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• 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.
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4000 SRM 522 Safety Procedures When Working Near Mast General 4000 SRM 521 for the description and operation of WARNING the masts. Before working on or near the mast, see Safety NOTE: Hoses have a service life that is determined Procedures When Working Near Mast in this by application and time.
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Safety Procedures When Working Near Mast 4000 SRM 522 A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST 1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER 2. INNER WELDMENT 5. FREE-LIFT CYLINDER 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts...
4000 SRM 522 Forks Repair Forks Repair INSTALL The forks are held on the carriage by hooks. The forks are kept in position by latch pins that fit Move the fork and carriage so the top hook on the through the top fork hooks and into slots in the top fork can engage the upper carriage bar.
4000 SRM 522 Carriages Repair HANG-ON SIDESHIFT CARRIAGE, bracket and cylinder will stay on the standard carriage. Remove the bearings. REMOVE 1. Lower the carriage completely. Remove the forks WARNING and the load backrest extension. Hydraulic oil is hot after system operation and can cause burns.
Carriages Repair 4000 SRM 522 STANDARD CARRIAGE AND HANG-ON SIDESHIFT CARRIAGE, REPAIR NOTE: The carriage can have four or six load rollers. When the carriage has four load rollers, shims are used behind all of the load rollers. When the carriage has six load rollers, shims are installed on the bottom and middle rollers only.
0.6 mm (0.024 in.). Install the 3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z) threaded rods to hold the cylinder in position and [A416], E2.00-3.20XM (E40-65Z) [G108], and tighten to 18 N•m (159 lbf in). S/E/J3.00XL (S/E/J60XL) units, tighten all of the capscrews to 755 N•m (557 lbf ft).
4000 SRM 522 Carriages Repair WARNING Hydraulic oil is hot after system operation and can cause burns. Do not disconnect any hy- draulic lines of the system until the oil for the system is cool and the pressure is relieved. 2.
Mast Repair 4000 SRM 522 Proper lower hook clearance requires the upper bear- WARNING ings be fully seated. Cleaning solvents may be flammable and toxic 1. If necessary, install the lower sideshift bearings. and can cause severe skin irritation. When Then install the upper sideshift bearings.
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