in this Masts 4000 SRM 522 for Two-Stage and Three-Stage
section. masts for these particular models.
This section has the repair procedures for the NOTE: Hoses have a service life that is determined
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full by application and time. Install a new hose if the
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL); hose is worn, damaged, soft or hard, and no longer
and Four-Stage, Full Free-Lift (FFL) masts and flexible. If necessary, make a comparison to a new
carriages. Procedures for Carriage Adjustments are hose that is the correct replacement for the hose you
located at the end of this section. are inspecting.

Safety Procedures When Working Near Mast

The following procedures MUST be used when in- push the lift/lower control lever forward un-
specting or working near the mast. Additional pre- til there is no movement in the mast. Make
cautions and procedures can be required when re- sure that all parts of the mast that move are
pairing or removing the mast. fully lowered.

OR
WARNING
Mast parts are heavy and can shift. Distances • If parts of the mast must be in a raised po-
between parts are small. Serious injury or sition, install a safety chain to restrain the
death can result if part of the body is hit by moving parts of the mast. Connect moving
parts of the mast or the carriage. parts to a part that does not move. Follow
• Never put any part of the body into or under these procedures:
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. 1. Put mast in vertical position.
Also make sure that the power is OFF and the 2. Raise mast to align bottom crossmember of mast
key is removed. Put a DO NOT OPERATE tag upright that moves in outer mast with crossmem-
in the operator’s compartment. Disconnect ber on outer mast. On the two-stage mast, the
the battery and put a tag or lock on the bat- moving part is the inner mast. On the three-
tery connector. stage mast, it is the intermediate mast. On the
• Be careful of the forks. When the mast is four-stage mast, it is the first intermediate mast.
raised, the forks can be at a height to cause See Figure 1.
an injury.
• DO NOT climb on the mast or lift truck at any 3. Use a 3/8-inch minimum safety chain with a hook
time. Use a ladder or personnel lift to work to fasten the crossmembers together so the mov-
on the mast. able member cannot lower. Put hook on back side
• Mast repairs require disassembly and re- of mast. Make sure hook is completely engaged
moval of parts and can require removal of with a link in the chain. Make sure safety chain
the mast or carriage. Follow the repair pro- does not touch lift chains or chain sheaves, tubes,
cedures in this section. hoses, fittings, or other parts on the mast.
WHEN WORKING NEAR THE MAST ALWAYS: 4. Lower mast until there is tension in safety chain
• Lower the mast and carriage completely: and free-lift cylinder (full free-lift models) is com-
Turn the key switch to the ON position and pletely retracted.

1
Safety Procedures When Working Near Mast 4000 SRM 1148

Figure 1. Safety Chaining the Mast

2
4000 SRM 1148 Fork Repair

Legend for Figure 1

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST

NOTE: Apply the parking brake. After lowering or 5. Install another safety chain (9.5 mm (3/8 in.)
restraining the mast, shut off the power, and remove minimum) between the top or bottom bar of the
key. Put a DO NOT OPERATE tag in the operator’s carriage (6) and a crossmember on the outer
compartment. Disconnect battery and put a tag or mast as a secondary safety device. Install a DO
lock on battery connector. NOT REMOVE tag on the safety chain(s).

Fork Repair
The forks are held on the carriage by hooks. The INSTALL
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage. Move the fork and carriage so the top hook on the
If pin does not remain engaged in carriage slot, re- fork can engage the upper carriage bar. Raise the
place with new pin. Always check that the pins for carriage to move the lower hook through the fork re-
the forks keep the forks in position on the carriage. moval notch. Slide the fork on the carriage so both
Replace damaged fork pin parts. The forks can be upper and lower hooks engage the carriage bars. En-
removed from the carriage by aligning the forks with gage the latch pin with a notch in the upper carriage
the fork removal notch. The fork removal notch is in bar.
the bottom bar of the carriage.

REMOVE

WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).

A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car- 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
riage further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away Figure 2. Hook Fork Removal
from the fork or use a lifting device to move the fork
away from the carriage.

3
Fork Repair 4000 SRM 1148

1. LOAD BACKREST 6. WEDGE

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

Figure 3. Carriage and Forks

CHECKS Table 1. Fork Tip Alignment

WARNING Fork Tip Alignment Specifications

Never repair damaged forks by heating or Standard Fork Maximum Fork Tip
welding. Forks are made of tempered steel Lengths Difference 1
using special procedures. Always replace dam-
mm (in.) mm (in.)
aged forks as a pair.
914 (36) 27 (1.08)
Inspect the forks for cracks and wear. Check the
alignment of the fork tips. The difference in height 1067 (42) 32 (1.26)
of the fork tips must be less than three percent of the 1219 (48) 37 (1.44)
length of the forks. See Table 1 and Figure 4.
1372 (54) 41 (1.62)
Some applications may require closer alignment. If
1524 (60) 46 (1.80)
the forks do not meet specification, they both must
be replaced. Check that the bottom of each fork is 1829 (72) 55 (2.16)
not excessively worn. Check for smooth and proper
operation of the fork lock pins. Repair or replace any 1Difference of alignment between fork tips must
be no more than 3% of the total fork length.
damaged or broken fork lock pins or components and
lubricate, as necessary. See Figure 3.

4
4000 SRM 1148 Carriages Repair

Legend for Figure 4

A. HEEL OF FORK (MUST BE 90% OF
DIMENSION B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3%
OF FORK LENGTH)
2. CRACKS
3. MAXIMUM ANGLE 93
4. FORK REMOVAL NOTCH
5. CARRIAGE

Figure 4. Fork Check

Carriages Repair
STANDARD CARRIAGE
Remove
1. Remove the forks. See Fork Repair.

2. Remove the four capscrews securing the load

backrest to the carriage. Remove the load back-
rest.

3. Connect a lifting device to the carriage. Lift the

carriage so that the lift chains become loose.

WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.

4. Remove the pin from each chain anchor at the

carriage. See Figure 5. Disconnect the lift chains NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
from the carriage. Use wire to connect the ends
of the lift chains to a part of the mast. Make sure 1. CARRIAGE 6. CHAIN PIN
the chains can move freely when the inner mast 2. SNAP RING 7. COTTER PIN
is raised. 3. SHIM 8. ANCHOR PIN
4. LOAD ROLLER 9. SPACER
5. CHAIN ANCHOR

Figure 5. Standard Carriage

5
Carriages Repair 4000 SRM 1148

Install
WARNING
To help prevent possible injury, make sure the 1. Use the hydraulic system of the lift truck or a
carriage is stable when the inner mast is above crane to raise the inner mast. If the hydraulic
the load rollers of the carriage. system cannot be used, disconnect the lift cylin-
ders from the inner or intermediate mast. See
5. Use the lift cylinders to raise the inner or inter- the section Cylinder Repair 2100 SRM 1139.
mediate mast. If the hydraulic system cannot be Connect a crane [the capacity of the crane must
used, disconnect the lift cylinders from the in- be at least 681 kg (1501 lb)] to the top of the in-
ner or intermediate mast. See the section Cylin- ner mast. Carefully raise the inner mast until
der Repair 2100 SRM 1139. Connect a crane it is above the load rollers of the carriage. In-
[the capacity of the crane must be at least 681 kg stall safety chains to secure the mast in its ex-
(1501 lb)] to the top of the inner mast. Carefully tended position and disconnect the crane. See
raise the inner mast until it is above the load Safety Procedures When Working Near Mast.
rollers of the carriage. Install safety chains to
secure the mast in its extended position and dis- 2. Move the lift truck toward the carriage until the
connect the crane. See Safety Procedures When inner mast is aligned with the carriage rollers.
Working Near Mast. If the inner mast has been raised and secured
using a crane and safety chains, connect the
6. Move the lift truck away from the carriage. Com- crane, raise the inner mast, and remove the
pletely lower the inner mast so it cannot move. safety chains. Carefully lower the inner mast
until it engages all of the load rollers. Discon-
Repair nect the crane, if attached, and reconnect the
lift cylinders. See the section Cylinder Repair
NOTE: The carriage can have four or six load rollers.
2100 SRM 1139.
When the carriage has four load rollers, shims are
used behind all of the load rollers. When the carriage 3. Check the clearance of the load rollers. See Car-
has six load rollers, shims are installed on the bottom riage Adjustments in this section.
and middle rollers only.
NOTE: Use new cotter pins each time the anchor pins
1. If any of the load rollers must be replaced, make are removed.
a note of the location and number of the shims.
Install the shims, load rollers, and snap rings. 4. Connect the lift chains to the chain anchors at
See Carriage Adjustments for correct adjustment the carriage. Install the cotter pins in the an-
of the load rollers. chor pins. Adjust the lift chains as described in
Carriage Adjustments in this section.
WARNING 5. Install the backrest on the carriage. Tighten the
Improper welding procedures can damage capscrews to 195 N•m (144 lbf ft).
the structure of the mast or cause incorrect
function of the mast. Consult your Hyster® 6. Install the forks. See Fork Repair.
lift truck dealer for more information before
welding on the mast. INTEGRAL SIDESHIFT CARRIAGE
2. If the carriage bars have any protruding welds Remove
or damaged notches, repair by grinding, filing,
or welding. 1. Lower the carriage completely. Remove the forks
and the load backrest extension. See Fork Repair
and Figure 6 or Figure 7.

6
4000 SRM 1148 Carriages Repair

NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 13. PIN
2. OUTER FRAME 14. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 15. SNAP RING
4. UPPER BEARING 16. PIN
5. LOWER BEARING 17. COTTER PIN
6. LOWER HOOK 18. LOAD ROLLER
7. CAPSCREW 19. SHIMS
8. WASHER 20. SPACER
9. CLEVIS PIN 21. SNAP RING
10. HAIRPIN 22. SPACER
11. PIN 23. FORK REMOVAL NOTCH
12. LUBE FITTING

Figure 6. Integral Sideshift Carriage for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)

7
Carriages Repair 4000 SRM 1148

NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 13. PIN
2. OUTER FRAME 14. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 15. SNAP RING
4. UPPER BEARING 16. PIN
5. LOWER BEARING 17. COTTER PIN
6. LOWER HOOK 18. LOAD ROLLER
7. CAPSCREW 19. SHIMS
8. WASHER 20. SPACER
9. CLEVIS PIN 21. SNAP RING
10. HAIRPIN 22. SPACER
11. PIN 23. FORK REMOVAL NOTCH
12. LUBE FITTING

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

8
4000 SRM 1148 Carriages Repair

3. Clean the bearing areas. Inspect the sideshift

WARNING bearings for wear as follows:
Always wear the proper protective equipment
including eye protection and petroleum-resis- a. Remove the upper bearings from the upper
tant gloves when handling hydraulic oil. Thor- apron. If either upper bearing is worn to less
oughly wash oil from exposed areas of skin as than 2.5 mm (0.1 in.) thickness, replace both
soon as possible. upper bearings by driving the upper bearings
from the upper apron.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the b. Remove the lower bearings from the lower
oil. carriage bar. If either lower bearing is worn
to less than 2.5 mm (0.1 in.) thickness, re-
Never check for leaks by putting hands on place both lower bearings by prying the lower
hydraulic lines or components under pressure. bearings from the lower carriage bar.
Hydraulic oil under pressure can be injected
into the skin. 4. Inspect the sideshift cylinder. Replace the en-
tire cylinder assembly if a cylinder rod is bent or
scored or if there is damage on the outside of the
CAUTION
cylinder shell that could impair performance or
Protect the hydraulic system from dirt and cause leaks under pressure. See Figure 9.
contaminants when servicing the hydraulic
system.

NOTE: Tag hydraulic lines prior to disconnecting to

insure correct connection during installation.

2. Disconnect the hydraulic lines at the sideshift

cylinder. Put caps on the open hydraulic lines.

3. Remove the lower mounting hooks by removing

the four capscrews securing the hooks.

4. Remove two hairpins, two pins, and sideshift

cylinder from the carriage. See Figure 6 or Fig-
ure 7.

5. Use a crane with a capacity of at least 450 kg

(992 lb) to lift the outer frame away from the in-
ner frame. Lay the outer frame flat on a pallet or
workbench.

Clean and Inspect A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
1.52 mm (0.06 in.) MAXIMUM.
1. Inspect the lower mounting hooks for wear. Re- B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
place the hooks if they are worn beyond the wear MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
limit. The wear limit clearance range is 0.76 mm
(0.03 in.) minimum and 1.52 mm (0.06 in.) max- Figure 8. Lower Mounting Hooks Wear Limit
imum. See A in Figure 8. and Clearance Adjustment

2. Clean and inspect the carriage bars for damage

and smoothness. Ensure the bars are parallel
and the ends are flush.

9
Carriages Repair 4000 SRM 1148

b. Unscrew the retainer from the cylinder.

Slide the retainer off the cylinder rod.

c. Clamp the other end of the cylinder in a

vise between the hydraulic fitting and the
retainer on the same end.

d. Unscrew the retainer from the cylinder.

NOTE: If new retainers that are already assembled

with seals are being installed, proceed to Step h.

e. Remove and discard the seals and O-ring

from each retainer with a brass O-ring tool.
DO NOT scratch the grooves.

WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
1. CYLINDER SHELL 3. O-RING solvent manufacturer’s recommended safety
AND ROD 4. RETAINER precautions.
2. SEAL 5. WIPER
f. Clean the retainers and the cylinder rod with
Figure 9. Integral Sideshift Cylinder
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
Repair
g. Install the seals into the retainer grooves.
NOTE: Drain the oil from the cylinder before under-
Form the seals into a "kidney" shape to ease
taking any repairs.
placement into the groove. Note the direc-
1. If any of the load rollers must be replaced, make a tion of the rod seals. Pressure seals are in-
note of the location and number of the shims. In- stalled with the lip toward the pressure
stall the shims, load rollers, and snap rings. See side of the cylinder.
Carriage Adjustments for correct adjustment.
h. Apply a film of hydraulic oil to the inside of
the retainers.
WARNING
Improper welding procedures can damage the i. Clamp one end of the cylinder in a vise be-
structure of the mast or cause incorrect func- tween the hydraulic fitting and the end.
tion of the mast. Consult your Hyster lift truck
j. Screw the retainer into the cylinder. Tighten
dealer for more information before welding on
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
the mast.
k. Clamp the other end of the cylinder in a vise
2. If the carriage bars have any protruding welds
between the hydraulic fitting and the end.
or damaged notches, repair by grinding, filing,
or welding. l. Slide the retainer onto the cylinder rod.
Screw the retainer into the cylinder. Tighten
3. Replace the cylinder rod seals as follows:
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
a. Clamp one end of the cylinder in a vise be-
tween the hydraulic fitting and the retainer
on the same end.

10
4000 SRM 1148 Mast Repair

Install 3. Use a crane with a capacity of at least 450 kg

(992 lb) to install the outer frame on the inner
NOTE: Use a wood block or a plastic hammer to fully frame.
seat the upper bearings onto the upper carriage bar.
Proper lower hook clearance requires the upper bear- 4. Install the lower mounting hooks using four cap-
ings be fully seated. screws. Tighten to 165 ±15 N•m (120 ±12 lbf ft).
For proper sideshift operation, make sure there
1. If necessary, install the lower sideshift bearings. is 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
Then install the upper sideshift bearings. Lubri- between the bottom of the hooks and the outer
cate the upper and lower sideshift bearings with frame. See B in Figure 8.
chassis grease. See Figure 6.
5. Connect the hydraulic lines, as noted during re-
NOTE: The pin, located on the left top of the cylinder moval, to the sideshift cylinder.
looking from the front of the carriage, is for align-
ment purposes and to prevent the cylinder from 6. Install the backrest on the sideshift carriage.
rolling to the front or to the back. Tighten the capscrews to 195 N•m (144 lbf ft).

2. Install sideshift cylinder onto the carriage with 7. Install the forks.
the pin in the up position. Install two pins and
two hairpins. See Figure 6 or Figure 7.

Mast Repair
MAST, REMOVE the mast using chains to support the mast in an
upright position when the tilt cylinders are dis-
connected.
WARNING
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift- WARNING
ing devices (hoists, cables, chains, slings, etc.) Always wear the proper protective equipment
are suitable and of adequate capacity to lift the including eye protection and petroleum-resis-
mast. tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
CAUTION
Make sure all the mast weldments are fastened Completely lower forks to relieve hydraulic
together. Make sure the safety chains will not pressure before disassembling any part of the
damage the sheaves, tubing, or other parts of lift pump or disconnecting any hoses.
the mast.
The hydraulic oil is hot at normal operating
NOTE: If the mast needs to be disassembled, remove temperatures. Be careful when draining the
the forks and carriage. If only the lift cylinders need oil.
to be removed for repair, the mast does not need to be
removed from the lift truck. See the section Cylin-
CAUTION
der Repair 2100 SRM 1139.
Protect the hydraulic system from dirt and
NOTE: The length of the lift chains must be checked contaminants when servicing the hydraulic
before the mast is removed. See Lift Chains Adjust- system.
ment.
2. Position a drip pan with a capacity of 19 liter
1. Fully lower all of the mast weldments. Tilt the (5 gal) under the area of the hydraulic fittings.
mast fully forward. Connect a crane with a ca- Disconnect the hydraulic line at the external low-
pacity of at least 907 kg (2000 lb) to the top of ering control valve on the outer mast.

11
Mast Repair 4000 SRM 1148

WARNING
Use a driver, NOT your fingers, to push the an-
chor pins from the clevises on the tilt cylinders.
The cylinder or mast can move and cause seri-
ous injury.

3. Remove the capscrews, washers, and anchor pins

at the tilt cylinder mounts on the outer mast. See
Figure 10, Figure 11, and Figure 12.

1. WASHER 6. CAPSCREW
2. NUT 7. RETAINER PIN
3. ROD END 8. CAPSCREW
4. PIVOT PIN 9. TILT CYLINDER
5. GREASE FITTING

Figure 11. Mast Mounting for Lift Truck Models

S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001)

1. O-RING 7. PIVOT PIN

2. SPACER 8. GREASE FITTING
3. SHIMS 9. RETAINER PIN
4. WASHER 10. CAPSCREW
5. NUT 11. ROD END
6. CAPSCREW 12. TILT CYLINDER

Figure 10. Mast Mounting for Lift Truck

Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z)
(G108)

12
4000 SRM 1148 Mast Repair

NOTE: Allow the mast to tilt forward enough to gain

access to the mast mount capscrews.

4. Disconnect the lower mast mounts from the lift

truck:

a. Pivot Pin Connections - Remove the cap-

screws that hold the mast pivot pins to the
mounts on the drive axle. See Figure 13 and
Figure 14.

b. Stub Shaft Connections - Remove the four

capscrews securing the retainer cap over the
stub shafts on each side of the mast. See
Figure 12.

WARNING
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.

5. Use the crane to lift the mast assembly from

the lift truck. Position the mast across wooden
1. RETAINER CAP
2. LOCKWASHER beams on the floor with the carriage side up.
3. TILT CYLINDER
4. OUTER MAST WELDMENT 6. Check the mast and mounting flanges for wear
5. BUSHING or damage:
6. NUT
7. PIN a. Pivot Pin Connections - Remove the mast
8. ROD END pivot pins from the outer mast. Check that
9. WASHER the pins fit snug in the outer mast. If pins
10. CAPSCREW
can be moved up and down a minimum of
Figure 12. Mast Mounting for Lift Truck 4 mm (0.20 in.), replace bushings in outer
Models J1.60-2.00XMT (J30-40ZT) [J160] and mast and/or mast pivot pins as required. See
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) Figure 16.

b. Stub Shaft Connections - Remove the bush-

ing from the stub shaft. Check that the bush-
ing fits snug over the stub shaft. Place the
bushing into the drive unit mounts and place
the retainer cap into position. Check that the
bushing is snug under the retainer cap. If
pins can be moved up and down a minimum
of 4.0 mm (0.2 in.), replace bushings as re-
quired.

13
Mast Repair 4000 SRM 1148

1. OUTER MAST 2. BUSHING 3. GREASE FITTING

Figure 13. Mast Mounts, Outer Mast

1. HANGER MOUNTS
1. DRIVE AXLE 2. TRACTION MOTOR
2. HANGER MOUNTS
Figure 15. Mast Mounting For Lift Truck Model
Figure 14. Mast Mounts, Drive Axle J2.00-3.20XM (J40-65Z) (B416)

14
4000 SRM 1148 Mast Repair

lift cylinders and put caps on the open lines. See

Figure 17 and Figure 18.

2. Remove the chains and header hoses. On the

two-stage FFL mast, remove the brackets and
disconnect the hydraulic line for the free-lift
cylinder. Remove the free-lift cylinder. Discon-
nect the free-lift chains at the crossmember. See
Figure 19 and Figure 20.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
Figure 16. Mast Pivot Pin ring pliers, and wear eye and face protection
during removal or installation.
TWO-STAGE LFL AND TWO-STAGE FFL 3. Remove the nut, bolt, and spacer at the mount
MASTS, DISASSEMBLE near the top of each main lift cylinder. Remove
the snap rings and washers from the top of
WARNING each main lift cylinder. Disconnect the main lift
Always wear the proper protective equipment chains at the mounts. See Figure 17, Figure 18,
including eye protection and petroleum-resis- Figure 19, and Figure 20.
tant gloves when handling hydraulic oil. Thor-
4. On the two-stage FFL mast, disconnect the FFL
oughly wash oil from exposed areas of skin as
supply tube and remove the hydraulic fitting
soon as possible.
from the top of the left- or right-hand main lift
Completely lower forks to relieve hydraulic cylinder.
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic WARNING
hoses. The mast weldments can slide when the mast
is moved. A weldment that slides can cause in-
The hydraulic oil is hot at normal operating
jury.
temperatures. Be careful when draining the
oil. 5. Slide the inner mast from the outer mast approx-
imately 30 cm (12 in.) to disengage the main lift
CAUTION cylinders from the inner mast. Remove the main
Protect the hydraulic system from dirt and lift cylinders from the outer mast. See Figure 17,
contaminants when servicing the hydraulic Figure 18, Figure 19, and Figure 20.
system.
6. Slide the inner mast from the bottom of the outer
NOTE: If the lift cylinders alone need to be removed mast approximately 30 cm (12 in.). Remove the
and repaired, see the section Cylinder Repair 2100 strip bearings and load rollers from the top of the
SRM 1139. When the mast has header hoses, see outer mast. Remove the load rollers from the bot-
Header Hose Arrangement. tom of the inner mast. Make a note of each shim
arrangement and load roller location. The shim
1. Clean the area around the hydraulic fittings for arrangements will be approximately the same
the lift cylinders. Disconnect the fittings at the during assembly.

15