MAST REPAIRS

2 AND 3-STAGE MASTS

S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004]; H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005]; E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) [E098]; S6.0FT,
S7.0FT, (S135FT, S155FT) [D024]; H6.0FT,
H7.0FT, (H135FT, H155FT) [H006]

PART NO. 1627340 4000 SRM 1250

 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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Mast Repairs Table of Contents

TABLE OF CONTENTS

Safety Procedures When Working Near Mast.................................................................................................... 1

Fork Repair .......................................................................................................................................................... 3
Remove ............................................................................................................................................................. 3
Install ............................................................................................................................................................... 4
Checks .............................................................................................................................................................. 4
Carriage Replacement ......................................................................................................................................... 5
Remove ............................................................................................................................................................. 5
Install ............................................................................................................................................................... 5
Integral Sideshift Carriage Repair ................................................................................................................... 11
Remove, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) ............................... 11
Disassemble ................................................................................................................................................... 11
Assemble ........................................................................................................................................................ 14
Install, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) ............................... 14
Hang On Sideshift Carriage Repair.................................................................................................................. 14
Remove, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) ............................................................................................................................ 14
Disassemble ................................................................................................................................................... 20
Cylinders, Disassemble ................................................................................................................................. 23
Sideshift Cylinder...................................................................................................................................... 23
Fork Positioner Cylinders ......................................................................................................................... 24
Clean and Inspect .......................................................................................................................................... 24
Cylinders, Assemble ...................................................................................................................................... 25
Fork Positioner Cylinders ......................................................................................................................... 25
Sideshift Cylinder...................................................................................................................................... 25
Assemble ........................................................................................................................................................ 26
Install ............................................................................................................................................................. 26
Two-Stage Mast With Limited Free-Lift Repair .............................................................................................. 27
Remove ........................................................................................................................................................... 27
Disassemble ................................................................................................................................................... 28
Clean and Inspect .......................................................................................................................................... 30
Assemble ........................................................................................................................................................ 39
Install, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006) Lift Truck Models ................................................................. 40
Install, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) Lift Trucks Models.............................................................................................................. 41
Header Hose Alignment ................................................................................................................................ 51
Two-Stage Mast With Full Free-Lift Repair..................................................................................................... 61
Remove ........................................................................................................................................................... 61
Disassemble ................................................................................................................................................... 61
Clean and Inspect .......................................................................................................................................... 67
Assemble ........................................................................................................................................................ 68
Install ............................................................................................................................................................. 70
Header Hose Installation and Adjustment .................................................................................................. 75
Installation ................................................................................................................................................ 75
Adjustment ................................................................................................................................................ 75
Three-Stage Mast With Full Free-Lift Repair.................................................................................................. 76

©2007 HYSTER COMPANY i

Table of Contents Mast Repairs

TABLE OF CONTENTS (Continued)

Remove ........................................................................................................................................................... 76
Disassemble ................................................................................................................................................... 76
Clean and Inspect .......................................................................................................................................... 90
Assemble ........................................................................................................................................................ 91
Install ............................................................................................................................................................. 93
Header Hose Alignment for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)...................................... 102
Header Hose Alignment for H6.0FT, H7.0FT (H135FT, H155FT) (H006) and S6.0FT, S7.0FT,
(S135FT,S155FT) (D024)............................................................................................................................. 109
Mast Operation Check ..................................................................................................................................... 113
Tilt Cylinder Adjustment ................................................................................................................................ 113
Lift Chains Adjustment ................................................................................................................................... 115
Mast Adjustments............................................................................................................................................ 117
Carriage Adjustments...................................................................................................................................... 119

This section is for the following models:

S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;

S120FTS; S120FTPRS) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
S6.0FT, S7.0FT, (S135FT, S155FT) [D024];
H6.0FT, H7.0FT, (H135FT, H155FT) [H006]

ii
4000 SRM 1250
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery and put a tag or lock on the bat-
tery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. 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 po-
sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put mast in vertical position.
2. Raise mast to align bottom crossmember of mast
upright that moves in outer mast with crossmem-
ber on outer mast. On the two-stage mast, the
moving part is the inner mast. On the three-
stage mast, it is the intermediate mast. See Fig-
ure 1.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side
of mast. Make sure hook is completely engaged
with a link in the chain. Make sure safety chain
does not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
4. Lower mast until there is tension in safety chain
and free-lift cylinder (full free-lift models) is com-
pletely retracted.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and remove
key. Put a DO NOT OPERATE tag in the operator’s
compartment. Disconnect battery and put a tag or
lock on battery connector.
5. Install another safety chain (9.5 mm (3/8 in.)
minimum) between the top or bottom bar of the
carriage (6) and a crossmember on the outer
mast as a secondary safety device. Install a DO
NOT REMOVE tag on the safety chain(s).
1
Safety Procedures When Working Near Mast 4000 SRM 1250

A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST

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

Figure 1. Safety Chaining the Mast

2
4000 SRM 1250 Fork Repair

Fork Repair
The forks are held on the carriage by hooks. The carriage further so the top hook of the fork is disen-
forks are kept in position by pins that fit through the gaged from the top carriage bar. Move the carriage
top fork hooks and into slots in the top bar carriage. away from the fork or use a lifting device to move the
Always check that the pins for the forks keep the fork away from the carriage.
forks in position on the carriage. Replace damaged
fork pin parts. The forks can be removed from the
carriage by aligning the forks with the fork removal
notch. The fork removal notch is in the bottom bar of
the carriage.

REMOVE

WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 66 to 183 kg (145 to 403 lb).

A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork 1. CARRIAGE BARS 3. BLOCKS
to the fork removal notch in the bottom bar of the car- 2. HOOK FORK
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through Figure 2. Hook Fork Removal
the fork removal notch. See Figure 3. Lower the

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

3
Fork Repair 4000 SRM 1250

INSTALL Some applications may require closer alignment. If

Move the fork and carriage so the top hook on the
fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork re-
moval notch. Slide the fork on the carriage so both
upper and lower hooks engage the carriage bars. En-
gage the latch pin with a notch in the upper carriage
bar.
the forks do not meet specification, they both must
be replaced. Check that the bottom of each fork is
not excessively worn. Check for smooth and proper
operation of the fork lock pins. Repair or replace any
damaged or broken fork lock pins or components and
lubricate, as necessary. See Figure 3.

CHECKS

WARNING
Never repair damaged forks by heating or
welding. Forks are made of tempered steel
using special procedures. Always replace dam-
aged forks as a pair.

Inspect the forks for cracks and wear. Check the

alignment of the fork tips. The difference in height
of the fork tips must be less than three percent of the
length of the forks. See Table 1 and Figure 4.

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications

A. HEEL OF FORK (MUST BE 90% OF
Standard Fork Maximum Fork Tip DIMENSION B)
Lengths Difference 1 B. ORIGINAL FORK THICKNESS (DIMENSION B)
mm (in.) mm (in.) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
914 (36) 27 (1.08) 2. CRACKS
1067 (42) 32 (1.26) 3. MAXIMUM ANGLE 93
4. FORK REMOVAL NOTCH
1219 (48) 37 (1.44) 5. CARRIAGE

1372 (54) 41 (1.62) Figure 4. Fork Check

1524 (60) 46 (1.80)
1829 (72) 55 (2.16)

1Difference of alignment between fork tips must

be no more than 3% of the total fork length.

4
4000 SRM 1250
Carriage Replacement
REMOVE
WARNING
Do not work under a raised carriage. Lower
the carriage or use a chain or blocks to prevent
the carriage and inner mast from lowering.
NOTE: If the mast is equipped with a sideshift car-
riage, see the paragraphs under Sideshift Carriage
Repair.
1. Tilt forks forward so carriage has stability and
will not fall when it is disconnected from the
mast.
2. Lower carriage and forks on blocks so 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 and causing an injury or damage.
3. Remove chain anchor pin from each chain an-
chor at the carriage. Disconnect lift chains from
carriage. Check chain anchors and anchor pins
for wear and serviceability. Discard worn or un-
serviceable chain anchors and chain anchor pins.
Discard cotter pin. See Figure 5, Figure 6. Fig-
ure 7, and Figure 8.
WARNING
Make sure the carriage is stable and will not
fall over when the inner mast is raised above
the load rollers of the carriage.
4. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage. If the hy-
draulic system cannot be used, connect a lifting
device to the top of the inner mast. Carefully
raise inner mast until it is above the load rollers
of the carriage.
5. Move lift truck from carriage. Connect a lifting
device to the carriage. Make sure carriage is sta-
ble. Remove load backrest and forks. Put car-
riage on floor so that load rollers are up.
Carriage Replacement
6. If any of the load rollers must be replaced, make
a note of the arrangement of the shims.
INSTALL
1. Connect a lifting device to the carriage. Install
load backrest and forks on the carriage. Move
lift truck up to the carriage. Make sure carriage
is stable.
2. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage, and care-
fully lower the inner mast onto the carriage.
3. For lift trucks E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) and S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) equipped with
two and three stage full free lift mast. The snap
rings must be installed into chain anchor into
back of carriage.
4. For lift trucks H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) equipped with two and three stage full
free lift mast. The snap rings must be installed
into chain anchor into front of carriage.
NOTE: Install chain anchor pins so that heads of pins
face inside and center of mast. Both legs of cotter pin
must be bent against chain anchor pin.
5. Replace worn or unserviceable chain anchor pins
and chain anchors on the carriage with new ones.
Connect lift chains to the chain anchors on the
carriage. Figure 5, Figure 6. Figure 7, and Fig-
ure 8.
6. Tighten chain anchor nuts to:
• For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004),
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
tighten to 210 N•m (155 lbf ft).
• For lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006), tighten to 370 N•m
(273 lbf ft).
5
Carriage Replacement 4000 SRM 1250

1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

2. LOAD ROLLER FULL FREE-LIFT MAST)
3. SHIMS 8. PIN
4. SNAP RING 9. COTTER PIN
5. SIDE ROLLER (OPTIONAL) 10. CHAIN ANCHOR PIN
6. CHAIN ANCHOR POSITION (TWO STAGE 11. GUARD (RH)
LIMITED FREE-LIFT MAST) 12. LUBE FITTING

Figure 5. Carriage for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT,
H7.0FT (H135FT, H155FT) (H006)

Legend for Figure 6

A. THREE STAGE FULL FREE-LIFT MAST B. TWO STAGE LIMITED FREE-LIFT MAST
1. PIN 10. COTTER PIN
2. PIN ASSEMBLY 11. CHAIN ANCHOR PIN
3. CARRIAGE 12. CHAIN ANCHOR
4. CAPSCREW 13. SNAP RING
5. WASHER 14. SHIM
6. LOAD ROLLER 15. WASHER
7. SNAP RING (EXTERNAL) 16. LUBE FITTINGS
8. SPACER 17. SIDE ROLLERS
9. NUT

6
4000 SRM 1250 Carriage Replacement

Figure 6. Pin-Type Carriage for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)

7
Carriage Replacement 4000 SRM 1250

Figure 7. Carriage for Lift truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098) and
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

8
4000 SRM 1250 Carriage Replacement

Legend for Figure 7

A. TWO STAGE LIMITED FREE-LIFT B. TWO AND THREE STAGE FULL FREE-LIFT
1. LOAD ROLLER 9. PIN
2. SHIM 10. SNAP RING (EXTERNAL)
3. SNAP RING 11. GUARD (RH)
4. SPACER 12. CAPSCREW
5. GUARD (LH) 13. WASHER
6. CHAIN ANCHOR PIN 14. NUT
7. COTTER PIN 15. CARRIAGE
8. CHAIN ANCHOR 16. LUBE FITTINGS

9
Carriage Replacement 4000 SRM 1250

Figure 8. Carriage for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005)

10
4000 SRM 1250 Integral Sideshift Carriage Repair

Legend for Figure 8

A. TWO AND THREE STAGE FULL FREE-LIFT C. H4.5FT6; H5.0-5.5FT (100, 110, 120FT) (N005)
MAST D. TWO STAGE LIMITED FREE-LIFT
B. H4.0FT5/FT6; H4.5FTS5 (H80 AND H90) (N005)
1. LOAD ROLLER 5. GUARD (LH) 10. CHAIN ANCHOR PIN 15. PIN
2. SHIM 6. CAPSCREW 11. COTTER PIN 16. SNAP RING
3. SNAP RING 7. WASHER 12. CAPSCREW 17. NUT
(EXTERNAL) 8. GUARD (RH) 13. PLATE 18. CARRIAGE
4. SPACER 9. CHAIN ANCHOR 14. LOCK NUT 19. LUBE FITTINGS

Integral Sideshift Carriage Repair

REMOVE, FOR LIFT TRUCK MODELS
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), AND
H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005)
1. Relieve hydraulic pressure to the sideshift cylin-
der by moving sideshift lever in both directions
several times.
NOTE: Tag hydraulic lines and fittings prior to dis-
connecting to aid in connecting during installation.
WARNING
Make sure the carriage is stable and will not
fall over when the inner mast is raised above
the load rollers of the carriage.
6. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage. If the hy-
draulic system cannot be used, connect a lifting
device to the top of the inner mast. Carefully
raise inner mast until it is above the load rollers
of the carriage.
7. Move lift truck away from carriage. Connect a
lifting device to the carriage. Make sure carriage
is stable. Remove load backrest and forks. Put
carriage on floor so that load rollers are up.

2. Disconnect hydraulic lines from sideshift cylin-
der. Put caps and plugs on open lines and cylin-
der ports.
3. Tilt forks forward so carriage is stable and will
not fall when it is disconnected from the mast.
4. Lower carriage and forks on blocks so lift chains
become loose. See Figure 2.
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 and causing an injury or damage.
5. Remove pin from each chain anchor at the car-
riage. Disconnect lift chains from carriage.
Check chain anchors and anchor pins for wear
and serviceability. Discard worn or unser-
viceable chain anchors and chain anchor pins.
Discard cotter pin. See Figure 5.
8. If any of the load rollers must be replaced, make
a note of the arrangement of the shims.
DISASSEMBLE
1. Remove capscrews from lower hooks and remove
the lower hooks. See Figure 9.
2. Lift the mobile frame from the bottom and rotate
it forward to free it from the fixed frame.
3. Remove upper and lower bearings from the fixed
frame.
4. If damaged, remove grease fittings from the fixed
frame. See Figure 10.
5. Remove sideshift cylinder rods from each end of
the cylinder body.
6. Remove snap rings from each end of the cylinder
body and remove rod scrapers, rod bushings, and
seals from cylinder body.

11
Integral Sideshift Carriage Repair 4000 SRM 1250

1. CAPSCREWS 12. FIXED FRAME

2. LOWER HOOK 13. CYLINDER BODY
3. MOBILE FRAME 14. SHIM
4. LOWER BEARINGS 15. SIDE ROLLER
5. UPPER BEARINGS 16. BRACKET
6. GREASE FITTINGS 17. PIN
7. CYLINDER ROD 18. SPACER
8. SNAP RING 19. GUARD (RH)
9. ROD SCRAPER 20. LOCKWASHER
10. ROD BUSHING 21. LUBE FITTING
11. SEAL

Figure 9. Integral Sideshift Carriage

12
4000 SRM 1250 Integral Sideshift Carriage Repair

1. SIDE LOAD ROLLERS 3. *LUBE FITTINGS

2. LUBE FITTING 4. FITTINGS

* LUBE FITTING NOT USED ON E3.50-4.00XL, E4.50XLS (E70-80Z, E100ZS) (E098) LIFT TRUCKS EQUIPPED
WITH INTEGRAL SIDESHIFT.

Figure 10. Integral Sideshift Carriage, Side Roller and Lube Fitting Location

13
Hang On Sideshift Carriage Repair
ASSEMBLE
1. Lubricate with clean hydraulic oil and install
seals, rod bushings, and rod scrapers into the
cylinder body and secure with snap rings. See
Figure 9.
2. Install cylinder rods into each end of the cylinder
body.
3. Install grease fittings into the fixed frame if re-
moved. See Figure 10.
4. Install upper and lower bearings onto the fixed
frame.
5. Install the mobile frame onto the fixed frame by
hooking it at the top of the fixed frame first and
lowering it to the bottom.
6. Install lower hooks and capscrews. Tighten the
capscrews to 78 N•m (58 lbf ft).
INSTALL, FOR LIFT TRUCK MODELS
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), AND
Hang On Sideshift Carriage Repair
REMOVE, LIFT TRUCK MODELS S6.0FT,
S7.0FT (S135FT, S155FT) (D024) AND
H6.0FT, H7.0FT (H135FT, H155FT) (H006)
NOTE: The hang on sideshift carriage assembly is
made up of either two or three other assemblies.
If the lift truck is equipped with a fork positioner,
the hang on sideshift carriage assembly consists of
the standard carriage (fixed frame), the hang on
sideshift assembly and the fork positioner assembly.
See Figure 11. If the lift truck is not equipped with
a fork positioner, the hang on sideshift carriage
assembly is made up of the standard carriage (fixed
14
4000 SRM 1250
H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005)
1. Connect a lifting device to the carriage. Install
load backrest and forks on the carriage. Move
lift truck up to the carriage. Make sure carriage
is stable.
2. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage, and care-
fully lower the inner mast onto the carriage.
NOTE: Install new chain anchor pins so that heads
of pins face inside and center of mast. Both legs of
cotter pin must be bent against chain anchor pin.
3. Replace worn or unserviceable chain anchor pins
and chain anchors on the carriage with new ones
and install new cotter pin. Connect lift chains
to the chain anchors on the carriage. See Fig-
ure 5. Tighten chain anchor nuts to 210 N•m
(155 lbf ft).
4. Remove protective caps and plugs from hydraulic
lines and cylinder ports. Connect lines to the
sideshift cylinder as tagged during removal.
frame) and the hang on sideshift assembly. When
the word carriage is used in procedures below, it
refers to the complete hang on sideshift carriage
assembly; either with the fork positioner or without
the fork positioner.
1. Move lift truck to a flat surface. Apply the park-
ing brake.
2. Position the carriage in the center of the truck.
3. Lower carriage and forks on blocks to loosen the
lift chains. See Figure 12.
4000 SRM 1250 Hang On Sideshift Carriage Repair

NOTE: FORKS REMOVED FOR CLARITY.

1. FORK POSITIONER ASSEMBLY 7. SIDESHIFT CYLINDER HYDRAULIC
2. FORK POSITIONER CYLINDERS CONNECTION
3. HYDRAULIC HOSES 8. SIDESHIFT CYLINDER
4. FORK POSITIONERS 9. GREASE FITTING
5. HANG ON SIDESHIFT ASSEMBLY 10. STANDARD CARRIAGE (FIXED FRAME)
6. LOWER MOUNTING HOOKS 11. VALVE BODY HYDRAULIC CONNECTIONS

Figure 11. Hang On Sideshift Carriage With Fork Positioner

15
Hang On Sideshift Carriage Repair
1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
Figure 12. Place Carriage On Blocks
NOTE: Make sure the lifting device has a capacity of
1450 kg (3200 lb).
4. Connect a lifting device to the carriage assembly.
Slowly raise lifting device until chain is taut to
provide carriage with stability.
WARNING
Before disconnecting the hydraulic hoses, re-
lieve the pressure in the hydraulic system.
Serious injury can occur if pressure is not
relieved from hydraulic system prior to dis-
connecting hydraulic hoses.
5. If lift truck is equipped with manual hydraulic
control valve, turn key to the ON position, if
lift truck is equipped with a key start option, or
press the power ON/OFF button, if lift truck is
equipped with a keyless start option. See the Op-
erating Manual. Relieve hydraulic pressure to
the sideshift cylinder by moving manual sideshift
lever in both directions several times.
NOTE: Tag hydraulic lines and fittings prior to re-
moval to aid in connecting during installation.
Disconnect hydraulic lines from sideshift cylin-
der (see Figure 11). Put caps and plugs on open
lines and cylinder ports.
NOTE: Tag hydraulic lines and fittings prior to re-
moval to aid in connecting during installation.
16
4000 SRM 1250
6. If lift truck is equipped with a E-Hydraulic con-
trol valve, turn key to the ON position, if lift
truck is equipped with a key start option, or
press the power ON/OFF button if lift truck is
equipped with a keyless start option. See the
Operating Manual. Disconnect the non-pres-
surized hose and put caps and plugs on the open
lines and cylinder ports. Move the sideshift
mini-lever in both directions several times to re-
lieve hydraulic pressure to the sideshift cylinder.
Disconnect the pressurized hose and put caps
and plugs on the open lines and cylinder ports.
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 and causing an injury or damage
to the lift truck.
7. Disconnect the lift chains by removing the pins
from each chain anchor at the carriage. See Fig-
ure 13.
8. If lift truck is not equipped with a fork positioner,
remove hang on sideshift carriage assembly from
the lift truck as follows:
a. Remove the forks. See Figure 14 and the
section Fork Repair for the procedures.
b. Remove capscrews that secure load backrest
to standard carriage and remove the load
backrest from carriage.
NOTE: If engine is not operational, connect a lifting
device to the inner mast and raise the inner mast
until it is above the load rollers of the carriage.
c. Make sure carriage is stable and connected
to lifting device. Start the engine and use the
lift cylinders and raise the inner mast until it
is above the load rollers of the carriage. Move
lift truck away from carriage.
d. Lift carriage assembly, using the lifting de-
vice, and place carriage assembly on a pallet
or blocks so that the load rollers are up. Re-
move lifting device from carriage assembly.
4000 SRM 1250 Hang On Sideshift Carriage Repair

1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

2. LOAD ROLLER FULL FREE-LIFT MAST)
3. SHIMS 8. PIN
4. SNAP RING 9. COTTER PIN
5. SIDE ROLLER (OPTIONAL) 10. CHAIN ANCHOR PIN
6. CHAIN ANCHOR POSITION (TWO STAGE 11. GUARD (RH)
LIMITED FREE-LIFT MAST) 12. GREASE FITTING

Figure 13. Carriage (Fixed Frame) for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

17
Hang On Sideshift Carriage Repair
1. LOAD BACKREST
2. CARRIAGE (STANDARD)
3. FORKS
4. FORK
5. KNOB
Figure 14. Load Backrest and Forks
9. If lift truck is equipped with a fork positioner car-
riage, remove the fork positioner frame and forks
as follows:
a. Attach lifting device to the fork positioner
frame. See Figure 15.
WARNING
Before disconnecting the hydraulic hoses, re-
lieve the pressure in the hydraulic system.
Serious injury can occur if pressure is not
relieved from hydraulic system prior to dis-
connecting hydraulic hoses.
NOTE: Tag hydraulic lines and fittings prior to re-
moval to aid in connecting during installation.
b. If lift truck is equipped with a manual hy-
draulic control valve, turn key to the ON
position, if lift truck is equipped with a key
start, or press the power ON/OFF button if
lift truck is equipped with a keyless start op-
tion. See the Operating Manual. Relieve
hydraulic pressure to the fork positioner
cylinders by moving auxiliary lever in both
directions several times. See Figure 11.
18
4000 SRM 1250
6. WEDGE
7. WASHER
8. SPRING
9. PIN
10. FORK REMOVAL NOTCH
Disconnect hydraulic lines from fork posi-
tioner cylinders and put caps and plugs on
open lines and cylinder ports.
c. If lift truck is equipped with a E-Hydraulic
control valve, turn key to the ON position,
if lift truck is equipped with a key start, or
press the power ON/OFF button if lift truck
is equipped with a keyless start option. See
the Operating Manual. Disconnect the
non-pressurized hose and put caps and plugs
on the open lines and cylinder ports. See Fig-
ure 11. Move the sideshift mini-lever in both
directions several time to relieve hydraulic
pressure to the sideshift cylinder. Discon-
nect the pressurized hose and put caps and
plugs on the open lines and cylinder ports.
d. Remove the mounting capscrews and wash-
ers that fasten the fork positioner frame and
fork carriers to the sideshift carriage and
forks.
e. Raise the fork positioner frame up, and re-
move frame from sideshift carriage assembly.
Place frame on a pallet or blocks.
4000 SRM 1250 Hang On Sideshift Carriage Repair

1. LIFTING DEVICE 5. SIDESHIFT CARRIAGE ASSEMBLY

2. MOUNTING CAPSCREW 6. FORK CARRIERS
3. WASHER 7. FORK POSITIONER FRAME
4. FORKS

Figure 15. Fork Positioner Removal

19
Hang On Sideshift Carriage Repair
f. Go to Step 8 and perform the procedures de-
scribed there. Do not do Step b.
10. If any of the load rollers must be replaced, make
a note of the arrangement of the shims.
DISASSEMBLE
1. Remove capscrews from lower hooks and remove
the lower hooks from hang on sideshift assembly.
See Figure 16.
NOTE: Make sure the lifting device has a capacity of
450 kg (1000 lb).
2. Attach a lifting device to the hang on sideshift
assembly (see Figure 16) and remove hang on
sideshift assembly from standard (fixed frame)
carriage assembly (see Figure 13).
3. If damaged, remove grease fittings from stan-
dard carriage and hang on sideshift carriage. See
Figure 13 and Figure 11.
4. Remove the two cotter pins and clevis pins and
remove the sideshift cylinder from hang on
sideshift frame. To disassemble the sideshift
cylinder, see Cylinders, Disassemble.
20
4000 SRM 1250
5. Remove the locknut and lug from cylinder rod
end anchors.
6. Remove two nuts (see Figure 17) that attach the
fork positioner cylinders to fork positioner frame.
7. Disengage the cylinders from fork positioner
frame by moving both cylinders inward into the
center plate. To disassemble the fork positioner
cylinders, see Cylinders, Disassemble.
NOTE: Make note of the number of shims removed.
8. Remove the capscrews, washers, and shims from
the center plate.
9. Remove the cylinders, center plate, and fork
carriers as an assembly from the fork positioner
frame.
10. Slide the fork carriers off of the cylinders and
disengage the cylinders from the center plate.
To disassemble the fork positioner cylinders, see
Cylinders, Disassemble.
4000 SRM 1250 Hang On Sideshift Carriage Repair

1. GREASE FITTING 6. O-RING 11. NUT

2. BEARING STRIP 7. CLEVIS PIN 12. LOWER HOOK
3. ANCHOR BRACKET 8. COTTER PIN 13. CAPSCREW
4. SIDESHIFT CYLINDER 9. RESTRICTOR WASHER 14. WASHER
5. FITTING 10. LOWER BEARING 15. FACEPLATE

Figure 16. Hang On Sideshift Assembly

21
Hang On Sideshift Carriage Repair 4000 SRM 1250

1. NUT 8. SNAP RING

2. HYDRAULIC LINES 9. BUSHING
3. CAPSCREW 10. FORK CARRIERS
4. WASHER 11. CENTER PLATE
5. VALVE BODY 12. SHIMS
6. FORK POSITIONER FRAME 13. LUG
7. FORK POSITION CYLINDERS 14. LOCKNUT

Figure 17. Fork Positioner Assembly

22
4000 SRM 1250 Hang On Sideshift Carriage Repair

CYLINDERS, DISASSEMBLE 4. Remove rod assembly and retainer from the

Sideshift Cylinder
To disassemble the sideshift cylinder, perform the fol-
lowing steps (see Figure 18):
1. Position the cylinder rod in the fully extended
position and remove the snap ring from the re-
tainer.
2. Push cylinder retainer into the shell approxi-
mately 50 mm (2 in.) until the retainer ring is
exposed.
3. Remove the retainer ring.
cylinder.
5. Remove retainer from rod.
CAUTION
To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings
6. Remove and discard wiper, seal, backup ring, and
O-ring from the retainer.
7. Remove lock nut from the rod and remove piston.
8. Remove and discard seal and backup ring from
the piston.

1. SNAP RING 6. WIPER 11. PISTON

2. RETAINER RING 7. SEAL 12. SEAL
3. ROD 8. BACKUP RING 13. BACKUP RING
4. RETAINER 9. O-RING
5. CYLINDER SHELL 10. LOCK NUT

Figure 18. Hang On Sideshift Cylinder

23
Hang On Sideshift Carriage Repair 4000 SRM 1250

Fork Positioner Cylinders CLEAN AND INSPECT

Disassemble the fork positioner cylinders as follows
(see Figure 19):
1. Unscrew and remove the cylinder rod retainer.
2. Remove the piston, rod, and cylinder rod retainer
as an assembly from cylinder shell.
CAUTION
To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings
3. Slide the cylinder rod retainer from the cylinder
rod. Remove all seals, O-rings, and backup rings
from cylinder rod.
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
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.

CAUTION
To prevent damage to the cylinder, DO NOT
clamp on the cylinder rod sealing surface.
4. Place cylinder in a soft-jawed vise and remove
the piston nut and piston.
CAUTION
DO NOT use steam to clean the side rollers and
load rollers. Steam will cause corrosion and
damage to rollers and roller parts.
1. Use steam or solvent to clean the metal parts of
the carriage. Dry with compressed air.

2. Inspect the carriage weldments and rollers for

CAUTION
To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings
5. Remove all seals, O-rings, and backup rings from
piston.
wear or damage. Inspect the welds for cracks.
3. Inspect chain anchors and anchor pins for wear
and serviceability. Discard worn or unservice-
able chain anchors and chain anchor pins. See
the Parts Manual for part numbers.

1. CYLINDER ROD 5. BACKUP RING 9. PISTON

2. ROD SEAL 6. O-RING 10. PISTON SEAL
3. ROD WIPER 7. SPACER 11. PISTON NUT
4. CYLINDER ROD RETAINER 8. CYLINDER SHELL

Figure 19. Fork Positioner Cylinders

24
4000 SRM 1250
4. Check the load rollers to make sure they are not
broken or worn.
WARNING
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
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.
5. Clean all parts of the sideshift cylinder and fork
positioner cylinders in solvent or steam. Dry
with compressed air.
6. Inspect the cylinder shell bores, pistons, rods,
bushings, and retainers for scratches or grooves.
If parts are worn or damaged, replace the part.
See the Parts Manual for part numbers.
CYLINDERS, ASSEMBLE
Fork Positioner Cylinders
Assemble the fork positioner cylinders as follows (see
Figure 19):
CAUTION
To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings
1. Lubricate new seals and O-rings with clean
hydraulic oil and install new cylinder rod seal,
wiper seal, O-rings and backup rings onto the
cylinder rod retainer.
CAUTION
To prevent damage to the cylinder, DO NOT
clamp on the cylinder rod sealing surface.
2. Place cylinder in a soft-jawed vise, and install
piston on the rod. Apply Loctite® 242 (Blue) to
threads of piston nut and tighten nut to 75 N•m
(55 lbf ft).
Hang On Sideshift Carriage Repair
3. Lubricate with clean hydraulic oil and install a
new piston seal on the piston.
4. Slide the cylinder rod retainer onto the cylinder
rod.
5. Apply an antiseize compound to the retainer
threads and screw the retainer into the shell.
Tighten the retainer to 75 N•m (55 lbf ft).
Sideshift Cylinder
Assemble the sideshift cylinder as follows (see Fig-
ure 18):
CAUTION
To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings
1. Lubricate with clean hydraulic oil and install
new seal and backup ring on the piston.
CAUTION
To prevent damage to the cylinder, DO NOT
clamp on the cylinder rod sealing surface.
2. Place cylinder in a soft-jawed vise, and install
piston on the rod.
3. Install and tighten lock nut on rod to 135 to
163 N•m (100 to 120 lbf ft).
4. Install rod and piston in the shell.
CAUTION
To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings
5. Install new O-ring and backup ring in the groove
of the retainer.
6. Push the retainer into the cylinder shell until the
retainer ring groove is exposed.
7. Install retainer ring into groove in the shell.
8. Pull rod and piston out of shell until the retainer
stops on the retainer ring and the snap ring
groove is exposed.
9. Install the snap ring on the retainer.
25
Hang On Sideshift Carriage Repair
ASSEMBLE
NOTE: Be sure to assemble the fork positioner cylin-
ders and sideshift cylinder before starting this sec-
tion. See Cylinders, Assemble for procedures to as-
semble the cylinders.
1. Slide the fork carriers onto the cylinders. Install
the cylinders into the holes in the center plate.
2. Install the cylinders, fork carriers, and center
plate into holes in fork positioner frame. See Fig-
ure 17.
3. Install the shims, noted during removal, to the
center plate with two capscrews and washers.
Tighten the capscrews to 44 N•m (30 lbf ft).
4. Install lugs to cylinder rod end anchors with lock-
nuts. Tighten locknuts to 220 N•m (160 lbf ft).
5. Secure the fork positioner cylinders, fork car-
riers, and center plate to fork positioner frame
with two nuts. Tighten the nuts to 220 N•m
(160 lbf ft).
6. Install assembled sideshift cylinder to sideshift
assembly frame using two cotter and clevis pins.
See Figure 16.
7. If grease fittings were removed due to damage,
install new grease fittings into standard carriage
and hang on sideshift carriage.
NOTE: Make sure the lifting device has a capacity of
450 kg (1000 lb).
8. Using a lifting device, lift the hang on sideshift
assembly (see Figure 11) up and place it onto the
standard carriage (fixed frame) by hanging the
anchor bracket over the standard carriage. See
Figure 13.
9. Install the lower hooks onto hang on sideshift as-
sembly using capscrews and washers. Tighten
capscrews to 155 to 170 N•m (115 to 125 lbf ft).
NOTE: Make sure the lifting device has a capacity of
450 kg (1000 lb).
10. Using a lifting device, install the fork positioner
assembly (see Figure 17) onto hang on sideshift
assembly (see Figure 16) using four capscrews
and washers. Tighten capscrews to 155 to
170 N•m (115 to 125 lbf ft).
26
4000 SRM 1250
INSTALL
NOTE: Make sure the lifting device has a capacity of
1450 kg (3200 lb).
1. If lift truck is not equipped with a fork positioner:
a. Connect a lifting device to the carriage as-
sembly and install load backrest to carriage
assembly. Tighten nuts to 70 to 80 N•m (56
to 60 lbf ft).
b. Install the forks to carriage assembly. See
the section Fork Repair for the procedures.
Make sure carriage is stable and move lift
truck up to the carriage assembly.
2. If lift truck is equipped with a fork positioner:
a. Install the forks onto hang on sideshift car-
riage. See the section Fork Repair for the
procedures.
b. Connect a lifting device to fork positioner
frame and lift frame up and align the fork
carriers with the top of the forks. See Fig-
ure 17.
c. Secure the fork positioner frame to hang on
sideshift frame using four capscrews and
washers. Tighten capscrews to 145 N•m
(110 lbf ft) Make sure carriage is stable and
move lift truck up to the carriage assembly.
3. Remove protective caps and plugs from hydraulic
lines and cylinder ports. Connect lines to the
sideshift cylinder, fork positioner cylinders, and
fork positioner valve body as tagged during re-
moval. See Figure 11 and Figure 17.
NOTE: Install new chain anchor pins so that the
heads of pins face inside and center of mast. Both
legs of cotter pin must be bent against chain anchor
pin.
4. Replace worn or unserviceable chain anchor pins
and chain anchors on the carriage with new ones
and install new cotter pin.
5. Connect lift chains to the chain anchors on the
carriage. See Figure 13. Tighten chain anchor
nuts to 210 N•m (155 lbf ft).
6. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage, and care-
fully lower the inner mast onto the carriage.
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

7. Operate the carriage assembly through several fittings and cylinder rod ends and to force any
complete cycles and check for any leaks at the air in the system to the hydraulic tank.

Two-Stage Mast With Limited Free-Lift Repair

REMOVE
1. Fully lower inner mast. If mast must be disas-
sembled, remove forks and carriage as described
in sections Fork Repair and Carriage Replace-
ment.

2. Connect a lifting device to all top crossmembers

of the mast weldments (see Figure 1). Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.

3. Remove lift and tilt cylinders following proce-

dures found in Cylinder Repair 2100 SRM 1139
for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) or Cylinder Repair 2100
SRM 1328 for lift truck models S6.0FT, S7.0FT,
(S135FT, S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006).

4. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
model lift trucks. Remove the capscrews that
hold the mast pivot pins to the J-hook mounts
on the drive axle. Check that the pins fit snug
in the outer mast. If pins can be moved up and
down a minimum of 4 mm (0.157 in.), replace
bushings in outer mast and/or mast pivot pins
as required. See Figure 21 and Figure 22. 1. MAST HANGER BUSHING
2. LUBE FITTINGS
5. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; 3. MAST BUSHING PLUGS
S80, 100FTBCS; S120FTS; S120FTPRS) (G004), 4. CAPSCREW
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and 5. WASHER
6. MAST MOUNTING CAP
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) model lift trucks. Remove the four cap- Figure 20. Mast Mounts Removal for Lift Truck
screws holding the left and right mast mounting Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
hangers to the drive axle. See Figure 20. 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) Shown
6. Remove the mast from lift truck. Put mast in a
position so the crossmembers are on the floor.

27
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

assembly procedures. See Figure 27 for S4.0,

4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), Figure 28 for H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 29 for S6.0FT, S7.0FT, (S135FT,
S155FT) (D024) , and Figure 30 for lift truck
models H7.0FT (H135FT, H155FT) (H006).

2. Slide inner mast halfway out of the top of outer

mast. Connect a crane to the center of inner
mast. See Figure 24. Slide inner mast out of the
outer mast until stub shafts are in the notches of
the outer mast. Remove inner mast from outer
mast.

3. Using a brass drift, remove tilt rod bushing from

outer mast. Discard tilt rod bushing. See Fig-
ure 25.
1. TILT CYLINDER 7. CAPSCREW
2. MAST 8. LOCKWASHER 4. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. ROD END 9. NUT H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
4. BUSHING 10. PIVOT PIN and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
5. PIN 11. SNAP RING model lift trucks, remove snap rings and bush-
6. RETAINIER PIN 12. BUSHING ings at the mast mount. See Figure 21 and
Figure 21. Mast Mounting and Tilt Cylinder Figure 22 or Figure 28 and Figure 30.
Removal for Lift Truck Models H4.0FT5/FT6; 5. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
100, 110, 120FT) (N005) and H6.0FT, H7.0FT S6.0FT, S7.0FT, (S135FT,S155FT) (D024), and
(H135FT, H155FT) (H006) E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) model lift trucks, remove bushings at
DISASSEMBLE the mast mounting hangers. See Figure 20 or
1. Slide inner mast from the bottom of outer Figure 27 and Figure 29.
mast approximately 30 cm (12 in.). Remove
6. Remove and disassemble chain sheaves as neces-
strip bearings. See Figure 23. Remove load
sary for cleaning and repair.
rollers from both weldments. Make a note of
the shim arrangement. The shim arrange-
ment will be approximately the same during

28
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

1. OUTER MAST 2. BUSHING 3. GREASE FITTING

Figure 22. Mast Mounts Removal, Outer Mast for Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
Legend for Figure 23
1. STRIP BEARING
2. SHIMS
3. TOP OF OUTER MAST
4. O-RINGS

Figure 23. Strip Bearings

29
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

and high-pressure water can remove the lu-

brication 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 sheaves and load rollers for wear or

damage. DO NOT use steam to clean lift chains,
sheaves, or load rollers. The bearings in the
sheaves and load rollers are sealed and lubri-
cated.

2. Inspect chain anchors and anchor pins for dam-

age. If damaged, replace.

WARNING
1. INNER MAST
2. OUTER MAST Commercial cleaning solvents may be
flammable and toxic and can cause severe skin
Figure 24. Inner Mast irritation. When using commercial cleaning
solvents, always comply with solvent manu-
facturer’s recommended safety precautions.

WARNING
Never replace just the worn section of a chain.
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains.

3. Clean lift chains with solvent. Inspect lift chains

for wear or damage. See Figure 26. A lift chain
becomes longer when it is worn. If a section of
chain is 3% longer than a similar section of new
chain, the chain is worn and must be replaced.
If a chain scale is available, check lift chains as
shown in Figure 26. If a chain scale is not avail-
able 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
1. TILT ROD BUSHING in Figure 26. Replace chain if the length of 20
links of the worn section is more than the maxi-
Figure 25. Mast Bushing Location mum wear limit. Lubricate chains with SAE 30
engine oil. The best procedure is to remove lift
CLEAN AND INSPECT chains from lift truck and soak them in SAE 30
engine oil.
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam

30
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

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

Pitch
Total Length of Wear Limit
20 Links (Pitch) The Maximum Length of
of New Chain 20 Links

25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 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 26. Lift Chains Check

31
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 27. Two-Stage Mast With Limited Free-Lift for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) Shown

32
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 27

A. INNER MAST C. OUTER MAST WITH MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 14. BRACKET
2. SNAP RING 15. LOCKWASHER
3. MAIN LIFT CYLINDER 16. CAPSCREW
4. LIFT CHAIN 17. FITTING
5. HOSES 18. NUT
6. WASHER 19. SPACER
7. SHIMS 20. CONTROL VALVE HOUSING
8. LOAD ROLLER 21. LOWERING CONTROL VALVE
9. BEARING STRIP 22. CLAMP
10. O-RING 23. COTTER PIN
11. OUTER MAST 24. CHAIN ANCHOR
12. CHAIN SHEAVE 25. PIN
13. BEARING 26. VELOCITY FUSE

33
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 28. Two-Stage Mast With Limited Free-Lift for Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

34
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 28

A. INNER MAST C. OUTER MAST WITH MAIN LIFT CYLINDERS
B. OUTER MAST
1. STUB SHAFT 18. HOUSING
2. SNAP RING 19. LOWERING CONTROL VALVE
3. SHIMS 20. CLAMP
4. BEARING STRIP 21. HOSE (RH)
5. O-RING 22. STRAP CLAMP
6. OUTER MAST 23. CLAMP
7. BUSHING 24. VELOCITY FUSE
8. LOAD ROLLER 25. HOSE
9. INNER MAST 26. HOSE (LH)
10. CAPSCREW 27. HOSE
11. LOCKWASHER 28. NUT
12. WASHER 29. CHAIN ANCHOR
13. BRACKET 30. COTTER PIN
14. CHAIN SHEAVE 31. ANCHOR PIN
15. SPACER 32. CHAIN
16. FITTING 33. HOSE
17. NUT

35
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 29. Two-Stage Mast With Limited Free-Lift for Lift Truck Models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024)

36
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 29

A. INNER MAST C. MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 16. CLAMP
2. STUB SHAFT 17. HOSE
3. LOAD ROLLER 18. STRAP CLAMP
4. SHIMS 19. HOSE CLAMP
5. SNAP RING 20. SPRING
6. CHAIN SHEAVE 21. WASHER
7. BEARING STRIP 22. HOUSING
8. BEARING STRIP SHIMS 23. LOWERING CONTROL VALVE
9. OUTER MAST 24. NUT
10. LUBE FITTING 25. LIFT CHAIN
11. BUSHING 26. LIFT CYLINDER
12. WASHER 27. CHAIN ANCHOR
13. CAPSCREW 28. PIN
14. CAP 29. COTTER PIN
15. FITTING

37
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 30. Two-Stage Mast With Limited Free-Lift for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006)

38
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 30

A. INNER MAST C. MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 15. FITTING
2. STUB SHAFT 16. CLAMP
3. LOAD ROLLER 17. HOSE
4. SHIMS 18. STRAP CLAMP
5. SNAP RING 19. HOSE CLAMP
6. CHAIN SHEAVE 20. SPRING
7. BEARING STRIP 21. WASHER
8. BEARING STRIP SHIMS 22. HOUSING
9. OUTER MAST 23. LOWERING CONTROL VALVE
10. SNAP RING 24. NUT
11. BUSHING 25. LIFT CHAIN
12. WASHER 26. LIFT CYLINDER
13. CAPSCREW 27. CHAIN ANCHOR
14. COTTER PIN 28. PIN

ASSEMBLE
NOTE: The shims for the load rollers keep the weld-
ments parallel and provide correct clearance. Dur-
ing assembly, the location of the shims will be ap-
proximately the same as they were before disassem-
bly. Check clearance and adjust shims for wear or
changes because of repairs. Strip bearings are also
adjusted by using shims. See Mast Adjustments in
this section for the instructions to make the neces-
sary adjustments.

1. Connect a lifting device to the center of inner

mast (see Figure 24). Put stub shafts through
notches in the outer mast. Slide inner mast into
the outer mast so stub shafts are seen at the top
and bottom of the weldments.

2. Install strip bearings, new O-rings, and shims,

as noted during disassembly, on the outer mast.
Apply grease to bearing surface. See Figure 31. 1. STRIP BEARING
2. SHIMS
3. Install the load rollers and shims on both weld- 3. TOP OF OUTER MAST
ments. Check the clearance of the load rollers 4. O-RINGS
and strip bearings as described in Mast Adjust-
Figure 31. Strip Bearings
ments and Carriage Adjustments.

4. Install new tilt rod bushing into outer mast. See

Figure 32.

39
Two-Stage Mast With Limited Free-Lift Repair
1. TILT ROD BUSHING
Figure 32. Mast Bushing Location
NOTE: When installing mast mounting bushings,
ensure bores and snap ring grooves are clean and
free from any obstructions. Be sure to install the
inner snap ring (nearest to truck center) first. Drive
bushings until contact with inner snap ring is made.
Clean bushing material from outer snap ring grooves
and install outer snap ring.
5. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
model lift trucks, install the bushings and snap
rings into the mast mount. See Figure 21.
6. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) model lift trucks, install bushings and
plugs until bushing edge is flush with mast
mounting hangers. See Figure 20.
7. Install lowering control valve on outer mast.
• For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098) tighten
capscrew to 18 N•m (13 lbf ft).
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrew to 38 N•m
(28 lbf ft).
40
4000 SRM 1250
• For lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) tighten capscrew to
33 N•m (24 lbf ft).
8. Connect hydraulic lines and fittings between
lowering control valve and lift cylinders. See
Figure 27, Figure 28, Figure 29, and Figure 30.
9. Install chain anchor and nut.
• For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) tighten nut to
66 N•m (49 lbf ft).
• For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005) tighten nut to
210 N•m (155 lbf ft).
• For lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) tighten nut to
370 N•m (273 lbf ft).
NOTE: Both legs of cotter pin must be bent against
chain anchor pin.
10. Install chain sheaves and brackets. Connect lift
chains to chain anchors and install new chain an-
chor pins and cotter pins. Attach wires between
the ends of the lift chains and crossmember to
control lift chains during installation.
INSTALL, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) AND H6.0FT, H7.0FT
(H135FT, H155FT) (H006) LIFT TRUCK
MODELS
1. Install pivot pins in the mounts in the outer mast
(see Figure 21). Make sure grease fittings are
toward the center of the truck. Connect a lifting
device to the top of the mast assembly. Make sure
all weldments are fastened together. Make sure
the chains do not damage any of the hydraulic
lines or other parts.
2. Raise mast assembly to a vertical position. Move
mast assembly into position on the lift truck.
3. Make sure the pivot pins are in the correct posi-
tion, and install capscrews. See Figure 21.
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
4000 SRM 1250
120FT) (N005) tighten capscrews to 522 to
572 N•m (385 to 422 lbf ft).
• For lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006) tighten capscrews
to 755 to 830 N•m (557 to 612 lbf ft).
4. Using Cylinder Repair 2100 SRM 1139 for lift
truck model H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
or Cylinder Repair 2100 SRM 1328 for lift
truck model H6.0FT, H7.0FT (H135FT, H155FT)
(H006), connect tilt cylinders to the outer mast.
5. Connect hydraulic hoses and fittings between
lowering control valve and lift cylinders to the
mast assembly. See Figure 40, for lift truck
models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
and Figure 42, for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006).
6. Install header hoses as shown in Figure 35,
for lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and Figure 37, for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006).
INSTALL, S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) S6.0FT,
S7.0FT, (S135FT,S155FT) (D024) AND
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) LIFT TRUCKS MODELS
1. Connect a lifting device to the top of the mast
assembly. Make sure all of the weldments are
fastened together. Make sure the chains do not
damage any of the hydraulic lines or other parts.
See Figure 27, for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004) and E3.50-
5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098) or
Figure 29, for lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024).
2. Install new bushings in the mast mounting hang-
ers. Raise the mast assembly to a vertical posi-
tion. Place mast mounting hangers on the drive
Two-Stage Mast With Limited Free-Lift Repair
axle and lift mast assembly into position on lift
truck. See Figure 20.
3. Secure mast assembly to lift truck by installing
the two mast mounting caps onto mast mount-
ing hangers. Insert capscrews and tighten to
320 N•m (236 lbf ft). See Figure 20.
4. Using Cylinder Repair 2100 SRM 1139 for lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) or Cylinder Repair
2100 SRM 1328 for lift truck model S6.0FT,
S7.0FT, (S135FT,S155FT) (D024) connect the
tilt cylinders to the outer mast.
5. Connect hydraulic hoses and fittings between
lowering control valve and lift cylinders to the
mast assembly. See Figure 39, for lift truck mod-
els S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
Figure 38, for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), and Fig-
ure 41, for lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024).
6. Install header hoses as shown in Figure 33,
for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and, Figure 34, for lift truck
models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), Figure 35, for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), Figure 36,
for lift truck models S6.0FT, S7.0FT, (S135FT,
S155FT) (D024), and Figure 37, for lift truck
models H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
7. Adjust lift chains, carriage, and tilt cylinders as
described in sections Lift Chains Adjustment,
Carriage Adjustments, and Tilt Cylinder Stroke
and Backward Tilt Angle Adjustment.
41
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 33. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

42
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 33

1. HOSES 10. FITTING
2. CLAMP 11. TUBE
3. SPACER 12. PLATE
4. STUB SHAFT 13. WASHER
5. SHEAVE 14. NUT
6. CAPSCREW 15. STRAIN RELIEF
7. LOCKWASHER 16. BRACKET
8. GROMMET 17. HOSE REEL (OPTIONAL)
9. NUT

43
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 34. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)

44
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 34

1. HOSES 10. FITTING
2. CLAMP 11. TUBE
3. SPACER 12. PLATE
4. STUB SHAFT 13. WASHER
5. SHEAVE 14. NUT
6. CAPSCREW 15. STRAIN RELIEF
7. LOCKWASHER 16. BRACKET
8. GROMMET 17. HOSE REEL (OPTIONAL)
9. NUT 18. JUNCTION BOX

45
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 35. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

46
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 35

1. HOSES 8. GROMMET
2. CLAMP 9. NUT
3. SPACER 10. FITTING
4. STUB SHAFT 11. TUBE
5. SHEAVE 12. WASHER
6. CAPSCREW 13. NUT
7. LOCKWASHER

47
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 36. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024)

48
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 36

1. STUBSHAFT 10. JAM NUT
2. SHEAVE 11. BRACKET
3. BUSHING 12. TUBE
4. NUT 13. HOSE
5. CLAMP 14. BRACKET
6. CAPSCREW 15. WASHER
7. FITTING 16. PLATE
8. CHECK VALVE 17. STRAIN RELIEF
9. O-RING 18. HOSE REEL

49
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Figure 37. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models H6.0FT,
H7.0FT (H135FT, H155FT) (H006)

50
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 37

1. STUBSHAFT 9. O-RING
2. SHEAVE 10. JAM NUT
3. BUSHING 11. BRACKET
4. NUT 12. TUBE
5. CLAMP 13. HOSE
6. CAPSCREW 14. BRACKET
7. FITTING 15. WASHER
8. CHECK VALVE

HEADER HOSE ALIGNMENT
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-hand side of the outer mast.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage.
Examples of these auxiliary functions are sideshift
carriages or roll clamps. These auxiliary functions
require header hoses for their operation.
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C,
and D. See Figure 38, for lift truck models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), Figure 39, for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), Figure 40,
for lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 41, for lift truck models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024), and Figure 42,
for lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006).

NOTE: This procedure is for the four-function option.

The three-function option will have hoses A and B
only.

51
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

A. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

B. HOSE (THREE FUNCTION) E. HOSE (FIVE FUNCTION)
C. HOSE (FOUR FUNCTION)

Figure 38. Header Hose Alignment for Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)

52
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Figure 39. Header Hose Alignment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

53
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Legend for Figure 39

A. HOSE (THREE FUNCTION) C. HOSE (FOUR FUNCTION) E. HOSE (FIVE FUNCTION)
B. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

A. HOSE (THREE FUNCTION) C. HOSE (FOUR FUNCTION)

B. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

Figure 40. Header Hose Alignment for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

54
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Figure 41. Header Hose Alignment for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024)

55
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Legend for Figure 41

A. HOSE (THREE FUNCTION) C. HOSE (FOUR FUNCTION) E. HOSE (FIVE FUNCTION)
B. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

A. HOSE (THREE FUNCTION) C. HOSE (FOUR FUNCTION)

B. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

Figure 42. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)

56
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

NOTE: The fifth function hose does not require ten- S155FT) (D024), and Figure 37, for lift truck
sion marks. models H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
2. Dimension E is determined by the height of
the outer mast channel from the ground and 6. Place the hoses at the location of the hose
the length of the outer mast channel. See sheave(s). The sheave(s) and stub shafts must
dimensions Y and Z in Figure 43. To deter- be assembled, and the hose(s) must be routed
mine E, use Table 2 for lift truck models S4.0, onto the sheave(s) before the hose(s) are attached
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, to the mast. Refer to Figure 33. Tighten the hose
100FTBCS; S120FTS; S120FTPRS) (G004), clamp hardware to 8 N•m (71 lbf in) and the
Table 3 for lift truck models H4.0FT5/FT6; sheave assembly capscrews to 66 N•m (49 lbf ft).
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), Table 4 for lift truck models 7. Put the clamps over the hoses and attach the
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) clamps to the upper brackets. DO NOT tighten
(E098), Table 5 for lift truck models S6.0-7.0FT the hardware.
(S135, 155FT) (D024), and Table 6 for lift truck
NOTE: To make the alignment of dimension E eas-
models H6.0-7.0FT (H135-155FT) (H006) to de-
ier, use a crane with a capacity of at least 907.2 kg
termine pre-calculated tension mark locations.
(2000 lb) to raise the carriage high enough to install
3. Clamp the end of the hose (the smaller fitting) a safety chain. See Figure 1.
that attaches to the carriage in a vise (do NOT
8. Align dimension mark E, which is determined
clamp on the threads), and pull on the other end
using Figure 43, at the bottom of the clamps.
until the hose is straight. Do NOT apply enough
Tighten the hardware to 8 N•m (71 lbf in). Refer
force to stretch the hose. See Figure 43.
to Figure 39 or Figure 41.
NOTE: This mark will be used to pretension the
9. Connect the header hoses to the cowl hoses.
header hoses during installation.
10. Use the rubber clamps and hose clamps to attach
4. Place a mark on all the hoses at dimension E (all
the hoses to the main lift cylinders. Make sure
measurements are made from the carriage end of
the hoses do NOT stretch or fold while tilting the
the hose [the smaller fitting]).
mast fully forward and backward.
5. Attach the hoses as shown in Figure 33, for
11. With no load on the forks, check the header hose
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
adjustment by operating the mast through the
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
full lift cycle two times. When properly adjusted,
S120FTPRS) (G004) and, Figure 34, for lift truck
the hoses will not be so tight that they compress
models E3.50-5.50XL, E4.50XLS (E70-120Z,
when they pass over the sheaves nor will they be
E100ZS) (E098), Figure 35, for lift truck models
so loose that they touch the load backrest or any
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
crossmember that is next to a sheave. If neces-
(H80, 90, 100, 110, 120FT) (N005), Figure 36,
sary, repeat until hoses are properly adjusted.
for lift truck models S6.0FT, S7.0FT, (S135FT,

57
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE

Figure 43. Header Hose Measurement

58
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair

Table 2. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2740 107.9 2025 79.7
2020 79.5
3000 118.1 2054 80.8
3340 131.5 2316 91.1
2320 91.3
3600 141.7 2345 92.3
3940 155.1 2607 102.6
2620 103.1
4200 165.4 2636 103.7

Table 3. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2740 107.9
2020 79.5 2473 97.3
3000 118.1
3340 131.5
2320 91.3 2768 108.9
3600 141.7
3940 155.1
2620 103.1 3061 120.5
4200 165.4
4640 182.7
3070 120.8 3503 137.9
4900 192.9
5240 206.3
3470 136.6 3896 153.3
5500 216.5
5840 229.9
3870 152.3 4289 168.8
6100 240.2

59
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250

Table 4. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck
Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2790 109.8 2025 79.7
2020 79.5
3050 120.1 2060 81.1
3390 133.5 2316 91.1
2320 91.3
3650 143.7 2351 92.5
3990 157.1 2607 102.6
2620 103.1
4250 167.3 2642 104.0
4690 184.6 3044 119.8
3070 120.8
4950 194.9 3079 121.2
5290 208.3 3432 135.1
3470 136.6
5550 218.5 3467 136.4
5840 231.9 3820 150.3
3870 152.3
6150 242.1 3855 151.7

Table 5. Standard Mast Height; Header Hose Tension Mark Location for Lift
Truck Models S6.0-7.0FT (S135, 155FT) (D024)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2340 92.1 1862 73.3
2084 82.0

3340 131.5 2584 101.7 2352 92.6

4340 170.9 3084 121.4 2842 111.9

Table 6. Standard Mast Height; Header Hose Tension Mark Location for Lift
Truck Models H6.0-7.0FT (H135-155FT) (H006)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2940 115.7
2384 93.9 2156 84.9

3340 131.5 2584 101.7 2352 92.6

60
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Table 6. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck
Models H6.0-7.0FT (H135-155FT) (H006) (Continued)

Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
4340 170.9 3084 121.4 2842 111.9

5340 210.2 3584 141.4 3332 131.1

5940 233.9 4009 157.8 3748 147.6

Two-Stage Mast With Full Free-Lift Repair

REMOVE
1. Fully lower inner mast. If mast must be disas-
sembled, remove forks and carriage as described
in sections Fork Repair and Carriage Replace-
ment.
2. Connect a lifting device to all top crossmembers
of the mast weldments (see Figure 1). Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.
3. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005) model
lift trucks. Remove the capscrews that hold the
mast pivot pins to the J-hooks mounts on the
drive axle. See Figure 21.
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), and Figure 47 for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).
2. Slide inner mast from the bottom of the outer
mast approximately 30 cm (12 in.). Remove strip
bearings. See Figure 31. Remove load rollers
from both weldments. Make a note of the shim
arrangement. Shim arrangement will be approx-
imately the same during assembly procedures.
3. Using a brass drift, remove tilt rod bushing from
outer mast. Discard tilt rod bushing. See Fig-
ure 44.

4. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,

120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) model lift trucks. Remove the
four capscrews and washers holding the left and
right mast mounting caps to the drive axle. Use
a lifting device to move mast from lift truck. Put
mast in a position so the crossmembers are on
the floor. See Figure 20.

DISASSEMBLE
1. Clean area around the hydraulic fittings for the
lift cylinders. Disconnect fittings at the lift cylin-
ders and put caps on open lines. See Figure 45
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 46 for lift 1. TILT ROD BUSHING
truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
Figure 44. Mast Bushing Location

61
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

4. Slide inner mast halfway out of the top of the
outer mast. Connect a lifting device to the center
of inner mast. See Figure 24. Slide inner mast
out of the outer mast until stub shafts are in the
notches of the outer mast. Remove inner mast
from the outer mast.
5. For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005). Check that the pins fit snug in the outer
mast. If pins can be moved up and down a min-
imum of 4 mm (0.157 in.), replace bushings in
outer mast and/or mast pivot pins as required.
See Figure 21.
S120FTPRS) (G004) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098). Re-
move bushings and plugs from mast mounting
hangers. See Figure 20.
7. Remove and disassemble sheaves and load
rollers as necessary for cleaning and repair. See
Figure 45 for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 46
for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), and Figure 47 for lift truck
models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005).

6. For lift trucks models S4.0, 4.5, 5.5FT, S5.5FTS,

(S80, 100, 120FT; S80, 100FTBCS; S120FTS;

Legend for Figure 45

A. INNER MAST AND FREE LIFT B. OUTER MAST AND MAIN LIFT
1. OUTER MAST 16. NUT
2. LOAD ROLLER 17. LOCKWASHER
3. SNAP RING 18. HOSE
4. SHIM 19. CLAMP
5. O-RING 20. PIN
6. TUBE 21. CHAIN GUARD
7. MAIN LIFT CYLINDER (RH) 22. CROSSHEAD
8. MAIN LIFT CYLINDER (LH) 23. FREE-LIFT CYLINDER
9. WASHER 24. LIFT CHAIN (LH SIDE SHOWN FOR CLARITY)
10. STRIP BEARING 25. CHAIN SHEAVES
11. FITTING 26. COTTER PIN
12. CAPSCREW 27. CHAIN ANCHOR
13. BRACKET 28. INNER MAST
14. LOWERING CONTROL VALVE HOUSING 29. VELOCITY FUSE
15. LOWERING CONTROL VALVE 30. STUB SHAFT

62
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Figure 45. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)

63
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 46. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

64
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 46

A. INNER MAST AND FREE-LIFT B. OUTER MAST AND MAIN LIFT
1. OUTER MAST 17. LOCKWASHER
2. LOAD ROLLER 18. HOSE
3. SNAP RING 19. CLAMP
4. SHIM 20. PIN
5. O-RING 21. CHAIN GUARD
6. TUBE 22. CROSSHEAD
7. MAIN LIFT CYLINDER (RH) 23. FREE-LIFT CYLINDER
8. MAIN LIFT CYLINDER (LH) 24. LIFT CHAIN (LH SIDE SHOWN FOR CLARITY)
9. WASHER 25. CHAIN SHEAVES
10. STRIP BEARING 26. COTTER PIN
11. FITTING 27. CHAIN ANCHOR
12. CAPSCREW 28. INNER MAST
13. BRACKET 29. VELOCITY FUSE
14. LOWERING CONTROL VALVE HOUSING 30. TIE DOWN CLAMP
15. LOWERING CONTROL VALVE 31. STUB SHAFT
16. NUT

65
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 47. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

66
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 47

A. INNER MAST AND FREE-LIFT B. OUTER MAST AND MAIN LIFT
1. OUTER MAST 18. HOSE
2. LOAD ROLLER 19. CLAMP
3. SNAP RING 20. PIN
4. SHIM 21. CHAIN GUARD
5. O-RING 22. CROSSHEAD
6. TUBE 23. FREE-LIFT CYLINDER
7. MAIN LIFT CYLINDER (RH) 24. LIFT CHAIN (LH SIDE SHOWN FOR CLARITY)
8. MAIN LIFT CYLINDER (LH) 25. CHAIN SHEAVES
9. WASHER 26. COTTER PIN
10. STRIP BEARING 27. CHAIN ANCHOR
11. FITTING 28. INNER MAST
12. CAPSCREW 29. VELOCITY FUSE
13. BRACKET 30. TIE DOWN CLAMP
14. LOWERING CONTROL VALVE HOUSING 31. STUB SHAFT
15. LOWERING CONTROL VALVE 32. SNAP RING
16. NUT 33. BUSHING
17. LOCKWASHER

CLEAN AND INSPECT irritation. When using commercial cleaning

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 lu-
brication 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 sheaves and load rollers for wear or
damage. DO NOT use steam to clean lift chains,
sheaves, or load rollers. The bearings in the
sheaves and load rollers are sealed and lubri-
cated.
2. Inspect tilt cylinder bushing in mast. If dam-
aged, replace.
3. Inspect chain anchors and chain anchor pins. If
damaged, replace.
WARNING
Commercial cleaning solvents may be
flammable and toxic and can cause severe skin
solvents, always comply with solvent manu-
facturer’s recommended safety precautions.
WARNING
Never replace just the worn section of a chain.
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains.
4. Clean lift chains with solvent. Inspect lift chains
for wear or damage. See Figure 48. A lift chain
becomes longer when it is worn. If a section of
chain is 3% longer than a similar section of new
chain, the chain is worn and must be replaced.
If a chain scale is available, check lift chains as
shown in Figure 48. If a chain scale is not avail-
able 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 48. Replace chain if the length of 20
links of the worn section is more than the maxi-
mum wear limit. Lubricate chains with SAE 30
engine oil. The best procedure is to remove lift
chains from lift truck and soak them in SAE 30
engine oil.

67
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

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

Pitch
Total Length of Wear Limit
20 Links (Pitch) The Maximum Length of
of New Chain 20 Links

25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 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 48. Lift Chains Check

ASSEMBLE
NOTE: Shims for the load rollers keep the weldments
parallel and provide correct clearance. During as-
sembly, the location of the shims will be approxi-
mately the same as they were before disassembly.
Check clearance and adjust shims for wear or
changes because of repairs. Strip bearings are also
adjusted by using shims. See the Mast Adjustments
in this section for instructions to make the necessary
adjustments.
in the outer mast. Slide inner mast into the outer
mast so stub shafts are seen at the top and bot-
tom of the weldments. See Figure 24.
2. Install strip bearings, O-rings and the shims on
the outer mast. Apply grease to bearing surface.
See Figure 31.
3. Install load rollers and shims on both weldments.
Check clearance of the load rollers and strip bear-
ings as described in Mast Adjustments and Car-
riage Adjustments.

1. Connect a lifting device to the center of the inner 4. Install new tilt rod bushing into outer mast. See
mast and insert stub shafts through the notches Figure 49.

68
4000 SRM 1250
1. TILT ROD BUSHING
Figure 49. Mast Bushing Location
NOTE: When installing mast mounting bushings,
ensure bores and snap ring grooves are clean and
free from any obstructions. Be sure to install the
inner snap ring (nearest to truck center) first. Drive
bushings until contact with inner snap ring is made.
Clean bushing material from outer snap ring grooves
and install outer snap ring.
5. For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005). Install the snap rings and bushing at the
mast mount. See Figure 21.
6. For lift trucks models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098). Install
mast hanger bushings and mast bushing plugs
onto mast mounting hangers. See Figure 20.
7. Install chain sheave assembly on free-lift cylin-
der. Install free-lift cylinder on inner mast. See
Figure 45 for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 46
for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
Two-Stage Mast With Full Free-Lift Repair
S120FTPRS) (G004), and Figure 47 for lift truck
models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005).
Tighten capscrews to:
• For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) tighten capscrews
to 210 N•m (13 lbf ft).
• For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) tighten capscrews to
175 N•m (129 lbf ft).
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrews to 175 N•m
(129 lbf ft).
8. Install lift cylinders. Make sure spacers, when
installed, are in their original positions at bot-
tom mounts. Push inner mast to engage rods
of lift cylinders. Install washers and snap rings
at top of lift cylinders. Install capscrews, wash-
ers, and brackets at lift cylinder mounts. Tighten
capscrews at mounts to 33 N•m (24 lbf ft).
9. Install lowering control valve on outer mast.
• For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098) tighten
capscrew to 18 N•m (13 lbf ft).
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrew to 38 N•m
(28 lbf ft).
10. Connect hydraulic hoses, tubes, and fittings be-
tween lowering control valve, lift cylinders, and
free-lift cylinder.
NOTE: Install new cotter pins and chain anchor pins.
Both legs of cotter pin must be bent against chain
anchor pin.
11. Connect lift chains to chain anchors at mount
on inner mast. Tighten chain anchor nuts to
210 N•m (155 lbf ft). Attach wires between ends
of lift chains and bottom crossmember to control
lift chains during installation.
69
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

INSTALL for lift truck models H4.0FT5/FT6; H4.5FTS5,

Install two-stage mast with full free-lift using the
same procedures described in Two-Stage Mast
With Limited Free-Lift Repair, Install, S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004) S6.0FT,
S7.0FT, (S135FT,S155FT) (D024) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098) Lift Trucks
Models. See Figure 45 for lift truck models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), Figure 46 for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), and Figure 47
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and see the arrangement of the header
hoses in Figure 50, for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), Figure 51, for lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), and Figure 52, for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).

Legend for Figure 50

1. HYDRAULIC HOSES 11. CAPSCREW
2. CHANNEL 12. PAD
3. BRACKET 13. LOCKWASHER
4. CLAMP 14. FITTING
5. WASHER 15. NUT
6. HOSE SHEAVE 16. STRAIN RELIEF
7. SNAP RING 17. HOSE REEL (OPTIONAL)
8. WASHER 18. FITTING AND O-RING
9. TUBE 19. PLATE
10. STRAP CLAMP

70
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Figure 50. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck ModelsS4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

71
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 51. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck ModelsE3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)

72
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 51

1. HYDRAULIC HOSES 11. CAPSCREW
2. CHANNEL 12. PAD
3. BRACKET 13. LOCKWASHER
4. CLAMP 14. FITTING
5. WASHER 15. NUT
6. HOSE SHEAVE 16. STRAIN RELIEF
7. SNAP RING 17. HOSE REEL (OPTIONAL)
8. WASHER 18. FITTING AND O-RING
9. TUBE 19. PLATE
10. STRAP CLAMP

73
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 52. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

74
4000 SRM 1250
Legend for Figure 52
1. BRACKET (RH)
2. BRACKET (LH)
3. PIN
4. HOSE SHEAVE
5. WASHER
6. SNAP RING
7. CLAMP
HEADER HOSE INSTALLATION AND
ADJUSTMENT
Installation
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: This procedure is for the three and four-func-
tion option.
The carriage height must be correct before the header
hoses can be installed. See Lift Chains Adjustment
for the carriage adjustment procedure.
1. Route hoses between channels, such that natural
curve of hose loop is between channels. Attach
hoses to the tube assemblies. See Figure 50, for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), Figure 51, for lift truck models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), and Figure 52, for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).
2. Install clamp 108 mm (4.25 in.) below the hose
fittings, to the bracket on channel. Tighten cap-
screw to 10.8 N•m (96 lbf in).
3. Connect hoses on sheaves and slide hose sheave
assembly over stub shaft on bracket. Install
washer and snap ring to retain sheave assembly.
4. Install fitting at the carriage and attach hoses
to fittings with the natural curve of the hoses
routed over the top of sheaves. Attach hoses to
fittings on the hose assembly.
5. Install clamps at the top of channel to retain
hoses.
Two-Stage Mast With Full Free-Lift Repair
8. CAPSCREW
9. FITTING
10. LOCK NUT
11. CAP
12. CHANNEL
13. HYDRAULIC HOSE
6. Ensure hoses routed between truck cowl and the
main lift cylinder are able to move freely during
forward/back tilt without kinking or stressing fit-
tings at cowl.
7. Cycle mast several times to ensure proper rout-
ing of hoses. Hoses should not bulge out over the
sheaves and should not rub up against adjacent
crossmembers.
Adjustment
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: This procedure is for the three and four-func-
tion option.
The carriage height must be correct before the header
hoses can be adjusted. See Lift Chains Adjustment
for the carriage adjustment procedure.
1. Loosen hardware at clamp located behind the
free-lift cylinder. See Figure 50, for lift truck
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), Figure 51, for lift truck models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), and Figure 52, for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).
2. Pull on hoses so that hoses move by half the
clamp width or 15 mm (0.6 in.). Tighten hard-
ware.
3. Repeat hose adjustment until hoses route
smoothly through the mast. Hoses should
not bulge over the sheaves and should not rub
against adjacent crossmembers.
75
Three-Stage Mast With Full Free-Lift Repair
Three-Stage Mast With Full Free-Lift Repair
REMOVE
1. Fully lower inner mast. If mast must be disas-
sembled, remove forks and carriage as described
in sections Fork Repair and Carriage Replace-
ment.
2. Connect a lifting device to all top crossmembers
of the mast weldments (see Figure 1). Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.
3. Remove tilt cylinders. See Cylinder Repair
2100 SRM 1328 for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006), S6.0FT,
S7.0FT, (S135FT, S155FT) (D024) or Cylinder
Repair 2100 SRM 1139 for lift truck models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
E098.
4. Remove Lift Cylinders. See Cylinder Re-
pair 2100 SRM 1328 for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006)
and S6.0FT, S7.0FT, (S135FT, S155FT) (D024)
or Cylinder Repair 2100 SRM 1139 for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098).
5. Remove Free Lift Cylinder. See Cylinder
Repair 2100 SRM 1328 for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006),
S6.0FT, S7.0FT, (S135FT, S155FT) (D024)
or Cylinder Repair 2100 SRM 1139 for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
76
4000 SRM 1250
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098).
6. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
or H6.0FT, H7.0FT (H135FT, H155FT) (H006)
model lift trucks. Remove the capscrews that
hold the mast pivot pins to the J-hooks mounts
on the drive axle. Check that the pins fit snug
in the outer mast. If pins can be moved up and
down a minimum of 4 mm (0.157 in.), replace
bushings in outer mast and/or mast pivot pins
as required. See Figure 21.
7. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), and S6.0FT, S7.0FT, (S135FT,S155FT)
(D024) model lift trucks. Remove the four cap-
screws holding the left and right mast mounting
caps to the mast. Use a lifting device to move
mast from lift truck. Put mast in a position so the
crossmembers are on the floor. See Figure 20.
DISASSEMBLE
1. Clean area around the hydraulic fittings for
the lift cylinders. Disconnect hoses at the lift
cylinders and put caps on open lines. See Fig-
ure 53, for lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), Figure 54, for
lift truck models, E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 55, for
lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 56, for lift truck models, S6.0FT,
S7.0FT, (S135FT,S155FT) (D024), and Figure 57
for lift truck models, H6.0FT, H7.0FT (H135FT,
H155FT) (H006).
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

NOTE: OUTER MAST ASSEMBLY SHOWN.

1. OUTER MAST 13. MAIN LIFT CYLINDERS
2. STUB SHAFT 14. VELOCITY FUSE
3. LOAD ROLLER 15. FITTING
4. SHIM 16. WASHER
5. SNAP RING 17. BRACKET
6. BEARING STRIP 18. LOCKWASHER
7. O-RING 19. CAPSCREW
8. CHAIN ANCHOR 20. CLAMP
9. PIN 21. HOSES
10. COTTER PIN 22. LOWERING CONTROL VALVE HOUSING
11. NUT 23. LOWERING CONTROL VALVE
12. LIFT CHAIN

Figure 53. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

77
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

NOTE: OUTER MAST ASSEMBLY SHOWN.

1. OUTER MAST 13. MAIN LIFT CYLINDERS
2. STUB SHAFT 14. VELOCITY FUSE
3. LOAD ROLLER 15. FITTING
4. SHIM 16. WASHER
5. SNAP RING 17. BRACKET
6. BEARING STRIP 18. LOCKWASHER
7. O-RING 19. CAPSCREW
8. CHAIN ANCHOR 20. CLAMP
9. PIN 21. HOSES
10. COTTER PIN 22. LOWERING CONTROL VALVE HOUSING
11. NUT 23. LOWERING CONTROL VALVE
12. LIFT CHAIN

Figure 54. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)

78
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

NOTE: OUTER MAST ASSEMBLY SHOWN.

1. OUTER MAST 14. VELOCITY FUSE
2. STUB SHAFT 15. FITTING
3. LOAD ROLLER 16. WASHER
4. SHIM 17. BRACKET
5. SNAP RING 18. LOCKWASHER
6. BEARING STRIP 19. CAPSCREW
7. O-RING 20. CLAMP
8. CHAIN ANCHOR 21. HOSES
9. PIN 22. LOWERING CONTROL VALVE HOUSING
10. COTTER PIN 23. LOWERING CONTROL VALVE
11. NUT 24. SNAP RING
12. LIFT CHAIN 25. BUSHING
13. MAIN LIFT CYLINDERS

Figure 55. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

79
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 56. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)

80
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 56

NOTE: OUTER MAST ASSEMBLY SHOWN.

1. RIGHT HAND LIFT CYLINDERS 17. SHIM
2. STRAP CLAMP 18. LOAD ROLLER
3. FITTING 19. SNAP RING
4. CLAMP 20. LUBE FITTING
5. HOSE 21. BUSHING
6. CAPSCREW 22. PLUG
7. HOUSING 23. CAP
8. NUT 24. E-RING
9. WASHER 25. O-RING
10. LOWERING CONTROL VALVE 26. BEARING STRIP
11. TUBE 27. MAST SHIM
12. LEFT HAND LIFT CYLINDER 28. CHAIN ANCHOR
13. SPACER 29. SNAP RING
14. HOSE CLAMP 30. COTTER PIN
15. OUTER MAST 31. PIN
16. STUB SHAFT 32. CHAIN

81
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 57. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
H6.0FT, H7.0FT (H135FT, H155FT) (H006)

82
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 57

NOTE: OUTER MAST ASSEMBLY SHOWN.

1. RIGHT HAND LIFT CYLINDER 16. STUB SHAFT
2. STRAP CLAMP 17. SHIM
3. FITTING 18. LOAD ROLLER
4. CLAMP 19. SNAP RING
5. HOSE 20. PIN
6. CAPSCREW 21. CHAIN
7. HOUSING 22. SNAP RING
8. NUT 23. BUSHING
9. WASHER 24. E-RING
10. LOWERING CONTROL VALVE 25. O-RING
11. TUBE 26. BEARING STRIP
12. LEFT HAND LIFT CYLINDER 27. MAST SHIM
13. SPACER 28. CHAIN ANCHOR
14. HOSE CLAMP 29. SNAP RING
15. OUTER MAST 30. COTTER PIN

83
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 58. Free-Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
SS4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

84
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 58

A. INNER MAST B. INTERMEDIATE MAST
1. INTERMEDIATE MAST 16. VELOCITY FUSE
2. INNER MAST 17. WASHER
3. STUB SHAFT 18. CROSSHEAD
4. LOAD ROLLER 19. PIN
5. SHIM 20. CLAMP
6. SNAP RING 21. NUT
7. BEARING STRIP 22. HOSE
8. O-RING 23. CHAIN ANCHOR
9. SPACER 24. COTTER PIN
10. CHAIN SHEAVE 25. LIFT CHAIN
11. BRACKET 26. CHAIN GUARD
12. LOCKWASHER 27. TIE DOWN CLAMP
13. CAPSCREW 28. BALL BEARING
14. HOSE SHEAVE 29. COLLAR
15. FREE-LIFT CYLINDER

85
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 59. Free-Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)

86
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 59

A. INNER MAST B. INTERMEDIATE MAST
1. INTERMEDIATE MAST 15. FREE-LIFT CYLINDER
2. INNER MAST 16. VELOCITY FUSE
3. STUB SHAFT 17. WASHER
4. LOAD ROLLER 18. CROSSHEAD
5. SHIM 19. PIN
6. SNAP RING 20. CLAMP
7. BEARING STRIP 21. NUT
8. O-RING 22. HOSE
9. SPACER 23. CHAIN ANCHOR
10. CHAIN SHEAVE 24. COTTER PIN
11. BRACKET 25. LIFT CHAIN
12. LOCKWASHER 26. CHAIN GUARD
13. CAPSCREW 27. INSERT
14. HOSE SHEAVE 28. SHIM

87
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 60. Free-Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

88
4000 SRM 1250
Legend for Figure 60
A. INNER MAST
1. INNER MAST
2. CHAIN ANCHOR
3. WASHER
4. SPACER
5. CAPSCREW
6. NUT
7. STUB SHAFT
8. LOAD ROLLER
9. SHIM
10. SNAP RING
2. Remove the pins for the lift chains at the chain
anchors on the inner mast. Remove chain sheave
assembly from the free-lift cylinder. Disconnect
and cap all hydraulic lines for the free-lift cylin-
der. Remove capscrews and clamps that hold
free-lift cylinder to the inner mast. Remove
free-lift cylinder. See Figure 58, for lift truck
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
Figure 59, for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), and Fig-
ure 60 for lift truck models, S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006).
3. Disconnect and remove lift chains between the
outer mast and the inner mast. Slide inner mast
from the bottom of the intermediate mast ap-
proximately 30 cm (12 in.). Remove strip bear-
ings. Remove load rollers from the inner and in-
termediate mast. Make a note of the shim ar-
rangement and remove shims. Shim arrange-
ment will be approximately the same during as-
sembly procedures.
4. Slide inner mast halfway out of the top of the
intermediate mast. Connect a lifting device to
the center of inner mast. See Figure 24. Slide
the inner mast out of the intermediate mast.
5. Slide intermediate mast from the outer mast
approximately 30 cm (12 in.) to disengage lift
cylinders from the intermediate mast. Remove
the lift cylinders from the mounts at the bottom
of the outer mast. See Figure 58, for lift truck
Three-Stage Mast With Full Free-Lift Repair
B. INTERMEDIATE MAST
11. FREE LIFT CYLINDER
12. LIFT CHAIN
13. PIN
14. BEARING
15. CHAIN SHEAVE
16. SET SCREW
17. CROSS HEAD
18. GUARD
19. INTERMEDIATE MAST
20. BEARING STRIP
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
Figure 59, for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), and Fig-
ure 60 for lift truck models, S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006).
6. Slide intermediate mast from the bottom of the
outer mast approximately 30 cm (12 in.). Remove
strip bearings and load rollers. Make a note of
the shim arrangement. Shim arrangement will
be approximately the same during assembly pro-
cedures.
7. Slide intermediate mast halfway out of the top of
the outer mast. Connect a lifting device to the
center of the intermediate mast. See Figure 24
Slide intermediate mast out of the outer mast
until stub shafts are in the notches of the outer
mast. Remove intermediate mast from the outer
mast.
8. Using a brass drift, remove tilt rod bushing from
outer mast. Discard tilt rod bushing. See Fig-
ure 61.
9. For lift trucks models S4.0, 5.0, 5.50FT
([S80, 100, 120FT;] S80, 100, 120FTBCS;
S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), and S6.0FT, S7.0FT,
(S135FT,S155FT) (D024). Remove bushings and
plugs from mast mounting hangers. See Fig-
ure 20.
89
Three-Stage Mast With Full Free-Lift Repair
1. TILT ROD BUSHING
Figure 61. Mast Bushing Location
10. For lift trucks models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006). Remove mast mounting snap rings and
bushings from outer mast. See Figure 21.
11. Remove and disassemble chain sheaves and
load rollers as necessary for cleaning and re-
pair. See Figure 58, for lift truck models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), Figure 59,
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), and Figure 60 for lift
truck models, S6.0FT, S7.0FT, (S135FT,S155FT)
(D024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
CLEAN AND INSPECT
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam
90
4000 SRM 1250
and high-pressure water can remove the lu-
brication 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 chains,
chain sheaves, or load rollers. The bearings in
the sheaves and load rollers are sealed and lu-
bricated.
2. Inspect chain anchors and anchor pins for dam-
age. If damaged, replace.
WARNING
Commercial cleaning solvents may be
flammable and toxic and can cause severe skin
irritation. When using commercial cleaning
solvents, always comply with solvent manu-
facturer’s recommended safety precautions.
WARNING
Never replace just the worn section of a chain.
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains.
3. Clean lift chains with solvent. Inspect lift chains
for wear or damage. See Figure 62. A lift chain
becomes longer when it is worn. If a section of
chain is 3% longer than a similar section of new
chain, the chain is worn and must be replaced.
If a chain scale is available, check lift chains as
shown in Figure 62. If a chain scale is not avail-
able 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 62. Replace chain if the length of 20
links of the worn section is more than the maxi-
mum wear limit. Lubricate chains with SAE 30
engine oil. The best procedure is to remove lift
chains from lift truck and soak them in SAE 30
engine oil.
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

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

Pitch
Total Length of Wear Limit
20 Links (Pitch) The Maximum Length of
of New Chain 20 Links

25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 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 62. Lift Chains Check

ASSEMBLE (N005), Figure 56, for lift truck models S6.0FT,

NOTE: Shims for load rollers keep weldments paral-
lel and provide correct clearance. During assembly,
location of the shims will be approximately the same
as they were before disassembly. Check clearance
and adjust shims for wear or changes because of
repairs. Strip bearings are also adjusted by us-
ing shims. See Mast Adjustments procedure in
this section for instructions to make the necessary
adjustments. See Figure 53, for lift truck mod-
els S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
Figure 54, for lift truck models, E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 55,
for lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
S7.0FT, (S135FT,S155FT) (D024), and Figure 57,
for lift truck models, H6.0FT, H7.0FT (H135FT,
H155FT) (H006), and Figure 58, for lift truck mod-
els S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), Figure 59, for lift
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), and Figure 60 for lift truck mod-
els, S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006).
1. Connect a lifting device to the center of the in-
termediate mast (see Figure 24). Put stub shafts
through the notches in the outer mast. Slide in-
termediate mast into the outer mast so that stub

91
Three-Stage Mast With Full Free-Lift Repair
shafts are seen at the top and bottom of the weld-
ments.
2. Install strip bearings, O-rings and shims on the
intermediate mast. Apply grease to bearing sur-
face. See Figure 31.
3. Install load rollers and shims on both weldments.
Check the clearance of the load rollers and strip
bearings as described in Mast Adjustments and
Carriage Adjustments.
4. Install new tilt rod bushing into outer mast. See
Figure 63.
1. TILT ROD BUSHING
Figure 63. Mast Bushing Location
5. For lift trucks models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), and S6.0FT, S7.0FT,
(S135FT,S155FT) (D024). Install bushings and
plugs from mast mounting hangers. See Fig-
ure 20.
NOTE: When installing mast mounting bushings,
ensure bores and snap ring grooves are clean and
free from any obstructions. Be sure to install the
inner snap ring (nearest to truck center) first. Drive
bushings until contact with inner snap ring is made.
Clean bushing material from outer snap ring grooves
and install outer snap ring.
92
4000 SRM 1250
6. For lift trucks models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006). Install mast mounting snap rings and
bushings into outer mast. See Figure 21.
7. Install main lift cylinders. Make sure the spac-
ers, when installed, are in their original positions
at the bottom mounts. Install capscrews, wash-
ers, and brackets at the bottom of each cylinder.
Tighten capscrews to 38 N•m (28 lbf ft). Push
the inner mast to engage the rods of the lift
cylinders. Install washers and snap rings at the
top of the lift cylinders. If removed, install shims
as noted during disassembly. Install cylinder
clamps to the brackets at the top of the outer
mast. Tighten nuts to 18 N•m (159 lbf in).
See Figure 53 for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), Figure 54,
for lift truck models, E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 55, for
lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 56, for lift truck models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024), and Figure 57,
for lift truck models, H6.0FT, H7.0FT (H135FT,
H155FT) (H006).
8. Install hose sheaves on the intermediate mast.
9. Connect lift chains to the chain anchors at the
bottom of the inner mast. Use wire to hold the
other end of the lift chains to the top of the outer
mast.
10. Connect a lifting device to the center of the inner
mast (see Figure 24). Put stub shafts through
the notches in the intermediate mast. Slide inner
mast into the intermediate mast so stub shafts
are seen at the top and bottom of the weldments.
11. Install strip bearings, O-rings and shims on the
outer mast. Apply grease to bearing surface. See
Figure 31.
12. Install load rollers and shims on both weldments.
Check clearance of the load rollers and strip bear-
ings as described in Mast Adjustments and Car-
riage Adjustments.
4000 SRM 1250
13. Connect lift chains to the mounts at the top of the
outer mast.
14. Install chain sheave assembly on the free-lift
cylinder. Install free-lift cylinder on the inner
mast. See Figure 58, for lift truck models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), Figure 59,
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), and Figure 60 for lift
truck models, S6.0FT, S7.0FT, (S135FT,S155FT)
(D024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
15. Connect lift chains to the chain anchors at the
mount on the inner mast. Attach wires between
the ends of the lift chains and the bottom cross-
member to control the lift chains during installa-
tion.
16. Install lowering control valve on the outer mast.
• For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098) tighten
capscrew to 18 N•m (13 lbf ft).
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrew to 38 N•m
(28 lbf ft).
• For lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) tighten capscrew to
33 N•m (24 lbf ft).
17. Connect hydraulic lines and fittings between
the lowering control valve and lift cylinders and
install header hose. See Figure 64, for lift truck
models E3.50-5.50XL, E4.50XLS (E70-120Z,
Three-Stage Mast With Full Free-Lift Repair
E100ZS) (E098), Figure 65, for lift truck models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
Figure 66, for lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), Figure 67, for lift truck mod-
els S6.0FT, S7.0FT, (S135FT,S155FT) (D024),
and Figure 68, for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006).
INSTALL
Install the three-stage mast using the procedures as
described in Two-Stage Mast With Limited Free-Lift
Repair, Install, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
Lift Trucks Models. See Figure 53, for lift truck
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
Figure 54, for lift truck models, E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 55,
for lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 56, for lift truck models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024), and Figure 57,
for lift truck models, H6.0FT, H7.0FT (H135FT,
H155FT) (H006). Also, see arrangement of the
header hoses in Figure 64, for lift truck mod-
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), Figure 65, for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), Figure 66, for lift
truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
Figure 67, for lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024), and Figure 68, for lift
truck models H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
93
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 64. Three-Stage Mast Header Hoses for Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)

94
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 64

1. SNAP RING 9. LOCKWASHER
2. WASHER 10. FITTING
3. SHEAVE 11. HOSE REEL (OPTIONAL)
4. CLAMP 12. PLATE
5. CAPSCREW 13. PIN
6. HYDRAULIC HOSE 14. JUNCTION BOX
7. NUT 15. SPACER
8. BRACKET

95
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 65. Three-Stage Mast Header Hoses for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

96
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 65

1. HYDRAULIC HOSES 9. LOCKWASHER
2. NUT 10. PIN
3. BRACKET 11. FITTING
4. HOSE SHEAVE 12. SPACER
5. WASHER 13. STRAIN RELIEF
6. SNAP RING 14. HOSE REEL (OPTIONAL)
7. CLAMP 15. PLATE
8. CAPSCREW

97
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

1. HYDRAULIC HOSE 7. CLAMP

2. WASHER 8. CAPSCREW
3. NUT 9. BRACKET (RH)
4. BRACKET 10. PIN
5. SHEAVE 11. FITTING
6. SNAP RING 12. BRACKET (LH)

Figure 66. Three-Stage Mast Header Hoses for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

98
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Figure 67. Three-Stage Mast Header Hoses for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT)
(D024)

99
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Legend for Figure 67

1. NUT 10. BRACKET
2. PLATE 11. CAP
3. CAPSCREW 12. BALL VALVE
4. HOSE REEL 13. O-RING
5. FITTINGSNAP RING 14. TUBE
6. CLAMP 15. SHEAVE
7. HYDRAULIC HOSES 16. BUSHING
8. WASHER 17. SNAP RING
9. STRAIN RELIEF 18. SHAFT

Legend for Figure 68

1. TUBE 13. CAP
2. HYDRAULIC HOSE (THREE FUNCTION) 14. WASHER
3. HYDRAULIC HOSE (FOUR FUNCTION) 15. STRAIN RELIEF
4. HOSE CLAMP 16. BRACKET
5. CLAMP 17. HOSE REEL
6. FITTING 18. PLATE
7. CAPSCREW 19. NUT
8. HOSE SHEAVE 20. BRACKET (LH)
9. MOUNTING BRACKET 21. CLAMP (INSULATED)
10. SHAFT 22. BALL VALVE
11. SNAP RING 23. O-RING
12. SHIM

100
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Figure 68. Three-Stage Mast Header Hoses for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006)

101
Three-Stage Mast With Full Free-Lift Repair
HEADER HOSE ALIGNMENT FOR S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) AND E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: This procedure is for the four-function option.
The three-function option is identified with hoses A
and B and fifth function is identified with hose E.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C, D
or E. See Figure 69.
2. Dimensions F, G and H are determined by the
height of the outer mast channel from the ground
and the length of the outer mast channel. See
dimensions Y and Z in Figure 70. To determine
F, G and H for lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) use Table 7. To
determine F, G and H for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005) use Table 8.
To determine F, G and H for lift truck models
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
102
4000 SRM 1250
(E098) use Table 9 for pre-calculated tension
mark locations.
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.
NOTE: These marks will be used to pretension the
header hose during installation.
4. Place a mark on all the hoses at dimensions F
and G (all measurements are made from the
carriage end of the hose [the smaller fitting]).
See Figure 65 and Table 7 for lift trucks models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004).
Table 8 for lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005) and Table 9 for lift truck
models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098).
5. Attach the hoses to the carriage bracket with
clamps. Apply spray lubricant to the surface of
the hose guide that contacts the hoses.
6. Place the hoses over the top of the free-lift chains
and under the hose guides. Attach the hose
guides to the lower crossmember and tighten
the mounting hardware to 33 N•m (24 lbf ft).
Make sure the bracket is between the crossmem-
ber and the hose guide. Put the clamps over
the hoses and attach the clamps to the free-lift
bracket. (DO NOT tighten the hardware.). See
Figure 69.
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Figure 69. Header Hose Alignment for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100, 120FT;] S80,
100, 120FTBCS; S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) (Sheet 1 of 2)

103
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 69. Header Hose Alignment for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100, 120FT;] S80,
100, 120FTBCS; S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) (Sheet 2 of 2)

104
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 69

A. HOSE A (THREE FUNCTION) G. ALIGN TENSION MARK "G" AT THE TOP OF
B. HOSE B (THREE FUNCTION) CLAMP.
C. HOSE C (FOUR FUNCTION) H. ALIGN TENSION MARK "H" AT THE BOTTOM
D. HOSE D (FOUR FUNCTION) OF CLAMP.
E. HOSE E (FIVE FUNCTION) I. TOP VIEW
F. ALIGN TENSION MARK "F" AT THE TOP OF J. MIDDLE VIEW
CLAMP. K. BOTTOM VIEW

105
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE

Figure 70. Header Hose Measurement

106
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

Table 7. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

Tension Marker
Tension Marker from Tension Marker
Channel from Carriage
Carriage End from Carriage End
Lift Height Length End
Dimension "F" Dimension "G"
(Reference) Dimension "H"
(Bottom) (Middle)
(Top)
mm in. mm in. mm in. mm in. mm in.
4087 160.9 2273 89.4 1619 63.7 4062 159.9
2020 79.5
4365 171.9 2418 95.1 1764 69.4 4207 165.6
4665 183.7 2120 83.4 2517 99.0 1814 71.4 4403 173.3
4640 182.7 2476 97.4 1722 67.7 4459 175.5
2220 87.4
4900 192.9 2615 102.9 1861 73.2 4598 181.0
5240 206.3 2673 105.2 1919 75.5 4850 190.9
2420 95.2
5500 216.5 2812 110.7 2058 81.0 4989 196.4
5950 234.3 2620 103.1 3009 118.4 2255 88.7 5380 211.8

Table 8. Standard Mast Height; Header Hose Tension Mark Location For lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

Tension Tension
Tension Marker
Marker from Marker from
Channel Length from Carriage End
Lift Height Carriage End Carriage End
(Reference) Dimension "H"
Dimension "F" Dimension "G"
(Top)
(Bottom) (Middle)
mm in. mm in. mm in. mm in. mm in.
4087 160.9 1619 63.7 2273 89.4 4062 159.9
2020 79.5
4365 171.9 1764 69.4 2418 95.1 4207 165.6
4387 172.7 1669 65.7 1669 65.7 4258 167.6
2120 83.4
4665 183.7 1814 71.4 2517 99.0 4403 173.3
4640 182.7 1722 67.7 1722 67.7 4459 175.5
2220 87.4
4900 192.9 1861 73.2 2615 102.9 4598 181.0
4940 194.5 1821 71.7 1821 71.6 4655 183.2
2320 91.3
5200 204.7 1960 77.1 2714 106.8 4794 188.7
5240 206.3 1919 75.5 1919 75.5 4850 190.9
2420 95.2
5500 216.5 2058 81.0 2812 110.7 4989 196.4
5950 234.3 2620 103.1 2255 88.7 2255 88.7 5380 211.8

107
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Table 9. Standard Mast Height; Header Hose Tension Mark Location For lift truck
models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)

Tension Tension
Tension Marker
Marker from Marker from
Channel Length from Carriage End
Lift Height Carriage End Carriage End
(Reference) Dimension "H"
Dimension "F" Dimension "G"
(Top)
(Bottom) (Middle)
mm in. mm in. mm in. mm in. mm in.
4087 160.9 1525 60.0 2224 87.5 4024 158.4
2020 79.5
4365 171.9 1681 66.1 2380 93.7 4180 164.5
4387 172.7 1624 63.9 2323 91.4 4220 166.1
2120 83.4
4665 183.7 1779 70.0 2478 97.5 4375 172.2
4640 182.7 1728 68.0 2427 95.5 4421 174.0
2220 87.4
4900 192.9 1878 73.9 2577 101.4 4571 179.9
4940 194.5 1827 71.9 2526 99.4 4617 181.7
2320 91.3
5200 204.7 1976 77.7 2675 105.3 4766 187.6
5240 206.3 1925 75.7 2624 103.3 4812 189.4
2420 95.2
5500 216.5 2075 81.6 2774 109.2 4962 195.3
5950 234.3 2272 89.4 2971 116.9 5353 210.7
2620 103.1
5690 224.0 2122 83.5 2821 111.0 5203 204.8

NOTE: To make the alignment of dimension H eas- Tighten the hardware to 8 N•m (71 lbf in). See
ier, use a crane with a capacity of at least 907.2 kg Figure 69, Sheet 2.
(2000 lb) to raise the carriage high enough to attach
a safety chain. See Figure 1. 11. Install the clamps. See Figure 65 and Figure 69.

7. Align the mark for dimension H at the bottom
of the clamp to create the proper hose tension.
Tighten the hardware to 8 N•m (71 lbf in).
8. Position the hoses at the hose sheave. The
hose sheave and stub shaft must be installed on
the hose before they are attached to the mast.
Tighten the hardware to 66 N•m (49 lbf ft).
9. Put the clamps over the hoses and attach the
clamps to the upper brackets. (DO NOT tighten
the hardware.)
NOTE: To make the alignment of dimension F and
G easier, use a crane to raise the inner channel high
enough to install a safety chain.
12. Connect the header hoses to the cowl hoses.
13. Use the rubber clamps and strap clamps to at-
tach the hoses to the main lift cylinders. Make
sure the hoses do not stretch or fold while tilting
the mast fully forward and backward.
14. With no load on the forks, check the header hose
adjustment by operating the mast through the
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 neces-
sary, repeat until hoses are properly adjusted.

10. Align mark F and G on hoses A, B, C and D at

the top edge of clamp to create the proper tension.

108
4000 SRM 1250
HEADER HOSE ALIGNMENT FOR H6.0FT,
H7.0FT (H135FT, H155FT) (H006) AND
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
NOTE: This procedure is for the four-function option.
The three-function option is identified with hoses A
and B and fifth function is identified with hose D.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C, or
D. See Figure 71.
2. Attach hoses A and B to the carriage bracket
with clamps. Apply spray lubricant to the sur-
face of the hose guide that contacts the hoses.
3. Place hoses A and B over the top of the free-
lift chains. Attach the hose guides to the guard
and tighten the mounting hardware to 31 N•m
(23 lbf ft). See Figure 71.
4. Insert spacers into the sheave. See Figure 72
Three-Stage Mast With Full Free-Lift Repair
5. Install guides and snap rings onto the sheave.
6. Position the hoses on the hose sheave. The hose
sheave must be installed on the hose before they
are attached to the mast. Install the sheave as-
sembly into the mast mount.
7. Install the pin into the sheave assembly. Install
the socket head set screw.
8. Put the clamps over the hoses and attach the
clamps to the upper brackets. (DO NOT tighten
the hardware.)
9. Install the clamps. See Figure 71.
10. Connect the header hoses to the cowl hoses.
11. Use the rubber clamps and strap clamps to at-
tach the hoses to the main lift cylinders. Make
sure the hoses do not stretch or fold while tilting
the mast fully forward and backward.
12. With no load on the forks, check the header hose
adjustment by operating the mast through the
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
cross member that is next to a sheave. If neces-
sary, repeat until hoses are properly adjusted.
109
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 71. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006) and S6.0FT, S7.0FT, (S135FT,S155FT) (D024) (Sheet 1 of 2)

110
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair

A. HOSE A (THREE FUNCTION) C. HOSE C (FOUR FUNCTION)

B. HOSE B (THREE FUNCTION) D. HOSE D (FIVE FUNCTION)

Figure 71. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006) and S6.0FT, S7.0FT, (S135FT,S155FT) (D024) (Sheet 2 of 2)

111
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250

Figure 72. Hose Sheave Installation

112
4000 SRM 1250
Legend for Figure 72
1. INTERMEDIATE MAST SECTION
2. PIN
3. SOCKET HEAD SET SCREW
4. SNAP RING
Mast Operation Check
WARNING
Lower the lift mechanism completely. 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.
Before making any repairs, use blocks and
chains on the mast weldments and carriage so
they cannot move. Make sure the moving parts
are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
Tilt Cylinder Adjustment
Check tilt cylinder stroke by slowly tilting mast fully
forward and backward several times. Both tilt cylin-
ders must stop their stroke at the same time. There
must be no twist in the mast weldments. See Fig-
ure 73 and Figure 74.
1. Adjust the tilt cylinders as follows:
a. Tilt mast backward slowly until one rod is
against its stop. On the opposite cylinder,
loosen capscrews on the rod end. Use a
wrench and turn the cylinder rod out until
both rods stop at the same time.
b. Repeat procedure to make sure rods stop at
same time within 1 mm (0.04 in.). Check the
tilt angles are correct as specified on Name-
plate of lift truck.
Tilt Cylinder Adjustment
5. GUIDE
6. SPACER
7. SHEAVE
1. Check for leaks in the hydraulic system. Check
condition of hydraulic hoses and tubes.
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
2. Slowly raise and lower the mast several times
without a load. Mast components must raise and
lower smoothly in correct sequence. Carriage
raises first, then inner mast and intermediate
mast (three-stage masts only).
3. Inner mast and the carriage must lower com-
pletely.
4. Check that controls for the attachment operate
the functions of the attachment. See symbols
by each of the controls. Make sure all hydraulic
lines are connected correctly and do not leak.
c. For lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), E3.50-
5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), S6.0FT, S7.0FT, (S135FT,S155FT)
(D024) and H6.0FT, H7.0FT (H135FT,
H155FT) (H006) tighten capscrews on rod
end to 90 N•m (66 lbf ft) and tighten the
anchor locking bolt to 68 N•m (50 lbf ft). For
lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrews on rod end
to 66 to 73 N•m (49 to 54 lbf ft) and tighten
the anchor locking bolt to 68 N•m (50 lbf ft).
113
Tilt Cylinder Adjustment 4000 SRM 1250

1. MAST HANGER BUSHING 8. NUT

2. LUBE FITTINGS 9. WASHER
3. MAST BUSHING PLUGS 10. ROD END BUSHING
4. TILT PIN 11. TILT CYLINDER ASSEMBLY
5. ROD END 12. MAST MOUNTING CAP
6. ANCHOR PIN 13. LUBE FITTINGS*
7. CAPSCREW

* LUBE FITTINGS USED ONLY ON LIFT TRUCK MODELS S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004)

Figure 73. Tilt Cylinder Arrangement for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) Shown

114
4000 SRM 1250 Lift Chains Adjustment

Legend for Figure 74

1. TILT CYLINDER 7. CAPSCREW
2. MAST 8. LOCKWASHER
3. ROD END 9. NUT
4. BUSHING 10. PIVOT PIN
5. PIN 11. SNAP RING
6. RETAINER PIN 12. BUSHING

Figure 74. Tilt Cylinder Arrangement for

Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006)

Lift Chains Adjustment

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
During test procedures for the hydraulic sys-
tem, fasten the load to the carriage with chains
to prevent 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
hydraulic lines or components under pressure.
Hydraulic 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.
• The chain length will be correct.
• The chains must travel freely through the complete
cycle.
NOTE: When the chain adjustments are complete,
make sure the threads on the nuts of the chain an-
chors are completely engaged. Make sure the chain
anchors are not adjusted too tight. The chain anchors
must be able to move on their mounting.
1. When adjusting the lift chains on forklift trucks
equipped with either pin or hook-type forks in-
stalled, go to Step 3. If the forklift truck is nor-
mally equipped with a hook-type carriage and
has an attachment without forks, go to Step 4.

115
Lift Chains Adjustment 4000 SRM 1250

NOTE: Install new cotter pins and chain anchor pins.

Both legs of cotter pin must be bent against chain
anchor pin.

2. Tighten chain anchor nuts to:

• For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004),
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
tighten to 210 N•m (155 lbf ft).
• For lift truck models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006), tighten to 370 N•m
(273 lbf ft).

NOTE: Prior to performing adjustment procedures, 1. MAST

make sure the forklift truck is parked on a level sur- 2. CARRIAGE
face and the mast is in the vertical position. 3. FORK
4. HEEL OF FORK IS 6.0 ±3.0 mm (0.24 ±0.12 in.)
3. Adjust the chain anchors that support the car- ABOVE FLOOR LEVEL
riage, until the bottom of the fork heel is 6.0
Figure 75. Lift Chain Adjustment, Forks
±3.0 mm (0.24 ±0.12 in.) above the floor level.
See Figure 75.

4. Adjust the chain anchors that support the car-

riage, until the bottom of the lower carriage bar
is 82.5 ±3.0 mm (3.25 ±0.12 in.) above the floor
level. See Figure 76.

Table 10. Hook-Type Carriage Chain

Adjustment

Class II and III 82.5 ±3.0 mm (3.25 ±0.12 in.)

Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR

Figure 76. Lift Chain Adjustment, Hook-Type

Carriage

116
4000 SRM 1250 Mast Adjustments

Mast Adjustments
NOTE: Shims are installed on both sides of the load the clearance and adjust shims after repairs have
rollers. Do not add or remove shims from the stub been completed.
shafts. To change the position of the roller on the
stub shaft, move the shims from one side of the load 1. The load rollers control the alignment of the mast
roller to the other. uprights. See Figure 77. The alignment condi-
tions are given on a list below with the most im-
During assembly, the shim arrangement will be ap- portant condition first.
proximately the same as before disassembly. Check

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 B. MAST FRONT VIEW C. CARRIAGE FRONT VIEW
1. CHANNEL 7. ZERO CLEARANCE AT POINT 10. PUT SPACER ON OUTSIDE OF
2. LOAD ROLLER OF TIGHTEST FIT TOP LOAD ROLLER, UNDER
3. STUB SHAFT 8. EQUAL SPACE ±1.5 mm SNAP RING
4. SNAP RING (0.060 in.) 11. SHIM FOR ZERO CLEARANCE
5. SHIMS 9. PARALLEL TO CHANNEL AT POINT OF TIGHTEST FIT
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
±1.5 mm (0.060 in.)

Figure 77. Mast Adjustments

117
Mast Adjustments
a. The 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 the uprights will be approximately
in the center.
2. Perform the following steps to adjust the 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.
1. STRIP BEARING
2. LOAD ROLLER
3. MAST UPRIGHT
Figure 78. Strip Bearings Arrangement
118
4000 SRM 1250
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 the point of the tightest fit.
d. Measure distance between channels of mast
uprights on top and bottom. Change shims
to keep distance equal between top and bot-
tom so mast uprights are parallel. Also make
sure the mast uprights are parallel within
1.5 mm (0.060 in.).
3. Adjust strip bearings. See Figure 78. Insert
shims under strip bearing. Adjust clearance un-
til there is less than 0.8 mm (0.030 in.) at the
tightest fit. See Figure 77.
4. SHIMS
5. O-RING
4000 SRM 1250
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. On
carriages equipped with six load rollers, there
are no shims under the top load rollers.
2. Use a lifting device to raise carriage. Find the
point of tightest fit between the carriage load
rollers and inner mast channels.
3. Remove carriage from mast. Adjust shim ar-
rangement for each roller for clearance between
roller and inner channel. Repeat Step 1 and
Step 2 until there is zero clearance at the point
of tightest fit.
Carriage Adjustments
4. Keep shim arrangement on each side of carriage
approximately equal. The carriage must be cen-
tered within the inner mast within +1.50 mm
(0.06 in.).
CAUTION
Too much grease will cause the rollers to slide
and wear flat areas on the rollers and intro-
duce contamination into and on mast channels.
5. After adjustment, lubricate channels with a thin
layer of grease. Adjust hydraulic hoses and make
sure connections are correct, if the carriage is
equipped with hydraulic attachments.
119
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

120
 TECHNICAL PUBLICATIONS

4000 SRM 1250 7/07 (3/07)(11/06)(6/06)(3/06) Printed in U.S.A.