Mast Repairs: 2, 3, and 4-Stage Masts

MAST REPAIRS
2, 3, AND 4-STAGE MASTS

S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z,
E40ZS) [E114/F114]; J1.60-2.00XMT (J30-
40ZT) [J160]; J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
PART NO. 1580524 4000 SRM 1148

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mast Repairs Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Fork Repair ........................................................................................................................................................ 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 3
Checks ............................................................................................................................................................ 4
Carriages Repair ................................................................................................................................................ 5
Standard Carriage ......................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Repair......................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Integral Sideshift Carriage ........................................................................................................................... 6
Remove....................................................................................................................................................... 6
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Mast Repair........................................................................................................................................................ 11
Mast, Remove................................................................................................................................................. 11
Two-Stage LFL and Two-Stage FFL Masts, Disassemble ........................................................................... 15
Clean and Inspect .......................................................................................................................................... 21
Three-Stage FFL Mast .................................................................................................................................. 22
Disassemble ............................................................................................................................................... 22
Clean and Inspect...................................................................................................................................... 26
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 27
Three-Stage FFL Mast, Assemble ................................................................................................................ 28
Four-Stage FFL, Disassemble....................................................................................................................... 30
Clean and Inspect .......................................................................................................................................... 34
Four-Stage FFL, Assemble............................................................................................................................ 36
Mast, Install................................................................................................................................................... 38
Header Hose Arrangement................................................................................................................................ 41
Two-Stage LFL............................................................................................................................................... 41
Two-Stage FFL............................................................................................................................................... 48
Three-Stage FFL............................................................................................................................................ 60
Four-Stage FFL ............................................................................................................................................. 75
Adjustment..................................................................................................................................................... 83
Lift Chains Adjustment ..................................................................................................................................... 84
Carriage Adjustments........................................................................................................................................ 86
Tilt Cylinders Adjustment................................................................................................................................. 86
Mast Adjustments.............................................................................................................................................. 90
Load Roller Adjustment ............................................................................................................................ 90
Mast Side Kicking Adjustment................................................................................................................. 92
©2008 HYSTER COMPANY i

Table of Contents Mast Repairs
TABLE OF CONTENTS (Continued)

This section is for the following models:
S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
ii
4000 SRM 1148 Safety Procedures When Working Near Mast
General
NOTE: For models J1.60-2.00XMT (J30-40ZT)
WARNING [J160], this section applies to only to Four-Stage
Before working on or near the mast, see Safety masts. Refer to Mast Repairs, 2 and 3-Stage
Procedures When Working Near Mast in this Masts 4000 SRM 522 for Two-Stage and Three-Stage
section. masts for these particular models.
This section has the repair procedures for the NOTE: Hoses have a service life that is determined
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full by application and time. Install a new hose if the
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL); hose is worn, damaged, soft or hard, and no longer
and Four-Stage, Full Free-Lift (FFL) masts and flexible. If necessary, make a comparison to a new
carriages. Procedures for Carriage Adjustments are hose that is the correct replacement for the hose you
located at the end of this section. are inspecting.
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- push the lift/lower control lever forward un-
specting or working near the mast. Additional pre- til there is no movement in the mast. Make
cautions and procedures can be required when re- sure that all parts of the mast that move are
pairing or removing the mast. fully lowered.
OR
WARNING
Mast parts are heavy and can shift. Distances • If parts of the mast must be in a raised po-
between parts are small. Serious injury or sition, install a safety chain to restrain the
death can result if part of the body is hit by moving parts of the mast. Connect moving
parts of the mast or the carriage. parts to a part that does not move. Follow
• Never put any part of the body into or under these procedures:
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. 1. Put mast in vertical position.
Also make sure that the power is OFF and the 2. Raise mast to align bottom crossmember of mast
key is removed. Put a DO NOT OPERATE tag upright that moves in outer mast with crossmem-
in the operator’s compartment. Disconnect ber on outer mast. On the two-stage mast, the
the battery and put a tag or lock on the bat- moving part is the inner mast. On the three-
tery connector. stage mast, it is the intermediate mast. On the
• Be careful of the forks. When the mast is four-stage mast, it is the first intermediate mast.
raised, the forks can be at a height to cause See Figure 1.
an injury.
• DO NOT climb on the mast or lift truck at any 3. Use a 3/8-inch minimum safety chain with a hook
time. Use a ladder or personnel lift to work to fasten the crossmembers together so the mov-
on the mast. able member cannot lower. Put hook on back side
• Mast repairs require disassembly and re- of mast. Make sure hook is completely engaged
moval of parts and can require removal of with a link in the chain. Make sure safety chain
the mast or carriage. Follow the repair pro- does not touch lift chains or chain sheaves, tubes,
cedures in this section. hoses, fittings, or other parts on the mast.
WHEN WORKING NEAR THE MAST ALWAYS: 4. Lower mast until there is tension in safety chain
• Lower the mast and carriage completely: and free-lift cylinder (full free-lift models) is com-
Turn the key switch to the ON position and pletely retracted.
1
Safety Procedures When Working Near Mast 4000 SRM 1148
Figure 1. Safety Chaining the Mast
2
4000 SRM 1148 Fork Repair
Legend for Figure 1

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
NOTE: Apply the parking brake. After lowering or 5. Install another safety chain (9.5 mm (3/8 in.)
restraining the mast, shut off the power, and remove minimum) between the top or bottom bar of the
key. Put a DO NOT OPERATE tag in the operator’s carriage (6) and a crossmember on the outer
compartment. Disconnect battery and put a tag or mast as a secondary safety device. Install a DO
lock on battery connector. NOT REMOVE tag on the safety chain(s).
Fork Repair
The forks are held on the carriage by hooks. The INSTALL
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage. Move the fork and carriage so the top hook on the
If pin does not remain engaged in carriage slot, re- fork can engage the upper carriage bar. Raise the
place with new pin. Always check that the pins for carriage to move the lower hook through the fork re-
the forks keep the forks in position on the carriage. moval notch. Slide the fork on the carriage so both
Replace damaged fork pin parts. The forks can be upper and lower hooks engage the carriage bars. En-
removed from the carriage by aligning the forks with gage the latch pin with a notch in the upper carriage
the fork removal notch. The fork removal notch is in bar.
the bottom bar of the carriage.
REMOVE
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car- 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
riage further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away Figure 2. Hook Fork Removal
from the fork or use a lifting device to move the fork
away from the carriage.
3
Fork Repair 4000 SRM 1148
1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. PIN
5. KNOB 10. FORK REMOVAL NOTCH
Figure 3. Carriage and Forks
CHECKS Table 1. Fork Tip Alignment
WARNING Fork Tip Alignment Specifications

Never repair damaged forks by heating or Standard Fork Maximum Fork Tip
welding. Forks are made of tempered steel Lengths Difference 1
using special procedures. Always replace dam-
mm (in.) mm (in.)
aged forks as a pair.
914 (36) 27 (1.08)
Inspect the forks for cracks and wear. Check the
alignment of the fork tips. The difference in height 1067 (42) 32 (1.26)
of the fork tips must be less than three percent of the 1219 (48) 37 (1.44)
length of the forks. See Table 1 and Figure 4.
1372 (54) 41 (1.62)
Some applications may require closer alignment. If
1524 (60) 46 (1.80)
the forks do not meet specification, they both must
be replaced. Check that the bottom of each fork is 1829 (72) 55 (2.16)
not excessively worn. Check for smooth and proper
operation of the fork lock pins. Repair or replace any 1Difference of alignment between fork tips must
be no more than 3% of the total fork length.
damaged or broken fork lock pins or components and
lubricate, as necessary. See Figure 3.
4
4000 SRM 1148 Carriages Repair
Legend for Figure 4

A. HEEL OF FORK (MUST BE 90% OF
DIMENSION B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3%
OF FORK LENGTH)
2. CRACKS
3. MAXIMUM ANGLE 93
4. FORK REMOVAL NOTCH
5. CARRIAGE
Figure 4. Fork Check
Carriages Repair
STANDARD CARRIAGE
Remove
1. Remove the forks. See Fork Repair.
2. Remove the four capscrews securing the load

backrest to the carriage. Remove the load back-
rest.
3. Connect a lifting device to the carriage. Lift the

carriage so that the lift chains become loose.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pin from each chain anchor at the

carriage. See Figure 5. Disconnect the lift chains NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
from the carriage. Use wire to connect the ends
of the lift chains to a part of the mast. Make sure 1. CARRIAGE 6. CHAIN PIN
the chains can move freely when the inner mast 2. SNAP RING 7. COTTER PIN
is raised. 3. SHIM 8. ANCHOR PIN
4. LOAD ROLLER 9. SPACER
5. CHAIN ANCHOR
Figure 5. Standard Carriage
5
Carriages Repair 4000 SRM 1148
Install
WARNING
To help prevent possible injury, make sure the 1. Use the hydraulic system of the lift truck or a
carriage is stable when the inner mast is above crane to raise the inner mast. If the hydraulic
the load rollers of the carriage. system cannot be used, disconnect the lift cylin-
ders from the inner or intermediate mast. See
5. Use the lift cylinders to raise the inner or inter- the section Cylinder Repair 2100 SRM 1139.
mediate mast. If the hydraulic system cannot be Connect a crane [the capacity of the crane must
used, disconnect the lift cylinders from the in- be at least 681 kg (1501 lb)] to the top of the in-
ner or intermediate mast. See the section Cylin- ner mast. Carefully raise the inner mast until
der Repair 2100 SRM 1139. Connect a crane it is above the load rollers of the carriage. In-
[the capacity of the crane must be at least 681 kg stall safety chains to secure the mast in its ex-
(1501 lb)] to the top of the inner mast. Carefully tended position and disconnect the crane. See
raise the inner mast until it is above the load Safety Procedures When Working Near Mast.
rollers of the carriage. Install safety chains to
secure the mast in its extended position and dis- 2. Move the lift truck toward the carriage until the
connect the crane. See Safety Procedures When inner mast is aligned with the carriage rollers.
Working Near Mast. If the inner mast has been raised and secured
using a crane and safety chains, connect the
6. Move the lift truck away from the carriage. Com- crane, raise the inner mast, and remove the
pletely lower the inner mast so it cannot move. safety chains. Carefully lower the inner mast
until it engages all of the load rollers. Discon-
Repair nect the crane, if attached, and reconnect the
lift cylinders. See the section Cylinder Repair
NOTE: The carriage can have four or six load rollers.
2100 SRM 1139.
When the carriage has four load rollers, shims are
used behind all of the load rollers. When the carriage 3. Check the clearance of the load rollers. See Car-
has six load rollers, shims are installed on the bottom riage Adjustments in this section.
and middle rollers only.
NOTE: Use new cotter pins each time the anchor pins
1. If any of the load rollers must be replaced, make are removed.
a note of the location and number of the shims.
Install the shims, load rollers, and snap rings. 4. Connect the lift chains to the chain anchors at
See Carriage Adjustments for correct adjustment the carriage. Install the cotter pins in the an-
of the load rollers. chor pins. Adjust the lift chains as described in
Carriage Adjustments in this section.
WARNING 5. Install the backrest on the carriage. Tighten the
Improper welding procedures can damage capscrews to 195 N•m (144 lbf ft).
the structure of the mast or cause incorrect
function of the mast. Consult your Hyster® 6. Install the forks. See Fork Repair.
lift truck dealer for more information before
welding on the mast. INTEGRAL SIDESHIFT CARRIAGE
2. If the carriage bars have any protruding welds Remove
or damaged notches, repair by grinding, filing,
or welding. 1. Lower the carriage completely. Remove the forks
and the load backrest extension. See Fork Repair
and Figure 6 or Figure 7.
6
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 13. PIN
2. OUTER FRAME 14. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 15. SNAP RING
4. UPPER BEARING 16. PIN
5. LOWER BEARING 17. COTTER PIN
6. LOWER HOOK 18. LOAD ROLLER
7. CAPSCREW 19. SHIMS
8. WASHER 20. SPACER
9. CLEVIS PIN 21. SNAP RING
10. HAIRPIN 22. SPACER
11. PIN 23. FORK REMOVAL NOTCH
12. LUBE FITTING
Figure 6. Integral Sideshift Carriage for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)
7
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 13. PIN
2. OUTER FRAME 14. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 15. SNAP RING
4. UPPER BEARING 16. PIN
5. LOWER BEARING 17. COTTER PIN
6. LOWER HOOK 18. LOAD ROLLER
7. CAPSCREW 19. SHIMS
9. CLEVIS PIN 21. SNAP RING
10. HAIRPIN 22. SPACER
11. PIN 23. FORK REMOVAL NOTCH
12. LUBE FITTING
Figure 7. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001)
8
3. Clean the bearing areas. Inspect the sideshift

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

insure correct connection during installation.
2. Disconnect the hydraulic lines at the sideshift

cylinder. Put caps on the open hydraulic lines.
3. Remove the lower mounting hooks by removing

the four capscrews securing the hooks.
4. Remove two hairpins, two pins, and sideshift

cylinder from the carriage. See Figure 6 or Fig-
ure 7.
5. Use a crane with a capacity of at least 450 kg

(992 lb) to lift the outer frame away from the in-
ner frame. Lay the outer frame flat on a pallet or
workbench.
Clean and Inspect A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
1.52 mm (0.06 in.) MAXIMUM.
1. Inspect the lower mounting hooks for wear. Re- B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
place the hooks if they are worn beyond the wear MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
limit. The wear limit clearance range is 0.76 mm
(0.03 in.) minimum and 1.52 mm (0.06 in.) max- Figure 8. Lower Mounting Hooks Wear Limit
imum. See A in Figure 8. and Clearance Adjustment
2. Clean and inspect the carriage bars for damage

and smoothness. Ensure the bars are parallel
and the ends are flush.
9
b. Unscrew the retainer from the cylinder.

Slide the retainer off the cylinder rod.
c. Clamp the other end of the cylinder in a

vise between the hydraulic fitting and the
retainer on the same end.
d. Unscrew the retainer from the cylinder.
NOTE: If new retainers that are already assembled

with seals are being installed, proceed to Step h.
e. Remove and discard the seals and O-ring

from each retainer with a brass O-ring tool.
DO NOT scratch the grooves.
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
1. CYLINDER SHELL 3. O-RING solvent manufacturer’s recommended safety
AND ROD 4. RETAINER precautions.
2. SEAL 5. WIPER
f. Clean the retainers and the cylinder rod with
Figure 9. Integral Sideshift Cylinder
cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
Repair
g. Install the seals into the retainer grooves.
NOTE: Drain the oil from the cylinder before under-
Form the seals into a "kidney" shape to ease
taking any repairs.
placement into the groove. Note the direc-
1. If any of the load rollers must be replaced, make a tion of the rod seals. Pressure seals are in-
note of the location and number of the shims. In- stalled with the lip toward the pressure
stall the shims, load rollers, and snap rings. See side of the cylinder.
Carriage Adjustments for correct adjustment.
h. Apply a film of hydraulic oil to the inside of
the retainers.
WARNING
Improper welding procedures can damage the i. Clamp one end of the cylinder in a vise be-
structure of the mast or cause incorrect func- tween the hydraulic fitting and the end.
tion of the mast. Consult your Hyster lift truck
j. Screw the retainer into the cylinder. Tighten
dealer for more information before welding on
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
the mast.
k. Clamp the other end of the cylinder in a vise
2. If the carriage bars have any protruding welds
between the hydraulic fitting and the end.
or damaged notches, repair by grinding, filing,
or welding. l. Slide the retainer onto the cylinder rod.
Screw the retainer into the cylinder. Tighten
3. Replace the cylinder rod seals as follows:
the retainer to 325 ±30 N•m (240 ±25 lbf ft).
a. Clamp one end of the cylinder in a vise be-
tween the hydraulic fitting and the retainer
on the same end.
10
4000 SRM 1148 Mast Repair
Install 3. Use a crane with a capacity of at least 450 kg

(992 lb) to install the outer frame on the inner
NOTE: Use a wood block or a plastic hammer to fully frame.
seat the upper bearings onto the upper carriage bar.
Proper lower hook clearance requires the upper bear- 4. Install the lower mounting hooks using four cap-
ings be fully seated. screws. Tighten to 165 ±15 N•m (120 ±12 lbf ft).
For proper sideshift operation, make sure there
1. If necessary, install the lower sideshift bearings. is 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
Then install the upper sideshift bearings. Lubri- between the bottom of the hooks and the outer
cate the upper and lower sideshift bearings with frame. See B in Figure 8.
chassis grease. See Figure 6.
5. Connect the hydraulic lines, as noted during re-
NOTE: The pin, located on the left top of the cylinder moval, to the sideshift cylinder.
looking from the front of the carriage, is for align-
ment purposes and to prevent the cylinder from 6. Install the backrest on the sideshift carriage.
rolling to the front or to the back. Tighten the capscrews to 195 N•m (144 lbf ft).
2. Install sideshift cylinder onto the carriage with 7. Install the forks.
the pin in the up position. Install two pins and
two hairpins. See Figure 6 or Figure 7.
Mast Repair
MAST, REMOVE the mast using chains to support the mast in an
upright position when the tilt cylinders are dis-
connected.
WARNING
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift- WARNING
ing devices (hoists, cables, chains, slings, etc.) Always wear the proper protective equipment
are suitable and of adequate capacity to lift the including eye protection and petroleum-resis-
mast. tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
CAUTION
Make sure all the mast weldments are fastened Completely lower forks to relieve hydraulic
together. Make sure the safety chains will not pressure before disassembling any part of the
damage the sheaves, tubing, or other parts of lift pump or disconnecting any hoses.
the mast.
NOTE: If the mast needs to be disassembled, remove temperatures. Be careful when draining the
the forks and carriage. If only the lift cylinders need oil.
to be removed for repair, the mast does not need to be
removed from the lift truck. See the section Cylin-
CAUTION
der Repair 2100 SRM 1139.
Protect the hydraulic system from dirt and
NOTE: The length of the lift chains must be checked contaminants when servicing the hydraulic
before the mast is removed. See Lift Chains Adjust- system.
ment.
2. Position a drip pan with a capacity of 19 liter
1. Fully lower all of the mast weldments. Tilt the (5 gal) under the area of the hydraulic fittings.
mast fully forward. Connect a crane with a ca- Disconnect the hydraulic line at the external low-
pacity of at least 907 kg (2000 lb) to the top of ering control valve on the outer mast.
11
Mast Repair 4000 SRM 1148
WARNING
Use a driver, NOT your fingers, to push the an-
chor pins from the clevises on the tilt cylinders.
The cylinder or mast can move and cause seri-
ous injury.
3. Remove the capscrews, washers, and anchor pins

at the tilt cylinder mounts on the outer mast. See
Figure 10, Figure 11, and Figure 12.
1. WASHER 6. CAPSCREW
2. NUT 7. RETAINER PIN
3. ROD END 8. CAPSCREW
4. PIVOT PIN 9. TILT CYLINDER
5. GREASE FITTING
Figure 11. Mast Mounting for Lift Truck Models

S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001)
1. O-RING 7. PIVOT PIN

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

Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z)
(G108)
12
NOTE: Allow the mast to tilt forward enough to gain

access to the mast mount capscrews.
4. Disconnect the lower mast mounts from the lift

truck:
a. Pivot Pin Connections - Remove the cap-

screws that hold the mast pivot pins to the
mounts on the drive axle. See Figure 13 and
Figure 14.
b. Stub Shaft Connections - Remove the four

capscrews securing the retainer cap over the
stub shafts on each side of the mast. See
Figure 12.
WARNING
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.
5. Use the crane to lift the mast assembly from

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

ing from the stub shaft. Check that the bush-
ing fits snug over the stub shaft. Place the
bushing into the drive unit mounts and place
the retainer cap into position. Check that the
bushing is snug under the retainer cap. If
pins can be moved up and down a minimum
of 4.0 mm (0.2 in.), replace bushings as re-
quired.
13
1. OUTER MAST 2. BUSHING 3. GREASE FITTING
Figure 13. Mast Mounts, Outer Mast
1. HANGER MOUNTS
1. DRIVE AXLE 2. TRACTION MOTOR
2. HANGER MOUNTS
Figure 15. Mast Mounting For Lift Truck Model
Figure 14. Mast Mounts, Drive Axle J2.00-3.20XM (J40-65Z) (B416)
14
lift cylinders and put caps on the open lines. See

Figure 17 and Figure 18.
2. Remove the chains and header hoses. On the

two-stage FFL mast, remove the brackets and
disconnect the hydraulic line for the free-lift
cylinder. Remove the free-lift cylinder. Discon-
nect the free-lift chains at the crossmember. See
Figure 19 and Figure 20.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
Figure 16. Mast Pivot Pin ring pliers, and wear eye and face protection
during removal or installation.
TWO-STAGE LFL AND TWO-STAGE FFL 3. Remove the nut, bolt, and spacer at the mount
MASTS, DISASSEMBLE near the top of each main lift cylinder. Remove
the snap rings and washers from the top of
WARNING each main lift cylinder. Disconnect the main lift
Always wear the proper protective equipment chains at the mounts. See Figure 17, Figure 18,
including eye protection and petroleum-resis- Figure 19, and Figure 20.
tant gloves when handling hydraulic oil. Thor-
4. On the two-stage FFL mast, disconnect the FFL
oughly wash oil from exposed areas of skin as
supply tube and remove the hydraulic fitting
soon as possible.
from the top of the left- or right-hand main lift
Completely lower forks to relieve hydraulic cylinder.
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic WARNING
hoses. The mast weldments can slide when the mast
is moved. A weldment that slides can cause in-
jury.
temperatures. Be careful when draining the
oil. 5. Slide the inner mast from the outer mast approx-
imately 30 cm (12 in.) to disengage the main lift
CAUTION cylinders from the inner mast. Remove the main
Protect the hydraulic system from dirt and lift cylinders from the outer mast. See Figure 17,
contaminants when servicing the hydraulic Figure 18, Figure 19, and Figure 20.
system.
6. Slide the inner mast from the bottom of the outer
NOTE: If the lift cylinders alone need to be removed mast approximately 30 cm (12 in.). Remove the
and repaired, see the section Cylinder Repair 2100 strip bearings and load rollers from the top of the
SRM 1139. When the mast has header hoses, see outer mast. Remove the load rollers from the bot-
Header Hose Arrangement. tom of the inner mast. Make a note of each shim
arrangement and load roller location. The shim
1. Clean the area around the hydraulic fittings for arrangements will be approximately the same
the lift cylinders. Disconnect the fittings at the during assembly.
15
1. OUTER MAST 8. WASHER 15. HOUSING

2. LOAD ROLLER 9. MAIN LIFT CYLINDER 16. LOWERING CONTROL VALVE
3. SHIM 10. MAIN LIFT CHAIN 17. INNER MAST
4. SNAP RING 11. CHAIN ANCHOR 18. PIN (2)
5. O-RING 12. VELOCITY FUSE 19. SPACER
6. SHIM(S) 13. NUT 20. CHAIN SHEAVE
7. STRIP BEARING 14. CAPSCREW 21. PIN
Figure 17. Two-Stage, Limited Free-Lift (LFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z (B416); and E2.00-3.20XM
(E45-65Z) (G108)
16
Figure 18. Two-Stage, Limited Free-Lift (LFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
(E010); E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
17
Legend for Figure 18

1. OUTER MAST 16. FITTING
2. STUBSHAFT 17. CAPSCREW
3. BEARING STRIP 18. HOUSING
4. SHIM(S) 19. HOSE
5. O-RING 20. NUT
6. LOAD ROLLER 21. LOWERING CONTROL VALVE
7. SHIM 22. LOCK NUT
8. CHAIN 23. SPACER
9. COTTER PIN 24. SNAP RING
10. PIN 25. INNER MAST
11. CHAIN ANCHOR 26. CHAIN SHEAVE ASSEMBLY
12. WASHER 27. CHAIN SHEAVE
13. NUT 28. BEARING
14. MAIN CYLINDERS 29. LOWER MAST MOUNT (J1.60-2.00XMT
15. SPRING (J30-40ZT) (J160) ONLY)
7. Slide the inner mast halfway out of the top of the
WARNING outer mast. Connect a crane [the capacity of the
The mast is heavy. The mast can weigh ap- crane must be at least 907 kg (2000 lb)] to the
proximately 907 kg (2000 lb). Make sure all lift- center of the inner mast. See Figure 21. Slide the
ing devices (hoists, cables, chains, slings, etc.) inner mast out of the outer mast until the mast
are suitable and of adequate capacity to lift the stub shafts of the inner mast are in the notches of
mast. the outer channels. Remove the inner mast from
the outer mast.
NOTE: When replacing the outer mast, copy the part
number and date code information from the old chan- 8. Remove the chain sheaves and disassemble them
nel and stamp that information on the new channel as necessary for repair and cleaning.
with a letter R at the end to indicate that it has been
replaced.

1. OUTER MAST 13. VELOCITY FUSE
2. LOAD ROLLER 14. HOUSING
3. SHIM 15. LOWERING CONTROL VALVE
4. SNAP RING 16. INNER MAST
5. O-RING 17. FREE-LIFT CHAIN
6. SHIM(S) 18. CHAIN ANCHOR
7. STRIP BEARING 19. FREE-LIFT CYLINDER
8. WASHER 20. CYLINDER BRACKET
9. MAIN LIFT CYLINDER (L) 21. CAPSCREW
10. MAIN LIFT CYLINDER (R) 22. CROSSHEAD
11. NUT 23. CHAIN GUARD
12. TUBE 24. SPACER
18
Figure 19. Two-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM
(E45-65Z) (G108)
19
Figure 20. Two-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
(E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT,
20

1. OUTER MAST 17. NUT
2. LOAD ROLLER 18. HOUSING
3. SHIM 19. SPRING
4. SNAP RING 20. INNER MAST
5. STUBSHAFT 21. CHAIN SHEAVE ASSEMBLY
6. O-RING 22. CHAIN SHEAVE
7. SHIM 23. BEARING
8. STRIP BEARING 24. CHAIN GUARD
9. WASHER 25. CROSSHEAD
10. CAPSCREW 26. CHAIN
11. SPACER 27. BRACKET
12. LOCK NUT 28. LOCK NUT
13. LIFT CYLINDER 29. BRACKET
14. FITTING 30. VALVE ASSEMBLY (FLOW LIMITING)
15. HOSE 31. FREE-LIFT CYLINDER
16. LOWERING CONTROL VALVE 32. LOWER MAST MOUNT (J1.60-2.00XMT
(J30-40ZT) (J160) ONLY)
2. Inspect the lift chains for wear or damage. A lift
chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain
must be replaced. If a chain scale is available,
check the lift chain as shown in Figure 22. If a
chain scale is not available, measure 20 links of
the lift chain. Compare the measurement with
the lengths given in Figure 22.
WARNING
solvent manufacturer’s recommended safety
precautions.
Figure 21. Inner Mast
Compressed air can move particles so that they
CLEAN AND INSPECT cause injury to the user or to other personnel.
Make sure that the path of the compressed air
CAUTION is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
DO NOT use steam to clean lift chains, sheaves,
eyes.
or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated. 3. Clean the lift chains by soaking in solvent for 30
minutes and remove all dirt and grease. Hang
1. Inspect the chain sheaves and load rollers for
lift chains up and remove solvent using com-
wear or damage.
pressed air. The lift chains must be installed in
the mast and the mast must be installed on the
WARNING lift truck before they can be checked for correct
Never replace only the worn section of a chain. length. Lubricate the chains by soaking them in
Replace the complete chain. Never replace SAE 30 engine oil for 30 minutes. Hang chains
only one chain of a chain pair. Replace both over a drip pan for one hour to remove excess oil.
chains.
4. Inspect the chain anchors and pins. Replace any
NOTE: The chains must be inspected in the area of parts that are worn or damaged.
chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum
wear.
21
5. Clean the mast weldments with steam or solvent.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect func-
the mast.
6. Inspect sliding surfaces for wear or damage. In-

spect load roller contact surfaces for wear or dam-
age. Inspect all welds for cracks.
THREE-STAGE FFL MAST

Disassemble
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
NOTE: THE INSTRUCTIONS FOR MEASURING tant gloves when handling hydraulic oil. Thor-
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR oughly wash oil from exposed areas of skin as
SCALE (HYSTER PART NO. 599737). soon as possible.
1. CHAIN WEAR SCALE
Completely lower forks to relieve hydraulic
Pitch Wear Limit pressure before disassembling any part of
Total length the lift pump or disconnecting any hydraulic
The
of 20 links hoses.
maximum
(pitch) of new
length of 20
chain The hydraulic oil is hot at normal operating
links
temperatures. Be careful when draining the
12.7 mm 254.0 mm 261.6 mm oil.
(0.5 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
CAUTION
(0.6 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm Protect the hydraulic system from dirt and
(0.8 in.) (15.0 in.) (15.5 in.) contaminants when servicing the hydraulic
25.4 mm 508.0 mm 523.3 mm system.
(1.0 in.) (20.0 in.) (20.6 in.) 1. Disconnect the free-lift chains at the crossmem-
ber. See Figure 23 and Figure 24.
Figure 22. Lift Chains Check
2. Disconnect and remove the hydraulic line for the
free-lift cylinder. Remove the brackets for the
WARNING free-lift cylinder. Remove the free-lift cylinder.
Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective cloth- 3. Disconnect the main lift chains from the chain
ing, gloves, and eye protection. Never expose anchors near the top of the main lift cylinders.
your skin to steam. Disconnect the other end of the main lift chains
at the bottom of the inner mast. Push the inner
Cleaning solvents may be flammable and toxic mast toward the bottom of the mast assembly
and can cause severe skin irritation. When until the bottom load rollers can be seen.
precautions.
22
6. Remove the snap rings and washers at the top of

WARNING the main lift cylinders. Remove the nut, bolt, and
The weldments can slide when the mast is spacer at the mount near the top of each main lift
moved. A weldment that slides can cause in- cylinder.
jury. Use a crane to turn the mast slowly and
carefully. 7. Push the intermediate mast to disengage the
main lift cylinders. Remove the main lift cylin-
4. Remove the strip bearings at the top of the inter- ders.
mediate mast. Remove the load rollers at the bot-
tom of the inner mast. Remove the load rollers 8. Slide the intermediate mast from the bottom of
at the top of the intermediate mast. Make a note the outer mast approximately 30 cm (12 in.). Re-
of each shim arrangement and load roller loca- move the strip bearings at the top of the outer
tion. The shim arrangements will be approxi- mast. Remove the snap rings and load rollers
mately the same during assembly. from both weldments. Make a note of each shim
arrangement and load roller location. The shim
arrangements will be approximately the same
WARNING during assembly.
proximately 907 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.) WARNING
are suitable and of adequate capacity to lift the The mast is heavy. The mast can weigh ap-
mast. proximately 907 kg (2000 lb). Make sure all lift-
5. Slide the inner mast halfway out of the top of the are suitable and of adequate capacity to lift the
intermediate mast. Connect a crane with a ca- mast.
pacity of at least 907 kg (2000 lb) to the center
of the inner mast. See Figure 21. Slide the in- 9. Slide the intermediate mast halfway out of the
ner mast out of the intermediate mast until the top of the outer mast. Connect a crane with a
stub shafts are in the notches of the intermediate capacity of at least 907 kg (2000 lb) to the center
mast. Remove the inner mast from the interme- of the intermediate mast. See Figure 21. Slide
diate mast. the intermediate mast out of the outer mast until
the stub shafts are in the notches of the outer
WARNING mast. Remove the intermediate mast from the
outer mast.
Be careful when removing or installing snap
rings. These snap rings can come loose dur- 10. Disassemble the chain sheaves as necessary for
ing removal or installation with enough force repair and cleaning. Remove the hydraulic lines
to cause an injury. Always use the correct snap and fittings from the weldments as necessary.
ring pliers, and wear eye and face protection
during removal or installation.
23
1. OUTER MAST 11. NUT 21. INNER MAST

2. LOAD ROLLER 12. HOSE 22. FREE-LIFT CYLINDER
3. SHIM 13. VELOCITY FUSE 23. BRACKET
4. SNAP RING 14. HOUSING 24. CAPSCREW
5. O-RING 15. LOWERING CONTROL VALVE 25. SPACER
6. SHIM(S) 16. CHAIN SHEAVE 26. FLOW CONTROL ASSEMBLY
7. STRIP BEARING 17. INTERMEDIATE MAST 27. CROSSHEAD
8. WASHER 18. HOSE 28. CHAIN GUARD
9. MAIN LIFT CYLINDER 19. HOSE SHEAVE 29. FREE-LIFT CHAIN
10. LIFT CHAIN 20. CHAIN ANCHOR
Figure 23. Three-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z ) (B416); and E2.00-3.20XM
(E45-65Z) (G108)
24
Figure 24. Three-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
25

1. OUTER MAST 14. NUT 27. BEARING
2. LOAD ROLLER 15. FREE-LIFT CYLINDER 28. CHAIN SHEAVE ASSEMBLY
3. SHIM 16. MAIN LIFT CYLINDER 29. CHAIN SHEAVE
4. SNAP RING 17. SPRING 30. INNER MAST
5. STUBSHAFT 18. FITTING 31. CHAIN GUARD
6. O-RING 19. HOSE 32. CROSSHEAD
7. SHIM 20. LOWERING CONTROL VALVE 33. BRACKET
8. BEARING STRIP 21. CAPSCREW 34. VALVE ASSEMBLY (FLOW
9. CHAIN 22. CLAMP LIMITING)
10. COTTER PIN 23. TUBE 35. LOWER MAST MOUNT
11. PIN 24. SPACER (J1.60-2.00XMT (J30-40ZT)
12. CHAIN ANCHOR 25. LOCK NUT (J160) ONLY)
13. WASHER 26. INTERMEDIATE MAST
Clean and Inspect Compressed air can move particles so that they
cause injury to the user or to other personnel.
CAUTION is away from all personnel. Wear protective
DO NOT use steam to clean lift chains, sheaves, goggles or a face shield to prevent injury to the
or load rollers. The bearings in the sheaves and eyes.
load rollers are sealed and lubricated.
3. Clean the lift chains by soaking in solvent for 30
1. Inspect the chain sheaves and load rollers for minutes and remove all dirt and grease. Hang
wear or damage. lift chains up and remove solvent using com-
WARNING the mast and the mast must be installed on the
Never replace only the worn section of a chain. lift truck before they can be checked for correct
Replace the complete chain. Never replace length. Lubricate the chains by soaking them in
only one chain of a chain pair. Replace both SAE 30 engine oil for 30 minutes. Hang chains
chains. over a drip pan for one hour to remove excess oil.
NOTE: The chains must be inspected in the area of 4. Inspect the chain anchors and pins. Replace any
chain that passes over the chain sheave during the parts that are worn or damaged.
first portion of a lift. Those links will show maximum
wear. WARNING
2. Inspect the lift chains for wear or damage. A lift
chain becomes longer when it is worn. If a chain
precautions.
chain scale is not available, measure 20 links of Be careful when cleaning with steam. Steam
the lift chain. Compare the measurement with can cause serious burns. Wear protective cloth-
the lengths given in Figure 25. ing, gloves, and eye protection. Never expose
your skin to steam.
WARNING
precautions.
26
TWO-STAGE LFL AND TWO-STAGE FFL

WARNING
MAST, ASSEMBLE
structure of the mast or cause incorrect func-
tion of the mast. Consult your Hyster lift truck WARNING
dealer for more information before welding on The mast is heavy. The mast can weigh ap-
the mast. proximately 907 kg (2000 lb). Make sure all lift-
6. Inspect the sliding surfaces for wear or damage. are suitable and of adequate capacity to lift the
Inspect the load roller contact surfaces for wear mast.
or damage. Inspect all welds for cracks.
NOTE: The shims for the load rollers keep the
mast weldments parallel and give correct clearance.
During assembly, the shim arrangement will be ap-
proximately the same as before disassembly. Check
the clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. See Carriage Adjust-
ments in this section for the adjustment procedures.
NOTE: When the mast has header hoses, see the pro-
cedures for Header Hose Arrangement.
1. Connect a crane with a capacity of at least 907 kg

(2000 lb) to the center of the inner mast. Fit
the stub shafts through the notches in the outer
mast. Slide the inner mast into the outer mast
so the stub shafts are seen at the top and bottom
of the weldments. See Figure 17, Figure 18, Fig-
ure 19, and Figure 20.
2. Install the strip bearings and the shims on the

outer mast. See Figure 26. Apply chassis lube to
Pitch Total length Wear Limit the bearing surface. Check the clearance of the
of 20 links The maximum strip bearings as described in Carriage Adjust-
(pitch) length of 20 ments.
of new chain links
12.7 mm (0.5 in.) 254.0 mm 261.6 mm

15.9 mm (0.6 in.) (10.0 in.) (10.3 in.)
19.1 mm (0.8 in.) 317.5 mm 327.0 mm
25.4 mm (1.0 in.) (12.5 in.) (12.9 in.)
381.0 mm 392.4 mm
(15.0 in.) (15.4 in.)
508.0 mm 523.3 mm
(20.0 in.) (20.6 in.)
NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE (HYSTER PART NO. 599737).
1. CHAIN WEAR SCALE
Figure 26. Strip Bearings
Figure 25. Lift Chains Check
27
3. Install the load rollers and shims on both weld- the lowering control valve in the housing. Con-
ments. Check the clearance of the load rollers as nect the hydraulic lines and fittings between the
described in Carriage Adjustments. housing and the main lift cylinders.
4. To install the main lift cylinders on the two-stage 8. Lift Truck Models S2.0-3.5FT (S40-70FT,
LFL mast, push the inner mast to engage the S55FTS) (F187), H2.0-3.5FT (H40-70FT)
rods of the lift cylinders. Install the washer and (L177), J2.00-3.20XM (B416), and E2.00-
snap ring. 3.20XM (E45-65Z) (G108) On the two-stage
LFL mast, install the chain sheaves at the inner
NOTE: The clearance check and adjustment in either mast. Be sure to install both pins that hold the
procedure for Step 5 is only an initial setup. The shaft for the chain sheave in position. Connect
final check and adjustment is done after the mast is the lift chains to the chain anchors at the main
installed on the lift truck. lift cylinder mounts. Attach wires between the
ends of the lift chains and the crossmember to
5. To install the main lift cylinders on the two-stage
control the lift chains during mast installation.
FFL mast, perform the following procedure (see
Figure 19 and Figure 20) 9. Lift Truck Models S30FT, S35FT, S40FTS
(E010), E1.50-2.00XM (E25-35Z, E40ZS)
a. Lift Truck Models S2.0-3.5FT (S40-70FT,
(E114/F114), J1.60-2.00XMT (J30-40ZT)
S55FTS) (F187), H2.0-3.5FT (H40-70FT)
(J160), and H1.6FT, H1.8FT, H2.0FTS
(L177), J2.00-3.20XM (J40-65Z) (B416),
(H30FT, H35FT, H40FTS) (F001) On the
and E2.00-3.20XM (E45-65Z) (G108) In-
two-stage LFL mast, install the chain sheaves at
stall the washers at the top of the right-hand
the inner mast. Be sure to install the snap rings
cylinder. Push the inner mast to engage the
that hold the chain sheave to the shaft for the
rods of the lift cylinders. Check the clear-
correct position. Connect the lift chains to the
ance at the top of the lift cylinder mounts.
chain anchors at the main lift cylinder mounts.
Add or remove washers at the right-hand
Attach wires between the ends of the lift chains
cylinder until it is even with the left-hand
and the crossmember to control the lift chains
cylinder. Install the snap ring at the top
during mast installation.
of the right-hand lift cylinder. Install the
hydraulic fitting on the left-hand cylinder. 10. On the two-stage FFL mast:
b. Lift Truck Models S30FT, S35FT, S40FTS a. Install the free-lift cylinder in the mounts
(E010), E1.50-2.00XM (E25-35Z, E40ZS) on the inner mast. Install the brackets for
(E114/F114), J1.60-2.00XMT (J30-40ZT) the cylinder and tighten the bolts to 53 N•m
(J160), and H1.6FT, H1.8FT, H2.0FTS (39 lbf ft).
(H30FT, H35FT, H40FTS) (F001): Install
the washers at the top of the left-hand cylin- b. Install the tubing or hoses that connect the
der. Push the inner mast to engage the rods free-lift cylinder to the main lift cylinder.
of the lift cylinders. Check the clearance at
the top of the lift cylinder mounts. Add or c. Connect the free-lift chains to the chain an-
remove washers at the left-hand cylinder chors at the crossmember. Attach a wire be-
until it is even with the right-hand cylin- tween the end of the lift chain and the bottom
der. Install the snap ring at the top of the of the mast to control the lift chain during in-
left-hand lift cylinder. Install the hydraulic stallation.
fitting on the right-hand cylinder.
THREE-STAGE FFL MAST, ASSEMBLE
6. Install the spacers, nuts, and bolts at the mounts
for the lift cylinders. Tighten the bolts to 53 N•m NOTE: The shims for the load rollers keep the weld-
(39 lbf ft). ments parallel and give correct clearance. During as-
sembly, the shim arrangement will be approximately
7. Install the housing for the lowering control valve the same as before disassembly. Check the clearance
on the outer mast. Tighten the nuts for the low- and adjust the shims for wear or for changes caused
ering control valve to 18 N•m (13 lbf ft). Install by repairs. The strip bearings are also adjusted by
using shims. See Carriage Adjustments in this sec-
tion for the adjustment procedures.
28
1. Put the outer mast on the floor with the carriage 7. Lift Truck Models S30FT, S35FT, S40FTS
side up. See Figure 23 and Figure 24. Connect a (E010), E1.50-2.00XM (E25-35Z, E40ZS)
crane with a capacity of at least 907 kg (2000 lb) (E114/F114), J1.60-2.00XMT (J30-40ZT)
to the center of the intermediate mast. Fit the (J160), and H1.6FT, H1.8FT, H2.0FTS
lower stub shafts of the intermediate mast into (H30FT, H35FT, H40FTS) (F001): Install
the notches in the top of the outer mast. Slide the chain sheaves at the intermediate mast. Be
the intermediate mast into the outer mast so the sure to install the snap rings that hold the chain
stub shafts are seen at the top and bottom of both sheave to the shaft for the correct position.
weldments.
8. Install the spacers, washers, nuts, and bolts at
NOTE: The load rollers must be in place before strip the mounts for the main lift cylinders. Tighten
bearing can be shimmed. the bolts to 53 N•m (39 lbf ft).
2. Install the strip bearings and the shims on the 9. Connect a crane with a capacity of at least 907 kg
channels of the outer mast. See Figure 26. Apply (2000 lb) to the center of the inner mast. Slide
chassis lube to the bearing surfaces. Check the the inner mast into the intermediate mast so the
clearance of the strip bearings as described in stub shafts are seen at the top and bottom of both.
Carriage Adjustments.
NOTE: Use multipurpose grease #2 with 2 to 4%
3. Install the load rollers and the shims on the outer Molybdenum Disulfide for normal operations.
mast and at the bottom of the intermediate mast.
Before doing the next step, adjust the interme- NOTE: The load rollers must be in place before bear-
diate mast and check the clearance of the load ing strips can be shimmed.
rollers as described in Carriage Adjustments.
10. Install the strip bearings and the shims on the
NOTE: The clearance check and adjustment in Step 4 channels of the intermediate mast. Apply grease
is only an initial setup. The final check and adjust- to the bearing surfaces. Install the load rollers
ment is done after the mast is installed on the lift and the shims on the intermediate and inner
truck. masts. Before doing the next step, adjust the in-
ner mast as described in Carriage Adjustments.
4. Install the main lift cylinders. Push the interme-
diate mast to engage the lift cylinders. Check the 11. Connect the main lift chains to the chain anchors
clearance at the top of the lift cylinder mounts. at the main lift cylinder mounts. Put the lift
Add or remove washers at the top of the cylinder chains over the chain sheaves and connect them
rods until they are even. Install the snap ring to the anchors at the bottom of the inner mast.
and washer at the top of the lift cylinders.
12. Install the free-lift cylinder in the mounts on the
5. Install the housing for the lowering control valve inner mast. Install the brackets for the cylinder
on the outer mast. Tighten the nuts for the low- and tighten the nuts to 38 N•m (28 lbf ft). On
ering control valve to 18 N•m (13 lbf ft). Install the three-stage FFL mast, the nuts are installed
the lowering control valve in the housing. Con- on the bracket side of the free-lift cylinder.
nect the hydraulic lines and fittings between the
13. Install the hose sheave for the free-lift cylinder.
housing and the main lift cylinders.
Tighten the capscrew for the hose sheave to
6. Lift Truck Models S2.0-3.5FT (S40-70FT, 66 N•m (49 lbf ft). Install the hydraulic hose
S55FTS) (F187), H2.0-3.5FT (H40-70FT) and tubing for the free-lift cylinder.
(L177), J2.00-3.20XM (J40-65Z) (B416), and
14. Connect the free-lift chains to the chain anchors
E2.00-3.20XM (E45-65Z) (G108) Install the
at the crossmember. Attach a wire between the
chain sheaves at the intermediate mast. Be sure
end of the lift chain and the bottom of the mast
to install both pins that hold the shaft for the
to control the lift chain during mast installation.
chain sheave in position.
29
FOUR-STAGE FFL, DISASSEMBLE lift chains. Push second intermediate mast to-
ward bottom of mast assembly until bottom load
NOTE: If only the lift cylinders need to be removed rollers are seen. See Figure 27 and Figure 28.
and repaired, see the section Cylinder Repair 2100
SRM 1139. When the mast has header hoses, see the 6. Remove strip bearings and spacers at top of first
procedures for the Header Hose Arrangements. intermediate mast. Remove load rollers at bot-
tom of second intermediate mast. Remove load
1. Disconnect and remove hydraulic lines for free- rollers at top of first intermediate mast. Make
lift cylinder. Remove brackets for free-lift cylin- a note of each shim arrangement and load roller
der. Remove free-lift cylinder. Disconnect free- location. The shim arrangements will be approx-
lift chains at crossmember. See Figure 27. imately the same during assembly. See Figure 27
and Figure 28.
2. Disconnect lift chains at bottom of inner mast
and top of first intermediate mast. Remove lift 7. Slide second intermediate mast halfway out of
chains. Push inner mast toward bottom of mast top of first intermediate mast. Connect crane
assembly until bottom load rollers are seen. See to center of second intermediate mast. See Fig-
Figure 27 and Figure 28. ure 29. Slide second intermediate mast out until
stub shafts are in notches of first intermediate
3. Remove strip bearings at top of second interme-
mast. Remove second intermediate mast.
diate mast. Remove load rollers at bottom of in-
ner mast. Remove load rollers at top of second 8. Disconnect hydraulic lines at top and bottom of
intermediate mast. Make a note of each shim ar- lift cylinders. Disconnect balance line at top of
rangement and load roller location. The shim ar- right-hand lift cylinder. See Figure 30.
rangements will be approximately the same dur-
ing assembly. 9. Remove snap rings and washers at top of main
lift cylinders. Remove nut, bolt, and spacer at
4. Slide inner mast halfway out of top of second in- mount near top of each main lift cylinder.
termediate mast. Connect crane to center of in-
ner mast. See Figure 29. Slide inner mast out 10. Push first intermediate mast to disengage lift
until stub shafts are in notches of second inter- cylinders. Remove main lift cylinders. Keep
mediate mast. Remove inner mast from second shims from top of right-hand lift cylinder with
intermediate mast. cylinder.
5. Disconnect lift chains at bottom of second inter-

mediate mast and top of outer mast. Remove

1. SNAP RING 10. SHIMS
2. BEARING 11. COTTER PIN
3. CHAIN SHEAVE 12. NUT
4. SECOND INTERMEDIATE MAST 13. WASHER
5. O-RING 14. CHAIN ANCHOR
6. SHIM(S) 15. ANCHOR PIN
7. STRIP BEARING 16. LIFT CHAIN
8. INNER MAST 17. FREE-LIFT CHAIN
9. LOAD ROLLER
30
Figure 27. Second Intermediate and Inner Mast (Four-Stage FFL)
31
Figure 28. Outer and First Intermediate Masts (Four-Stage FFL)
32

1. OUTER MAST 10. WASHER
2. O-RING 11. NUT
3. SHIM(S) 12. FIRST INTERMEDIATE MAST
4. STRIP BEARING 13. SNAP RING
5. LIFT CHAIN 14. SHIMS
6. SPACER 15. LOAD ROLLER
7. ANCHOR PIN 16. BEARING
8. COTTER PIN 17. CHAIN SHEAVE
9. CHAIN ANCHOR
11. Slide first intermediate mast from bottom of
outer mast approximately 30 cm (12 in.). Re-
move strip bearings at top of outer mast. Remove
snap rings and load rollers from both mast up-
rights. Make a note of each shim arrangement
and load roller location. The shim arrangements
will be approximately the same during assembly.
12. Slide intermediate mast halfway out of top of

outer mast. Connect crane to center of first in-
termediate mast. See Figure 29. Slide first inter-
mediate mast out of outer mast until stub shafts
are in notches of outer mast. Remove first inter-
mediate mast from outer mast.
13. Disassemble chain sheaves as necessary for re-

Figure 29. Mast Disassembly pair and cleaning. Remove hydraulic lines and
fittings from mast uprights as necessary.
33
1. BALANCE LINE 7. HOUSING

2. SNAP RING 8. HOSE
3. SHIM 9. LOWERING CONTROL VALVE
4. FITTING AND O-RING 10. MAIN LIFT CYLINDER (RH)
5. MAIN LIFT CYLINDER (LH) 11. SPACER
6. VELOCITY FUSE 12. RETAINER
Figure 30. Main Lift Cylinders (Four-Stage FFL)
CLEAN AND INSPECT NOTE: The chains must be inspected in the area of
chain that passes over the chain sheave during the
CAUTION first portion of a lift. Those links will show maximum
wear.
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and 2. Inspect the lift chains for wear or damage. A lift
load rollers are sealed and lubricated. chain becomes longer when it is worn. If a chain
1. Inspect the chain sheaves and load rollers for
wear or damage.
chain scale is not available, measure 20 links of
WARNING the lift chain. Compare the measurement with
Never replace only the worn section of a chain. the lengths given in Figure 31.
Replace the complete chain. Never replace
only one chain of a chain pair. Replace both
chains.
34
6. Inspect sliding surfaces for wear or damage. In-

WARNING spect load roller contact surfaces for wear or dam-
Cleaning solvents may be flammable and toxic age. Inspect all welds for cracks.
precautions.
Compressed air can move particles so that they

cause injury to the user or to other personnel.
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
3. Clean the lift chains by soaking in solvent for 30

minutes and remove all dirt and grease. Hang
lift chains up and remove solvent using com-
the mast and the mast must be installed on the
lift truck before they can be checked for correct
length. Lubricate the chains by soaking them in
SAE 30 engine oil for 30 minutes. Hang chains
over a drip pan for one hour to remove excess oil.
4. Inspect the chain anchors and pins. Replace any NOTE: THE INSTRUCTIONS FOR MEASURING
parts that are worn or damaged. CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE (HYSTER PART NO. 599737).
WARNING 1. CHAIN WEAR SCALE
Be careful when cleaning with steam. Steam
Pitch Wear Limit
can cause serious burns. Wear protective cloth- Total length
The
ing, gloves, and eye protection. Never expose of 20 links
maximum
your skin to steam. (pitch) of new
length of 20
chain
Cleaning solvents may be flammable and toxic links
and can cause severe skin irritation. When 12.7 mm 254.0 mm 261.6 mm
using cleaning solvents, always follow the (0.5 in.) (10.0 in.) (10.3 in.)
solvent manufacturer’s recommended safety 15.9 mm 317.5 mm 327.0 mm
precautions. (0.6 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.8 in.) (15.0 in.) (15.5 in.)
25.4 mm 508.0 mm 523.3 mm
WARNING (1.0 in.) (20.0 in.) (20.6 in.)
structure of the mast or cause incorrect func- Figure 31. Lift Chains Check
the mast.
35
FOUR-STAGE FFL, ASSEMBLE 6. Install chain sheaves and snap rings on second
intermediate mast.
NOTE: The shims for the load rollers keep the mast
uprights parallel and give correct clearance. Dur- 7. Connect crane to center of second intermediate
ing assembly, the shim arrangement will be approxi- mast. Slide mast into first intermediate mast so
mately the same as before disassembly. Check clear- stub shafts are seen at top and bottom of both
ance and adjust shims for wear or for changes caused mast uprights.
by repairs. The strip bearings are also adjusted by
using shims. See Mast Adjustments in this section 8. Install strip bearings and shims on channels of
for the adjustment procedures. first intermediate mast. Apply grease to bearing
surfaces. Install load rollers and shims on first
NOTE: When the mast has header hoses, see the pro- and second intermediate mast. Before doing the
cedures for the Header Hose Arrangements. next step, adjust second intermediate mast as de-
scribed in Mast Adjustments.
1. Put outer mast on floor with mast pivots toward
floor. See Figure 27 and Figure 32. Connect 9. Connect lift chains to chain anchors at outer
crane to center of first intermediate mast. Fit mast. Put lift chains over chain sheaves on first
lower stub shafts of first intermediate mast into intermediate mast and connect them to anchors
notches in top of outer mast. Slide first interme- at bottom of second intermediate mast.
diate mast into outer mast so stub shafts are seen
at top and bottom of both mast uprights. 10. Connect crane to center of inner mast. Slide mast
into second intermediate mast so stub shafts are
2. Install strip bearings and shims on channels of seen at top and bottom of both uprights.
outer mast. See Figure 33. Apply grease to bear-
ing surfaces. 11. Install strip bearings and shims on channels of
second intermediate mast. Apply grease to bear-
3. Install load rollers and shims on outer mast and ing surfaces. Install load rollers and shims on
at bottom of first intermediate mast. Before do- second intermediate and inner mast. Before do-
ing the next step, adjust first intermediate mast ing the next step, adjust inner mast as described
as described in Mast Adjustments. Install chain in Mast Adjustments.
sheaves, shims, and snap rings on first interme-
diate weldment. 12. Connect lift chains to chain anchors at top of first
intermediate mast. Put lift chains over chain
4. Install main lift cylinders in mounts at bottom of sheaves on second intermediate mast and con-
outer mast. See Figure 30. Push intermediate nect them to anchors at bottom of inner weld-
mast to engage lift cylinders. Check clearance at ment.
top of lift cylinder mounts. Add or remove shims
at top of left-hand cylinder rod until both cylin- 13. Install free-lift cylinder in mounts on inner mast.
ders are even. Install keeper at top of right-hand Install brackets for cylinder and tighten nuts and
cylinder. Install snap ring and washer at top of bolts. See Figure 32.
lift cylinders. Install nuts, bolts, and spacers at
14. Install hose sheave for free-lift cylinder. Install
lift cylinder mounts on outer mast. Tighten nuts
hydraulic hose and tubing that connect free-lift
to 53 N•m (39 lbf ft).
cylinder to right-hand lift cylinder. Install bal-
5. Install housing for lowering control valve on ance line between two main lift cylinders.
outer mast. Tighten nuts for lowering control
15. Connect free-lift chains to chain anchors at inner
valve to 18 N•m (13 lbf ft). Install lowering con-
crossmember. Attach wire between other end of
trol valve in housing. Connect hydraulic lines
lift chain and bottom of mast to control free-lift
and fittings between lowering control valve and
chain during installation of mast.
main lift cylinders. See Figure 30.
36
Figure 32. Crosshead and Free-Lift Cylinder Assembly (Four-Stage FFL)
37

1. HOSE 11. BRACKET
2. SHEAVE 12. PIN
3. STUB SHAFT 13. FREE-LIFT CYLINDER
4. LOCKWASHER 14. CLAMP
5. CAPSCREW 15. STANDOFF
6. CHAIN GUARD 16. CLAMP
7. SPACER 17. FITTING
8. CHAIN SHEAVE 18. BEARING
9. RETAINING RING 19. FLOW CONTROL ASSEMBLY
10. PIN
3. Use crane to position mast assembly onto its
lower mounts:
a. Pivot Pin Connection - Position mast so pivot

pins seat into hanger mounts on drive axle.
Install capscrews that hold mast pivot pins
to drive axle hangers. Tighten capscrews to
270 N•m (199 lbf ft). Refer to Figure 14 and
Figure 16.
b. Stub Shaft Connection - Position mast stub

shafts into the drive unit hangers. Install
retainer caps over stub shaft bushings. Ap-
ply Loctite® 290 or equivalent to capscrew
threads and install capscrews. Tighten to
35 N•m (26 lbf ft). See Figure 36.
Figure 33. Strip Bearings
MAST, INSTALL WARNING

Use a pry bar, NOT your fingers, to align the
1. Lubricate the lower mast mounting surface to tilt cylinder clevises with the outer mast. The
prepare for installation: cylinder or mast can shift and cause serious in-
jury.
a. Pivot Pin Connections - Apply an even coat of
grease to the pivot pins and install them into NOTE: Use multipurpose grease #2 with 2 to 4%
mounts at bottom of outer mast molybdenum disulfide for normal operations.
b. Stub Shaft Connections - Coat the inside and 4. Apply grease to pins and connect tilt cylinders to
outside of the stub shaft bushing and install mast using pins. Install retainer pins and cap-
onto the stub shaft. screws to rod ends. Apply antiseize compound
to capscrew threads and tighten to 38 N•m
2. Connect crane to top of mast using chains. Make
(28 lbf ft).
sure all mast uprights are fastened together.
Make sure chains will not damage sheaves, tub- Remove the capscrews, washers, and anchor pins
ing, or other parts of mast. Make sure crane has at the tilt cylinder mounts on the outer mast. See
a capacity of at least 1600 kg (3500 lb). Figure 34, Figure 35, and Figure 36.
5. Connect hydraulic line to lowering control valve.
6. Install carriage as described in the procedures for

the Carriages Repair.
38
1. O-RING 7. PIVOT PIN 1. WASHER 6. CAPSCREW

2. SPACER 8. GREASE FITTING 2. NUT 7. RETAINER PIN
3. SHIMS 9. RETAINER PIN 3. ROD END 8. CAPSCREW
4. WASHER 10. CAPSCREW 4. PIVOT PIN 9. TILT CYLINDER
5. NUT 11. ROD END 5. GREASE FITTING
6. CAPSCREW 12. TILT CYLINDER
Figure 35. Mast Mounting for Lift Truck Models
Figure 34. Mast Mounting for Lift Truck S30FT, S35FT, S40FTS (E010); E1.50-2.00XM
Models S2.0-3.5FT (S40-70FT, S55FTS) (F187); (E25-35Z, E40ZS) (E114/F114); and H1.6FT,
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (F001)
(G108)
39
8. If lift truck is equipped with a three-stage FFL

mast, adjust chain anchors on the main lift cylin-
ders until the tops of the inner and outer mast
are at the same level within ±1.5 mm (0.06 in.).
See Figure 23 and Figure 24.
For lift trucks equipped with a four-stage FFL

mast, adjust chain anchors on the outer mast
until the tops of the second intermediate and
outer mast are at the same level within ±1.5 mm
(0.06 in.). See Figure 28. Adjust chain anchors
on the first intermediate mast until the tops of
the inner and outer mast are at the same level
within ±1.5 mm (0.06 in.).
9. Raise the mast, without a load to its full height

and check for side kicking. Mast side kicking is
when the mast moves either to the right or left
as it is being raised. If the mast is side kicking,
see the Mast Adjustments section for procedures
to correct mast side kicking.
NOTE: The load rollers and sheaves have sealed bear-

ings and do not need additional lubrication.
1. RETAINER CAP 10. Lubricate sliding surfaces and load roller sur-
2. LOCKWASHER faces along full length of channels as shown in
3. TILT CYLINDER Figure 37. Apply lubricant only to surfaces indi-
4. OUTER MAST WELDMENT
5. BUSHING cated.
6. NUT
7. PIN
8. ROD END
9. WASHER
10. CAPSCREW
Figure 36. Mast Mounting for Lift Truck

ModelJ1.60-2.00XMT (J30-40ZT) [J160]
WARNING
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
into the skin.
7. Check tilt cylinder adjustment as described in

Tilt Cylinders Adjustment. Operate mast and
check for leaks and correct operation. Check lift
chains as described in Lift Chain Adjustments.
A. LOWER LOAD ROLLERS
NOTE: Before checking for mast side kicking and ad- B. UPPER LOAD ROLLERS
justing the chain anchors on the main lift cylinders
for lift trucks equipped with either a three or four- 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
stage FFL mast, the mast must be fully assembled 3. LOAD ROLLER
to include the carriage, forks, load backrest and any
attachments if the lift truck is equipped with one. Figure 37. Lubricate Mast
40
4000 SRM 1148 Header Hose Arrangement
Header Hose Arrangement

NOTE: The carriage height must be correct before the
WARNING header hoses can be adjusted. See Lift Chains Ad-
Always wear the proper protective equipment justment for the carriage adjustment procedure.
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor- 1. Mark each hose with a single letter: A, B, C, and
oughly wash oil from exposed areas of skin as D. See Figure 38.
soon as possible.
2. Dimension E is determined by the height of the
Never check for leaks by putting hands on outer mast channel from the ground and the
hydraulic lines or components under pressure. length of the outer mast channel. See dimen-
Hydraulic oil under pressure can be injected sions Y and Z in Figure 39. To determine E, use
into the skin. the formula shown in the tables associated with
Figure 39.
Before installing the header hoses, make sure you
know the lift height of the mast. The tension on the 3. Clamp the end of the hose (the smaller fitting)
header hoses is adjusted according to lift height. The that attaches to the carriage in a vise (DO NOT
lift height is on the Nameplate of the lift truck and clamp on the threads), and pull on the other end
on the right-hand side of the outer mast. until the hose is straight. DO NOT apply enough
force to stretch the hose. See Figure 39.
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage. NOTE: This mark will be used to pretension the
Examples of these auxiliary functions are sideshift header hoses during installation.
carriages or roll clamps. These auxiliary functions
require header hoses for their operation. 4. Place a mark on all the hoses at dimension E (all
measurements are made from the carriage end of
TWO-STAGE LFL the hose [the smaller fitting]).
5. Attach the hoses to the carriage brackets with

WARNING the clamps. See Figure 40.
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this 6. Place the hoses at the location of the hose sheave.
section. The sheave(s) and stub shafts must be assem-
bled, and the hose(s) must be routed onto the
NOTE: This procedure is for the four-function option. sheave(s) before the hose(s) are attached to the
The three-function option will have hoses A and B mast. Refer to Figure 40. Tighten the hose clamp
only. hardware (12) to 8 N•m (71 lbf in) and the sheave
assembly capscrews (13) to 66 N•m (49 lbf ft).
41
Header Hose Arrangement 4000 SRM 1148
Figure 38. Header Hose Alignment for Two-Stage Limited Free-Lift Mast
42

A. HOSE C. HOSE
B. HOSE D. HOSE
1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE
Figure 39. Header Hose Measurement for Two-Stage Limited Free-Lift Mast
43
Table 2. Pneumatic Tire Trucks
* Metric Formulas (All Dimensions are in Millimeters)

Dimension E = (Y + Z + 204) × 0.98
Example: Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98
Step 2. Dimension E = 2179 × 0.98
Step 3. Dimension E = 2135
* Inch Formulas (All Dimensions are in Inches)

Dimension E = (Y + Z + 8.0) × 0.98
Example: Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98
Step 2. Dimension E = 85.7 × 0.98
Step 3. Dimension E = 84.0
*All measurements are made with mast vertical and fully lowered.
Table 3. Cushion Tire Trucks

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98
44
Figure 40. Header Hoses for Two-Stage Limited Free-Lift Mast
45

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE 10. NUT
2. CAPSCREW 11. BRACKET
3. CLAMP 12. CAPSCREW
4. NUT 13. CAPSCREW
5. BRACKET 14. LOCKWASHER
6. CLAMP 15. STUB SHAFT
7. CLAMP 16. SHEAVE
8. CLAMP 17. SPACER
9. CAPSCREW 18. WASHER
7. Put the clamps (8) over the hoses and attach the (2000 lb) to raise the carriage high enough to install
clamps to the upper brackets. DO NOT tighten a safety chain. See Figure 41.
the hardware.
8. Align mark E at the bottom of the clamps.
NOTE: To make the alignment of dimension E eas- Tighten the hardware to 8 N•m (71 lbf in). Refer
ier, use a crane with a capacity of at least 907.2 kg to Figure 40.
1. HOOK
Figure 41. Chaining the Carriage (LFL)
46
9. Connect the header hoses to the cowl hoses. full lift cycle two times. When properly adjusted,
the hoses will not be so tight that they compress
10. Use the rubber clamps and hose clamps to attach when they pass over the sheaves nor will they
the hoses to the main lift cylinders. DO NOT be so loose that they touch the load backrest or
allow the hoses to stretch or fold while tilting the any crossmember that is next to a sheave. If nec-
mast fully forward and backward. essary, repeat until hoses are properly adjusted.
See Table 4.
11. With no load on the forks, check the header hose
adjustment by operating the mast through the
Table 4. Standard Two-Stage Hose Dimensions
Channel
Dimension "G" Dimension "G"
Lift Height Length Dimension "E"
Third Function Fourth Function
(Reference)
mm in. mm mm in. mm in. mm in.
2043 80.8 1440 1780 70.1 X X X X
3060 120.5 2040 1363 53.7 3183 125.3 3054 120.2

3159 124.4 2090 2420 95.3 X X X X
3252 128.0 2040 2370 93.3 X X X X
3260 128.3 2140 1412 55.6 3380 133.1 3251 128.0
3262 128.4 2040 1397 55.0 3234 127.3 3106 122.3
"E" = (0.985 × channel length in mm) 358.2 "G" = (2.095 × channel length in mm) 291.0
47
TWO-STAGE FFL 4. Place a mark on all the hoses at dimension E and

G (all measurements are made from the carriage
WARNING end of the hose [the smaller fitting]).
Before working on or near the mast, see Safety 5. Attach the hoses to the carriage bracket with
Procedures When Working Near Mast in this clamps.
section.
6. Lift truck models S2.0-3.5FT (S40-70FT,
NOTE: This procedure is for the four-function option. S55FTS) (F187), H2.0-3.5FT (H40-70FT)
The three-function option will have hoses A and B (L177), J2.00-3.20XM (J40-65Z) (B416), and
only. E2.00-3.20XM (E45-65Z) (G108) Put the header
hoses over the free-lift chains. See Figure 45 and
NOTE: The carriage height must be correct before the
Figure 47.
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedure. 7. Lift truck models S30FT, S35FT, S40FTS
(E010), E1.50-2.00XM (E25-35Z, E40ZS)
1. Mark each hose with a single letter: A, B, C, and
(E114/F114), J1.60-2.00XMT (J30-40ZT)
D.
2. Dimensions E and G are determined by the (H30FT, H35FT, H40FTS) (F001): Route
height of the outer mast channel from the ground header hose A and C over the bottom right-
and the length of the outer mast channel. See and left-hand free-lift hose sheaves. Then route
dimensions Y and Z in Figure 42 and Figure 43. header hose B and D over the top right- and
Use the formulas shown in the tables associated left-hand free-lift hose sheaves. See Figure 46
with Figure 42 and Figure 43 to calculate E and and Figure 48.
G.
8. Put the clamps over the header hoses and attach
3. Clamp the end of the hose (the smaller fitting) the clamps to the free-lift bracket. (DO NOT
that attaches to the carriage in a vise (DO NOT tighten the hardware.)
clamp on the threads), and pull on the other end
NOTE: To make the alignment of dimension E easier,
until the hose is straight. DO NOT apply enough
use a crane with a capacity at least 907.2 kg (2000 lb)
force to stretch the hose. See Figure 42.
to raise the carriage high enough to install a safety
NOTE: These marks will be used to pretension the chain. See Figure 44.
header hoses during installation.
9. Align mark E at the bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in).

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE
48
Figure 42. Header Hose Measurement for Two-Stage Full Free-Lift Mast, Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-60Z)
(B416); and E2.00-3.20XM (E45-65Z) (G108)
49
Figure 43. Header Hose Measurement for Two-Stage Full Free-Lift Mast, Lift Truck Models S30FT,
S35FT, S40FTS (E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT)
(J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
50

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98

Class II Mast Type (2.0 - 2.5 Ton Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
51
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303

Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
Step 3. Dimension E = 3284.7 + 303
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2482 mm to 2982 mm:
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
Dimension G (4 Function) for Lift Heights of 2482 mm to 2982 mm
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type (4000 - 5500 lb. Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156
52

Class III Mast Type (3.0 - 3.5 Ton Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 269
The Calculation For Dimension E For Class III Mast Is The Same As Class II Mast. See Class
II Mast - Metric Formula.
Dimension G Calculations Are Similar to Dimension E
(1.981 × Y) + (0.985 × Z) 851
(1.991 × Y) + (0.985 × Z) 972
Dimension G (4 Function) for Lift Heights of 2360 mm to 2960 mm
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type (6000 - 7000 lb. Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 41.156
53
1. HOOK 2. SHACKLE
Figure 44. Chaining the Carriage (FFL)
10. Apply a spray lubricant on the hoses in the area 11. Connect the header hoses (C and D) to the cowl
that will contact the channels. Make sure the hoses. Connect the header hoses (A and B) to the
hoses are properly aligned in the channels. Put tubes. See Figure 45, Figure 46, Figure 47, and
the clamps over the hoses and attach the clamps Figure 48.
to the channels. Tighten the hardware to 8 N•m
(71 lbf in).
NOTE: THREE-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CHANNEL 14. CARRIAGE BRACKET
2. COWL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
6. CLAMP 19. CAPSCREW
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUB SHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN
54
Figure 45. Header Hoses for Two-Stage Full Free-Lift Mast Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM
(E45-65Z) (G108)
55
Figure 46. Header Hoses for Two-Stage Full Free-Lift Mast Lift Truck Models S30FT, S35FT, S40FTS
56
NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CLAMP 9. STUBSHAFT
2. TUBE 10. NUT
3. CLAMP 11. STRAP CLAMP
4. CAPSCREW 12. CHANNEL
5. BRACKET 13. HOSE
6. LOCKWASHER 14. CAP
7. WASHER 15. HOSE SHEAVE
8. SPACER
12. Use the rubber clamps and strap clamps to at- 14. With no load on the forks, check the header hose
tach the hoses to the main lift cylinders. DO adjustment by operating the mast through the
NOT allow the cowl hoses to stretch or fold while full lift cycle two times. When properly adjusted,
tilting the mast fully forward and backward. the hoses will not be so tight that they compress
when they pass over the sheaves nor will they
13. With no load on the forks, operate the mast be so loose that they touch the load backrest or
through the full lift cycle two times. With the any crossmember that is next to a sheave. See
mast at full lift height, attach clamp at the bot- Figure 47 and Figure 48.
tom of the hose loop on the third and/or fourth
function hoses. This action allows the hoses to
fit properly in the hose channel.
57
Figure 47. Header Hose Alignment for Two-Stage Full Free-Lift Mast, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and
E2.00-3.20XM (E45-65Z) (G108)
58
Figure 48. Header Hose Alignment for Two-Stage Full Free-Lift Mast, Lift Truck Models S30FT,
59
THREE-STAGE FFL the lower crossmember and tighten the mount-

ing hardware to 33 N•m (24 lbf ft). Make sure
WARNING the bracket is between the crossmember and the
hose guide. Put the clamps over the hoses and
attach the clamps to the free-lift bracket. (DO
Procedures When Working Near Mast in this
NOT tighten the hardware). See Figure 49.
section.
7. Lift truck models S30FT, S35FT, S40FTS
NOTE: This procedure is for the four-function option.
(E010), E1.50-2.00XM (E25-35Z, E40ZS)
The three-function option will have hoses A and B
(E114/F114), J1.60-2.00XMT (J30-40ZT)
only.
NOTE: The carriage height must be correct before the (H30FT, H35FT, H40FTS) (F001) Route header
header hoses can be adjusted. See Lift Chains Ad- hose B and C over the left- and right-hand
justment for the carriage adjustment procedure. free-lift hose sheaves. Then route headers A and
D over the top left- and right-hand free-lift hose
1. Mark each hose with a single letter: A, B, C, or sheaves. See Figure 50.
D. See Figure 49 and Figure 50.
NOTE: To make the alignment of dimension E eas-
2. Dimensions E and G are determined by the ier, use a crane with a capacity of at least 907.2 kg
height of the outer mast channel from the (2000 lb) to raise the carriage high enough to attach
ground and the length of the outer mast chan- a safety chain. See Figure 44.
nel. See dimension Y and Z in Figure 51 and
Figure 52. Use formulas shown in associated 8. Align the mark for dimension E at the bottom
tables to calculate E and G. of the clamp to create the proper hose tension.
Tighten the hardware to 8 N•m (71 lbf in). In-
3. Clamp the end of the hose (the smaller fitting) stall the hose guards. Tighten the capscrews that
that attaches to the carriage in a vise (DO NOT mount the guards to 18 N•m (13 lbf ft).
clamp on the threads), and pull on the other end
until the hose is straight. DO NOT apply enough 9. Position the hoses at the hose sheave. The
force to stretch the hose. hose sheave and stub shaft must be installed on
the hose before they are attached to the mast.
NOTE: These marks will be used to pretension the Tighten the hardware to 66 N•m (49 lbf ft).
header hose during installation.
10. Put the clamps over the hoses and attach the
4. Place a mark on all the hoses at dimensions E clamps to the upper brackets. (DO NOT tighten
and G (all measurements are made from the car- the hardware.)
riage end of the hose [the smaller fitting]). See
Figure 51 and Figure 52 and Table 9. NOTE: To make the alignment of dimension G easier,
use a crane to raise the inner channel high enough to
5. Attach the hoses to the carriage bracket with install a safety chain.
clamps. Apply spray lubricant to the surface of
the hose guide that contacts the hoses. 11. Align mark G on hoses A and D at the bottom
edge of clamp to create the proper tension. Align
6. Lift truck models S2.0-3.5FT (S40-70FT, mark G on hoses B and C at the top edge of clamp
S55FTS) (F187), H2.0-3.5FT (H40-70FT) to create the proper tension. Tighten the hard-
(L177), J2.00-3.20XM (J40-65Z) (B416), and ware to 8 N•m (71 lbf in). See Figure 49, Sheet 3
E2.00-3.20XM (E45-65Z) (G108) Place the and Figure 50, Sheet 3.
hoses over the top of the free-lift chains and
under the hose guides. Attach the hose guides to 12. Install the clamps. See Figure 53 and Figure 54.
60
Figure 49. Header Hose Alignment for Three-Stage Full Free-Lift Mast Lift Truck Models
(B416); and E2.00-3.20XM (E45-65Z) (G108) (Sheet 1 of 3)
61
62
A. HOSE A G. LEFT-HAND CYLINDER

B. HOSE B H. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
C. HOSE C I. REAR VIEW
D. HOSE D J. RIGHT-HAND CYLINDER
E. FRONT VIEW K. FORKS
F. ALIGN G ON HOSES A AND D AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES B AND C AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. FREE-LIFT CYLINDER
2. HOSE 5. CYLINDER GUARD
3. BOTTOM CROSSMEMBER, INNER CHANNEL
63
Figure 50. Header Hose Alignment for Three-Stage Full Free-Lift Mast Lift Truck Models S30FT,
(J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) (Sheet 1 of 3)
64
65
A. HOSE A G. MAIN LIFT CYLINDER (LH)

B. HOSE B H. MAIN LIFT CYLINDER (RH)
C. HOSE C I. FREE-LIFT CYLINDER
D. HOSE D
E. FRONT VIEW
F. ALIGN G ON HOSES B AND C AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES A AND D AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. NUT
2. CAPSCREW 5. HOSE CLAMP
3. WASHER
66
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 51. Header Hose Measurement for Three-Stage Full Free-Lift Mast Lift Truck Models
(B416); and E2.00-3.20XM (E45-65Z) (G108)
67
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 52. Header Hose Measurement for Three-Stage Full Free-Lift Mast Lift Truck Models S30FT,
68

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
69
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
Dimension G Calculations are similar to Dimension E
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
Dimension G for Lift Heights of 146.1 to 240.6:
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
70

(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.
Table 9. Standard Three-Stage Hose Dimensions
Channel
Lift Height Length Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
4310 169.7 1840 1594 62.8 3683 145.0
4568 179.8 2040 1811 71.3 4293 169.0

4718 185.7 2140 1910 75.2 4293 169.0
4760 187.4 1990 1741 68.5 4076 160.5
4910 193.3 2040 1791 70.5 4272 168.2
5060 199.2 2140 1889 74.4 4272 168.2
5318 209.4 2390 2156 84.9 4784 188.3
5510 216.9 2290 2037 80.2 4567 179.8
5768 227.1 2540 2304 90.7 5078 199.9
71
Figure 53. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and
E2.00-3.20XM (E45-65Z) (G108)
72

1. HOSE 17. CLAMP
2. NUT 18. CLAMP
3. CLAMP 19. SNAP RING
4. CAPSCREW 20. HOSE GUIDE
5. CAPSCREW 21. BRACKET
6. RESTRAINT 22. NUT
7. WASHER 23. STUB SHAFT
8. NUT 24. HOSE GUIDE AND SHEAVE
10. CAPSCREW 26. WASHER
11. SHEAVE 27. CAPSCREW
12. CAPSCREW 28. BRACKET (RH)
13. TUBE 29. STUB SHAFT
14. CAPSCREW 30. SHEAVE
15. CLAMP 31. WASHER
16. PLATE 32. BRACKET (LH)
73
Figure 54. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast, Lift Truck Models S30FT,
74

1. LOCK NUT 9. CLAMP
2. HOSE SHEAVE 10. HOSE
3. SPACER 11. NUT
4. WASHER 12. BRACKET
5. CAPSCREW 13. HOSE GUIDE
6. STUBSHAFT 14. CAP
7. BRACKETS 15. FREE-LIFT CYLINDER BRACKET
8. LOCKWASHER
13. Connect the header hoses to the cowl hoses. 1. Raise carriage so free-lift chains are not tight.
See Figure 55, Figure 56, and Figure 57. Raise
14. Use the rubber clamps and strap clamps to at- inner channel so main-lift chains are not tight.
tach the hoses to the main lift cylinders. Make Install chains to prevent inner channel and car-
sure the hoses do not stretch or fold while tilting riage from moving. The chains must not be in the
the mast fully forward and backward. path of the header hose. See Figure 44.
15. With no load on the forks, check the header hose 2. Install all hose sheaves loosely. DO NOT tighten
adjustment by operating the mast through the capscrews and nuts until header hoses are in-
full lift cycle two times. When properly adjusted, stalled.
the hoses will not be so tight that they compress
when they pass over the sheaves nor will they be 3. Make sure replacement header hose is correct
so loose that they touch the load backrest or any part number for your mast assembly. Make sure
crossmember that is next to a sheave. If neces- header hoses are straight on a flat surface. Mark
sary, repeat until hoses are properly adjusted. header hose at points E and G (mm) as shown in
Table 10. Measure from end of hose with small
FOUR-STAGE FFL fitting.
4. Loosely assemble hose sheaves as shown in Fig-

WARNING
ure 56:
Procedures When Working Near Mast. a. Put coating of multipurpose grease on stub
shafts before assembly.
NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B b. The nuts for the sheave capscrew (axle) must
only. be on the inside of each assembly.
NOTE: The carriage height must be correct before the c. DO NOT tighten any nuts or capscrews.
header hoses can be adjusted. See Lift Chain Adjust- They must be loose to allow installation of
ments for the carriage adjustment procedure. hoses on hose sheave.
NOTE: If the header hoses were removed, use this 5. Install plate at middle hose clamp and tighten
procedure to install the header hoses. See Table 10. capscrews to 8 N•m (71 lbf in).
If the mast components have not been assembled, as-
semble the mast as described in the previous proce-
dure.
75
Table 10. Standard Four-Stage Hose Dimensions
Channel
Lift Height Length Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
4839 190.5 1735 1351 53.2 4750 187.0
5143 202.5 1811 1426 56.1 4971 195.7
5450 214.6 1888 1501 59.1 5192 204.4
5754 226.5 1964 1576 62.1 5414 213.1
6058 238.5 2040 1651 65.0 5635 221.9
6364 250.6 2141 1751 68.9 5930 233.5
6670 262.6 2243 1851 72.9 6225 245.1
6977 274.7 2345 1951 76.8 6520 256.7
7274 286.4 2446 2051 80.8 6815 268.3
7583 298.5 2548 2151 84.7 7110 279.9
7886 310.5 2649 2251 88.6 7405 291.6
8192 322.5 2751 2351 92.6 7701 303.2
8496 334.5 2853 2452 96.5 7996 314.8
8799 346.4 2954 2552 100.5 8291 326.4
9108 358.6 3056 2652 104.4 8586 338.0
76

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842
77

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.

1. CARRIAGE 5. FRONT HOSE SHEAVES
2. MAST ASSEMBLY 6. MIDDLE HOSE SHEAVES
3. CHAIN AND HOSE SHEAVES AT FREE-LIFT 7. MIDDLE HOSE CLAMP
CYLINDER 8. CABLE MOUNT BLOCKS
4. REAR HOSE SHEAVES 9. BOTTOM HOSE CLAMP ASSEMBLIES
A B C D = HOSES
78
Figure 55. Hose Sheaves and Routing, Four-Stage Mast
79
Figure 56. Header Hoses, Four-Stage Mast
80

1. HOSE 18. ROLLER 35. WASHER
2. CLAMP 19. SPACER 36. NUT
3. CLAMP 20. IDLER 37. CLAMP
4. CAPSCREW 21. CABLE 38. STRAP CLAMP
5. CLAMP 22. WASHER 39. BRACKET
6. NUT 23. SPRING 40. CAPSCREW
7. LOCK NUT 24. NUT 41. PLATE
8. SPACER 25. COTTER PIN 42. SNAP RING
9. SHEAVE 26. PIN 43. WASHER
10. STUB SHAFT 27. BLOCK 44. STUB SHAFT
11. WASHER 28. CAPSCREW 45. GUARD
12. CAPSCREW 29. LOCKWASHER 46. WASHER
13. STUB SHAFT 30. CAPSCREW 47. CAPSCREW
14. CAPSCREW 31. WASHER 48. CAPSCREW
15. HOSE GUARD 32. HOSE GUARD (RH INNER) 49. CLAMP
16. HOSE GUARD 33. HOSE GUARD (RH OUTER)
17. STUB SHAFT 34. CAPSCREW
6. Install bottom hose clamps as shown in Fig- 11. Partially assemble floating sheaves as shown in
ure 55. Put some grease on bottom of brackets so Figure 55 and Figure 56. Install loops of hoses
hoses can slip to equalize the pressure. Ensure under sheaves. Then install roller guide assem-
that the inside hose goes through the rear of the blies over hoses and between hose guards. See
bracket and tracks to the inside. The outside Figure 55 and Figure 57. Tighten roller guide
hose goes through the front of the bracket and capscrews and nuts to 8 N•m (71 lbf in).
becomes the outside. Tighten capscrews and
nuts of bracket to 18 N•m (13 lbf ft). DO NOT 12. Fasten looped ends of cables of floating sheaves
tighten capscrews and nuts for strap clamps at to cable mount blocks. Use pins, washers, and
this time. cotter pins to fasten cable loops. See Figure 56.
If necessary, install mount blocks on bottom
7. If the crosshead of the free-lift cylinder does not crossmember of intermediate channel using
have hose guides, remove chain guard brackets, capscrews and washers. Tighten capscrews to
chains, and chain sheaves. Install hose guides 18 N•m (13 lbf ft).
(flare toward outside) and snap rings to chain
sheaves. Install free-lift sheaves, chains, and 13. Make sure cables are in grooves of idler wheels
chain guard brackets as shown in Figure 55 and and under formed feature of hose guards of float-
Figure 57. ing sheaves. Install ends of cables in brackets so
there is spring tension on cables. Make sure axle
8. Install hoses over free-lift cylinder with marks capscrews and nuts of sheaves are tightened to
E aligned with top edge of clamp of middle hose 53 N•m (39 lbf ft).
clamp assemblies. Tighten capscrews and nuts of
clamps to 8 N•m (71 lbf in). Refer to Figure 53, 14. Slowly operate hydraulic system so lift chains
Sheet 3 or Figure 50, Sheet 3. are tight. Remove chains that fasten carriage
and channel weldment. Slowly raise carriage us-
9. Pass hoses under lower hose clamps and install ing hydraulic system. Make sure hoses move
strap clamps on hoses. Align marks G to bot- through all sheaves correctly.
toms of lower hose clamps. Tighten capscrews
and nuts of strap clamps to 18 N•m (13 lbf ft). 15. Slowly operate mast through a few cycles to
make sure hoses track correctly. Tighten strap
10. Install hoses on hose sheaves (Figure 55) with clamps at bottom hose clamps to 18 N•m
loops long enough to install on floating hose (13 lbf ft). Fasten hose assemblies to main
sheaves. Tighten axle capscrews and nuts of cylinders using hose clamps and screw clamps
sheaves to 53 N•m (39 lbf ft). as shown in Figure 55 and Figure 56.
81
Figure 57. Header Hose Arrangement, Four-Stage Mast
82

A. BACK VIEW B. SIDE VIEW
1. HOSE SHEAVE NO. 1 6. GUIDE BRACKET
2. HOSE SHEAVE NO. 2 7. C-D CLAMP
3. FLOATING SHEAVE ASSEMBLY 8. C-D CLAMP
4. A-B CLAMP 9. A-B CLAMP
5. CABLE MOUNT 10. FREE-LIFT CROSSHEAD
ADJUSTMENT push (if the hoses are tight) on the hoses so they
move 15.0 mm (0.6 in.) side to side. Tighten the
When properly adjusted, the hoses will not be so tight hardware to 8 N•m (71 lbf in).
that they compress when they pass over the sheaves,
nor will they be so loose that they touch the load back- NOTE: If the hose tension between the clamp at the
rest or any crossmember that is next to a sheave. upper bracket and the clamp at the free-lift bracket
is correct, go to Step 8.
1. Cap off hoses when attachments have been re-
moved. 7. If the tension of the hoses is incorrect, loosen the
clamps and pull the hoses down (if too loose) or
2. Check that hoses and cables are routed properly. push the hoses up (if too tight) so they can move
15.0 mm (0.6 in.) side to side. Retighten the
3. Slowly raise the free-lift and main cylinders to
hardware to 8 N•m (71 lbf in).
take up slack in the lift chains.
8. With no load on the forks, check the header hose
4. Tighten strap clamps at the bracket weldment.
adjustment by operating the mast through the
5. Cycle the mast a few times to ensure proper full lift cycle two times. When properly adjusted,
tracking of hoses. the hoses will not be so tight that they compress
when they pass over the sheaves nor will they
6. Secure hose assemblies to main lift cylinders be so loose that they touch the load backrest or
with hose clamp and screw clamp. any crossmember that is next to a sheave. If nec-
essary, repeat until the hoses are properly ad-
NOTE: If the hose tension between the carriage and justed.
the clamp at the free-lift bracket is correct, go to
Step 7. 9. On four-stage masts, adjust the floating sheave
cable tensions to ensure that they are approx-
If the hose tension between the carriage and the imately the same. Check that the sheaves are
clamp at the free-lift bracket is incorrect, loosen aligned properly with the header hoses.
the clamps and pull (if the hoses are loose) or
83
Lift Chains Adjustment 4000 SRM 1148
Lift Chains Adjustment

2. Adjust the chain anchors that support the car-
WARNING riage, until the bottom of the fork heel is 6.0
When working on or near the mast, see Safety ±3.0 mm (0.24 ±0.12 in.) above the floor level.
Procedures When Working Near Mast in this See Figure 58.
section.
3. See Figure 59. Adjust the chain anchors that
During test procedures for the hydraulic sys- support the carriage, until the bottom of the
tem, fasten the load to the carriage with chains lower carriage bar is above the floor level as
to prevent it from falling. Keep all personnel shown in Table 11. Adjust the chain anchors
away from the lift truck during the tests. that support the carriage, until the bottom of
the lower carriage bar is 82.5 ±3.0 mm (3.25
Never allow anyone under a raised carriage.
±0.12 in.) above the floor level. See Figure 59.
DO NOT put any part of your body in or
through the lift mechanism unless all parts Table 11. Hook-Type Carriage Chain
of the mast are completely lowered and the Adjustment
engine is STOPPED.
Class II and III 82.5 ±3.0 mm (3.25 ±0.12 in.)
Never check for leaks by putting hands on
hydraulic lines or components under pressure. Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)
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 2. If the forklift truck is nor- 1. MAST
mally equipped with a hook-type carriage and 2. CARRIAGE
has an attachment without forks, go to Step 3. 3. FORK
4. HEEL OF FORK IS 6.0 ±3.0 mm (0.24 ±0.12 in.)
If the forklift truck is normally equipped with a
ABOVE FLOOR LEVEL
pin-type carriage and has an attachment without
forks, go to Step 4. Figure 58. Lift Chain Adjustment, Hook- or
Pin-Type Forks
NOTE: Prior to performing adjustment procedures,
make sure the forklift truck is parked on a level sur-
face and the mast is in the vertical position.
84
4000 SRM 1148 Lift Chains Adjustment
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 59. Lift Chain Adjustment, Hook-Type

Carriage
4. See Figure 60. Adjust the chain anchors, which

support the carriage, until the center line of the
fork pin is above the floor level as shown in Ta-
ble 12.
Table 12. Pin-Type Carriage Chain Adjustment
H70/80, 90XLS 545.0 ±3.0 mm (21.5 1. LOAD BACK REST

±0.12 in.) 2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
H90-110XL 708.0 ±3.0 mm (27.87
±0.12 in.) Figure 60. Lift Chain Adjustment, Pin-Type
H135-155XL 907.0 ±3.0 mm (35.71 Carriage
±0.12 in.)
85
Tilt Cylinders Adjustment 4000 SRM 1148
Carriage Adjustments
1. Install the load rollers on the carriage. Install 4. Keep shim arrangement on each side of carriage
the shims for the load rollers onto the stubshaft approximately equal. The carriage must be cen-
in the same sequence as when disassembled. On tered within the inner mast within +1.50 mm
carriages equipped with six load rollers, there (0.06 in.).
are no shims under the top load rollers.
2. Use a lifting device to raise carriage. Find the CAUTION

point of tightest fit between the carriage load Too much grease will cause the rollers to slide
rollers and inner mast channels. and wear flat areas on the rollers and intro-
duce contamination into and on mast channels.
3. Remove carriage from mast. Adjust shim ar-
rangement for each roller for clearance between 5. After adjustment, lubricate channels with a thin
roller and inner channel. Repeat Step 1 and layer of grease. Adjust hydraulic hoses and make
Step 2 until there is zero clearance at the point sure connections are correct, if the carriage is
of tightest fit. equipped with hydraulic attachments.
Tilt Cylinders Adjustment

wrench and turn the cylinder rod IN un-
WARNING til the dimension starts to decrease, then
When the tilt cylinders have tilt limit spacers, stop. Repeat this procedure until both cylin-
make sure they are installed during installa- der rods stop at the same position within
tion procedures. Without the tilt limit spacers, 0.50 mm (0.02 in.). After the adjustments
the mast can tilt too much and cause an acci- are complete, tighten the capscrews on the
dent or serious injury. rod ends.
Check tilt cylinder stroke by slowly tilting mast fully c. Tilt the mast fully backward and measure
forward and backward several times. Both tilt cylin- the tilt angle. (See the Nameplate for tilt
ders must stop their stroke at the same time. Adjust angles.) If necessary, adjust both rod ends
rod ends as shown in Figure 63, Figure 61, Figure 64, equally for the correct angle.
Figure 65, andFigure 66.
2. Lift truck models S2.0-3.5FT (S40-70FT,
1. Lift truck models S30FT, S35FT, S40FTS S55FTS) (F187), H2.0-3.5FT (H40-70FT)
(E010), E1.50-2.00XM (E25-35Z, E40ZS) (L177), J2.00-3.20XM (J40-65Z) (B416), and
(E114), J1.60-2.00XMT (J30-40ZT) (J160), E2.00-3.20XM (E45-65Z) (G108) Adjust the
and H1.6FT, H1.8FT, H2.0FTS (H30FT, stroke of the tilt cylinders WITH tilt limit spac-
H35FT, H40FTS) (F001): Adjust the stroke ers as follows:
of the tilt cylinders WITHOUT tilt limit spacers
as follows: a. Adjust the rod ends to 15 mm (0.6 in.) for all
tilt cylinders as shown in Figure 63.
a. Adjust the rod ends to 20 mm (0.8 in.) for all
tilt cylinders shown in Figure 61 and 32 mm b. Slowly tilt the mast forward until one cylin-
(1.25 in.)for all tilt cylinder shown in Fig- der rod stops. On the opposite cylinder,
ure 62. loosen the capscrews on the rod end. Use
a wrench and turn the cylinder rod IN as
b. Slowly tilt the mast backward until one necessary. Repeat this procedure until both
cylinder rod stops. On the opposite cylin- cylinder rods stop at the same position
der, loosen the capscrews on the rod end. within 0.50 mm (0.02 in.).
Measure the distance from the end of cylin-
der to the back end of the rod end. Use a
86
4000 SRM 1148 Tilt Cylinders Adjustment
NOTE: THE END OF THE ROD IS EVEN WITH THE 1. MAST

FRONT FACE OF THE ROD END. 2. ROD ENDS
3. TILT CYLINDER
1. MAST 3. TILT CYLINDER
2. ROD ENDS Figure 62. Tilt Cylinder Adjustments for Lift
Truck Model J1.60-2.00XMT (J30-40ZT) (J160)
Figure 61. Tilt Cylinder Adjustments for Lift
Truck Models S30FT, S35FT, S40FTS (E010);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
87
Tilt Cylinders Adjustment 4000 SRM 1148
e. Tilt the mast fully backward and measure

the tilt angle. (See the Nameplate for tilt
angles.) If necessary, add an equal number
of shims to both rods for the correct angle.
A. DIMENSION A = 15 mm (0.60 in.)

1. MAST
2. ROD END
3. SHIMS
4. TILT LIMIT SPACER
5. TILT CYLINDER
Figure 63. Tilt Cylinder Adjustments for

Lift Truck Models S2.0-3.5FT (S40-70FT,
1. O-RING 7. PIVOT PIN
S55FTS) (F187); H2.0-3.5FT (H40-70FT) 2. SPACER 8. GREASE FITTING
(L177); J2.00-3.20XM (J40-65Z) (B416); and 3. SHIMS 9. RETAINER PIN
E2.00-3.20XM (E45-65Z) (G108) 4. WASHER 10. CAPSCREW
5. NUT 11. ROD END
c. Slowly tilt the mast backward until one rod 6. CAPSCREW 12. TILT CYLINDER
end just contacts the spacer. Add shims to
fill the gap at the opposite rod end until both Figure 64. Mast Mounting for Lift Truck
rod ends contact the spacers within 0.5 mm Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
(0.02 in.). H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z)
d. After the adjustments are complete, tighten (G108)
the capscrews on the rod ends to 90 N•m
(66 lbf ft). See Figure 64, Figure 65, and
Figure 66.
88
4000 SRM 1148 Tilt Cylinders Adjustment
1. RETAINER CAP
2. LOCKWASHER
1. WASHER 6. CAPSCREW 3. TILT CYLINDER
2. NUT 7. RETAINER PIN 4. OUTER MAST WELDMENT
3. ROD END 8. CAPSCREW 5. BUSHING
4. PIVOT PIN 9. TILT CYLINDER 6. NUT
5. GREASE FITTING 7. PIN
8. ROD END
Figure 65. Mast Mounting for Lift Truck Models 9. WASHER
S30FT, S35FT, S40FTS (E010); E1.50-2.00XM 10. CAPSCREW
(E25-35Z, E40ZS) (E114/F114); and H1.6FT, Figure 66. Mast Mounting for Lift Truck Model
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) J1.60-2.00XMT (J30-40ZT) (J160)
(F001)
89
Mast Adjustments 4000 SRM 1148
Mast Adjustments
Load Roller Adjustment 2. Perform the following steps to adjust the mast
load rollers:
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub a. Use a crowbar to move mast uprights from
shafts. To change the position of the roller on the side to side to measure movement. Measure
stub shaft, move the shims from one side of the load movement in a minimum of three different
roller to the other. positions of each mast upright.
During assembly, the shim arrangement will be ap- b. Separate mast uprights and change shim ar-
proximately the same as before disassembly. Check rangements as required. Assemble uprights.
the clearance and adjust shims after repairs have Slide upright all the way to the top and bot-
been completed. tom to find the tightest fit.
1. The load rollers control the alignment of the mast c. Repeat Step a and Step b until there is zero
uprights. See Figure 67. The alignment condi- clearance at the point of the tightest fit.
tions are given on a list below with the most im-
portant condition first. d. Measure distance between channels of mast
uprights on top and bottom. Change shims
a. The mast uprights must be parallel to each to keep distance equal between top and bot-
other. tom so mast uprights are parallel. Also make
sure the mast uprights are parallel within
b. Use shims to adjust load rollers so there is 1.5 mm (0.060 in.).
zero clearance between load roller and chan-
nel at point of tightest fit. 3. Adjust strip bearings. See Figure 68. Insert
shims under strip bearing. Adjust clearance un-
c. The number of shims under a load roller til there is less than 0.8 mm (0.030 in.) at the
must be approximately the same as the stub tightest fit. See Figure 67.
shaft in the opposite side of the upright. This
ensures the uprights will be approximately
in the center.
90
4000 SRM 1148 Mast Adjustments
NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY EQUAL
SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE AT POINT
OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW
B. MAST FRONT VIEW
1. CHANNEL 7. ZERO CLEARANCE AT POINT OF TIGHTEST FIT
2. LOAD ROLLER 8. EQUAL SPACE ±1.5 mm (0.060 in.)
3. STUB SHAFT 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
4. SNAP RING 10. PUT SPACER ON OUTSIDE OF TOP LOAD
5. SHIMS ROLLER, UNDER SNAP RING
6. PARALLEL TO CHANNEL 11. SHIM FOR ZERO CLEARANCE AT POINT OF
±1.5 mm (0.060 in.) TIGHTEST FIT
Figure 67. Mast Adjustments
91
Mast Adjustments 4000 SRM 1148
1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT
Figure 68. Strip Bearings Arrangement
Mast Side Kicking Adjustment See Figure 17 through Figure 20, Figure 23, Fig-
ure 24, and Figure 30 for shim location on the
To adjust the mast for side kicking, do the following: main lift cylinders.
1. Place the lift truck on a level surface and apply 4. If shims are to be added, use the smallest shim
the parking brake. size available on the cylinder being adjusted. See
the Parts Manual for shim sizes and part num-
2. Raise the mast and visually inspect it as it
bers.
reaches its full height.
5. Raise the mast again and visually inspect it to
3. If the mast is moving to the left, shims will need
ensure that it is no longer side kicking. If it is,
to either be added or removed from the top of the
repeat Step 3 and Step 4.
right main lift cylinder. If mast moves to the
right, shims will need to either be added or re-
moved from the top of the left main lift cylinder.
92
TECHNICAL PUBLICATIONS
4000 SRM 1148 11/08 (12/07)(3/07)(3/06)(1/06)(5/05)(12/04) Printed in U.S.A.

Mast Repairs: 2, 3, and 4-Stage Masts

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Mast Repairs: 2, 3, and 4-Stage Masts

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MAST REPAIRS

2, 3, AND 4-STAGE MASTS

PART NO. 1580524 4000 SRM 1148

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

S30FT, S35FT, S40FTS [E010];

Safety Procedures When Working Near Mast

Figure 1. Safety Chaining the Mast

Legend for Figure 1

A fork can be removed from the carriage for replace-

1. LOAD BACKREST 6. WEDGE

Figure 3. Carriage and Forks

CHECKS Table 1. Fork Tip Alignment

WARNING Fork Tip Alignment Specifications

Legend for Figure 4

Figure 4. Fork Check

2. Remove the four capscrews securing the load

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

4. Remove the pin from each chain anchor at the

Figure 5. Standard Carriage

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

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

3. Clean the bearing areas. Inspect the sideshift

NOTE: Tag hydraulic lines prior to disconnecting to

2. Disconnect the hydraulic lines at the sideshift

3. Remove the lower mounting hooks by removing

4. Remove two hairpins, two pins, and sideshift

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

2. Clean and inspect the carriage bars for damage

b. Unscrew the retainer from the cylinder.

c. Clamp the other end of the cylinder in a

d. Unscrew the retainer from the cylinder.

NOTE: If new retainers that are already assembled

e. Remove and discard the seals and O-ring

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

3. Remove the capscrews, washers, and anchor pins

Figure 11. Mast Mounting for Lift Truck Models

1. O-RING 7. PIVOT PIN

Figure 10. Mast Mounting for Lift Truck

NOTE: Allow the mast to tilt forward enough to gain

4. Disconnect the lower mast mounts from the lift

a. Pivot Pin Connections - Remove the cap-

b. Stub Shaft Connections - Remove the four

5. Use the crane to lift the mast assembly from

b. Stub Shaft Connections - Remove the bush-

1. OUTER MAST 2. BUSHING 3. GREASE FITTING

Figure 13. Mast Mounts, Outer Mast

lift cylinders and put caps on the open lines. See

2. Remove the chains and header hoses. On the

1. OUTER MAST 8. WASHER 15. HOUSING

Legend for Figure 18

Legend for Figure 19

Legend for Figure 20

5. Clean the mast weldments with steam or solvent.

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

THREE-STAGE FFL MAST

6. Remove the snap rings and washers at the top of